Detailed Process Flow Diagram with Discussion

The Ethylene dichloride (EDC) undergoes oxychlorination process to produce Perchloroethylene

(PCE), Trichloroethylene (TCE) and water. Equation (1) shows the reaction of EDC oxychlorination

process. The raw materials for this process are, EDC, chlorine, hydrogen chloride (HCl), and oxygen.

Ethylene dichloride will be produced via direct chlorination using ethylene and chlorine. Equation (2)

shows the reaction of direct chlorination using ethylene and chlorine.

2C2H4Cl2 + Cl2 + 2O2 + HCl -> C2HCl3 + 4H2O + C2Cl4 (1)

C2H4 + Cl2 -> C2H4Cl2 (2)

Ethylene is stored in a vessel (V-100) with a pressure of 101.3 kPa, and a temperature of -104.1oC.

Chlorine is stored in a vessel (V-101) with a pressure of 101.3 kPa and a temperature of -33.46oC. Ethylene

will be mixed with chlorine in a mixer (MIX-100), having a mass flow of 3,735 kg/h of ethylene and 4,858

kg/h of chlorine. The product of the mixer will be heated by passing through the tube side of a heat

exchanger (E-100) with water on the shell side. The temperature and pressure of the tube side inlet is -

97.97oC and 101. 3 kPa while the temperature and pressure of the tube side outlet is 90oC and 152 kPa. For

the shell side, the water will pass through a fired heater (FR-100) having a temperature of 90oC, pressure

of 101.3 kPa and mass flow of 207,200 kg/h.

The product of the heat exchanger will pass through a continuous stirred tank reactor (CSTR-100)

in the presence of a ferric chloride catalyst (FeCl3) having the equation (2) for the reaction. The kinetic data

for the reactor are A = 1.1493x107 and E = 17,931. The CSTR will yield EDC with a temperature of 90oC,

pressure of 152 kPa and mass flow of 8,593 kg/h. Air is stored in a vessel (V-104) with 27oC and 101.3

kPa. It will be cooled by passing through the tube side of a heat exchanger (E-101) having an inlet of 27oC

and 101.3 kPa, outlet of 25oC and 5,000 kPa and a mass flow of 1,000 kg/h. For the shell side, the water

will pass through a cooling tower (CT-100) giving a shell side inlet of 5oC and 101. 3 kPa and outlet of

25oC and 101.3 kPa.

 The cooled air from the heat exchanger will pass through a column (T-100) for the separation of

O2 and N2. The nitrogen from the column will be sent to the flare to be used as a purge gas. The oxygen

from the column has a temperature of -183.2oC and a pressure of 101.3 kPa. Hydrogen chloride from the

vessel (V-102) has a temperature of -84.31oC, pressure of 101.3 kPa and a mass flow of 8,500 kg/h. Chlorine

from the vessel (V-103) has a temperature of 20oC, pressure of 666 kPa and mass flow of 4,308 kg/h. EDC,

hydrogen chloride, chlorine and oxygen will be fed to the mixer (MIX-101) together having a product of

1,290,000 kg/h with temperature and pressure of 184.4oC and 101.3 kPa.

The product of the mixer will be heated by passing through the tube side of a heat exchanger (E-

102) which will give an outlet temperature and pressure of 3,000oC and 2,500 kPa. The shell side of this

heat exchanger will also have the water passing through the fired heater (FR-100) having an inlet and outlet

of 3,200oC and 3,000oC. The outlet of the tube side will pass through a plug flow reactor (PFR-100) in the

presence of a copper(II) chloride catalyst having the equation (1) for the reaction and kinetic data of A =

1x1014 and E = 199,900. The product of the reactor will be cooled by water from the cooling tower passing

through the shell side while the product pass through the tube side of a heat exchanger (E-103). Then, the

condensed product will be fed to a three-phase separator (S-100). The vapour phase that contains HCl and

other impurities will pass through the tube side of a heat exchanger (E-104) cooling it by water from the

cooling tower passing through the shell side of a heat exchanger. Water will be separated from the product

along with catalyst fines and it will be sent to wastewater treatment plant. The liquid phase containing small

amounts of PCE, TCE and other impurities are fed to a distillation column (T-101) with a mass flow of

1,984,000 kg/h at 10.09oC and 279.4 kPa.

The distillation column will have a bottoms product containing PCE, TCE and other impurities

with a mass flow of 1,975,000 kg/h at 43.04oC and 500 kPa. It will be further distilled to a distillation

column (T-102) producing a bottoms product of 99% PCE with a mass flow of 3420 kg/h at 164.6oC and

300 kPa. While the overhead product of T-101 contains HCl will be fed to a mixer (MIX-103) with the

cooled HCl from E-104. The product from the mixer will be recycled and will be reacted with ethylene and
air. Air will be compressed to 506.6 kPa from 101.3 kPa and 250.6oC from 25oC before feeding it to the

mixer (MIX-104) with recycled HCl and ethylene.

The overhead product of T-102 containing 63% EDC will be heated to 200oC by passing through

the tube side of a heat exchanger (E-105) then it will be recycled to the mixer (MIX-101). The mixed

product will be heated by a heat exchanger (E-106) to 300oC then it will be fed to a continuous stirred tank

reactor (CSTR-101) with equation (3) for the reaction. The kinetic data are A = 1.8490x108 and E = 97.720.

The reactor will yield EDC and other impurities at 300oC and 101.3 kPa.

HCl + O2 + C2H4 -> C2H4Cl2 +H2O (3)

EDC and other impurities will be cooled by passing through the tube side of heat exchanger (E-

107) to a temperature of 20oC then it will be fed to a three-phase separator (S-101). Water will be separated

and will be sent to wastewater treatment plant. Nitrogen will also be sent to the flare to be used as a purge

gas. The liquid phase of the separator containing 95% EDC will be heated to 55oC then will be recycled to

the mixer (MIX-101).

 FR-100

V-105

E-108
V-102 V-103
RCY-2

V-101 V-106
RCY-1

TO
V-100 FLARE
MIX-103 E-106

E-104
E-107 S-101
MIX-104 TO
V-107 CSTR-101 WASTEWATER
E-100 TREATMENT
MIX-100 CSTR-100 E-102
PFR-100 E-103 S-100
E-105
TO
TO MIX-101 WASTEWATER
V-104 T-101
FLARE TREATMENT

COMP-100
T-102
E-101 V-108

T-100
PCE

TEE-100

MIX-102

CT-100

No Revision Date Group Number: 2

Group Names:
CRUZ, AIKO ROWYENA C. PROCESS FLOW
DE GUZMAN, ARIELLE FRANCES E.

PEREZ, CRISTINE B. DIAGRAM