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Plant Design Process Synthesis
Plant Design Process Synthesis
Learning Outcome
R4. Thermal cracking of dicholoroethane from R5. Balanced Process for Chlorination of Ethylene
oxychlorination of ethylene
C2H4 + 2HCl + ½ O2 → C2H4Cl2 + H2O C2H4 + Cl2 → C2H4Cl2
C2H4Cl2 → C2H3Cl + HCl C2H4 + 2HCl + ½ O2 → C2H4Cl2 + H2O
C2H4 + HCl + ½ O2 → C2H3Cl + H2O 2C2H4Cl2 → 2C2H3Cl + 2HCl
C2H4 + HCl + ½ O2 → 2C2H3Cl + H2O
Advantages:
• Attractive solution
• Occurs spontaneously at a few hundred celcius
Disadvantages:
• Low percentage of yield
• Producing large amount of byproducts (Dichloroethylene)
• Half of the expensive Cl is consumed
14
Advantages:
• Good conversion (98%)
• Moderate reaction conditions
• Temp : 150 ◦C, Catalyst: HgCl2, Pressure: 1 atm
Disadvantages:
• Flammability of C2H2
15
Advantages:
• Conversion Ethylene to Dichloroethane is 98% (90 ◦C , 1 atm, Catalyst: FeCl3)
• Conversion of intermediate is 65% (spont. at 500 ◦C)
Disadvantages:
• Produce HCl
16
Advantages:
• Highly exothermic reaction with 95% conversion (250 ◦C , Catalyst: CuCl2)
oxychlorinates ethylene 1,2-dichloroethane
Disadvantages:
• Economics dependent on cost of HCl
17
Advantages:
• Combines path 3 and 4
• All Cl2 converted to Vinyl Chloride
• No by-products
18
C2H4Cl2
DIRECT
PYROLYSIS
CHLORINATION
C2H4 C2H3Cl
Cl2
HCl
C2H4Cl2
DIRECT
PYROLYSIS
CHLORINATION
C2H4 C2H3Cl
Target
100,000 lb/h
*For preliminary calculation, assume 100% conversion.
25
Step 2: Distribute the chemicals by matching sources and sinks
Cl2
HCl
113,400 lb/h 58,300 lb/h
C2H4Cl2
DIRECT
PYROLYSIS
CHLORINATION
C2H4 C2H3Cl
Target
44,900 lb/h 100,000 lb/h
*For preliminary calculation, assume 100% conversion.
27
Step 2: Distribute the chemicals by matching sources and sinks
58,300 lb/h
Cl2
158,300 lb/h HCl
98% conversion
(neglect the unconverted)
113,400 lb/h
C2H4Cl2 HCl
DIRECT
PYROLYSIS C2H3Cl
CHLORINATION
C2H4Cl2
C2H4
Target
C2H3Cl
44,900 lb/h
100,000 lb/h
28
Step 2: Distribute the chemicals by matching sources and sinks
58,300 lb/h
Cl2 158,300 lb/h HCl
98% conversion 60%
(neglect the unconverted) conversion
113,400 lb/h
C2H4Cl2 HCl
DIRECT
PYROLYSIS C2H3Cl
CHLORINATION
C2H4Cl2
C2H4
Target
C2H3Cl
44,900 lb/h
100,000 lb/h
Pyrolysis Recycle Mass Balance 105,533 lb/h
(1-0.6) x 158,300 lb/hr = 105,533 lb/hr
0.6
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Reaction path 3
Energy Balance
52 × 106 Btu/hr 58,300 lb/h
Cl2 150 × 106 Btu/hr 158,300 lb/h HCl
113,400 lb/h
DIRECT C2H4Cl2 PYROLYSIS HCl
CHLORINATION 500oC C2H3Cl
90oC, 1.5 atm 26 atm C2H4Cl2
C2H4
C2H3Cl
44,900 lb/h
100,000 lb/h
105,533 lb/h
30
C2H3Cl
158,300 lb/h HCl
Cl2 100,000 lb/h
C2H3Cl
113,400 lb/h PYROLYSIS -26.2 oC 33 oC
