Chemical engineering senior design project

1. CO-PRODUCTION OF
JAE CHO, JOHN CHE & PO CHEN
(soil fumigant)
DEPT. OF CHEMICAL ENGINEERING, UCSB
JUNE 11, 2013
ALLYL CHLORIDE &
1,3-DICHLOROPROPENE

2. PROPYLENE CHLORINATION
2
HCl HCl
DESIRED
UNDESIRED
polychlorinated hydrocarbons
heavy ends
(e.g. tar, coke)
1,2-dichloropropane (12DA)
propylene (P) allyl chloride (AC) 1,3-dichloropropene (13DE)
1,3-Dichloropropene: a profile, Dow Agrosciences LLC, Indianapolis, IN, 1996.
H. P. A. Groll and G. Hearne, Industrial and Engineering Chemistry, vol. 31, no. 12, pp. 1530-1537, 1939.
$1.87/kg $2.53/kg $2.35/kg*
*assume Floraglow price of $10/gal (92 wt%)
$0.36/kg
Challenge: selectively produce target values of AC and 13DE

3. 3
CONCEPTUAL DESIGN
Col-1
Absorber Dryer
Col-2 Col-3
13DE12DA 13DE
Furnace
PFR
Expander
AC 12DA 13DE
Compressor
P Cl HCl
AC
12DA
H2O
P Cl
36 wt% aq. HCl
NaOH
wet NaOH
Recycle P Cl
P Cl
MR=11
T=400°C
P=15 bar

4. 4
Optimizing profitability
0.00 0.25 0.50 0.75 1.00
0
5
10
15
20
25
water
furnace compressor
steam
Expenses[$MM/Yr]
ConversionCl
refrigeration
0.25 0.50 0.75 1.00
0
25
50
75
PR
12DA/AC =0.1
Revenue[$MM/Yr]
PR13DE/AC
PR
12DA/AC =0
0.0634
60
67.3
Revenue(PR12DA/AC, PR13DE/AC) – Expenses(ConversionCl)
increasing PR12DA/AC
decreases revenue
Revenue peaks with PR13DE/AC
decreasing ConversionCl
asymptotically increases expenses
(minimize) (optimize)

5. 0.0 0.2 0.4 0.6 0.8 1.0
0
10
20
30
NPV%
[%/Yr]
ConversionCl
PFR
200 300 400 500 600 700
5
10
15
20
NPV%
T [C]
MRP/Cl
-0.6000
-0.4000
-0.2000
0.03000
0.1000
0.1350
0.1450
0.1490
0.1530
5
Reactor design:
INLET COMPOSITION AND TEMPERATURE
*MR =
P
Cl

6. 6
Separator design:
ASPEN PLUS
1 2 3 4 5 6
0.00
0.25
0.50
0.75
1.00
Cl
P
0.36 HCl
Massfractioninliquid
Stage
AC
12DA
(13DE)
Cl
(HCl,P)
12DA
13DE AC
HCl-P-Cl
AC-12DA-13DE AC
12DA-13DE
12DA
13DE
P-Cl-H2O
P-Cl
15 bar
1 bar
1 bar
1 bar
1 bar

7. 7
Process simulation:
HYSYS
1 3 5 7 9 11 13 15
0.50
0.75
1.00
1.25
1.50
Column 3
Column 2
Normalizedoperationcosts
Column pressure [bar]
Column 1
PRSV equation of state model
accurate densities and energies
at high T and p
UNIFAC semi-empirical activity model
correctly predicts VLE
Electrolyte-NTRL
Electrolytic dissociation process during absorption
ConversionCl=0.9373
S13DE/AC=0.2609
S12DA/AC=0.1840
MR=11
T=400 °C
p=15 bar HCl-P-Cl / AC-12DA-13DE
p=15 bar
AC / 12DA-13DE
p=1 bar
12DA / 13DE
p=1 bar
HCl / P-Cl
p=1 bar
0.00 0.25 0.50 0.75 1.00
0.0
0.1
0.2
0.3
0.4
PR
13D
E/ACT=450
T=400
T=350
T=350
T=400
PR12DA/AC
T=450
ProductRatios
ConversionCl

