INTRODUCTION

Chloroethane or monochloroethane, commonly known by its old name ethyl chloride, is

a chemical compound with chemical formula C2H5Cl, once widely used in

producing tetraethyllead, a gasoline additive. It is a colorless, flammable gas or refrigerated

liquid with a faintly sweet odor. Ethyl chloride is a chemical compound with chemical formula

C2H5Cl, once widely used in producing tetra-ethyl lead, a gasoline additive. It is a colourless,

flammable gas or refrigerated liquid with a faintly sweet odour. Ethyl chloride is produced by the

reaction of ethylene and hydrogen chloride over an aluminium chloride catalyst at temperatures

ranging from 130-250°C. Under these conditions, ethyl chloride is produced according to the

chemical equation:

C2H4 + HCl → C2H5Cl

At various times in the past, ethyl chloride has also been produced from ethanol and hydrochloric

acid, or from ethane and chlorine, but these routes are no longer economical. Some ethyl chloride

is generated as a by-product of polyvinyl chloride production.

Industrial use of this chlorinated hydrocarbon has declined sharply due to environmental

concerns. In fact, the only consistent use of this chemical in manufacturing today is in the

production of cosmetics and paints, where it is used to enhance the binding and thickening

properties of cellulose. Ethyl chloride has retained value as a skin coolant and anaesthetics,

however, and has emerged as a treatment for pain relief from muscle soreness.

Ethane may be chlorinated thermally, catalytically, photochemically or electrolytically.

Monochlorination is favoured because ethyl chloride chlorinates at about one-fourth of the rate

of which it is itself produced from ethane. Thermal chlorination of ethane is generally carried out

at 250-500 C. The chlorine and ethane are brought together in a fluid bed of finely, inert, solid

heat-transfer medium at 380-440 C the linear velocity of the gas is sufficient to maintain the

finely divided solid in suspension within the reactor.

The chlorination of ethane may be catalyzed by bringing the reacting gases into contact with metal chlorides, or crystalline carbon. Photochemical chlorination is not used industrially

OBJECTIVES

To install and converge a conversion reactor

To simulate a process involving reaction and separation

To use the Recycle operation in HYSYS

THEORY

PRODUCTION OF ETHYL CHLORIDE

Process:

One of the routes to produce ethyl chloride is by the gas-phase reaction of HCl with ethylene

over a copper chloride catalyst supported on silica:

C2H4 + HCl - C2H5Cl

In this process, the feed stream is composed of 50 mol% HCl, 48 mol% C2H4 and 2 mol% N2 at

100 kmol/hr, at 25oC and 1 atm. Since the reaction only achieves 90 mol% conversion, the ethyl

chloride product is separated from the unreacted reagents and the latter are recycled. The

separation process is operated at atmospheric pressure and pressure drops are ignored. To

prevent the accumulation of inerts in the system, 10 kmol/hr is withdrawn in a purge stream.

Hints:

1. Use Peng-Robinson equation of state (Use SI unit)

2. Assumed no pressure drop in all equipment

3. Use the TEE model to split the distillate into purge stream and recycle stream

4. Always specify/guess the outlet stream of the Recycle, never the inlet

5. Specify the mole fraction of the outlet of the Recycle, equal to the mole fraction of the

feed with a flow rate of zero

6. Process flow as shown in the following diagram

PROCEDURE

1. ASPEN PLUS User interface is open and the blank simulation was select.

2. For the first test, Stoic reactor, and heater flash2 separator is place in the simulation.

3. The entire stream was connected as can saw in PFD below.

4. The given information from question is entering into the simulation including the

reaction.

5. The simulation was run and the result from the run was shown in the workbook below.

6. For the second test recycle stream was introduce.

7. Stoic reactor, 2 heater, 2 splitter, and two outlet separator was place in the new

simulation.

