Process Description

Raw Material Storage & Handling

The raw materials are obtained from the respective distributors. Intermediate inspection of raw

materials are to be done to prevent mix-ups and prevent the occurrence of unfortunate especially those

that likely to occur because of the mishandling of these materials since they are hazardous. Proper

handling and storage of these materials is strictly followed.

Dehydrochlorination Process Section

The reaction process is carried out with two to ten percent excess of caustic soda and the product

yields a percentage range of 85 to 90 percent. The concentrated caustic soda or the sodium hydroxide is

diluted with water to about 5 to 10 percent weight and it is mixed with the 1,1,2-trichloroethane feed.

After that, it is fed to the dehydrochlorination reactor for the reaction process. The reaction is then carried

out in the liquid phase at about 100 degrees Celsius without using a catalyst. The reason why the reaction

is carried out in a liquid dispersion is because the organic and the aqueous reactants are not miscible. The

dehydrochlorination reactor is continuously purged with nitrogen to prevent the accumulation of impurity

like the monochloroacetylene in the product dichloroethylene. The nitrogen is then discharged from a

vent.

Separator Section

The dichloroethylene-containing product from the dehydrochlorination reactor is separated in an

equipment which is the decanter into an aqueous and organic phase. The aqueous phase which comprises

of sodium hydroxide/sodium chloride solution is then divided. The one fraction of the aqueous phase is

recycled to the reactor of dehydrochlorination and the other part or fraction is steam stripped in order to

remove organics. Then, it is discharged to a wastewater treatment system.

Drying Section
 The organics coming from the aqueous phase are then combined with the organic from the

decanter. The combined organics will be fed to a drying column wherein the bottom stream is the residual

water that is removed. Then, the water that is removed from the drying column is fed to the steam stripper

along with the aqueous stream from the decanter product.

Distillation Section

From the drying column, the organic stream is then fed to a distillation column to remove the

unreacted 1, 1, 2-trichloroethane as an overhead. The unreacted 1, 1, 2-trichloroethane is recycled back to

the dehydrochlorination reactor.

Finishing Section

The purified dichloroethylene product which is removed from the finishing column is either used

onsite or will be stored in a pressurized tanks before being shipped to the consumers.
 22

dichloroethylene
1,1,2-trichloroethane

1 23
N2, monochloroacetylene

TK-1004
19
2
16
P-1001 3

TK-1001 N2 T-1003
NaOH solution 9 20 21
4 15 T-1002
6
TK-1003
14 E-1004
10
17 18
5 7 R-1001 8

P-1002

E-1001 E-1003
TK-1002

T-1001 13 Wastewater effluent

11 12
WW-1001

E-1002
 22.7576
50.0000
22

dichloroethylene
1,1,2-trichloroethane 95.5667 Temperature (°C)
72.7576 23
1
N2, monochloroacetylene Mass Flowrate, kg/day
111.3159
TK-1004
19
2
16
3 404.9887 100
P-1001
25.1014
9.3665
TK-1001 N2 T-1003
NaOH solution 9 20 21
286.6644 47.9248
4 15 T-1002
6
200 TK-1003
14 E-1004
175.8263
10
17 18 100
5 7 R-1001 8 41.6354
293.6728
P-1002

E-1001 E-1003
TK-1002

332.2311

T-1001 13 Wastewater effluent

11 12
WW-1001

E-1002 100
117.8512
 22.7576 tons/day
22

Dichloroethylene, 50 tons/day
1,1,2-trichloroethane, 95.5667 tons/day

1 23
N2, monochloroacetylene 72.7576 tons/day

TK-1004
95.5667 tons/day 19
111.3159 tons/day
2
16

P-1001 3

404.9887 tons/day
TK-1001 N2 T-1003
NaOH solution, 286.6644 tons/day 9 20 21
4 25.1014 tons/day
6 15 T-1002
47.9248 tons/day
TK-1003
14 E-1004
286.6644 tons/day 10
293.6728 tons/day 17 18
5 7 R-1001 8
41.6354 tons/day
P-1002
175.8263 tons/day
E-1001 E-1003
TK-1002

