Epichlorohydrin from allyl chloride [106-89-8]

CONTENTS OF FACTORY GATE TO FACTORY GATE

LIFE CYCLE INVENTORY SUMMARY

Chemistry ....................................................................................................................................................... 1
Process Summary ........................................................................................................................................... 3
Summary of LCI Information ......................................................................................................................... 4
Process Diagram Interpretation Sheet ............................................................................................................ 6
Process Diagram or Boundary of LCI ............................................................................................................ 7
Mass Balance of Chemicals in Each Process Stream ....................................................................................18
Graph of Cumulative Chemical Losses through Manufacturing Process ......................................................26
Graph of Cumulative Contaminated Water Use / Emission through Manufacturing Process .......................27
Graph of Cumulative Non-Contaminated Water Use / Emission through Manufacturing Process ...............28
Energy Input for each Unit Process, Cumulative Energy Requirements, Cooling Requirements (exotherms),
and Assumed Heat Recovery from Hot Streams Receiving Cooling ............................................................29
Graph of Cumulative Energy Requirements ..................................................................................................32

Authors E. Griffing and

Peer reviews, name (date) MR Overcash (1-1-1999); MR Overcash (9-4-2007)
Gtg report last modified on 10-3-2010
Additional notes This gtg may be improved.

Checked for database consistency on 10-4-2010

First gtg version finalized on 1-1-1999
Modification history, Author (date) EMG (9-4-2007), (4-1-2009), and EMG (10-3-2010)

Products allyl trichloride, Calcium dichloride, Epichlorohydrin

Standard inputs Chlorine, Allyl Chloride, calcium monoxide

Methodology: Environmental Clarity gtg lci reports are based on industrial practice information, standard
methods of engineering process design, and technical reviews. These reports are intended to be
representative of industrial production based on the stated route.
Terms of use: Environmental Clarity does not assume any liability due to use of these lci data. Integration
of these data with lci data based on other methodologies is the responsibility of the user. Each report may
be updated to improve model accuracy or representativeness.
Users of this report should cite: E. Griffing and M. Overcash, Chemical Life Cycle Database,
www.environmentalclarity.com, 1999 - present.

Chemistry

updated on 10/3/2010 1
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Primary reactions:
Cl2 + H20 HOCl + HCl [Rxn. 1]
Chlorine Water Hypochlorous Acid Hydrochloric Acid
CH2ClCH=CH2 + HOCl CH2ClCHClCH2OH (2 Isomers) [Rxn 2]
Allyl Chloride Hypochlorous Acid Glycerol Dichlorohydrin
CaO + H2O Ca(OH)2 [Rxn. 4]
Lime Water Calcium Hydroxide
CH2ClCHClCH2OH + 1/2 Ca(OH)2 C3H5ClO + 1/2 CaCl2 + H2O [Rxn. 5]
Glycerol Dichlorohydrin Calcium Hydroxide Epichlorohydrin Calcium Chloride Water

Net CH2ClCH=CH2 + Cl2 + 1/2 CaO +1/2 H2O C3H5ClO + 1/2 CaCl2 + HCl
Allyl chlorine Calcium water Epichlorohydrin Calcium Hydrogen
Chloride hydroxide Chloride chloride

Neutralization reactions: CaO + H 2O Ca(OH)2 [Rxn. 4]

Ca(OH)2+ HCl CaCl2 + H2O [Rxn 6]
Net CaO + HCl CaCl2+ H2O [Rxn 7]

Net (with neutralization)

CH2ClCH=CH2 + Cl2 + CaO C3H5ClO + CaCl2
Allyl chlorine lime Epichlorohydrin Calcium
chloride chloride

Side reactions
CH2ClCH=CH2 + Cl2 C3H5Cl3 [Rxn 3]
Allyl Chloride Chlorine Trichloropropane

updated on 10/3/2010 2
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Process Summary
LCI design
Epichlorohydrin is formed from allyl chloride through a series of reactions and
separations. Vaporized allyl chloride is mixed with dilute hypochlorous acid in the
hypochlorination reactor at 1 atm and 55 oC to produce glycerol dichlorohydrin (93% of
reactor input). The output from the reactor is fed to a series of separators to isolate the
glycerol dichlorohydrin, to recover the allyl chloride for recycle back to the reactor, and
to remove the unreacted acid-water solution. The unreacted water solution is sent to the
acid treatment center, where it is neutralized with calcium hydroxide and sewered.
The glycerol dichlorohydrin is mixed with a calcium hydroxide slurry in the
prehydrolysis mix tank and then sent to the hydrolysis reactor. The reactor operates at
100 oC and 1 atm and produces epichlorohydrin (92% conversion). The reactor bottoms
is a waste slurry of calcium chloride. The tops are gaseous epichlorohydrin, unreacted
glycerol dichlorohydrin, organic by-products and some water vapor. These are removed
from the top of the reactor and separated in a series of distillation columns. The glycerol
dichlorohydrin is recycled back to the prehydrolysis mix tank, and the organic by-
products exit the system in a waste stream.
The epichlorohydrin recovered at this point has an azeotrope with water. This azeotrope
is broken by adding acetic acid, which forms a new, lower-boiling azeotrope with the
water. The mixture is separated in a distillation column operated 100 oC and 1 atm. The
acetic acid-water mixture is sent to the acid treatment center for neutralizing and
sewering. The epichlorohydrin is run through a final distillation column at 100 oC and 1
atm to remove a small amount of organic contaminants, producing 1000 kilograms per
hour of 97 % pure epichlorohydrin.
Critical parameters

Yield information (calculated from process mass balance)

