Rajshahi University of Engineering & Technology, Bangladesh

Department of Chemical & Food Process Engineering

Report on

Design of a 985 MTPD VCM Plant

Submitted by

Farzana Haque Reeti (1611007) Abdullah-Al-Amin (1611020)

Tahmid Al Refat (1611008) Tandra Ghosh (1611021)

Md. Minhajul Abedin (1611009) S. M. Sohanur Rahman (1611027)

Amartya Kumer Sarker (1611016) Maria Mostari (1611029)

Supervised by
Sajib Dey

Lecturer

Department of Chemical & Food Process Engineering

Rajshahi University of Engineering & Technology

November, 2022

i
 Report on
Design of a 985 MTPD VCM Plant

Submitted by

Farzana Haque Reeti (1611007) Abdullah-Al-Amin (1611020)

Tahmid Al Refat (1611008) Tandra Ghosh (1611021)

Md. Minhajul Abedin (1611009) S. M. Sohanur Rahman (1611027)

Amartya Kumer Sarker (1611016) Maria Mostari (1611029)

Supervised by
Sajib Dey

Lecturer

Department of Chemical & Food Process Engineering

Rajshahi University of Engineering & Technology

November, 2022.

ii
Work Distribution:

Student ID No. Name Individual work Signature

Material Energy
Balance Balance

1611007 Farzana Haque Oxychlorination Heater-2

Reeti reactor (HEAT-201)
(REACT-200)

1611008 Tahmid Al Refat Direct Heater-1

chlorination (HEAT-100)
reactor
(REACT-100)

1611009 Md. Minhajul Extractor Cooler-1

Abedin (EXTRACT- (COOL-304)
300)

1611016 Amartya Kumer Mixer (MIX- Cooler-2

Sarker 302) (COOL-305)

1611020 Abdullah-Al-Amin Mixer (MIX- Heater-4

200) (HEAT- 301)

1611021 Tandra Ghosh Separator (SEP- Pump (P-302)

300)

1611027 S.M. Sohanur Distillation Heater-3

Rahman column (DC- (HEAT-202)
301)

1611029 Maria Mostari Pyrolysis Compressor

reactor (COM-200)
(REACT-300)

iii
Table of Contents

Chapter 1 .................................................................................................................................... 1
Introduction ............................................................................................................................ 2
Chapter 2 .................................................................................................................................... 4
2.1 Definition of the Project .............................................................................................. 5
2.2 Design Basis ................................................................................................................ 6
Chapter 3 .................................................................................................................................... 7
3.1 Processes Available for VCM (Vinyl Chloride Monomer) Production [1] ................ 8
3.2 Direct Chlorination of Ethylene .................................................................................. 9
3.3 Hydrochlorination of Acetylene .................................................................................. 9
3.4 Thermal Cracking of Dichloroethane from Chlorination of Ethylene ........................ 9
3.5 Thermal Cracking of Dichloroethane from Oxychlorination of Ethylene .................. 9
3.6 Process Selection ....................................................................................................... 10
Chapter 4 .................................................................................................................................. 13
Chapter 5 .................................................................................................................................. 15
Chapter 6 .................................................................................................................................. 17
6.1 Direct Chlorination Reactor (REACT-100) .............................................................. 18
6.2 Oxychlorination Reactor (REACT-200) ................................................................... 19
6.3 Pyrolysis Reactor (REACT-300) .............................................................................. 20
6.4 Distillation Column (DC-301) .................................................................................. 21
6.5 Separator (SEP-300) .................................................................................................. 22
6.6 Extractor (EXTRACT – 300) .................................................................................... 23
6.7 Mixer (MIX- 302) ..................................................................................................... 24
6.8 Mixer (MIX-200) ...................................................................................................... 25
Chapter 7 .................................................................................................................................. 26
7.1 Heater-1 (HEAT-100) ............................................................................................... 27
7.2 Heater-2 (HEAT-201) ............................................................................................... 28
7.3 Heater-3 (HEAT-202) ............................................................................................... 30
7.4 Heater-4 (HEAT-301) ............................................................................................... 31
7.5 Cooler 1 (COOL-304) ............................................................................................... 32
7.6 Cooler 2 (COOL-305) ............................................................................................... 34

1
 7.7 Compressor (COM-200) ........................................................................................... 35
7.8 Pump (P-302) ............................................................................................................ 37
Chapter 8 .................................................................................................................................. 38
References ................................................................................................................................ 40

List of Tables
Table 3.1 Assumed Cost of Chemicals Purchased or Sold in Bulk Quantities………………11

Table 3.2 Economic potential analysis……………………………………………………….11

Table 3.3 Gross Profit for Production of Vinyl Chloride…………………………………….11

2
 Chapter 1

Introduction

1
Introduction

Vinyl Chloride Monomer (VCM) is among the largest top twenty petro chemicals (petroleum
- derived chemicals) in world production. Its chemical formula is C2H3Cl.