DIRECT C2H4Cl2
CHLORINATION C2H4Cl2 500oC
90oC, 1.5 atm 26 atm
112 oC
C2H4 Liquid at
Assign for the last column first. Set a pressure
44,900 lb/h Assignwhere:
for the next upstream
Bubble column. Set93 aC pressure where: o
146 oC
Point, 6 C o
• The top product can be condensed by•cooling water
Pressure (avoid from
gradient the use high to100,000
low lb/h C H Cl 2 3
105,500 lb/h C H Cl
of refrigerant). C H Cl
• The condenser temperature 2
not too low
4 2
2 4 2
52 × 106 Btu/hr
C2H3Cl
150 × 106 158,300 lb/h
Cl2 100,000 lb/h
Btu/hr
113,400 lb/h -26.2 oC 33 oC
DIRECT C2H4Cl2 PYROLYSIS
CHLORINATION 500oC
90oC, 1.5 atm 112 oC 26 atm
C2H4
Liquid at
44,900 lb/h Bubble
Point, 6 oC 93 oC 146 oC
100,000 lb/h C2H3Cl
105,533 lb/h C2H4Cl2
C2H4Cl2
105,533 lb/h
33
DIRECT
CHLORINATION
Which PYROLYSIS
500oC
90oC, 1.5 atm configuration 26 atm
C2H4Cl2 C2H4Cl2
Begin State: is better? End State:
Require compressor to
90 oC, 1.5 atm 500 oC, 26 atm
Liquid Phase raise the pressure
Vapour Phase
DIRECT PYROLYSIS
Temp. Phase Temp. Pressure
Configuration 1 CHLORINATION 500oC
90oC, 1.5 atm Change Change Change Change 26 atm
C2H4Cl2 242 oC 242 oC 499 oC C2H4Cl2
Begin State: 1.5 atm 1.5 atm 1.5 atm End State:
90 oC, 1.5 atm Liquid Vapour Vapour 500 oC, 26 atm
Liquid Phase Phase Phase Phase Vapour Phase
DIRECT Temp. PYROLYSIS
Pressure Phase Temp.
Configuration 2 CHLORINATION 500oC
90oC, 1.5 atm Change Change Change Change 26 atm
C2H4Cl2 91 oC 242 oC 242 oC C2H4Cl2
Begin State: 26 atm 26 atm 26 atm End State:
90 oC, 1.5 atm Liquid Liquid Vapour 500 oC, 26 atm
Liquid Phase Phase Phase Phase Vapour Phase
Require pump to raise
the pressure
35
DP
Distillation Distillation
58,300 lb/h
Calculate Tower Tower
12 atm HCl 4.8 atm
Temp. C2H3Cl
energy Change 100,000 lb/h
90 oC DP DP
26 atm Change Change
4.8 atm
6 oC
3.4 x 106 12 atm
Temp.
Btu/hr 93 oC 146 oC
Change 100,000 lb/h C2H3Cl
105,533 lb/h C2H4Cl2
37
Cooling
Spray Water Distillation
58,300 lb/h
Distillation
Tower Tower
Quench 12 atm HCl 4.8 atm
Temp.Tank C2H3Cl
Steam
Cooling
Water
Cooling
Water
Distillation Distillation
Tower 58,300 lb/h Tower
12 atm HCl 4.8 atm
C2H3Cl
Cooling
100,000 lb/h
Water
Final flowsheet -26.2 oC 33 oC
after task
integration for Refrigerant
the vinyl- 93 oC 146 oC
process.
40
Working Session
• Individual: Calculate Economic Potential for Reaction
Pathway 2, 4 and 5. (20 mins)
• Individual: Calculate the mass balance up to recycle stream
for Reaction 3 but for a production of 150,000 lb/h of VC. (20
mins)
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Homework
• Read the whole Chapter 2 before class on Thursday. And prepare
mind-map.
• Discuss and solve Exercise 2.5 to 2.7 from the Chapter 2 textbook in
your team.
• Deadline: 7 Nov 2022