Yield Yield from allyl Yield from
from chloride lime
Chlorine
Total yield of Epichlorohydrin in Process: 88 92 87
(% yield produced by the overall process based on
reactant input to process)
Notes:

Product purity
Epichlorohydrin Comments
Used here 100
LiteratureSource

updated on 10/3/2010 3
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Summary of LCI Information

Standard inputs
UID Name Flow Purity Units Comments
7782-50-5 Chlorine 872 - [kg/hr]
107-05-1 Allyl Chloride 899 - [kg/hr] includes
18kg/hr
fugitive
replacement
1305-78-8 calcium 693 - [kg/hr]
monoxide
Total 2465 [kg/hr]
Non-reacting inputs
UID Name Flow Purity Units Comments
7732-18-5 Water 2.63E+05 - [kg/hr]
Total 2.63E+05 [kg/hr]
Ancillary inputs
UID Name Flow Purity Units Comments
64-19-7 Acetic acid 7.35 - [kg/hr]
Total 7.35 [kg/hr]
Products
UID Name Flow Purity Units Comments
96-18-4 allyl trichloride 18.0 100 [kg/hr]
10043-52-4 Calcium 1375 96.8 [kg/hr]
dichloride
106-89-8 Epichlorohydrin 1000 100 [kg/hr]
Total 2393 [kg/hr]
Benign outflows
UID Name Flow Purity Units Comments
7732-18-5 Water 2.63E+05 - [kg/hr]
Total 2.63E+05 [kg/hr]

Process emissions
UID Name Gas Liquid Solid Solvent Units Comments
UIDCalciumSalt calcium salt 0 9.68 0 0 [kg/hr]
64-19-7 Acetic acid 0.0735 0 0 0 [kg/hr]
7647-01-0 Hydrogen 2.23 0 0 0 [kg/hr]
chloride
7790-92-3 Hypochlorous 0.161 6.43 0 0 [kg/hr]
acid
106-89-8 Epichlorohydrin 10.3 0 0 0 [kg/hr]
7782-50-5 Chlorine 4.34 0 0 0 [kg/hr]
107-05-1 Allyl Chloride 18.7 0 0 0 [kg/hr]
UIDEpichlorohydrinOrganicWaste organic waste 0 39.9 0 0 [kg/hr]
Total 35.8 56.0 0 0

Mass balance
Total inputs 2.66E+05
Total outflows 2.66E+05
Net input -9.25

updated on 10/3/2010 4
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Energy use
Energy type Amount Units Comments
electricity 258 [MJ/hr] Net electricity use at
plant
heating steam 8.24E+04 [MJ/hr] heating by steam (0.85
efficiency included)
Net input requirement 8.27E+04 [MJ/hr] Net of energies input to
system
cooling water - 9.45E+04 [MJ/hr] net cooling by cooling
water
potential recovery - 2.34E+04 [MJ/hr] potential energy
recovery (negative)
Net energy 5.93E+04 [MJ/hr] Net input requirement -
potential recovery

updated on 10/3/2010 5
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Process Diagram Interpretation Sheet

1) As much as possible, standard symbols are used for all unit processes.
2) Only overall input and output chemicals are labeled on these diagrams. All intermediate information is
given on the attached Process Mass Balance sheet
3) The physical state of most streams is shown (gas, g; liquid, l; solid, s)
4) The process numbering is as follows,
generally numbers progress from the start to the end of the process
numbers are used for process streams
C i , i = 1,..n are used for all cooling non-contact streams
S j, j = 1,...n are used for all steam heating non-contact streams
5) Recycle streams are shown with dotted lines
For most streams, the temperature and pressure are shown, if the pressures are greater than 1 atm

updated on 10/3/2010 6
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Process Diagram or Boundary of LCI
Steam enters the process as a gas at 207 oC and leaves as a liquid at 207 oC. Cooling water enters at 20 oC and leaves at 50 oC.
Unless otherwise indicated, all processes are at 1 atm and 25oC.

B
4 (l)
5 (l)
55 C 55 F

P2
C

27 (l)
55 C
S2
C1
2 (l) Blwr 2
33 (l) P1
26.8 C HX 1
13 (g)
55 oC
3 (g) R1 C2
1 (l) 55 C Hypochlorination
881 kg Allyl Chloride
25.0 oC S1 Reactor
A

16 (g)
12 (l)
55 C

S4 10 (l)
55 C
15 (g) S6 2.49E+05 kg Water
Blwr 1 25.0 oC
HX 2
14 (g) HX 3
25 C
868 kg Chlorine
25.0 oC 11 (l)
S3 S5 P4

updated on 10/3/2010 7
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 27 (l)
26 (l) C
6 (l) 55 C
5 (l)
B Liquid 7 (l) Liquid 55 C
55 C Separator 55 C 55 C Separator
B C P12
P42

24 (l)
8 (l) 55 C
55 C

P13
25 (l)
55 C
9 (l) P5
55 C

Central Acid
Treatment
A

updated on 10/3/2010 8
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 C3

20 (l)
18.1 kg allyl trichloride
19 (l) 25.0 oC
C2b HX 5
18 (l)
157 C
C2a
157 C
S8 P6 C4

Di 1
9 (l) 17 (l) Distillation C5
A HX 4 Column G
55 C 157 C
22 (l) 23 (l)
21 (l) HX 6
157 C 100 C
S7
157 C
S9
S10
P7
C6

updated on 10/3/2010 9
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 40 (l)
42 (l)
2450 kg Water
25 C
25.0 oC

K P17

44 (s)
Screw Feeder 1
693 kg lime
25.0 oC

79 (l)
78 (l) 100 C
45 (l)

