FINALYEAR

PROJECT
WATER GAS SHIFT REACTION

1
 Project Objectives

Revamping
Designing &
analysis of
simulation of
equipment at
purification
uprated
trains
capacity

Rating &
Capacity
debottlenecki
uprating of
ng of
process
purification
equipment
trains

2
 Project Progress

In Pakistan, EPCL is only fully integrated chloro-vinyl complex and is planning to

increase ethylene dichloride and vinyl chloride monomer production due to
increasing demand of poly vinyl chloride. According to Engro’s 2019 status,
highest ever domestic demand of poly vinyl chloride from Government
projects, increased usage of poly vinyl chloride pipes in agricultural sector,
export of pipes and fittings to Afghanistan.

Current Capacity of EPCL Plant has been increased from 195 kta to 245 kta on
Aspen Plus through rating and sensitivity analysis. Aspen plus has been used to
simulate the current plant production capacity of purification trains at 195 kta
and uprated production capacity 245 kta and stream conditions have been
obtained through running process of plant.

3
 Project Methodology

Literature Review Process Design Equipment Simulation Process Simulation System Rating

Simulation Tool & Fluid Package for Designing

Continuou
Aspen Plus UNIFAC
s Process

4
 Ethylene Based Process of VCM Production
HCL Recycle

Air Oxy- Light Ends

Chlorination

EDC
Ethylene EDC Purification EDC Pyrolysis VCM Purification

Direct EDC Recycle

Chlorination
VCM
Cl2

Heavy Ends
5
Head Column ( AS401COL)

Light Column (AS402COL)

Hi-Boil Column (AS403COL)

Vacuum Column (AS404COL)

Ethylene
Dichloride
Purification
Section (Area 400)
Designing and Rating Analysis

6
 Components Sheet in Area 400
Component Formula Component Formula
Hydrogen H2 Vinylidene Chloride C2H2Cl2
Nitrogen N2 Trans-1,2-Dichloroethylene C2H2Cl2
Oxygen O2 Cis-1,2-Dichloroethylene C2H2Cl2
Ethylene C2H4 1,1-Dichloroethane C2H4Cl2
Hydrogen Chloride HCl Chloroform CHCl3
Carbon Monoxide CO Carbon Tetrachloride CCl4
Carbon Dioxide CO2 Chloroprene C4H5Cl
Methane CH4 Benzene C6H6
Ethane C2H6 Ethylene Dichloride (EDC) C2H4Cl2
Acetylene C2H2 Trichloroethylene C2HCl3
Water H2O 1,1,2-Trichloroethane C2H3Cl3
Chlorine Cl2 Per-chloroethane C2Cl4
Vinyl Chloride (VCM) C2H3Cl Ethyl Chloride C2H5Cl
7
Process Simulation Diagram of Purification Trains in Area 400

8
 Streams Description Sheet in Area 400
Stream Description Stream Symbol Stream Description Stream Symbol

Crude EDC S1 Feed of Decanter S3

Bottom Product of VCM Column S9 Liquid EDC S6
Chlorine Gas S12 Reflux of Head Column S7
Nitrogen Gas S23 Bottom Product of Head Column S8

Total Wash Feed of Decanter S29 Feed of Light Column S11

Water Stream Inlet of Decanter S30 Bottom Product of Light Column S14
Gases Vent of Decanter S4 Discharge of Pump-2 S15
Liquid Water S5 Feed of Hi-Boil Column S16
Vent ofSplitter-1 S10 Hi-Boil Column Side Stream S18
Gases Vent of Light Column S13 Bottoms of Hi-Boil Column S20
Vapors of Hi-Boil Column S17 Discharge of Pump-3 S21
EDC Stock S19 Feed of Vacuum Column S22
Compress Vent Gases of Vacuum Column S25 Vents Gases of Vacuum Column S24

Heavy Ends of Vacuum Column S28 Top Product of Vacuum Column S26
Vapors of Head Column S2 Recycle EDC S27
9
 Equipment Description Sheet in Area 400

Equipment Equipment Equipment Equipment Equipment Equipment Equipment Equipment

Symbol Description Symbol Description Symbol Description Symbol Description
C-1 Heads P-1 Centrifugal H-1 Shell & Tube T-1 Crude EDC Tank
Purification Pump-1 Heat
Train Exchanger-
C-2 Light P-2 Centrifugal H-2 Shell & Tube T-2 EDC Stock Tank
Purification Pump-2 Heat
Train Exchanger

C-3 Hi-Boil P-3 Centrifugal H-3 Shell & Tube D-1 Decanter
Purification Pump-3 Heat
Train Exchanger
C-4 Vacuum P-4 Centrifugal M-1 Static Mixer SP-1 Separator
Purification Pump-4
Train
CM-1 Vacuum            
Vent Gases
Compressor
10
 Number of Stages (70)

Fluid Package (UNIFAC)

EDC Purity (99%)

Reboiler (Thermosiphon)

HEADS
COLUMN
OPERATION
Design and Rating Analysis

11
 HEADS Column (AS401) Simulation Diagram

Water-EDC Azeotrope and Lights removed as vent.

light components.

