Lecture Note 5 Key Synthesis Steps (SRWA)
Lecture Note 5 Key Synthesis Steps (SRWA)
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
Criteria 1
Criteria 2
Criteria 3
Total
*Score: 0 (worst) to 5 (best)
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
11
Advantages:
• Good conversion (98%)
• Moderate reaction conditions
• Temp : 150 ◦C, Catalyst: HgCl2, Pressure: 1 atm
Disadvantages:
• Flammability of C2H2
12
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
13
Advantages:
• Highly exothermic reaction with 95% conversion (250 ◦C , Catalyst: CuCl2)
oxychlorinates ethylene 1,2-dichloroethane
Disadvantages:
• Economics dependent on cost of HCl
14
Advantages:
• Combines path 3 and 4
• All Cl2 converted to Vinyl Chloride
• No by-products
15
C2H4Cl2
DIRECT
PYROLYSIS
CHLORINATION
C2 H4 C2H3Cl
Cl2
HCl
C2H4Cl2
DIRECT
PYROLYSIS
CHLORINATION
C2H4 C2H3Cl
Target
100,000 lb/h
*For preliminary calculation, assume 100% conversion.
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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.
24
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
25
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
27
C2H3Cl
158,300 lb/h HCl
Cl2 100,000 lb/h
C2H3Cl
113,400 lb/h -26.2 oC 33 oC
DIRECT PYROLYSIS C2H4Cl2
C2H4Cl2
CHLORINATION 500oC
90oC, 1.5 atm 112 oC 26 atm
C2H4 Liquid at
Assign for the last column first. Set a pressure
44,900 lb/h Assignwhere:
for the next upstream column. Set93 aC pressure where: 146
Bubble o
o
C
Point, 6 oC
•The top product can be condensed by cooling water
•Pressure (avoid from
gradient the use of to low
high 100,000 lb/h C H Cl 2 3
105,500 lb/h C H Cl
refrigerant). •The condenser temperature
C H Cl
not too low
2 4 2
2 4 2
•The reboiler can heat up the bottom by•using MPS can 105,500
The reboiler heat lb/h
up the bottom by using LPS
Boiling Points and
•The operating CriticalisConstants
condition far from Tc and
•ThePoperating
c. condition is far from Tc and Pc.
Boiling Point (oC) Critical Constants
Normal
Boiling
Chemical
Point 4.8 atm 12 atm 26 atm Tc (oC) Pc (atm)
(1 atm, oC)
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
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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
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P Distillation
Distillation
58,300 lb/h Tower
Calculate
Tower
12 atm HCl 4.8 atm
Temp. C2H3Cl
energy Change 100,000 lb/h
balance 170 Co
Phase Temp.
-26.2 oC 33 oC
90 oC 26 atm P P
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
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Cooling
Spray Water Distillation
58,300 lb/h
Distillation
Tower
Tower
Quench 12 atm HCl 4.8 atm
Temp. C2H3Cl
Tank Cooler 100,000 lb/h
Change
90 oC -26.2 oC 33 oC
4.8 atm 170 C o
Phase Temp.
26 atm P P
Change Change PRV o
6 C
PRV
Cooling Refrigerant
Water 12 atm
Temp. Condensor 93 oC 146 oC
Change 100,000 lb/h C2H3Cl
Cooler 105,500 lb/h C2H4Cl2
P
PRV
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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.
37
Design separation
processes