Leverage Engineering Consultancy Sdn. Bhd.

Design Project Memo 2

Date:
To:
Cc:
From:
Re:

13th September 2013

Dr. Mesfin Getu
Ong May Hoong, Ngu See Hua, Michele Wee Sing Yee, Lai Jia Yen and Fatimah Thohirah
Vinyl Chloride Monomer (VCM) Plant Design Initial Stage Process Evaluation

Summary
In this memo, detail process of VCM has been simulated using HYSYS and it is found out
that the number of distillation column can be reduced as one distillation column are able to achieve
99% VCM purity. A manual mass and energy balance calculations has been performed for the major
equipment. It is found that the results agree with the simulation value with slight variation. Heat
integration conducted proves to reduce the energy consumption of hot and cold utilities of 41.6 % and
20.3 % respectively. The utilities required for this plant are 6 heat exchangers, 7 cooler and 2 heaters.
Major equipments used are reactors and distillation column with carbon steel and stainless steel 304
used as the material. Pipe sizing is conducted for major pipelines connecting and the industrial
diameter for each pipeline is obtained. Environmental Impact Assessment (EIA) is done to assess the
potential environmental impact the plant may experience and taking necessary mitigation to reduce
the impact. The effluents produced by VCM process are properly treated and disposed according to
the standards. Analysis of the process material hazards has been studied for its magnitude of risk in
order to take prevention method. The likelihood of hazards is presented in the contingency plan and
detail HAZOP study and its mitigation measures are also listed.
Process Flow Diagram
The modified process flow diagram for production of VCM from base case flow sheet is showed
in Appendix A with the stream composition. One distillation column is removed in EDC purification
section since one distillation column is sufficient enough to purify EDC to 99% for thermal cracking
process. .
Manual Mass and Energy Balance
Manual mass and energy balances are conducted to compare the calculated results with the results
obtained from HYSYS simulation, and it is observed that there are deviations between the two. Huge
variations exist for distillation columns as the calculated number of stages is unable to achieve the
desired purity of product, hence the number of stages is increased and consequently, the outlet flow
will deviate. For other components, the results are rather compatible. Hence, the results generated
from HYSYS simulation are valid. Appendix B shows the steps for manual mass and energy balances
conducted for major equipments.
Heat Integration (Targeting and Network Design) and Utilities Specifications
Process integration is conducted in the flowsheet to reduce plant energy consumption by designing a
network for heat exchange between the streams. One of the targeting tools used in this design is the
problem table algorithm (PTA) and the procedure can be shown in Appendix C. After cascading, the
total hot and cold utilities needed are 51.19 MW and 143.32 MW which shows a total savings of 44.6%
and 24.3% of utilities respectively compared to the design before performing heat integration, which
are QH,min= 92.47 MW and QC,min=189.44 MW. The hot and cold pinch temperatures obtained are
261.6C and 251.6C correspondingly. From heat exchange network (HEN) as seen in Appendix C as
well , a total of six heat exchangers, two heaters and 7 coolers are required for effective heat transfer.
Although the utilities achieved are considerably higher compared to the values obtained in PTA
method which are QH,min=53.92 MW and QC,min=151.0 MW, it is still acceptable as 41.6% of hot
utility and 20.3% of cold utility can be saved after targeting. The results of utility consumption are
shown in Appendix D.