Separation of organic and

inorganic phases.

Crude-wet EDC enters

the column as feed.

12
 Heads COLUMN
Number of Trays 70  
Diameter of Column 2.5 m
Height of Column 61.2 m
Head Loss 5.6 m
Material of Construction Carbon Steel  
     
Section Geometry
Property Value Unit
Tray type SIEVE  
Number of passes 1  

Hydraulic Design Hole area / Active area.

Deck gauge thickness value
0.1
0.003
m2
m

Heads Purification Train Cross-sectional area

Active area
4.90
3.95
m2
m2
Net area 4.43 m2
Diameter 2.5 m
Tray spacing 0.9 m
Hole diameter 0.01 m
Tray Geometry
Property Side Unit
Down comer area top 0.38 m2
Down comer area bottom 0.38 m2
Down comer clearance 0.05 m
Down comer width top 0.47 m
Down comer width bottom 0.47 m
Weir Geometry
Property Side Unit
Weir height 0.07 m
Weir length 1.8 m
13
 Thermal Design Specification Sheet
Heads Purification Train
Parameters
 

Condenser None
Reboiler Thermosyphon
Valid Phase Vapor-Liquid

Thermal Design Convergence

Strongly
Non-Ideal Liquid
Heads Purification Train
Condenser Pressure 9.8 psi

Reboiler Outlet
Temperature 109.86 C

Operating Condition Before uprating After uprating

Condenser Duty 3570.68 kW 4402.19 kW

Reboiler Duty 4887.31 kW 6013.46 kW
Pressure Drop 8.29 psi 9.59 psi
14
Top Stage Operating Variation Heads Purification Train at 195 kta

15
Bottom Stage Operating Variation Heads Purification Train at 195 kta

16
Top Stage Operating Variation Heads Purification Train at 245 kta

17
Bottom Stage Operating Variation Heads Purification Train at 245 kta

18
Heads Purification Train Flooding Factor VS Stages Analysis at 195 kta

19
Heads Purification Train Flooding Factor VS Stages Analysis at 245 kta

20
 Number of Stages (65)

Fluid Package (UNIFAC)

EDC Purity (99%)

Reboiler (Thermosiphon)

LIGHTS
COLUMNS
OPERATION
Designing & Rating Analysis

21
 LIGHTS Column(AS402 ) Simulation Diagram

Light components
removed as vent.

Feed from VCL column (VCM

Section) containing crude EDC with
light components (HCl, Cl2, VCl etc.)

EDC recovered with heavies as Bottom

Product.
22
 Light COLUMN
Number of Trays 65  
Diameter of Column 2.29 m
Height of Column 38.404 m
Head Loss 5.94 m
Material of Construction Carbon Steel  
     
Section Geometry
Property Value Unit
Tray type SIEVE  
Number of passes 1  
Hydraulic Design Hole area / Active area. 0.1 m2
Deck gauge thickness value 0.003 m
Lights Purification Train Cross-sectional area 4.11 m2
Active area 3.29 m2
Net area 3.70 m2
Diameter 2.29 m
Tray spacing 0.60 m
Hole diameter 0.01 m
Tray Geometry
Property Side Unit
Down comer area top 0.41 m2
Down comer area bottom 0.41 m2
Down comer clearance 0.03 m
Down comer width top 0.35 m
Down comer width bottom 0.35 m
Weir Geometry
Property Side Unit
Weir height 0.05 m
Weir length 1.66 m 23
 Thermal Design Specification Sheet
Lights Purification Train
Parameters
 

Condenser Partial-Vapor
Reboiler Thermosyphon

Valid Phase Vapor-Liquid

Thermal Design Convergence Standard

Lights Purification Train
Condenser Pressure 12 psi

Reboiler Outlet
Temperature 77.5 C

Operating Condition Before uprating After uprating

Condenser Duty 3312.83 kW 3751.8 kW

Reboiler Duty 2399.3 kW 2636.4 kW
Pressure Drop 6.23 psi 7.1 psi
24
Top Stage Operating Variation Lights Purification Train at 195 kta