Vinyl Chloride Monomer (VCM) is a colorless gas which has a pleasant sweet odor. It is
highly toxic and flammable gas at room temperature. At concentrations of about 3.6 percent
VCM in air, VCM can be an explosion hazard. It has a high vapor pressure at ambient
temperature and is therefore manufactured under strict quality and safety control. It is often
stored as a liquid under pressure. The liquid evaporates readily at ambient temperatures. At
high concentrations, it has a sweet odor typical of chlorinated hydrocarbons. VCM vapors
are heavier than air and tend to sink to low areas. It is soluble in water and it’s melting and
boiling points are -153.8°C ( -244.8°F) and -13.4°C ( 7.9°F) respectively.

Vinyl chloride monomer (VCM) is an important chemical intermediate used almost

exclusively to produce polyvinyl chloride (PVC) resins (over 99% globally) which is a very
stable, non-flammable, lightweight, durable plastic. Therefore, VCM follows the PVC market
trend very closely. The vinyl’s chain— ethylene dichloride (EDC), vinyl chloride monomer
(VCM), and polyvinyl chloride (PVC)—is a key component of the global petrochemical and
thermoplastics sectors.

VCM production is based mainly on the ethylene feedstock route. There are actually two
ways to manufacture VCM from ethylene (obtained from thermal cracking); the direct
chlorination method and oxychlorination method.

In the ethylene process, EDC is produced by direct chlorination from chlorine and ethylene,
and in turn cracked to produce VCM. The manufacture of VCM also results in the release of
by-product hydrogen chloride, which is typically recycled to produce EDC by
oxychlorination with additional ethylene. VCM is then polymerized to produce PVC. In the
acetylene process, however, no EDC is involved; instead, VCM is produced directly from
acetylene, which in turn is produced from coal-based calcium carbide.

2
VCM is not sold to household consumers. It is used primarily as a raw material in industrial
operations that manufacture polyvinyl chloride (PVC). The polyvinyl chloride, in turn, is
used widely in products such as:

1. Building materials – siding, roofing, water distribution, irrigation, sewer and

sprinkler pipe, fencing; wire and cable insulation; electrical conduit; floor and wall
coverings, window frames, gutters and downspouts
2. Industrial processes - landfill liners, piping used in food processing, chemical
processing and other manufacturing
3. Medical devices - for blood and intravenous bags, kidney dialysis and blood
transfusions, cardiac catheters, endotracheal tubes, artificial heart valves and many
others
4. Automotive components - for body side mouldings, interior upholstery, under-the
hood wiring, under-the-car abrasion coatings, floor mats, dashboards and arm rests
5. Electronics – components in air conditioners, floppy disks, components, housings,
keyboards, phone systems, computers, power tools, electrical cords, refrigerators,
fibre optics, washers
6. Toys - for rigid and flexible parts
7. Packaging materials - for flexible food wrap, shrink wrap, jar lids and can linings;
and for rigid blister and clamshell packaging, and bottles to store household,
personal care products, and automotive lubricants.

VCM has very high demand globally. About 13 million metric tons of VCM are produced
every year. Its demand in Bangladesh is also increasing. VCM as well as PVC can be
produced from the available natural gas in the country which will fulfill the local demand as
well as earn foreign currency by exporting PVC.

3
 Chapter 2

Project Definition and Design Basis

4
2.1 Definition of the Project

A vinyl chloride manufacturing plant will be set up at Narayanganj district in the division of
Dhaka, Bangladesh, that will use ethylene, chlorine, hydrochloric acid to produce 985 metric
ton of vinyl chloride monomer (VCM) per day; corresponding to 3,25,050 metric ton per year
considering the plant operates for 330 days a year; including all off sites, auxiliaries, utilities
and supporting facilities.

5
2.2 Design Basis

Meteorological Data for This Site

• Highest temperature – 36.11℃ (June)

• Average annual temperature −30℃
• Lowest temperature −<23.41℃

• Minimum average monthly rainfall – 1 mm

• Annual rainfall – 200mm
• Maximum average monthly rainfall – 15.03 mm

• Minimum humidity –49.16%

• Average annual humidity– 61.01%
• Maximum humidity– 67.01%

• Average wind speed – 10.9 km/h (July)

• Maximum wind speed – 22.4 km/h

• Maximum barometric pressure – 1014 mb

• Minimum barometric pressure – 1012 mb

Climatic Condition

• Maximum dry bulb temperature in summer – 36.11°C

• Maximum wet bulb temperature in summer – 29°C
• Minimum dry bulb temperature in winter – 23.41°C

Raw Material

Ethylene, chlorine will be obtained from Japan- LG Chem Ltd., oxygen from Linde,
Bangladesh, hydrochloric acid from Asm Chemical Industries Ltd and lastly water will be
collected from Sitalakhya River, Narayanganj.