77 (l)
100 C
100 C
M
100 C
P18
P19 Central Acid
Lime Slaker K
Treatment
MxE 2
R2
46 (l)
100 C
S11
S12

D 23 (l)
Mix Tank H
100 C
MxE 1
47 (l)
100 C

48 (l) P
100 C

P20

updated on 10/3/2010 10
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 C9

63 (l) E
HX 8 100 C
61 (v) 62 (l)
R3 100 C 100 C
P22
Hydrolysis reactor
C10

C11

P 48 (l)
100 C

50 (l)
HX 9
52 (l) N
25 C
100 C 51 (l)
P23 100 C
C12

C8

C7

S14

HX 7
100 (g)
100 C 49 (l)
1.19E+04 kg Water
S13 25.0 oC

updated on 10/3/2010 11
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 64 (l)
65 (l) 25 C
25 C

N Decanter 98 (l) F
52 (l) 53 (l) 25 C
L
25 C 25 C
P25 Central Acid
Treatment

54 (l)
25 C

67 (l)
25 C
55 (l)
25 C P26

Drum Filter M 59 (l)

25 C

56 (l)
C13
25 C Liquid
57 (l) 66 (l)
Separator
HX 10 25 C 25 C
T P28
58c (g)
58 (s) P27
100 oC
25 C
58d (l)
C14
221 kg Water 68 (l)
o
25.0 C Dryer 1
25 C

S15
58.a (s)
25 C Conveyor 2 69 (l) J
25 C
S16
Air cooling P29

58b (s)
652 kg Calcium dichloride
9.07 kg Calcium hydroxide
100.0 oC

updated on 10/3/2010 12
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 C17
73 (l)
72 (l) 9.30 kg organic waste
C16
J 135 C 25.0 oC
C15
HX 12
69 (l) S18
25 C
70 (l)
P44
135 C Di S
HX 11 C18
Distillation
Column S

S17
41 (l)
S19
S20 135 C

43 (l)
C19 P45
135 C
77 (l)
100 C
K
HX 13

C20

updated on 10/3/2010 13
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 S24
74 (l)
76 (l) 75 (l) 7.35 kg Acetic acid
100 C 25 C 25.0 oC
HX 14
81 (l)
C22
100 C
C21
S23 P48

80 (l) P31
Di N
100 C
E
63 (l) Distillation
100 C Column N MixE 3

S21 85 (l)
S22
100 C 82 (l) Mixer P
100 C
Q
83 (l)
100 C
P32

C23
86 (l)
100 C
P36

HX 15

87 (l)
1.18E+04 kg Water
25.0 oC C24

updated on 10/3/2010 14
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 90 (l)
100 C
C26
C25 84 (l)
100 C
L
P34 Central Acid
Treatment
Di Q

Q 83 (l)
100 C
88 (l)
100 C 89 (l)
100 C
S25
S26 G
P33

updated on 10/3/2010 15
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 C27

93 (l)
115 C
C26b
C26a HX 17
92 (l)
115 C
S28 94 (l)
P37 1000 kg Epichlorohydrin
89 (l) 25.0 oC
C28
100 C Di R
G HX 16
91 (l)
115 C C29

96 (l)
S27 115 C
S28a
S28b HX 18

95 (l) 97 (l)
115 C 30.6 kg organic waste
P38 25.0 oC
C30

updated on 10/3/2010 16
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Fugitive Losses (Total) (g)
38 (l)
18.7 kg Allyl Chloride 2.51E+05 kg Water
Replacement of Fugitive Losses
10.3 kg Epichlorohydrin 9.68 kg calcium salt
18.7 kg Allyl Chloride
4.34 kg Chlorine 6.43 kg Hypochlorous acid
4.34 kg Chlorine
2.23 kg Hydrogen chloride 25.0 oC
0.161 kg Hypochlorous acid
0.0735 kg Acetic acid 37 (l)
25 C

36 (l)
25 C
35 (l)
29 (l) 25 C P9
60 (l) 25 C Decanter
25 C
E
34 (l)
25 C
P11
P8
30 (l)
C31
25 C
C7 (l)
32 (s)
20 C 31 (l)
25 C
HeatX 19

25 C

Drum Filter F
90 (l) P10
100 C
C32 79 (l) Conveyor 1
L 107 C
C33
32.a (s)
25 C

M 32d (l) 32c (g)

221 kg Water Dryer 2
25.0 oC
64 (l) HX 20
25 C S29
C34
F S30

25 (l) H 32b (s)

55 C
28 (l) 679 kg Calcium dichloride
55.1 oC MixE 4 35.0 kg calcium chlorite
1.0 atm MX 3 Mix Tank D 100.0 oC
Central Acid Treatment

updated on 10/3/2010 17
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Mass Balance of Chemicals in Each Process Stream
All flow rates are given in kg / hr Gas
Physical state of chemical losses: Liquid
Solid