8. 8
PROPOSED DESIGN
Col-1
Absorber
2.22 kg/s
Dryer
18.13 kg/s
Col-2
Col-3
0.54 kg/s
107.1 °C
1 bar
Fresh Feed
Propene
12DA Product
AC Product
13DAE Product
HCl
3.52 kg/s 36 wt% HCl
Mixer
17.85 kg/s
27.92 °C
1 bar
1.60 kg/s H2O
1.15 kg/s
97.44 °C
1 bar
PFR
1 bar
2.83 kg/s
176.8 °C
15 bar
490.5 °C
400 °C 310 °C 220 °C
130 °C 40 °C
Sat. liq.
32.3 °C
15 bar
22.23 kg/s
27.57 °C
1 bar
400 °C
15 bar
0.28 kg/s H2O
53.18 °C
1 bar
19.41 kg/s
37.14 °C
15 bar
Fresh Feed
Chlorine
2.78 kg/s
1.68 kg/s
44.61 °C
1 bar
0.61 kg/s
94.67 °C
1 bar
0.17 m3
X=0.9373
S54=0.2609
S64=0.1840 15 bar
22 Stages
R=0
6 Stages
Wet NaOH
NaOH
1 bar
37 Stages
R=0.51
1 bar
39 Stages
R=2.45

9. CSTR
Proposed Design
9
ABSORBER FIRST
ConversionCl=0.6528
PR13DE/AC=0.2695
PR12DA/AC=0.1856
HCl/P-Cl-AC-12DA-13DE
p=1 bar
P-Cl / AC-12DA-13DE
p=1 bar
AC / 12DA-13DE
p=1 bar
12DA / 13DE
p=1 bar
NPVproj=$6.3 MM
NPV%=1.3%
NPVproj=$32.6 MM
NPV%=6.6%
NPVproj=$35.2 MM
NPV%=7.7%

10. 10
Col-1
PFR
H2O Water
Exit
NaOH
Col-2
Col-3
TC
2
TC
3
TC
4
TC
5
TC
6
TC
7
AC
6
FC
6
LC
5
TC
1
LC
4
FC
5
AC
5
FC
1
LC
1
TC
8
FC
4
AC
2
AC
3
FC
2 PC
5
LC
2
PC
6
FC
3
AC
4
LC
3
Fresh Propene
Fresh Chlorine
FT
÷RC
AC
1
PC
3
PC
2
PC
1
PC
4
HCl
12DA
13DE
AC
PROCESS CONTROLS:
PRODUCTION AND SAFETY

11. ECONOMIC ANALYSIS
11
0.75
1.00
1.25
1.50
1.75
2.00
P
2011
2010
2009
2008
2007
2006
AC
2005
Price($/kg)
Commodity Chemicals, IndexMundi.com, 2012, accessed 2013
Chemical Economics Handbook:, SRI Consulting, Menlo Park, California, 2010.
P
Cl
HCl
AC
13DE
∆NPV
%∆price Pay-out time: 4.7 years
NPVproj: $35.2 MM
NPV% 7.7%
IRR: 18.7%
PBT: $14.7 MM/Yr
TCI: $37.8 MM

12. SAFETY ANALYSIS
12
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
400
420
440
460
480
500
Temperature[C]
Reactor volume [m
3
]
Summary Stability and reactivity Auto-ignition [⁰C] Flash point [⁰C]
P Highly flammable, harmful Stable; reactive to oxidizing agents 454.85 -108.15
Cl Non-flamable, harmful Stable; reactive to reducing and combustible agents N/A N/A
HCl Non-flamable, highly harmful Stable; highly reactive to metals N/A N/A
AC Highly flammable, harmful Stable; reactive to oxidizing agents 485 -28.9
13DE Flammable, highly harmful Stable; incompatible with metals N/A 28
12DA Highly flammable, harmful Stable; incompatible with alkali and alkaline metals 557 15
Material Safety Data Sheet, ScienceLab.com, 2005, accessed 2013.
490.5