6
 Chapter 3

Process Selection and Description

7
3.1 Processes Available for VCM (Vinyl Chloride Monomer) Production [1]
Some of the processes used for production of VCM are mentioned below –

• Direct Chlorination of Ethylene

• Hydrochlorination of Acetylene
• Thermal Cracking of Dichloroethane from Chlorination of Ethylene
• Thermal Cracking of Dichloroethane from Oxychlorination of Ethylene
• Balanced Process for Chlorination of Ethylene

8
3.2 Direct Chlorination of Ethylene
C2H4 + Cl2 → C2H3Cl + HCl (4.1)

This reaction appears to be an attractive solution to design alternative 2. It occurs

spontaneously at a few hundred degrees Celsius, but unfortunately does not give a high yield
of vinyl chloride without simultaneously producing large amounts of byproducts such as
dichloroethylene. Another disadvantage is that one of the two atoms of expensive chlorine is
consumed to produce the byproduct hydrogen chloride, which may not be sold easily.

3.3 Hydrochlorination of Acetylene

C2H2 + HCl → C2H3Cl (4.2)

This exothermic reaction is a potential solution for the concept denoted as alternative 3. It
provides a good conversion (98%) of acetylene to vinyl chloride at 150°C in the presence of
mercuric chloride (HgCl2) catalyst impregnated in activated carbon at atmospheric pressure.
These are fairly moderate reaction conditions, and hence, this reaction deserves further study.

3.4 Thermal Cracking of Dichloroethane from Chlorination of Ethylene

C2H4 + Cl2 → C2H4Cl2 (4.3)

C2H4Cl2 → C2H3Cl + HCl (4.4)

C2H4 + Cl2 → C2H3Cl + HCl (overall) (4.1)

The sum of reactions (4.3) and (4.4) is equal to reaction (4.1). This two-step reaction path
has the advantage that the conversion of ethylene to 1,2-dichloroethane in exothermic
reaction (4.3) is about 98% at 90°C and 1 atm with a Friedel– Crafts catalyst such as ferric
chloride (FeCl3). Then, the dichloroethane intermediate is converted to vinyl chloride by
thermal cracking according to the endothermic reaction (4.4), which occurs spontaneously at
500°C and has conversions as high as 65%. The overall reaction presumes that the unreacted
dichloroethane is recovered entirely from the vinyl chloride and hydrogen chloride and
recycled. This reaction path has the advantage that it does not produce dichloroethylene in
significant quantities, but it shares the disadvantage with reaction path 1 of producing HCl. It
deserves further examination as a solution to design alternative 2.

3.5 Thermal Cracking of Dichloroethane from Oxychlorination of Ethylene

C2H4 + 2HCl + ½ O2 → C2H4Cl2 + H2O (4.5)

C2H4Cl2 → C2H3Cl + HCl (4.4)

C2H4 + HCl + ½ O2 → C2H3Cl + H2O (overall) (4.6)

9
In reaction (4.5), which oxychlorinates ethylene to produce 1,2-dichloroethane, HCl is the
source of chlorine. This highly exothermic reaction achieves a 95% conversion of ethylene to
dichloroethane at 250°C in the presence of cupric chloride (CuCl2) catalyst, and is an
excellent candidate when the cost of HCl is low. As in reaction path 3,the dichloroethane is
cracked to vinylchloride in a pyrolysis step. This reaction path should be considered also as a
solution for design alternative 3.

3.6 Balanced Process for Chlorination of Ethylene

C2H4 + Cl2 → C2H4Cl2 (4.3)

C2H4 + 2HCl + ½ O2 → C2H4Cl2 + H2O (4.5)

2C2H4Cl2 → 2C2H3Cl + 2HCl (4.4)

2C2H4 + Cl2 + ½ O2 → 2C2H3Cl + H2O (overall) (4.7)

This reaction path combines paths 3 and 4. It has the advantage of converting both atoms of
the chlorine moleculeto vinyl chloride. All ofthe HCl produced in the pyrolysis reaction is
consumed in the oxychlorination reaction. Indeed, it is a fine candidate for the solution of
design alternative 2.

3.6 Process Selection

Given this information, it seems clear that the design team would reject reaction path 1 on the
basis of its low selectivity with respect to the competing reactions (not shown) that produce
undesirable byproducts. This leaves the other reaction paths as potentially attractive to be
screened on the basis of the chemical prices. Although it is too early to estimate the cost of
the equipment and its operation, before the remaining process operations are in place, the
design team normally computes the gross profit (i.e., the profit excluding the costs of
equipment and the operating costs) for each reaction path and uses it as a vehicle for
screening out those that cannot be profitable. To illustrate this process for the production of
vinyl chloride, Table 4.2 provides a representative set of prices for the principal chemicals,
obtained from a source such as the ICIS Business Americas (formerly the Chemical
Marketing Reporter), as discussed earlier. The gross profit is computed as the income derived
from the sales of the products and byproducts less the cost of the raw materials. It is
computed by first converting to a mass basis, as illustrated for reaction path 3:

10
 Table 3.1 Assumed Cost of Chemicals Purchased or Sold in Bulk Quantities

Chemical Cost (cents/lb)

Ethylene 30

Acetylene 80

Chlorine 18

Vinyl chloride 35

Hydrogen chloride 25

Water 0

Oxygen (air) 0

Table 3.2 Economic potential analysis

C2H4 + Cl2 = C2H3Cl + HCl

Lbmol 1 1 1 1
Molecular weight 28.05 70.91 62.50 36.46
Lb 28.05 70.91 62.50 36.46
lb/lb of vinyl chloride 0.449 1.134 1 0.583
cents/lb 30 18 35 25