Dichlorohydrin
Epichlorohydri

allyl trichloride

organic waste
Hypochlorous
Allyl Chloride

calcium salt
Acetic acid
Comments

Total Flow

Hydrogen

hydroxide

dichloride
Temp [C]
Streams

Chlorine

Calcium

Calcium
chloride

calcium
chlorite
Phase

Water

acid

lime
P

n
Input 1 25.0 1.00 l 881 881
2 30.0 1.00 l 937 937
3 55.0 1.00 l 937 937
R1 859 kg Chlorine
871 kg Allyl Chloride is lost in rxn 2
9.36 kg Allyl Chloride is lost in rxn 3
Input to reactor : 2.51E+05 937 868 2.49E+05 0 0 0 0 0 0 0 0 0 0 0 0
R1 Reaction Coefficient : -1.00 -1.00 1.00 1.00
1
R1 Conversion 1 [kg/hr] : 0 -859 -218 635 442
R1 Conversion 1 : 12.1 -12.1 -12.1 12.1 12.1
[kgmol/hr]
R1 Reaction Coefficient : -1.00 -1.00 1.00
2
R1 Conversion 2 [kg/hr] : 0 -871 -598 1469
R1 Conversion 2 : 11.4 -11.4 -11.4 11.4
[kgmol/hr]
R1 Reaction Coefficient : -1.00 -1.00 1.00
3
R1 Conversion 3 [kg/hr] : -9.36 -8.69 18.1
R1 Conversion 3 : - -0.122 0.122
[kgmol/hr] 0.122
Flow out of reactor : 2.51E+05 56.5 0.0101 2.49E+05 0 37.7 442 1469 18.1 0 0 0 0 0 0 0
Primary product : Epichlorohydrin
Total conversion : 100.0 100.0 0.0827 NA NA NA NA NA -0 NA NA NA -0 NA NA
Per pass conversion : 94.0 100.0 0.0874 NA NA NA NA
Total yield from reactor : NA
Reactor Convergence 0.257 0.0101 2.72 0 5.55 - 0.146 3.06E- 0 0 0 0 0 0 0
4.67 03
updated on 10/3/2010 18
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Dichlorohydrin
Epichlorohydri

allyl trichloride

organic waste
Hypochlorous
Allyl Chloride

calcium salt
Acetic acid
Comments

Total Flow

Hydrogen

hydroxide

dichloride
Temp [C]
Streams

Chlorine

Calcium

Calcium
chloride

calcium
chlorite
Phase

Water

acid

lime
P

n
4 55.0 1.00 l 2.51E+05 56.2 2.49E+05 32.1 446 1468 18.1
5 55.0 1.00 l 2.51E+05 56.2 2.49E+05 32.1 446 1468 18.1
6 55.0 1.00 l 2.49E+05 56.2 2.49E+05 32.1 446
7 55.0 1.00 l 2.49E+05 56.2 2.49E+05 32.1 446
8 55.0 1.00 l 1486 1468 18.1
9 55.0 1.00 l 1486 1468 18.1
Input 10 25.0 1.00 l 2.49E+05 2.49E+05
11 25.0 1.00 l 2.49E+05 2.49E+05
12 55.0 1.00 l 2.49E+05 2.49E+05
13 55.0 1.00 g 937 937
Input 14 25.0 1.00 g 868 868
15 25.0 1.00 g 868 868
16 55.0 1.00 g 868 868
17 157 1.00 l 1486 1468 18.1
18 157 1.00 l 18.1 0 18.1
19 157 1.00 l 18.1 18.1
By-product 20 25.0 1.00 l -18.1 0 0 0 0 0 0 0 -18.1 0 0 0 0 0 0 0
21 157 1.00 l 1468 1468
22 157 1.00 l 1468 1468
23 100 1.00 l 1468 1468
24 55.0 1.00 l 2.49E+05 2.49E+05 32.1 446
25 55.0 1.00 l 2.49E+05 2.49E+05 32.1 446
26 55.0 1.00 l 56.2 56.2
27 55.0 1.00 l 56.2 56.2
28 55.1 1.00 l 2.52E+05 0 0 2.51E+05 0 6.43 0 0 0 0 0 679 35.0 0 9.68 0
29 25.0 1.00 l 2.52E+05 2.51E+05 6.43 679 35.0 9.68
30 25.0 1.00 l 9757 9043 679 35.0
31 25.0 1.00 l 9757 9043 679 35.0
32 25.0 1.00 s 935 221 679 35.0
32a 25.0 1.00 s 935 221 679 35.0
By-product 32b 100 1.00 s -714 0 0 0 0 0 0 0 0 0 0 -679 - 0 0 0
35.0
32c 100 1.00 g 221 221
Waste 32d 25.0 1.00 l -221 0 0 -221 0 0 0 0 0 0 0 0 0 0 0 0
33 30.0 1.00 l 937 937
34 25.0 1.00 l 8823 8823
35 25.0 1.00 l 8823 8823
updated on 10/3/2010 19
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Dichlorohydrin
Epichlorohydri

allyl trichloride

organic waste
Hypochlorous
Allyl Chloride

calcium salt
Acetic acid
Comments

Total Flow

Hydrogen

hydroxide

dichloride
Temp [C]
Streams

Chlorine

Calcium

Calcium
chloride

calcium
chlorite
Phase

Water

acid

lime
P

n
36 25.0 1.00 l 2.42E+05 2.42E+05 6.43 9.68
37 25.0 1.00 l 2.51E+05 2.51E+05 6.43 9.68
Waste 38 25.0 1.00 l -2.51E+05 0 0 -2.51E+05 0 -6.43 0 0 0 0 0 0 0 0 - 0
9.68
Input 40 25.0 1.00 l 2450 2450
41 135 1.00 l 126 126
42 25.0 1.00 l 2450 2450
43 135 1.00 l 126 126
Input 44 25.0 1.00 s 693 693
45 100 1.00 l 1743 1235 508
46 100 1.00 l 1743 1235 508
47 100 1.00 l 3338 0 0 1235 0 0 0 1595 0 0 508 0 0 0 0 0
48 100 1.00 l 3338 0 0 1235 0 0 0 1595 0 0 508 0 0 0 0 0
Input 49 25.0 1.00 l 1.19E+04 1.19E+04
R3 1468 kg Dichlorohydrin
kg is lost in rxn 2
kg is lost in rxn 3
Input to reactor : 1.52E+04 0 0 1.31E+04 0 0 0 1595 0 0 508 0 0 0 0 0
R3 Reaction Coefficient : 1.00 1.00 -1.00 -0.500 0.500
1
R3 Conversion 1 [kg/hr] : 0 205 1053 -1468 -421 632
R3 Conversion 1 : 11.4 11.4 11.4 -11.4 -5.69 5.69
[kgmol/hr]
R3 Reaction Coefficient :
2
R3 Conversion 2 [kg/hr] : 0 7.00 -22.0 -14.0 20.0 9.00
R3 Conversion 2 : Non-
[kgmol/hr] Number in
input
R3 Reaction Coefficient :
3
R3 Conversion 3 [kg/hr] :
R3 Conversion 3 :
[kgmol/hr]
Flow out of reactor : 1.52E+04 0 0 1.33E+04 1031 0 0 127 0 0 72.9 652 0 0 0 9.00
Primary product : Epichlorohydrin
Total conversion : -0 -0 -0.0804 NA NA NA NA NA -0 NA NA NA -0 NA NA