8. Step 3 to step 5 was follow and the result of the to test is compare

PFD OF PRODUCTION OF ETHYL CHLORIDE BEFORE RECYCLE

PFD OF PRODUCTION OF ETHYL CHLORIDE AFTER RECYCLE

WORKBOOK OF PRODUCTION OF ETHYL CHLORIDE BEFORE RECYCLE

Heat and Material Balance Table

Stream ID 1 2 3 4 5

From R-101 E-101 V-101 V-101

To R-101 E-101 V-101

Phase VAPOR VAPOR MIXED VAPOR LIQUID

Substream: MIXED

Mole Flow kmol/hr

HCL 50 .00000 6.800000 6.800000 .1914239 6.608576

C2H4 48 .00000 4.800000 4.800000 .4899899 4.310010

N2 2.000000 2.000000 2.000000 1.931456 .0685444

C2H5CL 0.0 43 .20000 43 .20000 2.76605E-3 43 .19723

Total Flow kmol/hr 100.0000 56 .80000 56 .80000 2.615635 54 .18436

Total Flow kg/hr 3225.639 3225.639 3225.639 75 .01074 3150.629

Total Flow cum/sec .6754760 .3787914 .0114614 .0106114 8.49974E-4

Temperature C 25 .00000 25 .00000 -93.80000 -93.80000 -93.80000

Pressure atm 1.000000 1.000000 1.000000 1.000000 1.000000

Vapor Frac 1.000000 1.000000 .0460499 1.000000 0.0

Liquid Frac 0.0 0.0 .9539501 0.0 1.000000

Solid Frac 0.0 0.0 0.0 0.0 0.0

Enthalpy J/kmol -2 .0993E+7 -9 .2148E+7 -1 .2250E+8 -7 .2985E+5 -1 .2838E+8

Enthalpy J/kg -6 .5082E+5 -1 .6226E+6 -2 .1572E+6 -25450.05 -2 .2079E+6

Enthalpy Watt -5 .8314E+5 -1 .4539E+6 -1 .9328E+6 -530.2854 -1 .9323E+6

Entropy J/kmol-K -14264.02 -1 .2928E+5 -2 .4996E+5 -19077.06 -2 .6111E+5

Entropy J/kg-K -442.2076 -2276 .457 -4401 .587 -665.2199 -4490 .543

Density kmol/cum .0411 232 .0416529 1.376598 .0684699 17 .70786

Density kg/cum 1.326488 2.365447 78 .17623 1.963569 1029.649

Average MW 32 .25639 56 .78943 56 .78943 28 .67783 58 .14645

Liq Vol 60F cum/sec 1.90310E-3 1.11987E-3 1.11987E-3 4.31685E-5 1.07670E-3

WORKBOOK OF PRODUCTION OF ETHYL CHLORIDE AFTER RECYCLE

Heat and Material Balance Table

Stream ID 1 2 3 4 5 6 7 8 9

From M -101 R-101 E-101 V-101 V-101 S-101 S-101 E-102

To M -101 R-101 E-101 V-101 S-101 E-102 M -101

Phase VAPOR VAPOR VAPOR M IXED VAPOR M IXED VAPOR VAPOR VAPOR

Substream: MIXED

M ole Flow kmol/hr

HCL 50.00000 51.80000 7.456604 7.456604 6.800000 .6566040 5.000000 1.800000 1.800000

C2H4 48.00000 49.27044 4.927044 4.927044 4.799440 .1276040 3.529000 1.270440 1.270440

N2 2.000000 2.529560 2.529560 2.529560 2.000560 .5290000 1.471000 .5295600 .5295600

C2H5CL 0.0 1.7599E-12 44.34340 44.34340 6.6486E-12 44.34340 4.8887E-12 1.7599E-12 1.7599E-12

Total Flow kmol/hr 100.0000 103.6000 59.25660 59.25660 13.60000 45.65660 10.00000 3.600000 3.600000

Total Flow kg/hr 3225.639 3341.744 3341.744 3341.744 438.6173 2903.127 322.5127 116.1046 116.1046

Total Flow cum/sec .6754760 .6998194 .3953246 .0143640 .0544891 2.64394E-3 .0400655 .0144235 .0243428

Temperature C 25.00000 24.99969 25.00000 -93.80000 -93.80000 -93.80000 -93.80000 -93.80000 25.00000

Pressure atm 1.000000 1.000000 1.000000 1.000000 1.000000 1.000000 1.000000 1.000000 1.000000

Vapor Frac 1.000000 1.000000 1.000000 .0561119 1.000000 .0101179 1.000000 1.000000 1.000000

Liquid Frac 0.0 0.0 0.0 .9438880 0.0 .9898820 0.0 0.0 0.0

Solid Frac 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Enthalpy J/kmol -2.0993E+7 -2.1225E+7 -9.1407E+7 -1.2143E+8 -3.1532E+7 -1.4463E+8 -3.1532E+7 -3.1532E+7 -2.7661E+7

Enthalpy J/kg -6.5082E+5 -6.5800E+5 -1.6209E+6 -2.1532E+6 -9.7769E+5 -2.2746E+6 -9.7769E+5 -9.7769E+5 -8.5766E+5

Enthalpy Watt -5.8314E+5 -6.1080E+5 -1.5046E+6 -1.9987E+6 -1.1912E+5 -1.8343E+6 -87588.42 -31531.83 -27660.51