Table 3.3 Gross Profit for Production of Vinyl Chloride

(Based on Chemical Prices in Table 3.1)

Reaction path Overall reaction Gross profit (cents/lb of vinyl

chloride)

2 C2H2+ HCl = C2H3Cl -16.00

3 C2H4+ Cl2 = C2H3Cl = HCl 15.69

4 C2H4 + HCl + ½ O2 = C2H3Cl + H2O 6.96

5 2C2H4 + Cl2 + ½ O2 = 2C2H3Cl + H2O 11.32

Then, the gross profit is 35(1) + 25(0.583) – 30(0.449) – 18(1.134) = 15.69 cents/lb of vinyl
chloride. Similar estimates are made for the overall reaction in each of the reaction paths, it
being assumed that complete conversion can be achieved without any side reactions (not
shown), with the result shown in Table 3.3. Even without the capital costs (for construction of
the plant, purchase of land, etc.) and the operating costs (for labor, steam, electricity, etc.),

11
the gross profit for reaction path 2 is negative, he gross profits for the other reaction paths are
positive. This is principally because acetylene is very expensive relative to ethylene. The
fairly high price of HCl also contributes to the inevitable conclusion that vinyl chloride
cannot be produced profitably using this reaction path.

It should be noted that the price of HCl is often very sensitive to its availability in a
petrochemical complex. In some situations, it may be available in large quantities as a
byproduct from another process at very low cost. At a much lower price, reaction path 2
would have a positive gross profit, but would not be worthy of further consideration when
compared with the three reaction paths involving ethylene. Turning to these paths, all have
sufficiently positive gross profits, and hence are worthy of further consideration. It is noted
that the price of HCl strongly influences the gross profits of reaction paths 3 and 4, with the
gross profit of reaction path 5 midway between the two. Before proceeding with the
synthesis, the design team would be advised to examine how the gross profits vary with the
price of HCl.

Here, economic potential in path 3 is highest. So this is the most suitable path.

12
 Chapter 4

Process Block Diagram

13
 PROCESS BLOCK DIAGRAM OF 985 MTPD VCM PLANT

Light key

Direct
Cl2 Mixer 1 Heater 1 Cooler 1 Mixer 3 Flash
chlorination
separator
Reactor

splitter
C2H4 Cooler 2

Water
Oxychlorination
Air Mixer 2 Compressor Heater 2
Reactor Pump 1

Reboiler
Heater 4 absorber Extractor
HCL

Cooler 3 Pyrolysis Heater 3 Pump 2

Reactor
Distillation Water
Column-1
VCM Storage tank

Distillation
Valve Column-2 EDC Recycled

Heater

14
 Chapter 5

Process Flow Diagram

15
16
 Chapter 6

Material Balance

17
6.1 Direct Chlorination Reactor (REACT-100)

CH2=CH2 + Cl2 ClCH2 -ClCH2

60℃
ṅ1 kg mole E/h
433.955 kg mole E/h 152 kPa
ṅ2 kg mole EDC/h
368 kg mole Cl/h
ṅ3 kg mole Cl/h

Additional Information [2]

84.795% conversion of ethylene,

(433.955 − ṅ1)
= 0.84795
433.955
⸫ ṅ1 = 65.9829 kg mole E/h

Ethylene Balance

433.955 = ṅ1+ cons. E

⸫ Cons. E = 433.955 - 65.9829 = 367.9721 kg mole E/h

EDC Balance

Gen. EDC = ṅ2

⸫ ṅ2=467.9721 kgmole EDC/h

Cl Balance

368 = ṅ3 + cons. Cl

⸫ ṅ3 = 368 - 367.971 = 0.079 kgmole Cl/h

18
6.2 Oxychlorination Reactor (REACT-200)

CH2=CH2 + 2 HCl + 0.5 O2 ClCH2-CH2Cl + H2O

225℃

331.4858 kg mole E/h 405.3 kPa ṅ1 kg mole E/h

656.9971 kg mole HCl/h ṅ2 kg mole EDC/h
210 kg mole O2/h ṅ3 kg mole O2/h
5.9718 kg mole VCM/h ṅ4 kg mole H2O/h
790 kg mole N2/h ṅ5 kgmole VCM/h
ṅ5 kg mole N2/h

H2O Balance

Gen. H2O = ṅ4 = 328.4986 kg mole H2O/h

EDC Balance

Gen. EDC = ṅ2= 328.4896 kg mole EDC/h

Oxygen balance

210= ṅ3+ cons. O2

210= ṅ3+ 164.249

⸫ ṅ3 = 45.7507 kgmole O2/h

Ethylene balance

331.485 = ṅ1 + cons. E

331.4845 = ṅ1 + 328.4986

⸫ ṅ1 = 2.9859 kgmole E/h

Nitrogen Balance

ṅ5 = 790 kg mole N2/h

19
6.3 Pyrolysis Reactor (REACT-300)
Δ
2 ClCH2-CH2Cl 2 CH2 = CHCl + 2 HCl

550℃

1116.6510 kg mole EDC/h 2643 kPa ṅ1 kg mole EDC/h

10.8411 kg mole H2O/h ṅ2 kg mole HCl/h
ṅ3 kg mole H2O/h
ṅ4 kg mole VCM/h

Additional Information [3]