332.2311 tons/day

T-1001 13 Wastewater effluent

11 12
WW-1001
117.8512 tons/day

E-1002
 Component 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1,1,2-trichloroethane 95.5667 95.566 95.566 22.5537 2.2554 5.3517 5.3517 2.255 20.2984 17.202 17.2020
7 7 4 0
NaOH 28.6664 28.6664 28.6664 1.6053 1.6053 1.6053
dichloroethylene 71.1111 7.1111 15.5556 15.5556 7.111 64.0000 55.555 5.5556 50.0000
1 6
NaCl 39.5431 39.5431 39.5431
H2O 257.997 257.9979 257.997 175.826 175.826 270.1754 243.157 117.851 117.851 270.1754 27.0175 27.0175 41.6354 41.6354 25.101 25.101
9 9 3 3 9 2 2 4 4
Total 95.5667 95.566 95.566 286.664 286.6644 286.664 175.826 175.826 404.9887 293.672 117.851 117.851 332.2311 47.9248 9.366 111.315 41.6354 41.6354 72.757 25.101 25.101 22.7576 50.0000
7 7 4 4 3 3 8 2 2 5 9 6 4 4
Code Equipment Capacity Energy Requirement
E-1001 Heat exchanger 175.8263 tons/day
E-1002 Heat exchanger 117.8512 tons/day
E-1003 Heat exchanger 41.6354 tons/day
E-1004 Heat exchanger 25.1014 tons/day
P-1001 Pump with spare pump 95.5667 tons/day
P-1002 Pump with spare pump 286.6644 tons/day
R-1001 Reactor 404.9887 tons/day No energy requirement
T-1001 Stripping column 341.5976 tons/day No energy requirement
T-1002 Drying column 120.6824 tons/day No energy requirement
T-1003 Distillation column 72.7576 tons/day No energy requirement
TK-1001 1,1,2-trichloroethane storage 95.5667 tons/day No energy requirement
TK-1002 NaOH solution storage 286.6644 tons/day No energy requirement
TK-1003 Decanter 404.9887 tons/day No energy requirement
TK-1004 Product storage 50.0000 tons/day No energy requirement
WW-1001 Wastewater treatment 332.2311 tons/day
 Computations

Mass Balance

C 2 H 3 Cl3 + NaOH → H 2 O+ NaCl+ H 2 C=C Cl 2

Stream 1, 2, and 3

Assumption(s)

o The daily production rate is 50tons/day.

o The percent conversion and recovery are 80% and 90%.

o The concentration of NaOH is 10% weight NaOH.

o No formation of monochloroacetylene.

tons 1 kmol 1 kmol C 2 H 3 Cl 3 133.35 kg

50 C2 H 2 Cl 2 × C 2 H 2 Cl2 × × C 2 H 3 Cl3
day 96.9 kg 1kmol C2 H 2 Cl 2 1 kmol tons
mC H Cl3 = =95.5667
2 3
90 % ×80 % day

Stream 4, 5, and 6

tons 1 kmol 1 kmol NaOH 40 kg

50 C 2 H 2 Cl 2 × C 2 H 2 Cl2 × × NaOH
day 96.9 kg 1kmol C2 H 2 Cl 2 1kmol tons
mNaOH = =28.6664
90 % × 80 % day

tons 90 % tons
m H O =28.6664 × =257.9979
2
day 10 % day

Around distillation section

Stream 22
 tons (100 %−90 %) tons
mC H Cl2 =50 × =5.5556
2 2
day 90 % day

tons tons
mC H Cl3 =95.5667 × ( 100 %−80 % ) × 90 %=17.2020
2 3
day day

Stream 19

tons tons tons

mC H Cl2 =50 +5.5556 =55.5556
2 2
day day day

tons tons
mC H Cl3 =95.5667 × ( 100 %−80 % ) × 90 %=17.2020
2 3
day day

Around R-1001
Assumption(s)
o No organic compounds in stream 11
o 80% conversion
o The specific heat of solution and steam are 1.15kJ𝑘𝑔−𝐾 and 2kJ𝑘𝑔−𝐾.
o The initial and final temperature of the heating media (steam) are 200°C and
100°C.
o The initial and final temperature of the solution are 20°C and 100°C.

Stream 9

tons tons tons

mC H
2 3 Cl3 (
= 95.5667
day
+17.2020
day )
× ( 100 %−80 % )=22.5537
day

tons tons 1 kmol 1kmol C2 H 2 Cl 2 96.9 kg

mC H
2 2 Cl2 (
= 95.5667
day
+17.2020
day
× )
133.35 kg
C 2 H 3 Cl 3 × × C H Cl × 80 %=71.11
1kmol C 2 H 3 Cl 3 1 kmol 2 2 2

tons tons tons 1 kmol 1 kmol NaOH 40 kg

mNaOH =28.6664
day (
− 95.5667
day
+17.2020
day )
×
133.35 kg
C 2 H 3 Cl 3 × ×
1 kmol C 2 H 3 Cl 3 1 kmol
NaOH ×8

tons tons 1 kmol 1 kmol NaCl 58.45 kg t

mNaCl = 95.5667 ( day
+17.2020
day )
× C H Cl × ×
133.35 kg 2 3 3 1 kmol C 2 H 3 Cl3 1 kmol
NaCl ×80 %=39.5031
d

tons tons tons 1 kmol 1 kmol H 2 O 18 kg

mH O =257.9979
2
day (
+ 95.5667
day
+17.2020
day )
×
133.35 kg
C 2 H 3 Cl3 × × H O× 80
1kmol C2 H 3 Cl 3 1 kmol 2
Stream 7, and 8

kg kJ K
382.2311 ×1.15 ×(100−20)
day kg−K ℃ tons
mH O (g) = =175.8263
2
kJ K day
2 ×(200−100)
kg−K ℃