updated on 10/3/2010 20
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Dichlorohydrin
Epichlorohydri

allyl trichloride

organic waste
Hypochlorous
Allyl Chloride

calcium salt
Acetic acid
Comments

Total Flow

Hydrogen

hydroxide

dichloride
Temp [C]
Streams

Chlorine

Calcium

Calcium
chloride

calcium
chlorite
Phase

Water

acid

lime
P

n
Per pass conversion : NA NA 92.1 85.7 NA NA
Total yield from reactor : NA 97.9 94.8
Reactor Convergence 0.130 0 0 0.217 -4.34E- 0 0 0.430 0 0 0.296 - 0 0 0 -
03 0.509 0.300
50 100 1.00 l 2307 1447 126 72.6 652 9.30
51 100 1.00 l 2307 1447 126 72.6 652 9.30
52 25.0 1.00 l 2307 1447 126 72.6 652 9.30
53 25.0 1.00 l 950 904 45.4
54 25.0 1.00 l 1358 543 126 27.2 652 9.30
55 25.0 1.00 l 1358 543 126 27.2 652 9.30
56 25.0 1.00 l 696 543 126 18.1 9.30
57 25.0 1.00 l 696 543 126 18.1 9.30
58 25.0 1.00 s 882 221 9.07 652
58a 25.0 1.00 s 882 221 9.07 652
By-product 58b 100 1.00 s -661 0 0 0 0 0 0 0 0 0 -9.07 -652 0 0 0 0
58c 100 1.00 g 221 221
Waste 58d 25.0 1.00 l -221 0 0 -221 0 0 0 0 0 0 0 0 0 0 0 0
59 25.0 1.00 l 221 221
60 25.0 1.00 l 2.52E+05 0 2.51E+05 0 6.43 0 0 0 0 0 679 35.0 0 9.68 0
61 100 1.00 g 1.29E+04 1.19E+04 1031
62 100 1.00 l 1.29E+04 1.19E+04 1031
63 100 1.00 l 1.29E+04 1.19E+04 1031
64 25.0 1.00 l 1290 1226 63.5
65 25.0 1.00 l 950 904 45.4
66 25.0 1.00 l 561 543 18.1
67 25.0 1.00 l 561 543 18.1
68 25.0 1.00 l 136 126 9.30
69 25.0 1.00 l 136 126 9.30
70 135 1.00 l 136 126 9.30
71 135 1.00 l 9.30 9.30
72 135 1.00 l 9.30 9.30
Waste 73 25.0 1.00 l -9.30 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -9.30
Input 74 25.0 1.00 l 7.35 7.35
75 25.0 1.00 l 7.35 7.35
76 100 1.00 l 7.35 7.35
77 100 1.00 l 126 126
R2 693 kg lime
updated on 10/3/2010 21
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Dichlorohydrin
Epichlorohydri

allyl trichloride

organic waste
Hypochlorous
Allyl Chloride

calcium salt
Acetic acid
Comments

Total Flow

Hydrogen

hydroxide

dichloride
Temp [C]
Streams

Chlorine

Calcium

Calcium
chloride

calcium
chlorite
Phase

Water

acid

lime
P

n
kg is lost in rxn 2
kg is lost in rxn 3
Input to reactor : 3144 0 0 2450 0 0 0 0 0 693 0 0 0 0 0 0
R2 Reaction Coefficient : -1.00 - 1.00
1 1.00
R2 Conversion 1 [kg/hr] : 0 -223 -693 916
R2 Conversion 1 : 12.4 -12.4 - 12.4
[kgmol/hr] 12.4
R2 Reaction Coefficient :
2
R2 Conversion 2 [kg/hr] :
R2 Conversion 2 :
[kgmol/hr]
R2 Reaction Coefficient :
3
R2 Conversion 3 [kg/hr] :
R2 Conversion 3 :
[kgmol/hr]
Flow out of reactor : 3144 0 0 2228 0 0 0 0 0 0 916 0 0 0 0 0
Primary product : Calcium hydroxide
Total conversion : -0 -0 0.0846 NA NA NA NA NA 100 NA NA NA -0 NA NA
Per pass conversion : 9.09 100 NA
Total yield from reactor : 100 100 NA
Reactor Convergence 0 0 -0.0539 0 0 0 0 0 0 3.93E- 0 0 0 0 0
03
78 100 1.00 l 1401 993 408
79 100 1.00 l 1401 0 0 993 0 0 0 0 0 0 408 0 0 0 0 0
IntoMixTankb 0 0 2.51E+05 0 32.1 446 0 0 0 472 0 0 7.35 0 0
r1 stoich. 2.00 - -1.00 1.00
2.00
r1 kg/hr 0 220 -446 -453 679
(additional rxn) kg/hr 6.99 0 -25.7 0 0 0 0 -19.1 0.503 35.0 -7.35 9.68 0
80 100 1.00 l 1103 72.8 1031
81 100 1.00 l 1103 72.8 1031
82 100 1.00 l 1111 72.8 1031 7.35
83 100 1.00 l 1111 72.8 1031 7.35
84 100 1.00 l 80.1 72.8 7.35