Conversion of EDC is 59.23%,

(1116.6510 − ṅ1)
= 0.0.5923
1116.6510
⸫ ṅ1 = 455.2586 kg mole EDC/h

EDC balance

1116.6510 = 455.2586 + cons. EDC

⸫Cons. EDC = 661.3924 kg mole EDC/h

HCl balance

Gen. HCl = ṅ2 = cons. EDC = 661.3924 kgmole HCl/h

VCM balance

Gen. VCM = ṅ4 = cons. EDC = 661.3924 kgmole VCM/h

20
6.4 Distillation Column (DC-301) ṅ1 kg mole/h
0.0062 kg mole E/kg mole
0.6608kg mole EDC/kg mole
0.0005 kg mole O2/kg mole
0.3149 kg mole H2O/kg mole
0.0137 kg mole VCM/kg mole
Distillation 0.0038 kg mole N2/kg mole
Column
1.5595 kg mole E/h
0.009 kg mole Cl/h
1.284 kg mole EDC/h
0.1325 kg mole O2/h
90.6596 kg mole H2O/h
3.4836 kg mole VCM/h ṅ2 kg mole/h
0.9608 kg mole N2/h
0.9904 kg mole EDC/kg mole
0.0096 kg mole H2O/kg mole

EDC balance

1284.141= ṅ1 × 0.6608 + ṅ2× 0.9904

H2O balance

90.6596= ṅ1× 0.3149+ ṅ2× 0.0096

Solving two simultaneous equations,

⸫ ṅ1= 253.84 kg mole/h

⸫ ṅ2= 1127.43 kg mole/h

21
6.5 Separator (SEP-300)
68.9630 kgmole E/h
0.0222 kgmole Cl/h
31.1684 kgmole EDC/h
45.75 kgmole O2/h
SEP-300 10.5807 kgmole H2O/h
70.5246 kgmole E/h 5.9886 kgmole VCM/h
0.0312 kgmole Cl/h 789.9916 kgmole N2/h
1315.315 kgmole EDC/h
45.8825 kgmole O2/h
15.4499 kgmole H2O/h
9.4722 kgmole VCM/h
790.9556 kgmole N2/h
ṅ1 kg mole E/h
ṅ2 kg mole Cl/h
ṅ3 kg mole EDC/h
ṅ4 kg mole O2/h
ṅ5 kg mole H2O/h
ṅ6 kg mole VCM/h
ṅ7 kg mole N2/h

ṅ1 = 70.5246-68.9630 = 1.5595 kg mole E/h

Similarly,

ṅ2 = 0.0090 kg mole Cl/h

ṅ3 = 1284.1472 kg mole EDC/h

ṅ4 = 0.1325 kg mole O2/h

ṅ5 = 404.8692 kg mole H2O/h

ṅ6 = 3.4836 kg mole VCM/h

ṅ7 = 0.9640 kg mole N2/h

22
6.6 Extractor (EXTRACT – 300)

100 kg mole H2O/h 1.5595 kg mole E/h

0.0090 kg mole Cl/h
1284.1412 kg mole EDC/h
0.1325 kg mole O2/h
Extractor 90.6596 kg mole H2O/h
3.4836 kg mole VCM/h
0.9608 kg mole N2/h
1.5595 kg mole E/h
0.0090 kg mole Cl/h
1284.1472 kg mole EDC/h
0.1325 kg mole O2/h
404.8692 kg mole H2O/h
3.4836 kg mole VCM/h
0.9640 kg mole N2/h ṅ1 kg mole EDC/h
ṅ2 kg mole H2O/h
ṅ3 kg mole N2/h

EDC Balance

⸫ ṅ1 = 1284.1472 - 1284.1412 = 0.0062 kg mole EDC/h

H2O Balance

⸫ ṅ2 = 100 + 404.8692 - 90.6596 = 414.2096 kg mole H2O/h

Nitrogen Balance

⸫ ṅ3 = 0.9640 – 0.9608 = 3.2× 10-3 kg mole N2/h

23
6.7 Mixer (MIX- 302)

434 kg mole/h ṅ1 kg mole/h

1502 kg mole/h
MIX-302
252.1 kg mole/h
459.8 kg mole/h

Overall Mass Balance

ṅ1 = 434 + 1502 + 252.1 + 459.8 = 2647.9 kg mole/h

24
 6.8 Mixer (MIX-200)

331.5 kg mole/h
Mixer ṅ1 kg mole/h

1000 kg mole/h

663 kg mole / h

Overall Balance:

ṅ1= (331.5 + 1000 + 663) = 1994.5 kg mole/h

25
 Chapter 7

Energy Balance

26
7.1 Heater-1 (HEAT-100)