13. SAFETY ANALYSIS
13
Safe to use? CS SS Monel Ti
P Yes Yes Yes Yes
Cl No Yes Yes Yes
HCl No No Yes* Yes
13DE Yes Yes Yes Yes
12DA Yes Yes Yes Yes
AC No Yes Yes Yes
Compatibility Manual, FMC Technologies, Houston, TX, 1996.
Material Safety Data Sheet, ScienceLab.com, 2005, accessed 2013.
P
Cl
Recycle P & Cl
H2O aq. HCl
AC 12DA
13DE
NaOH H2O-NaOH
*up to 20 wt% concentration
Monel
SS CS
MonelTi
H2O-HCl
H2O-P-Cl P-Cl
H2O-NaOH
AC
12DA-13DE
12DA
13DE
REACTOR
HCl-P-Cl
AC-12DA-13DE

14. NOT RECOMMENDED
CONCLUSION
14
Optimized to selectively produce target values of AC and 13DE…
Pay-out Time: 4.7 years, NPV% = 7.7%, NPVproj = $35.2 MM, TCI = $37.8 MM
Sensitive to uncertain market; high safety risk
Col-1
Absorber
2.22 kg/s
Dryer
18.13 kg/s
Col-2
Col-3
0.54 kg/s
107.1 °C
1 bar
Fresh Feed
Propene
12DA Product
AC Product
13DAE Product
HCl
3.52 kg/s 36 wt% HCl
Mixer
17.85 kg/s
27.92 °C
1 bar
1.60 kg/s H2O
1.15 kg/s
97.44 °C
1 bar
PFR
1 bar
2.83 kg/s
176.8 °C
15 bar
490.5 °C
400 °C 310 °C 220 °C
130 °C 40 °C
Sat. liq.
32.3 °C
15 bar
22.23 kg/s
27.57 °C
1 bar
400 °C
15 bar
0.28 kg/s H2O
53.18 °C
1 bar
19.41 kg/s
37.14 °C
15 bar
Fresh Feed
Chlorine
2.78 kg/s
1.68 kg/s
44.61 °C
1 bar
0.61 kg/s
94.67 °C
1 bar
0.17 m3
X=0.9373
S54=0.2609
S64=0.1840 15 bar
22 Stages
R=0
6 Stages
Wet NaOH
NaOH
1 bar
37 Stages
R=0.51
1 bar
39 Stages
R=2.45

15. THANK YOU
15
Acknowledgements:
Professor Brad Chmelka
Professor Michael Doherty
Professor Duncan Mellichamp
Professor Scott Shell
Jae Cho, John Che, Po Chen | Department of Chemical Engineering, University of California, Santa Barbara | 2013

16. 16
CONCEPTUAL DESIGN
REACTOR SEPARATOR
P
Cl
Recycle P & Cl
AC
13DE
12DA
+minor
byproducts
water 36 wt% aq. HCl

17. 17
F
22.23 kg/s
27.57°C
1 bar
FCl
2.78 kg/s
25°C
1 bar
FP
1.60 kg/s
25°C
1 bar
Col-1
HEX-101
HEX-102
HCl
Absorber
H2O
Absorber
Col-2
HEX-202
HEX-201
Col-3
HEX-302
HEX-301
Fresh Feed
Propene
12DA
Incineration
AC Product
13DEProduct
HCl
Mixer
NaOH
H2O
Furnace
PFR
Expander
Valve
Compressor
HEX-007
Fresh Feed
Chlorine
178.7°C
15 bar
400°C
15 bar
490.5°C 400.°C 310.°C
220.°C 40.°C
D1
19.41 kg/s
37.14°C
15 bar
B1
2.83 kg/s
176.8°C
15 bar
-36.55°C
1 bar
36 wt% HCl
3.52 kg/s
W1
2.22 kg/s
25°C
1 bar
R/W
18.13 kg/s
28.27°C
1 bar
R
17.85 kg/s
27.92°C
1 bar
53.18°C
1 bar
D2
1.68 kg/s
D3
0.61 kg/s
B2
1.15 kg/s
97.44°C
1 bar
B3
0.54 kg/s
0.17 m3
X=0.9373
S54=0.2609
S64=0.1840
15 bar
22 Stages
R=0.00
FLK,D = 0.9894
FHK,B = 0.9087
1 bar
37 Stages
R=0.51
FLK,D = 1.0000
FHK,B = 0.9842
1 bar
39 Stages
R=2.45
FLK,D = 0.9769
FHK,B = 0.7860
9 Stages
FHCl = .9994
HEX-001 HEX-002 HEX-003
HEX-004 HEX-005 HEX-006
130.°C
P
22.23 kg/s
490.5°C
15 bar
220.°C
Sat. liq.
22.23 kg/s
32.3.°C
15 bar
135°C
1 bar
Contaminated
NaOH
W2 H2O
0.28 kg/s
PROPOSED DESIGN