updated on 10/3/2010 22
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Dichlorohydrin
Epichlorohydri

allyl trichloride

organic waste
Hypochlorous
Allyl Chloride

calcium salt
Acetic acid
Comments

Total Flow

Hydrogen

hydroxide

dichloride
Temp [C]
Streams

Chlorine

Calcium

Calcium
chloride

calcium
chlorite
Phase

Water

acid

lime
P

n
85 100 1.00 l 1.18E+04 1.18E+04
86 100 1.00 l 1.18E+04 1.18E+04
Waste 87 25.0 1.00 l -1.18E+04 0 0 -1.18E+04 0 0 0 0 0 0 0 0 0 0 0 0
88 100 1.00 l 1031 1031
89 100 1.00 l 1031 1031
90 100 1.00 l 80.1 72.8 7.35
91 115 1.00 l 1031 1031
92 115 1.00 l 1000 1000
93 115 1.00 l 1000 1000
Main product 94 25.0 1.00 l -1000 0 0 0 -1000 0 0 0 0 0 0 0 0 0 0 0
95 115 1.00 l 30.6 30.6
96 115 1.00 l 30.6 30.6
Waste 97 25.0 1.00 l -30.6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -30.6
98 25.0 1.00 l 729 684 45.4
100 100 1.00 g 1.19E+04 1.19E+04
Product purity (%) 100
Main product Epichlorohydrin
Overall Rxn coefficients -1.00 1.00 1.00 -1.00 -1.00 0.500
Total yield of process (from reactant) 92.0 NA NA 3.53E+05
Waste Fugitive Losses (Total) g -35.8 -18.7 -4.34 0 -10.3 -0.161 - 0 0 0 0 0 0 -0.0735 0 0
2.23
Input Sum 2.66E+05 881 868 2.63E+05 0 0 0 0 0 693 0 0 0 7.35 0 0
Fugitive Replacement of 18.9 18.7 0.161 0
Reactants
Total Input (Input + g 2.66E+05 899 868 2.63E+05 0 0.161 0 0 0 693 0 0 0 7.35 0 0
Fugitive Replacement)
Product Sum 2393 0 0 0 1000 0 0 0 18.0 0 9.07 1331 35.0 0 0 0
Main product flow 1000 0 0 0 1000 0 0 0 0 0 0 0 0 0 0 0
Net Input (in - out, omitting 4.11
fugitives)

updated on 10/3/2010 23
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Comments

Total Flow
Temp [C]
Streams

Steam
Phase

Water
P
Input C1 20.0 1.00 l 9932 9932
Cooling out C2 50.0 1.00 l -9932 0 -9932
Input C2a 20.0 1.00 l 4707 4707
Cooling out C2b 50.0 1.00 l -4707 0 -4707
Input C3 20.0 1.00 l 18.9 18.9
Cooling out C4 50.0 1.00 l -18.9 0 -18.9
Input C5 20.0 1.00 l 283 283
Cooling out C6 50.0 1.00 l -283 0 -283
Input C7 20.0 1.00 l 2.04E+04 2.04E+04
Cooling out C8 50.0 1.00 l -2.04E+04 0 -2.04E+04
Input C9 20.0 1.00 l 1.79E+05 1.79E+05
Cooling out C10 50.0 1.00 l -1.79E+05 0 -1.79E+05
Input C11 20.0 1.00 l 3376 3376
Cooling out C12 50.0 1.00 l -3376 0 -3376
Input C13 20.0 1.00 l 3791 3791
Cooling out C14 50.0 1.00 l -3791 0 -3791
Input C15 20.0 1.00 l 73.0 73.0
Cooling out C16 50.0 1.00 l -73.0 0 -73.0
Input C17 20.0 1.00 l 6.93 6.93
Cooling out C18 50.0 1.00 l -6.93 0 -6.93
Input C19 20.0 1.00 l 15.0 15.0
Cooling out C20 50.0 1.00 l -15.0 0 -15.0
Input C21 20.0 1.00 l 2466 2466
Cooling out C22 50.0 1.00 l -2466 0 -2466
Input C23 20.0 1.00 l 2.51E+04 2.51E+04
Cooling out C24 50.0 1.00 l -2.51E+04 0 -2.51E+04
Input C25 20.0 1.00 l 1.04E+04 1.04E+04
Cooling out C26 50.0 1.00 l -1.04E+04 0 -1.04E+04
Input C26a 20.0 1.00 l 6904 6904
Cooling out C26b 50.0 1.00 l -6904 0 -6904
Input C27 20.0 1.00 l 870 870
Cooling out C28 50.0 1.00 l -870 0 -870
Input C29 20.0 1.00 l 18.7 18.7
Cooling out C30 50.0 1.00 l -18.7 0 -18.7
Input C31 20.0 1.00 l 3.69E+05 3.69E+05
Cooling out C32 50.0 1.00 l -3.69E+05 0 -3.69E+05
Input C33 20.0 1.00 l 3791 3791
updated on 10/3/2010 24
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 Comments