Stream 3 Stream R1_heated feed

24.96°C 60°C

Heater-1

433.9555 kg mole E/h 433.9555 kg mole E/h

368 kg mole Cl2/h 368 kg mole Cl2/h

Reference: Ethylene (E), Chlorine (Cl2) at 24.96°C [4]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

Ethylene (E) 433.955 0 433.955 H1

Chlorine (Cl2) 368 0 368 H2

60
H1 = ∫24.96(40.75 × 10−3 + 11.47 × 10−5 𝑇 − 6.891 × 10−8 𝑇 2 + 17.66 × 10−12 𝑇 3 )𝑑𝑇

= 1.594 kJ/ mole

60
H2 = ∫24.96(33.60 × 10−3 + 1.367 × 10−5 𝑇 − 1.607 × 10−8 𝑇 2 + 6.473 × 10−12 𝑇 3 )𝑑𝑇

= 1.196 kJ/ mole

Q = ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛

= (433.955 × 1.594 + 368 × 1.196) × 103

= 1.132 × 106 kJ/ h

27
7.2 Heater-2 (HEAT-201)

Stream 5 Stream R2_heated feed

129.2°C 225°C
Heater-2

331.4845 kg mole E/h 331.4845 kg mole E/h

656.9971 kg mole Cl2/h 656.9971 kg mole Cl2/h

210 kg mole O2/h 210 kg mole O2/h

5.9718 kg mole VCM/h 5.9718 kg mole VCM/h

790 kg mole N2/h 790 kg mole N2/h

Reference: Ethylene (E), Chlorine (Cl2) at 129.2°C [4], Cp of VCM at 25°C = 0.05947
kJ/mole°C [5]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

Ethylene (E) 331.4845 0 333.4845 H1

HCl 656.9971 0 656.9971 H2

Oxygen (O2) 210 0 210 H3

VCM 5.9718 0 5.9718 H4

Niotrogen (N2) 790 0 790 H5

225
H1 = ∫129.2(40.75 × 10−3 + 11.47 × 10−5 𝑇 − 6.891 × 10−8 𝑇 2 + 17.66 × 10−12 𝑇 3 )𝑑𝑇

= 5.64 kJ/ mole

225
H2 = ∫129.2(29.13 × 10−3 − 0.1341 × 10−5 𝑇 + 0.9715 × 10−8 𝑇 2 − 4.335 × 10−12 𝑇 3 )𝑑𝑇

= 2.8 kJ/ mole

225
H3 = ∫129.2(29.10 × 10−3 + 1.158 × 10−5 𝑇 − 0.6076 × 10−8 𝑇 2 + 1.311 × 10−12 𝑇 3 )𝑑𝑇

= 2.97 kJ/ mole

28
 25 225
H4 = ∫129.2 0.05947 𝑑𝑇+∫25 0.05947 𝑑𝑇

= -6.197+11.894

= 5.697 kJ/ mole

225
H5 = ∫129.2(29 × 10−3 + 0.2199 × 10−5 𝑇 + 0.5723 × 10−8 𝑇 2 − 2.871 × 10−12 𝑇 3 )𝑑𝑇

= 2.83 kJ/ mole

Q = ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛

= (5.64 × 331.4845 + 2.8 × 656.9971 + 2.97 × 210 + 5.697 × 5.9718 + 2.83 ×

790) × 103

= 6.6 × 106 kJ/ h

29
7.3 Heater-3 (HEAT-202)

Stream HCl Stream 22

-16.9°C 26°C

Heater-3

661.3045 kg mole HCl/h 661.3045 kg mole HCl/h

6.0569 kg mole VCM/h 6.0569 kg mole VCM/h

Reference: HCl, VCM (C2H3Cl) at -16.9°C [4]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

HCl 661.3045 0 661.3045 H1

VCM (C2H3Cl) 6.0569 0 6.0569 H2

−85
H1 = ∫−16.9(29.13 × 10−3 − 0.1349 × 10−5 𝑇 + 0.9715 × 10−8 𝑇 2 − 4.335 × 10−12 𝑇 3 )𝑑𝑇

−26
+ 16.1 + ∫−85 (29.13 × 10−3 − 0.1341 × 10−5 𝑇 + 0.9715 × 10−8 𝑇 2 − 4.335 ×
10−12 𝑇 3 )𝑑𝑇

= − 1.99 + 16.1 + 3.24

= 17.35 kJ/ mole

−15 26
H2 = ∫−16.9 0.05947 𝑑𝑇 + 22.9 + ∫−15 0.05947 𝑑𝑇

= 0.113+22.9+2.438

= 25.451 kJ/ mole

Q = ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛

= [(17.35 × 661.3045) + (25.451 × 6.0569)] × 103

= 11.63 × 106 kJ/ h

30
7.4 Heater-4 (HEAT-301)

Stream 17 Stream R3_Heated Feed

138.4°C 550°C

Heater-4

1116.6510 kg mole EDC/h 1116.6510 kg mole EDC/h

10.8411 kg mole H2O/h 10.8411 kg mole H2O/h

Reference: EDC (C2H4Cl2), H2O at 138.4°C [4], Hv of EDC= 34.8 kJ/mol [6]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