25
Bottom Stage Operating Variation Lights Purification Train at 195 kta

26
Top Stage Operating Variation Lights Purification Train at 245 kta

27
Bottom Stage Operating Variation Lights Purification Train at 245 kta

28
Lights Purification Train Flooding Factor VS Stages Analysis at 195 kta

29
Lights Purification Train Flooding Factor VS Stages Analysis at 245 kta

30
 Number of Stages (30)

Fluid Package (UNIFAC)

EDC Purity (99.6%)

Reboiler (Thermosiphon)

HI-BOIL
COLUMN
(AS 403COL)
Designing & Rating Analysis

31
 Hi-Boil Column (AS403) & Heat Exchanger (HXEDC) Simulation
Temperature (C)
HI-Biol Column (AS403COL) Simulation Diagram
Vacuum Column Recycle Pressure (atm)

Mass Flow Rate (kg/hr)

Hi-Boil Column Lights

EDC STOCK
Hi-Boil Column Feed

Hi-Boil Column Bottom 32

 Hi-Boil COLUMN
Number of Trays 30  
Diameter of Column 3.40 m
Height of Column 22.6 m
Head Loss 4.15 m
Material of Construction Carbon Steel  
     
Section Geometry
Property Value Unit
Tray type SIEVE
Number of passes 1  
Hydraulic Design Hole area / Active area.
Cross-sectional area
0.1
9.07
m2
m2
Hi-Boil Purification Train Active area
Net area
6.67
7.87
m2
m2
Diameter 3.4 m
Tray spacing 0.80 m
Hole diameter 0.01 m
Deck gauge thickness 0.003 m
Tray Geometry
Property Side Unit
Down comer area top 1.20 m2
Down comer area bottom 1.20 m2
Down comer clearance 0.05 m
Down comer width top 0.64 m
Down comer width bottom 0.64 m
Weir Geometry
Property Side Unit
Weir height 0.06 m
Weir length 2.66 m
33
 Thermal Design Specification Sheet
Parameters Hi-Boil Purification Train

Condenser Total

Reboiler Thermosyphon

Valid Phase Vapor-Liquid

Standard
Thermal Design Convergence
Hi-Boil Purification Train
Condenser Pressure 16.69 psi

Reboiler Outlet
Temperature 88.76 C

Operating Condition Before uprating After uprating

Condenser Duty 9267.6 kW 9610.4 kW

Reboiler Duty 8897.2 kW 9158.3 kW
Pressure Drop 2.9 psi 3.33 psi
34
Top Stage Operating Variation Hi-Boil Purification Train at 195 kta

35
Bottom Stage Operating Variation Hi-Boil Purification Train at 195 kta

36
Top Stage Operating Variation Hi-Boil Purification Train at 245 kta

37
Bottom Stage Operating Variation Hi-Boil Purification Train at 245 kta

38
Hi-Boil Purification Train Flooding Factor VS Stages Analysis at 195 kta

39
High-Boil Purification Train Flooding Factor VS Stages Analysis at 245 kta

40
Number of Stages (20)

Fluid Package (UNIFAC)

EDC Purity (99.84%)

Reboiler (Thermosiphon)

VACUUM
COLUMN
(AS 404COL)
OPERATION
Material & Energy Balance

41
 Vacuum Column (AS404) & Pump (PP404REC) Simulation
Temperature (C)
Vacuum Column Recycle
Pressure (atm)

Mass Flow Rate (kg/hr)

Vacuum Column Vents

Nitrogen Feed

Vacuum Column Heavies

Vacuum Column Feed
42
 Vacuum COLUMN
Number of Trays 20  
Diameter of Column 1.52 m
Height of Column 15.3 m
Head Loss 2.81 m
Material of Construction Carbon Steel  
     
Section Geometry
Property Value Unit
Tray type SIEVE
Number of passes 1  
Hydraulic Design Cross-sectional area 1.81 m2
Active area 1.38 m2
Vacuum Purification Train Net area 1.60 m2
Hole area / Active area. 0.1 m2
Deck gauge thickness 0.003 m
Diameter 1.52 m
Tray spacing 0.85 m
Hole diameter 0.01 m
Tray Geometry
Property Side Unit
Down comer area top 0.21 m2
Down comer area bottom 0.21 m2
Down comer clearance 0.05 m
Down comer width top 0.26 m
Down comer width bottom 0.26 m
Weir Geometry
Property Side Unit
Weir height 0.07 m
Weir length 1.15 m 43
 Thermal Design Specification Sheet
Vacuum Purification Train
Parameters
(C-4) 