Total Flow
Temp [C]
Streams

Steam
Phase

Water
P
Cooling out C34 50.0 1.00 l -3791 0 -3791
Input S1 207 1.00 l 272 272
Steam out S2 207 1.00 l -272 -272 0
Input S3 207 1.00 l 7.67 7.67
Steam out S4 207 1.00 l -7.67 -7.67 0
Input S5 207 1.00 l 1.93E+04 1.93E+04
Steam out S6 207 1.00 l -1.93E+04 -1.93E+04 0
Input S7 207 1.00 l 47.4 47.4
Steam out S8 207 1.00 l -47.4 -47.4 0
Input S9 207 1.00 l 427 427
Steam out S10 207 1.00 l -427 -427 0
Input S11 207 1.00 l 2160 2160
Steam out S12 207 1.00 l -2160 -2160 0
Input S13 207 1.00 l 1.85E+04 1.85E+04
Steam out S14 207 1.00 l -1.85E+04 -1.85E+04 0
Input S15 207 1.00 l 365 365
Steam out S16 207 1.00 l -365 -365 0
Input S17 207 1.00 l 4.90 4.90
Steam out S18 207 1.00 l -4.90 -4.90 0
Input S19 207 1.00 l 6.63 6.63
Steam out S20 207 1.00 l -6.63 -6.63 0
Input S21 207 1.00 l 700 700
Steam out S22 207 1.00 l -700 -700 0
Input S23 207 1.00 l 0.696 0.696
Steam out S24 207 1.00 l -0.696 -0.696 0
Input S25 207 1.00 l 942 942
Steam out S26 207 1.00 l -942 -942 0
Input S27 207 1.00 l 13.6 13.6
Steam out S28 207 1.00 l -13.6 -13.6 0
Input S28a 207 1.00 l 628 628
Steam out S28b 207 1.00 l -628 -628 0
Input S29 207 1.00 l 367 367
Steam out S30 207 1.00 l -367 -367 0

updated on 10/3/2010 25
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Graph of Cumulative Chemical Losses through Manufacturing Process

Cumulative Chemical Loss

100

90

80

70
kg chemical loss / hr

60

50

40

30

20

10

0
32c

58c
32a
32b
32d

58a
58b
58d

100
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

33
34
35
36
37
38
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
1
2
3
4
5
6
7
8
9

Fu
Process Stream

updated on 10/3/2010 26
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Graph of Cumulative Contaminated Water Use / Emission through Manufacturing Process

Cumulative Contaminated Water Use

300,000

250,000

200,000
kg contaminated water / hr

150,000

100,000

50,000

0
32c

58c
32a
32b
32d

58a
58b
58d

100
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

33
34
35
36
37
38
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
0
1
2
3
4
5
6
7
8
9

Process Stream

updated on 10/3/2010 27
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Graph of Cumulative Non-Contaminated Water Use / Emission through Manufacturing Process

Cumulative Non-Contamintated Water Use

800,000

700,000

600,000
kg non-contaminated water / hr

500,000

400,000

300,000

200,000

100,000

0
C26a
C26b
C2a
C2b

C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26

C27
C28
C29
C30
C31
C32
C33
C34

S28a
S28b
C1
C2

C3
C4
C5
C6
C7
C8
C9

S10
S11
S12
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22
S23
S24
S25
S26
S27
S28

S29
S30
S1
S2
S3
S4
S5
S6
S7
S8
S9
Process Stream

updated on 10/3/2010 28
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Energy Input for each Unit Process, Cumulative Energy Requirements, Cooling Requirements (exotherms),
and Assumed Heat Recovery from Hot Streams Receiving Cooling
Energy Input [MJ / batch] Cooling Requirements [MJ / batch]
Diagram Label

recovered [MJ
diagram label
[MJ / 1000 kg

cooling water
Type
Energy input

Energy Loss
energy type)
energy [MJ /
Cumulative

Cumulative

Cumulative
Recovered
Tef [C] (for

efficiency)
determine

Efficiency
Recovery

/ 1000 kg
recovery
(Used to
Product]

Product]