EDC (C2H4Cl2) 1116.6510 0 1116.6510 H1

H2O 10.8411 0 10.8411 H2

21 550
H1 = ∫138.4 0.1294 𝑑𝑇 – 34.8 + ∫21 0.1294 𝑑𝑇

= −11.192 − 34.8 + 68.4526

= 88.06 kJ/ mole

100 550
H2 = ∫138.4 75.4 𝑑𝑇 +40.656 + ∫100 75.4 𝑑𝑇

= −2895.36 + 40.656 + 30160

= 27305.296 kJ/ mole

Q = ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛

= (88.06 × 1116.6510 + 27305.296 × 10.8411) × 103

= 394.28 × 106 kJ/ h

31
7.5 Cooler 1 (COOL-304)

Stream 19 Stream 20

186°C 50°C

Cooler 1

455.2805 kg mole EDC/h 455.2805 kg mole EDC/h

661.3706 kg mole HCL/h 661.3706 kg mole HCL/h
10.8411kg mole H2O/h 10.8411kg mole H2O/h
661.3706 kg mole VCM/h 661.3706 kg mole
VCM/h

Reference: EDC (C2H4Cl2), HCl, H2O, VCM (C2H3Cl) at 186°C [4], Hv of VCM = 40.656
kJ/mole [6], Cp of EDC at 21°C = 0.1294 kJ/mole°C [7]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

EDC (C2H4Cl2) 455.2791 0 455.2791 H1

H2O 7.53 0 7.53 H2

VCM (C2H3Cl) 0.0655 0 0.0655 H3

21 50
H1 = ∫186 0.1294 𝑑𝑇 − 34.8 + ∫21 0.1294 𝑑𝑇

= −21.351 − 34.8 + 3.7526

= −52.3984 kJ/ mole

−85
H2 = ∫186 (29.13 × 10−3 − 0.1341 × 10−5 𝑇 + 0.9715 × 10−8 𝑇 2 − 4.335 × 10−12 𝑇 3 )𝑑𝑇

−50
−16.1 + ∫−85 (29.13 × 10−3 − 0.1341 × 10−5 𝑇 + 0.9715 × 10−8 𝑇 2 − 4.335 ×
10−12 𝑇 3 )𝑑𝑇

= − 17.897 − 16.1 + 3.94 = −20.057 kJ/ mole

32
 100
H3 = ∫186 (33.46 × 10−3 + 0.6880 × 10−5 𝑇 + 0.7604 × 10−8 𝑇 2 − 3.593 × 10−12 𝑇 3 )𝑑𝑇

50
−40.656 + ∫100(33.46 × 10−3 − 0.6880 × 10−5 𝑇 + 0.7604 × 10−8 𝑇 2 −
3.593 × 10−12 𝑇 3 )𝑑𝑇

= − 2.975 − 40.656 + 1.7

= −45.331 kJ/ mole

−15 50
H4 = ∫186 0.05947 𝑑𝑇 – 22.9 + ∫−15 0.05947 𝑑𝑇

= −11.953 − 22.9 + 3.87

= −30.983 kJ/ mole

Q = ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛 − ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡

= 0 − [(−52.3984 × 455.2805) + (−20.057 × 661.3706) + (−45.331 × 10.8411) +

(−45.331 × 10.8411) + (−30.983 × 661.3706)] × 103

= 58.104 × 106 kJ/ h

33
7.6 Cooler 2 (COOL-305)

Stream EDC Stream 21

144.2°C 90°C
Cooler 2

455.2791 kg mole EDC/h 455.2791 kg mole EDC/h

7.53 kg mole H2O/h 7.53 kg mole H2O/h
0.0655 kg mole VCM/h 0.0655 kg mole VCM/h

Reference: EDC (C2H4Cl2), H2O, VCM (C2H3Cl) at 144.2°C [4]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

EDC (C2H4Cl2) 455.2791 0 455.2791 H1

H2O 7.53 0 7.53 H2

VCM (C2H3Cl) 0.0655 0 0.0655 H3

25 90
H1 = ∫144.2 0.1294 𝑑𝑇 + ∫25 0.1294 𝑑𝑇

= -15.424 + 8.411

= -7.013 kJ/ mole

90
H2 = ∫144.2 75.4 𝑑𝑇

= -4086.68 kJ/ mole

25 90
H3 = ∫144.2 0.05947 𝑑𝑇 + ∫25 0.05947 𝑑𝑇

= -7.08 + 3.87

= -3.21 kJ/ mole

Q = ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛 − ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡

= 0 − [(−7.013 × 455.2791) + (−4086.68 × 7.53) + (−3.21 × 0.0655)] × 103

= 33.96 × 106 kJ/ h

34
7.7 Compressor (COM-200)

Stream 4 Stream 5

152 kPa 405.3 kPa

18.49°C 129.2°C
Compressor

331.4845 kg mole E/h 331.4845 kg mole E/h

656.9971 kg mole Cl2/h 656.9971 kg mole Cl2/h
210 kg mole O2/h 210 kg mole O2/h
5.9718 kg mole VCM/h 5.9718 kg mole VCM/h
790 kg mole N2/h 790 kg mole N2/h

