UNIVERSITI TEKNOLOGI MARA

FAKULTI KEJURUTERAAN KIMIA

PROCESS SIMULATION LABORATORY
(CPE613)

NAME : AHMAD AZIZAN BIN MADJAIS

STUDENT I.D : 2014814576
EXPERIMENT : LAB 5 PRODUCTION OF ETHYL CHLORIDE
SEMESTER :5
PROGRAM : EH241 5A
SUBMIT TO : DR. SHAWALLIAH IDRIS

No. Title Allocated Marks (%) Marks

1 Procedure 10
2 Process Flow Diagram (PFD) 20
3 Workbook 30
4 Questions & Discussions 40
TOTAL MARKS 100

Remarks:

Checked by: Rechecked by:

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( ) ( )
Date: Date:
OBJECTIVES:
To install and converge a conversion reactor.
To simulate a process involving reaction and separation.
To use the recycle operation in Hysys.

PROCEDURE:

1. Firstly, the Aspen Hysys software was clicked then a new iCON project started by clicking the
NEW button.
2. The Component List button clicked in order to add the components involved in the production of
acetic anhydride.
Ethylene
Hydrochloric acid
Ethyl chloride
Nitrogen
3. The Fluid Package button was clicked to choose the desired thermodynamics model. For this lab,
Peng-Robinson fluid package had been choose.
4. This lab involved a reaction, so needed to add reaction set in the simulation by clicking the
Reaction button.
The reaction was based on Conversion
The components involved in the reaction were added
The mole fraction and stoichiometric coefficients for every components
stated according to the reaction equation
The reaction set are added to FP so that the reaction set was added to the
fluid package

5. Simulation button was clicked. To insert all the unit operations needed in this reaction, are by
using the palette box.
6. The mixer, conversion reactor, TEE splitter and cooler icons was dragged from the palette box to
the case window. All the equipment involved in the production of acetic anhydride were put in
correct order in the PFD flowsheet window.
7. The initial condition or parameters values for mixer and conversion reactor was inserted by
double-clicking the conversion reactors icon and also the reaction set was selected. (Molar
flowrate, composition, temperature and pressure)
8. Then, double-clicking the distillation column in order to insert all the parameters or specifications
provided in the question.
9. After that, from the liquid outlet of the distillation column, the TEE splitter was added into the
case window.
10. TEE splitter split the stream into two outlet streams which are purge and recycle streams. The
data given was inserted in the TEE splitter.
11. At the recycle stream, recycle tool was added.
12. A cooler needed to be added before the recycle stream mixed with the feed stream by using mixer.
This is because to cool down the higher temperature in the recycle stream before entering mixer.

(To match with the temperature of the mixer which at 25 .

13. By stating or listing all the data provided in the question, all the equipment should converge by
now. The results obtained, needed to be discussed in the discussion and also to answer the
question given.
PROCESS FLOW DIAGRAM (PFD):
WORKBOOK:
QUESTIONS:

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

At vapor effluent:
Ethylene = 0.0811
HCL = 0.1351
CCL = 0.7298
Nitrogen = 0.0540

At liquid effluent:

Ethylene = 0.0811
HCL = 0.1351
CCL = 0.7298
Nitrogen = 0.0540

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

Using Distillation Column (DC)

3. What is the flowrate of the recycle stream?

214.6 Kg/h

4. What is the flowrate of the final product stream after recycling? (after separation
process).

322.5 Kg/h
DISCUSSIONS:

The objectives of this simulation are to install the conversion reactor, to stimulate a process involving
reaction and separation and also to use the recycle operation in Hysys.

Ethyl chloride is a chemical substances that widely used in producing tetra-ethyl lead and
gasoline additive. One of the routes to produce ethyl chloride are by gas phase reaction of HCL with
ethylene over a copper chloride catalyst supported on silica.

C2 H 4 + HCL C2 H 5 Cl

In this lab, the feed stream are contained 50mol% HCL, 48mol% C2 H 4 and 2mol% N 2 at

100kmol/hr, temperature at 25 and 1atm pressure. Since this reaction only achieved about 90%

conversion, the unreacted reactant will be recycled back to the feed stream in order to prevent the
accumulation of inert gas in the system. While the ethyl chloride product flow out at the purge stream. To
achieve 100% purity of the ethyl chloride product, the ethyl chloride must be separated from the
unreacted reagents by using a distillation column.

Since the reaction took place in a vapor phase, thus the vapor effluent from the reactor was fed to
component splitter. The separation process operated at atmospheric pressure, 1atm and it was assumed
that for this lab, the pressure drop for all equipment will be ignored.

The latter from the reaction must be recycled, therefore the distillate effluent of the distillation
column was recycled. The stream then split by TEE splitter into two distinguish streams which are purge
and recycle streams. The purge stream used to prevent the accumulation of the inert gas in the system.
The recycle stream has a flow rate of 214.6 Kg/h and the purge stream flow at 10kmol/hr. After that, the

recycle stream connected to the recycle tool then enter the cooler to reduce the temperature to 25

before mix with the feed stream using a mixer.