Product]
Process

Process
1000 kg

Energy

Energy
energy
To [C]
Unit

Unit
Hx1 Heat exchanger 1 442 442 55.0 S R1 Reactor 1 -1467 -1467 55.0 0 0 0
P1 Pump 1 0.0543 442 E DiG Distillation condenser -695 -2162 155 0.450 -313 -313
G
Blw2 Blower 2 0.325 443 E Hx5 Heat exchanger 5 -2.79 -2164 157 0.450 -1.26 -314
Blw1 Blower 1 2.58 445 E Hx6 Heat exchanger 6 -41.9 -2206 157 0.450 -18.8 -333
Hx2 Heat exchanger 2 12.5 458 55.0 S R3 Reactor 3 -3010 -5216 100 0.250 -752 -1085
P4 Pump 4 16.2 474 E Hx8 Heat exchanger 8 -2.64E+04 -3.16E+04 100 0.250 -6596 -7681
Hx3 Heat exchanger 3 3.13E+04 3.18E+04 55.0 S Hx9 Heat exchanger 9 -499 -3.21E+04 100 0.250 -125 -7806
P2 Pump 2 16.4 3.18E+04 E Hx10 Heat exchanger 10 -560 -3.27E+04 100 0.250 -140 -7946
P5 Pump 5 0.0867 3.18E+04 E Dis Distillation condenser -10.8 -3.27E+04 135 0.250 -2.69 -7948
s
P42 Pump 42 16.3 3.18E+04 E Hx12 Heat exchanger 12 -1.02 -3.27E+04 135 0.250 -0.256 -7949
P13 Pump 13 16.3 3.18E+04 E Hx13 Heat exchanger 13 -2.21 -3.27E+04 135 0.250 -0.553 -7949
P12 Pump 12 1.42E-07 3.18E+04 E DiN Distillation condenser -364 -3.30E+04 116 0.250 -91.0 -8040
N
Hx4 Heat exchanger 4 77.0 3.19E+04 157 S Hx15 Heat exchanger 15 -3704 -3.67E+04 100 0.250 -926 -8966
DiG Distillation reboiler G 693 3.26E+04 155 S DiQ Distillation condenser -1533 -3.83E+04 98.9 0.250 -383 -9350
Q
P6 Pump 6 1.04E-03 3.26E+04 E DiR Distillation condenser -1019 -3.93E+04 116 0.250 -255 -9604
R
P7 Pump 7 0.0857 3.26E+04 E Hx17 Heat exchanger 17 -128 -3.94E+04 115 0.250 -32.1 -9637
P17 Pump 17 0.145 3.26E+04 E Hx18 Heat exchanger 18 -2.76 -3.94E+04 115 0.250 -0.689 -9637
P18 Pump 18 0.0817 3.26E+04 E Hx19 Heat exchanger 19 -3.17E+04 -7.11E+04 55.1 0 0 -9637
P19 Pump 19 0.102 3.26E+04 E Hx20 Heat exchanger 20 -560 -7.17E+04 100 0.250 -140 -9777
P20 Pump 20 0.201 3.26E+04 E
R2 Reactor 2 3511 3.61E+04 100 S
Hx7 Heat exchanger 7 3.01E+04 6.62E+04 100 S
P22 Pump 22 0.359 6.62E+04 E
P23 Pump 23 0.136 6.62E+04 E
P25 Pump 25 0.110 6.62E+04 E
updated on 10/3/2010 29
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
P26 Pump 26 0.157 6.62E+04 E
Cnv2 Conveyer 2 3.70E-03 6.62E+04 E
Dry1 Dryer 1 593 6.68E+04 100 S
P27 Pump 27 0.0403 6.68E+04 E
P28 Pump 28 0.0324 6.68E+04 E
P29 Pump 29 7.83E-03 6.68E+04 E
Hx11 Heat exchanger 11 7.97 6.68E+04 110 S
DiS Distillation reboiler S 10.8 6.68E+04 135 S
P44 Pump 44 5.37E-04 6.68E+04 E
P45 Pump 45 7.30E-03 6.68E+04 E
DiN Distillation reboiler N 1137 6.80E+04 116 S
Hx14 Heat exchanger 14 1.13 6.80E+04 100 S
P31 Pump 31 0.0641 6.80E+04 E
P32 Pump 32 0.0646 6.80E+04 E
P36 Pump 36 0.140 6.80E+04 E
P48 Pump 48 4.24E-04 6.80E+04 E
DiQ Distillation reboiler Q 1531 6.95E+04 98.9 S
P33 Pump 33 0.0598 6.95E+04 E
P34 Pump 34 4.63E-03 6.95E+04 E
Hx16 Heat exchanger 16 22.1 6.95E+04 115 S
P37 Pump 37 0.0579 6.95E+04 E
P38 Pump 38 1.77E-03 6.95E+04 E
P8 Pump 8 1.93 6.95E+04 E
P9 Pump 9 0.954 6.95E+04 E
P10 Pump 10 1.29 6.95E+04 E
P11 Pump 11 0.125 6.95E+04 E
Cnv1 Conveyer 1 3.93E-03 6.95E+04 E
Dry2 Dryer 2 596 7.01E+04 100 S
MxE1 Mixer electricity 1 0.817 7.01E+04 E
MxE2 Mixer electricity 2 0.758 7.01E+04 E
MxE3 Mixer electricity 3 0.201 7.01E+04 E
MxE4 Mixer electricity 4 182 7.03E+04 E
Potential recovery -9777 6.05E+04
Net energy 6.05E+04 Potential recovery: -9777

updated on 10/3/2010 30
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
Electricity 258 E [MJ/hr]
Heating steam 7.01E+04 S [MJ/hr]
Energy input requirement 7.03E+04 [MJ/hr]
Cooling water -7.17E+04 [MJ/hr]
Cooling refrigeration [MJ/hr]
Potential heat recovery -9777 [MJ/hr]
Net energy 6.05E+04 [MJ/hr]

updated on 10/3/2010 31
Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.
 MJ / hr

10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000

0
Start
Heat exchanger 1

updated on 10/3/2010
Pump 1
Blower 2
Blower 1
Heat exchanger 2
Pump 4
Heat exchanger 3
Pump 2
Pump 5
Pump 42
Pump 13
Pump 12
Heat exchanger 4
Distillation reboiler G
Pump 6
Pump 7
Pump 17
Pump 18
Pump 19
Pump 20
Reactor 2
Graph of Cumulative Energy Requirements

Heat exchanger 7
Pump 22
Pump 23
Pump 25
Pump 26
Conveyer 2
Dryer 1
Pump 27
Pump 28
Pump 29

Process Unit

Griffing and Overcash, Chemical Life Cycle Database, www.environmentalclarity.com, 1999-present.

Heat exchanger 11
Cumulative Energy Input

Distillation reboiler S

32
Pump 44
Pump 45
Distillation reboiler N
Heat exchanger 14
Pump 31
Pump 32
Pump 36
Pump 48
Distillation reboiler Q
Pump 33
Pump 34
Heat exchanger 16
Pump 37
Pump 38
Pump 8
Pump 9
Pump 10
Pump 11
Conveyer 1
Dryer 2
Mixer electricity 1
Mixer electricity 2
Mixer electricity 3
Mixer electricity 4
Potential recovery