:NORASYIKIN BINTI MOKTAR :2011635672 :PRODUCTION OF ETHYL CHLORIDE :12.11.2012 :5 : EH220 : DR JAGANNATHAN KRISHNAN Allocated Marks (%) 10 10 20 30 30 100

No. 1 2 3 4 5

Title Theory Methodology / Procedure Process Flow Diagram (PFD) Workbook Results TOTAL MARKS


Remarks: Checked by: ----------------------------------------------------------------( DR JAGANNATHAN KRISHNAN) ) Date:

Rechecked by:

( Date:

THEORY Given process: Process 1: Non-recycle process One of the routes to produce ethyl chloride is by the gas phase reaction of HCL with ethylene over the copper chloride catalyst supported on silica:

In this process, the feed stream is composed of 50 mol% HCl, 48 mol% C 2H4 and 2mol % N2 at 100 kmol/hr at 25oC and 1 atm.the reaction only achived 90% conversion of HCl. Outlet flowrate from the reactor is 56.8 kmol/hr with the mole fraction are as listed below:HYDRO-01 ETHYL-01 ETHYL-02 NITRO-01 0.1197 0.0845 0.7606 0.0352

The separation process is operated at atmospheric pressure and pressure drop along the process is ignored. The separator temperature I -93.8oC Bottom product at the separation process is totally pure ethyl chloride with the amount of 43.2 kmol/hr. The purity at the bottom product must achieve at least 95%. Process 1: Recycle process Total vapour outlet from the separator is 13.6 kmol/hr with the mole fraction are as listed below:HYDRO-01 ETHYL-01 NITRO-01 0.5 0.3529 0.1471

To prevent the accumulation of inert in the system,10 kmol/hr pure inert is withdrawn in a purge stream. The balance from the purge being recycles to the feed stream, with the split ratio of 0.9.

PROCEDURE 1. The Hysys was started. From the File tab, a new case is open and components are selected. By choosing ethylene, HCL, ethyl chloride and nitrogen, the component is named as Component List 1. 2. Than Peng-Robinson EOS is added as a fluid package and closed the fluid package. 3. The reactions are click and the conversion is choosing since this I the process of conversion. 4. Three components (ethylene,HCL and ethyl chloride) and Stoich Coeff (-1,1,1) was added. Click basis tab and the value Co of Ethylene as 90 are inserting. 5. Click Enter Simulation Environment and in the object palette select mixture and place it in the process flow diagram (PFD). The same thing was doing to Conversion reactor, Flash Separator, and Tee. 6. Click the Conversion Reactor. Than Global Rxn Set was selected as reaction set. 7. Then the Workbook was open and checks the unit to see if it is in SI units. 8. Workbook was filling with the given condition. Started from the Feed stream: temperature 25oC, pressure 1 atm and molar flow rate 100kmol/h. 9. After that, the flash separator was selected. All the data given was insert. 10.The vapor outlet was crated as Vap nd liq_out as Liquid. 11.To adding the recycle processes do the same procedure as above and change the name of stream to separate non-recycle and recycle. 12. From the vapor outlet, TEE splitter is added. 13.The out stream of TEE are split into 2 stream, Overhead and Bottom 14.At the recycle stream, the recycle tool is added. 15.The outlet stream is mixed with the feed by adding the mixture.

16.From the data of simulation it was answer the question given.

RESULT QUESTION 1. What are the mole fractions for each component at the effluent of the catalytic reactor before and after recycle. Non recycle Mole fraaction vapor liquid With recycle Ethylene 0.0845 0.001992 CLC2 0.7606 0.005253 HCl 0.1197 0.992714 N2 0.0352 0.000041

Mole fraaction vapor liquid

Ethylene 0.0845 0.001988

CLC2 0.7606 0.006388

HCl 0.1197 0.991552

N2 0.0352 0.000071

2. What is other equipment that can replace flash separator to get 100% of ethyl chloride?

The other equipment that can replace flash separator to get 100% of ethyl chloride is Component splitter and distillation column.

3. What is the flow rate of the recycle stream in unit of kgmole/hr? 12.24 kgmole/hr 4. What is the flow rate of the final product after recycling? 43.20 kgmole/hr