Entropy J/kmol-K -14264.02 -13914.86 -1.2676E+5 -2.4643E+5 -22144.61 -2.9704E+5 -22144.61 -22144.61 -5639.478

Entropy J/kg-K -442.2076 -431.3854 -2247.747 -4369.741 -686.6275 -4671.496 -686.6275 -686.6275 -174.8606

Density kmol/cum .0411232 .0411217 .0416370 1.145932 .0693308 4.796776 .0693308 .0693308 .0410798

Density kg/cum 1.326488 1.326431 2.348101 64.62419 2.236008 305.0084 2.236008 2.236008 1.324879

Average MW 32.25639 32.25622 56.39446 56.39446 32.25127 63.58613 32.25127 32.25127 32.25127

Liq Vol 60F cum/sec 1.90310E-3 1.96765E-3 1.16369E-3 1.16369E-3 2.43863E-4 9.19827E-4 1.79311E-4 6.45520E-5 6.45520E-5

QUESTION

1. What is the mole fraction for each component at the effluent of the catalytic reactor

before recycle?

Before recycle, the mole fraction for each component is 0.5 for HCL,0.48 for C2H4, 0.02

nitrogen and none C2H5CL. After the recycle effluent, the mole fraction for each

component is 0.4996 for HCL, 0.4752 for C2H4, 0.0251 nitrogen and 1.6398e-14

respectively.

2. How to get 100% purity of ethyl chloride?

By adding a distillation column.

3. What is the flow rate of the recycle stream? (in kgmole/h)

The flow rate of recycle stream is 116.1046 kgmole/h.

DISCUSSION

This experiment is about the production ethyl chloride by the gas-phase reaction of HCl with ethylene over a copper chloride catalyst on silica. The main objectives of this experiment are to install and converge a conversion reactor, to simulate a process involving reaction and separation and to use Recycle operation in HYSYS. In this process, 50 mol% of HCl, 48 mol% of C2H4 and 2 mol% of N2 were fed at 100 kmol/hr and 1 atm. Peng-Robinson equation of state was chosen as the fluid package and no pressure drop was assumed in all equipment.

Then, the entire component is fed to a conversion reactor where 90% conversion was achieved. Initially, the mole fraction for each component at the effluent of the catalytic reactor is 51.80000 kmol/hr, for HCL, 49.27044kmol/hr for C2H4, 2.529560kmol/hr nitrogen and 1.7599e-

12 respectively. For this reaction, the conversion reached only 90%, so to achieve pure 100% ethyl chloride; the ethyl chloride product must be separated from the unreacted reagents by using a distillation column. Since the reaction is in vapour phase, the vapour effluent from the reactor was

The product from distillation column is passes through the splitter to divide the product and unreacted reactant to recycle stream. Small amount of product is also channeling in to the recycle stream. Therefore the flowrate for each component is increase, from 50.00000 kmol/hr for HCL,48.00000kmol/hr for C2H4, 2.00000kmol/hr nitrogen and none C2H5CL to51.80000 kmol/hr for HCL, 49.27044kmol/hr for C2H4, 2.529560kmol/hr nitrogen and 1.7599e-12 respectively

CONCLUSION

As the conclusion, this laboratory work is successful. The conversion was successfully installed

and converged, a process involving reaction and separation was simulated and the Recycle

operation in ASPEN was used. The mole fraction for each component before recycle stream is

0.5 for HCL,0.48 for C2H4, 0.02 nitrogen and none C2H5CL. After the recycle effluent, the mole

fraction for each component is 0.4996 for HCL, 0.4752 for C2H4, 0.0251 nitrogen and 1.6398e-14

respectively

.

UNIVERSITI TEKNOLOGI MARA FAKULTI KEJURUTERAAN KIMIA

CHEMICAL ENGINEERING LAB IV @PROCESS ENGINEERING LABORATORY III

(CHE612/CPE612)

No. Title Allocated Marks (%) Marks

1 Procedure 10

2 Process Flow Diagram (PFD) 20

3 Workbook 30

4 Theory/Questions/Discussion 40

TOTAL MARKS 100

Remarks:

Checked by: Rechecked by:

------------------------------- -----------------------------------

Date: Date:

NAME :MUHAMAD AIMAN BIN HASSANSTUDENT NO. :2012266886EXPERIMENT :PRODUCTION OF ETHYL CHLORIDEDATE PERFORMED :SEMESTER : EH2205DPROGRAMME / CODE : EH220SUBMIT TO : MDM NOORSUHANA MOHD YUSOF