18. 18
F
22.23 kg/s
27.57°C
1 bar
FCl
2.78 kg/s
25°C
1 bar
FP
1.60 kg/s
25°C
1 bar
Col-1
HEX-101
HEX-102
HCl
Absorber
H2O
Absorber
Col-2
HEX-202
HEX-201
Col-3
HEX-302
HEX-301
Fresh Feed
Propene
12DA
Incineration
AC Product
13DEProduct
HCl
Mixer
NaOH
H2O
Furnace
PFR
Expander
Valve
Compressor
HEX-007
Fresh Feed
Chlorine
178.7°C
15 bar
400°C
15 bar
490.5°C 400.°C 310.°C
220.°C 40.°C
D1
19.41 kg/s
37.14°C
15 bar
B1
2.83 kg/s
176.8°C
15 bar
-36.55°C
1 bar
36 wt% HCl
3.52 kg/s
W1
2.22 kg/s
25°C
1 bar
R/W
18.13 kg/s
28.27°C
1 bar
R
17.85 kg/s
27.92°C
1 bar
53.18°C
1 bar
D2
1.68 kg/s
D3
0.61 kg/s
B2
1.15 kg/s
97.44°C
1 bar
B3
0.54 kg/s
0.17 m3
X=0.9373
S54=0.2609
S64=0.1840
15 bar
22 Stages
R=0.00
FLK,D = 0.9894
FHK,B = 0.9087
1 bar
37 Stages
R=0.51
FLK,D = 1.0000
FHK,B = 0.9842
1 bar
39 Stages
R=2.45
FLK,D = 0.9769
FHK,B = 0.7860
9 Stages
FHCl = .9994
HEX-001 HEX-002 HEX-003
HEX-004 HEX-005 HEX-006
130.°C
P
22.23 kg/s
490.5°C
15 bar
220.°C
Sat. liq.
22.23 kg/s
32.3.°C
15 bar
135°C
1 bar
Contaminated
NaOH
W2 H2O
0.28 kg/s

19. 19
0.00 0.25 0.50 0.75 1.00
0
10
20
30
40
50
13DE
production
3 MM gal/year
Molarflowrate[kmol/hr]
S13DE/AC
Optimizing profitability
0.00 0.25 0.50 0.75 1.00
0
5
10
15
20
25
water
furnace compressor
steam
Expenses[$MM/Yr]
ConversionCl
refrigeration
0.00 0.25 0.50 0.75 1.00
0
1000
2000
3000
4000
5000
recycle
feed
effluent
fresh feed
Molarflows[kmol/hr]
ConversionCl
0.25 0.50 0.75 1.00
0
25
50
75
PR
12DA/AC =0.1
Revenue[$MM/Yr]
PR13DE/AC
PR
12DA/AC =0
0.0634
60
67.3
Revenue(PR12DA/AC, PR13DE/AC) – Expenses(ConversionCl)
decreasing ConversionCl
asymptotically increases expenses
(minimize) (optimize)