Reference: Ethylene (E), Chlorine (Cl2) at 24.96°C [4]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

Ethylene (E) 331.4845 0 333.4845 H1

HCl 656.9971 0 656.9971 H2

Oxygen (O2) 210 0 210 H3

VCM 5.9718 0 5.9718 H4

Niotrogen (N2) 790 0 790 H5

129.2
H1 = ∫18.49 (40.75 × 10−3 + 11.47 × 10−5 𝑇 − 6.891 × 10−8 𝑇 2 + 17.66 × 10−12 𝑇 3 )𝑑𝑇

= 5.4 kJ/ mole

129.2
H2 = ∫18.49 (29.13 × 10−3 − 0.1341 × 10−5 𝑇 + 0.9715 × 10−8 𝑇 2 − 4.335 × 10−12 𝑇 3 )𝑑𝑇

= 3.22 kJ/ mole

129.2
H3 = ∫18.49 (29.10 × 10−3 + 1.158 × 10−5 𝑇 − 0.6076 × 10−8 𝑇 2 + 1.311 × 10−12 𝑇 3 )𝑑𝑇

= 3.31 kJ/ mole

35
 25 129.2
H4 = ∫18.49 0.05947 𝑑𝑇+∫25 0.05947 𝑑𝑇

= 0.387+ 6.197

= 6.58 kJ/ mole

129.2
H5 = ∫18.49 (29 × 10−3 + 0.2199 × 10−5 𝑇 + 0.5723 × 10−8 𝑇 2 − 2.871 × 10−12 𝑇 3 )𝑑𝑇

= 3.21 kJ/ mole

Power to the compressor = ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛

= (5.4 × 331.4845 + 3.22 × 656.9971 + 3.31 × 210 +

6.58 × 5.9718 + 3.21 × 790) × 103

= 7.18 × 106 kJ/ h

= 1993.29 KW

36
7.8 Pump (P-302)

Stream 16 Stream 17

136.9°C 138.4°C
Pump

1116.6510 kg mole EDC/h 1116.6510 kg mole EDC/h

10.8411 kg mole H2O/h 10.8411 kg mole H2O/h

Reference: EDC (C2H4Cl2), H2O at 136.9°C [4]

Substance nin (kmol/h) Hin (kJ/mol) nout (kmol/h) Hout (kJ/mol)

EDC (C2H4Cl2) 1116.6510 0 1116.6510 H1

H2O 10.8411 0 10.8411 H2

138.4
H1 = ∫136.9 0.1294 𝑑𝑇

= 0.1941kJ/ mole
138.4
H2 = ∫136.9 75.4 𝑑𝑇

= 113.1 kJ/ mole

Q = ∑ 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 𝐻𝑖𝑛

= (0.1941 × 1116.6510 + 113.1 × 10.8411) × 103

= 3.4 × 105 kJ/ h

37
 Chapter 8

List of Equipments

38
List of Equipment

Type of Equipment Tag Number Total Number of Units

Reactor REACT-100, REACT-200, 3
REACT-300
Heater HEAT-100, HEAT-201, 5
HEAT-202, HEAT-301,
HEAT-302
Cooler COOL-301, COOL-302, 5
COOL-303, COOL-304,
COOL-305
Mixer MIX-100, MIX-200, MIX- 4
301, MIX-302
Distillation Column DC-301, DC-302, DC-303 3
Pump P-301, P-302 2
Extractor EXTRACT-300 1
Separator SEP-300 1
Compressor COM-200 1
Decanter DECANT-100 1

*Tag number convention

Chlorination section (starting with digit 1)
Oxychlorination section (starting with digit 2)
Pyrolysis and purification section (starting with digit 3)

39
References

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[3] H. Zhao et al., “Catalytic Dehydrochlorination of 1,2-Dichloroethane into Vinyl
Chloride over Nitrogen-Doped Activated Carbon,” ACS Omega, vol. 4, no. 1, pp.
2081–2089, 2019, doi: 10.1021/acsomega.8b01622.
[4] Suparyanto dan Rosad (2015, Elementary Principles of Chemical Processes, vol. 5, no.
3. 2020.
[5] B. V. Lebedev, I. B. Rabinovich, and V. A. Budarina, “Heat capacity of vinyl chloride,
polyvinylchloride and polyvinylidene chloride in the region of 60-300°K,” Polym. Sci.
U.S.S.R., vol. 9, no. 3, pp. 545–552, 1967, doi: 10.1016/0032-3950(67)90073-1.
[6] R. M. Stephenson and S. Malanowski, Handbook of the Thermodynamics of Organic
Compounds. 1987.
[7] D. Hallén, “Enthalpies of solution and heat capacities for some α,ω-dichloroalkanes in
water,” Journal of Chemical Thermodynamics, vol. 25, no. 4. pp. 519–524, 1993, doi:
10.1006/jcht.1993.1160.

40