Around TK-1003

Assumption(s)

o 90% recovery on organic compounds and 10% of water went with top phase.
o No inorganic compound mixed in stream 18.

Stream 16

tons tons
mC H Cl3 =22.5537 × 90 %=20.2984
2 3
day day

tons tons
mC H Cl2 =71.1111 × 90 %=64.0000
2 2
day day
tons tons
m H O =270.1754 ×10 %=27.0175
2
day day

Stream 10

tons tons
mC H Cl3 =22.5537 ×(100−90 %)=2.2554
2 3
day day

tons tons
mC H Cl2 =71.1111 ×(100−90 %)=7.1111
2 2
day day

tons tons tons 1 kmol 1 kmol NaOH 40 kg

mNaOH =28.6664
day (
− 95.5667
day
+17.2020
day )
×
133.35 kg
C 2 H 3 Cl 3 × ×
1 kmol C 2 H 3 Cl 3 1 kmol
NaOH ×8

tons tons 1 kmol 1 kmol NaCl 58.45 kg t

mNaCl = 95.5667 ( day
+17.2020
day
×)133.35 kg
C2 H 3 Cl 3 × ×
1 kmol C 2 H 3 Cl3 1 kmol
NaCl ×80 %=39.5031
d
 tons tons
m H O =270.1754 ×90 %=243.1579
2
day day

Around T-1001, and T-1002

Assumption(s)

o Stream 15 contains only organic compounds.

Stream 13

tons tons tons tons

mC H Cl3 =2.2554 +20.2984 −17.2020 =5.3517
2 3
day day day day

tons tons tons tons

mC H Cl2 =7.1111 +64.0000 −55.5556 =15.5556
2 2
day day day day

tons tons tons 1 kmol 1 kmol NaOH 40 kg

mNaOH =28.6664
day (
− 95.5667
day
+17.2020
day )
×
133.35 kg
C 2 H 3 Cl 3 × ×
1 kmol C 2 H 3 Cl 3 1 kmol
NaOH ×8

tons tons 1 kmol 1 kmol NaCl 58.45 kg t

mNaCl = 95.5667 ( day
+17.2020
day )
×
133.35 kg
C2 H 3 Cl 3 × ×
1 kmol C 2 H 3 Cl3 1 kmol
NaCl ×80 %=39.5031
d

tons tons tons

m H O =243.1579 + 27.0175 =270.1754
2
day day day

Stream 15
tons tons
mC H Cl3 =22.5537 ×(100−90 %)=2.2554
2 3
day day

tons tons
mC H Cl2 =71.1111 ×(100−90 %)=7.1111
2 2
day day
Stream 14

tons tons tons tons

mC H Cl3 =2.2554 +20.2984 −17.2020 =5.3517
2 3
day day day day

tons tons tons tons

mC H Cl2 =7.1111 +64.0000 −55.5556 =15.5556
2 2
day day day day
 tons tons
m H O =270.1754 ×10 %=27.0175
2
day day

Stream 11, and 12

Assumption(s)

o The specific heat of solution and steam are 1.15kJ/𝑘𝑔−𝐾 and 2kJ/𝑘𝑔−𝐾.
o The initial and final temperature of the heating media (steam) are 120°C and
100°C.
o The initial and final temperature of the solution are 20°C and 32°C.

kg kJ K
341.5976 ×1.15 ×(32−20)
day kg−K ℃ tons
mH O (g) = =117.8512
2
kJ K day
2 ×(120−100)
kg−K ℃

Stream 17, and 18

Assumption(s)

kg kJ K
120.6824 × 1.15 ×(32−20)
day kg−K ℃ tons
mH O (g) = =41.6824
2
kJ K day
2 ×(120−100)
kg−K ℃

Stream 20, and 21

Assumption(s)

kg kJ K
72.7576 ×1.15 ×(32−20)
day kg−K ℃ tons
mH O (g) = =25.1014
2
kJ K day
2 ×(120−100)
kg−K ℃