20. 20
0.0 0.2 0.4 0.6 0.8 1.0
-30
-20
-10
0
10
20
30
CSTR
NPV%
[%/Yr]
ConversionCl
PFR
0.0 0.2 0.4 0.6 0.8 1.0
0.0
0.2
0.4
0.6
0.8
1.0
T=550T=550
T=450
CSTR
T=350
T=450
PFR
T=350
S12DA/AC
Conversion
0.0 0.2 0.4 0.6 0.8 1.0
0.0
0.2
0.4
0.6
0.8
1.0
PFR
T=550
T=350
T=450
T=350
T=450
S13DE/AC
ConversionCl
CSTR
T=550
Reactor design:
CSTR or PFR?
CSTR S13DE/AC vs. ConversionCl
increases more with T
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
400
420
440
460
480
500
CSTR
PFR
Temperature[C]
Reactor volume [m
3
]
D. A. Mellichamp, Computers and Chemical Engineering, vol. 48, pp. 251-263, 2013.
NPV% =
NPVproj
TCI ∙ Project Lifetime

21. 21
0.0000
0.0002
0.0004
0.0006
5 10 15 20
0.00
0.15
0.30
0.45
T=250
T=350
T=450
S13DE/AC
T=250
T=350
S12DA/AC
T=450
MR
200 300 400 500 600 700
0
1
2
3
4
5
6
7
0.00000
0.00005
0.00010
0.00015
0.00020
0.00025
S12DA/AC
Temperature [C]
S13DE/AC
MR=7
MR=11
MR=15
MR=7
MR=11
MR=15
Reactor design:
INLET COMPOSITION AND TEMPERATURE
*MR =
P
Cl

22. SAFETY ANALYSIS
22
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
400
420
440
460
480
500
Temperature[C]
Reactor volume [m
3
]
Summary Stability and reactivity Auto-ignition [⁰C] Flash point [⁰C]
P Highly flammable, harmful Stable; reactive to oxidizing agents 454.85 -108.15
Cl Non-flamable, harmful Stable; reactive to reducing and combustible agents N/A N/A
HCl Non-flamable, highly harmful Stable; highly reactive to metals N/A N/A
AC Highly flammable, harmful Stable; reactive to oxidizing agents 485 -28.9
13DE Flammable, highly harmful Stable; incompatible with metals N/A 28
12DA Highly flammable, harmful Stable; incompatible with alkali and alkaline metals 557 15
Material Safety Data Sheet, ScienceLab.com, 2005, accessed 2013.
490.5

23. SAFETY ANALYSIS
23
Safe to use? CS SS Monel Ti
P Yes Yes Yes Yes
Cl No Yes Yes Yes
HCl No No Yes* Yes
13DE Yes Yes Yes Yes
12DA Yes Yes Yes Yes
AC No Yes Yes Yes
Compatibility Manual, FMC Technologies, Houston, TX, 1996.
Material Safety Data Sheet, ScienceLab.com, 2005, accessed 2013.
P
Cl
Recycle P & Cl
H2O aq. HCl
HCl-P-Cl
AC-12DA-13DE
H2O-HCl
H2O-P-Cl P-Cl
H2O-NaOH
AC
12DA-13DE
12DA
13DE
AC 12DA
13DE
REACTOR NaOH H2O-NaOH
*up to 20 wt% concentration
Monel
SS CS
MonelTi

24. ECONOMIC ANALYSIS
24
Construction Rate 6.0% PBT $14.7 MM/Yr TCI $37.8 MM
Finance Rate 4.0% Revenue $147.5 MM/Yr TI $37.4 MM
Enterprise Rate 8.0% HCl Stream $9.7 MM/Yr FC $15.0 MM
Tax Rate 48.0% AC Stream $127.7 MM/Yr Reactor $0.0 MM
Salvage Value 3.0% 13DE Stream $10.1 MM/Yr Distillation $0.5 MM
Start-up Capital 10.0% Operating Costs $132.9 MM/Yr Absorbers $1.5 MM
Construction Time 2 years Propylene Stream $94.2 MM/Yr Heat Exchangers $1.0 MM
Project Lifetime 10 years Chlorine Stream $31.2 MM/Yr Compressor $1.6 MM
Pay-out Time 4.7 years Inceration Cost $3.2 MM/Yr Furnace $1.9 MM
NPV0 $41.1 MM Steam Cost $1.2 MM/Yr Working Capital $20.9 MM
NPVproj $35.2 MM Water Cost $0.7 MM/Yr Start-up Cost $1.5 MM
NPV% 7.7% Refrigeration Cost $0.9 MM/Yr
ROIBT 39.2% Furnace Cost $1.2 MM/Yr
IRR 18.7% Compressor Cost $0.3 MM/Yr
P
Cl
HCl
AC
13DE
0.75
1.00
1.25
1.50
1.75
2.00
P
2011
2010
2009
2008
2007
2006
AC
2005
Price($/kg)
Commodity Chemicals, IndexMundi.com, 2012, accessed 2013
Chemical Economics Handbook:, SRI Consulting, Menlo Park, California, 2010.
sensitivity