Condenser Partial-Vapor-liquid

Reboiler Thermosyphon

Valid Phase Vapor-Liquid

Standard
Thermal Design Convergence
Vacuum Purification Train
Condenser Pressure 7.9 psi

Reboiler Outlet
Temperature 94.44 C

Operating Condition Before uprating After uprating

Condenser Duty 1702.04 kW 1993.09 kW

Reboiler Duty 1598.63 kW 1866.2 kW
Pressure Drop 1.455 psi 1.7 psi
44
Top Stage Operating Variation Vacuum Purification Train at 195 kta

45
Bottom Stage Operating Variation Vacuum Purification Train at 195 kta

46
Top Stage Operating Variation Vacuum Purification Train at 245 kta

47
Bottom Stage Operating Variation Vacuum Purification Train at 245 kta

48
Vacuum Purification Train Flooding Factor VS Stages Analysis at 195 kta

49
Vacuum Purification Train Flooding Factor VS Stages Analysis at 245 kta

50
 Number of Stages (30)

Fluid Package (UNIFAC)

EDC Purity (99.6%)

Reboiler (Thermosiphon)

HI-BOIL
COLUMN
(AS 403COL)
HAZOP Analysis

51
Guide word Cause Consequences Action required Current Recommendation
actions

• Control valve to feed • Level in column rises • Independent high

is fail safe opened at bottom flow alarm 
Interlock and relief valve.
High Flow • Pump producing • Temperature falls • Check
more pressure than maintenance
what is required • Harbinger of procedure and 
flooding in column schedule

• Pump failure • Temperature rise in • Install low level 

column may cause alarm
Low Flow • Tube leakage and dry out Bypass line along with
blocking • Make bypass sensor, actuator and FCE
• Change in product assembly.
• Valve jammed quality • Emergency plant
shutdown 

• Control valve to feed • Level in column rises • Independent high

is fail safe opened at bottom flow alarm  . Interlock and relief valve.

• Pump producing • Temperature falls • Check

High Level more pressure than maintenance
what is required • Harbinger of procedure and  .
flooding in column schedule

52
Guide Cause Consequences Action required Current Recommendation
word actions

• Feed line rupture • Column trays would • Independent low  .

run dry flow alarm Regular Checking and
Low Level • Feed valve fails to maintenance
open • Variations in • Check maintenance  .
temperature profiles procedures and
• Depletion of reflux schedules
rate

• Fail safe close • Distillate recovery will • Pressure relief

distillate valve decreases valve  Regular checking of the
Pressure valve is needed
High • Steam valve open • Vapor will produce
and increase the
pressure of column

• Feed line rupture • Heavies will move • Proper insulation of

toward upward the line  By-pass line is needed
Low Pressure • Bottom product along with the top vapor
valve fail-safe open line

53
Guide Cause Consequences Action required Current Recommendation
word actions

• Steam inlet • High temperature • Alarm to Indicate  • Feed is increases if

valves fail safe resulting heavies to High temperature capacity of column
open move toward upward allows
High Temperatur section • Shut off valve at
e • Temperature distillate  • Transmitter
transmitter • Product quality maintenance
indicator decreases
failure showing
lower value

• Feed valve fail • Liquid level of • Alarm line  • Feed and utility flow
safe open temperature increase control
thus temperature
Low Temperatur • Reflux decreases
e downstream • By-pass line with 
fail safe open • Reflux Increases as automatic control
temperature decreases

54
Current Progress Future Proceedings

Project selection Sensitivity Analysis Using CTT (Column

Targeting tool)

Capacity selection Holistic working of debottlenecks

Selection of Methodology & Soft Tools Capacity uprating

Simulation of EDC and VCM on Actual

Literature review Parameters

Simulation of EDC and VCM Section Environmental Impact Assessment

55
 Results and Discussion

• The hydrodynamic analysis of the purification trains was completed. It was observed that at uprated
capacity of 245 kta, the increase in flooding percentage is accommodated via available heat duty
margins in condensers and reboilers.
• It can be concluded from the above design and rating analysis that the current dimensions of the
purification trains have further ability to operate on uprated plant load .

56
 References

• Seader, J.D. and Henley, E.J., Separation Process Principles, Wiley, New York (1998).
• Wankat, P. C., Equilibrium Staged Separations: Separations for Chemical Engineers, Elsevier (1988).
• McCabe, W. L. and Smith, J. C., Unit Operations of Chemical Engineering, (3rd ed.), McGraw-Hill (1976).
• Branan, Carl, Rules of Thumb for Chemical Engineers, Chapter 3, 4th ed., 2005, Gulf Publishing. Watkins,
R.N., Petroleum Refinery Distillation.

57
THANK YOU

58