25. 25
P Cl HCl AC 13DE 12DA
price [$/kg pure] 1.87 0.36 0.09 2.53 2.17 -0.30
price [$/kmol pure] 76.69 25.53 8.61 193.60 245.27 -22.60
price common units $85/ton
(36 wt% in H2O)
$10/US gallon
(92 wt% soln)

26. 26
Construction Rate 6.0% PBT $14.7 MM/Yr TCI $37.8 MM
Finance Rate 4.0% Revenue $147.5 MM/Yr TI $37.4 MM
Enterprise Rate 8.0% HCl Stream $9.7 MM/Yr FC $15.0 MM
Tax Rate 48.0% AC Stream $127.7 MM/Yr Reactor $0.0 MM
Salvage Value 3.0% 13DE Stream $10.1 MM/Yr Distillation $0.5 MM
Start-up Capital 10.0% Operating Costs $132.9 MM/Yr Absorbers $1.5 MM
Construction Time 2 years Propylene Stream $94.2 MM/Yr Heat Exchangers $1.0 MM
Project Lifetime 10 years Chlorine Stream $31.2 MM/Yr Compressor $1.6 MM
Pay-out Time 4.7 years Inceration Cost $3.2 MM/Yr Furnace $1.9 MM
NPV0 $41.1 MM Steam Cost $1.2 MM/Yr Working Capital $20.9 MM
NPVproj $35.2 MM Water Cost $0.7 MM/Yr Start-up Cost $1.5 MM
NPV% 7.7% Refrigeration Cost $0.9 MM/Yr
ROIBT 39.2% Furnace Cost $1.2 MM/Yr
IRR 18.7% Compressor Cost $0.3 MM/Yr

27. 27

28. 28

29. 29

30. 30

31. 31

32. 32

33. 33

34. 34
0 5 10 15 20
0.0
0.2
0.4
0.6
0.8
1.0
Molarfraction
Stage
Propylene
Chlorine
Hydrogen-Chloride
Allyl-Chloride
1 2 3 4 5 6
0.0
0.2
0.4
0.6
0.8
1.0
Massfraction
Stage
Propylene
Chlorine
Hydrogen-Chloride
Allyl-Chloride
0 10 20 30 40
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Molefraction
Stage
3-dichloropropene* (Light Liq)
2-Dichloropropane (Light Liq)
0 5 10 15 20 25 30 35
0.0
0.2
0.4
0.6
0.8
1.0
Molefraction
Stage
Allyl-Chloride (Light Liq)
3-dichloropropene* (Light Liq)
2-Dichloropropane (Light Liq)

35. 35
0.0 0.2 0.4 0.6 0.8 1.0
0
20
40
60
80
100
TCI
NPVproj
NPV%
TCI[$MM],ROIBT
[%/Yr],NPVproj
[$MM/Yr],NPV%
[%/Yr]
Conversion
ROIBT
0.0 0.2 0.4 0.6 0.8 1.0
0
20
40
60
80
100
FC MM
PBT[$MM/Yr],FC[$MM]
Conversion
PBT MM

36. 36
0.0 0.2 0.4 0.6 0.8 1.0
0
5
10
15
20
25
AB/CD A/B C/D
A/BCD BC/D B/C
NPV%
[%/Yr]
Conversion
A/BCD B/CD C/D
1 3 5 7 9 11 13 15
0.50
0.75
1.00
1.25
1.50
Column 3
Column 2
Normalizedoperationcosts
Column pressure [bar]
Column 1