Confidential

Preliminary Equipment Schedule

The major equipments used which are CSTR reactors, PFR Reactor and distillation columns are listed
in Appendix E. Carbon steel and Stainless Steel 304 are used as the material due to its high resistant
to corrosion and cost effective.
Preliminary Pipe Sizing and Specifications
The pipe sizing is done for all the major pipeline connected to the major equipment .The calculated
diameter of the pipe is obtained from the flow rate connected for each major stream and listed in
Appendix F. Since VCM process contains corrosive chemicals, Stainless Steel 304 and Carbon steel
are used as the material for most of the pipelines. The industrial diameter of the pipeline is
calculated based on equation (3) shown below.The thickness of the pipe is obtained from
the pipe schedule chart (Atlast Steel 2012).
(
) (
Calculated Di : Eqn 1 : Carbon Steel
)
(
) (
Eqn 2 : Stainless Steel 304
)
Industrial Di : Eqn 3 :
(
Preliminary Environmental Impact Assessment and Effluent Disposal Plan
Preliminary EIA is carried out to study the potential impact that will be experienced by the plant
during the construction process or production stage. In Appendix G .there are four environmental
factors being considered which are biophysical, pollution, social and decommissioning.For every
factor being evaluated, there are mitigation measures suggested to reduce the consequences from the
VCM production or construction. VCM process produces different type of effluents ranging from
solid , liquid and gas. These effluents will be properly treated and disposed according to Appendix H.
The sustainability of the plant has also been assessed thoroughly in Appendix J.
Initial Process Hazards & Safety Review and Sustainable Development
Analysis of hazards have been studied on the process materials such as ethylene, chlorine, ethyl
dichloride (EDC), hydrogen chloride, pure oxygen and vinyl chloride monomer (VCM) and also
byproducts like trichloromethane and acetylene. The hazards are shown in Appendix J to elaborate
briefly on the magnitude of risks and the handling measure taken for respective chemicals. Besides
that, contingency plan is summarized in Appendix K to discuss about the likelihood of the course of
industry events. The study of Hazard and Operability (HAZOP) are also prepared in Appendix L to
determine the major hazards of the precarious equipment chosen because of some particular variations
in process. The HAZOP also listed out the appropriate measures taken on certain parts of plant in
order to ensure superior safety in process.
Conclusions
In conclusion, the simulation of VCM process has been successfully conducted using HYSYS.
The heat integration performed has help to reduce the energy usage from utilities. The manual mass
and energy balance calculation has variation from the HYSYS value due to high number of stages in
the distillation column to reach the purity desired.Based on the EIA analysis , the plant has
manageable impact to the surroundings an d the effluents are discharged according to the standards.
From the hazards analysis , the safety of plan can be ensure with proper safe guards being
implemented.

Confidential

Appendix A Process Flow Diagram

HCL Recycle_2
CSTR-100
DIRECT
CHLORINATOR

To Wastetreatment
Vent_1
H2O

Chlorine

V-102
3-phase
Separator

CombinedFeed_1

Vent_3

Vent-2

E-100
Heater

VCM

To wastewater
treatment

MIX-100
Mixer
Ethylene_1

EDC2
EDC recycle
to Light
Column

Ethylene

Cstr-101
Oxychlorinator

10
9

NaOH

TEE-100
Splitter

Light End

P-100
Pump

MIX -102
Mixer

Ethylene_2

Vent_4

V-100 Crude
EDC Storage
Tank

Combined EDC
CombinedFeed_2

11

T-105 Light
Column
PFR-100
Pyrolysis
Reactor

EDC1
Flue Gas Product

T-101 VCM
Column

Oxygen

E-103 Cooler
V-101Caustric
Scrubber

CombinedFeed_3

E-105 Heater

T-100 HCL
Coumn

P-101
Pump
Bot_1

HCL Removed
MIX-101
Mixer
Heated HCl to
reactor

12

FH-100
Furnace

Fuel
HCl in

CombinedFeed_4
Air

K-100
Expander

E-101
Heater

Recycled EDC_1

Figure A1 : PFD of VCM Plant

Project A001
Plant Design for Vinyl Chloride
Monomer Production Plant
Confidential

Prepared by:
Lai Jia Yen
Checked by:
Michele Wee Sing Yee
Client: Mesfin Getu
Date: 10th September
2013

Stream Table
Table A1 :Stream Table of VCM Plant
Vap. Frac
Temp (Celcius)
Pressure (Kpa)
Mass Flow (Kg/h)
Heat Flow (KJ/h)
Comp Mole Frac (12-ClC2)
Comp Mole Frac (Ethylene)
Comp Mole Frac (Cl2)
Comp Mole Frac (112-ClC2)
Comp Mole Frac (Oxygen)
Comp Mole Frac (Nitrogen)
Comp Mole Frac (CO2)
Comp Mole Frac (Methane)
Comp Mole Frac (Ethane)
Comp Mole Frac (HCl)
Comp Mole Frac (H2O)
Comp Mole Frac (CO)
Comp Mole Frac (n-Butane)
Comp Mole Frac (VinylCl)
Comp Mole Frac (NaCl*)
Comp Mole Frac (NaOH)
Comp Mole Frac (Propane)
Comp Mole Frac (Acetylene)

Chlorine
1
25
101.324997
55585.7027
-994137.2429
0
0
0.9855
0
0.0075
0.004
0.003
0
0
0
0
0
0
0
0
0
0
0

CombinedFeed_1
1
24.976892
101.324997
78023.54585
40694857.94
0
0.502491
0.489651
0
0.003726
0.001987
0.001491
0.000327
0.000327
0
0
0
0
0
0
0
0
0

To Wastetreatment
1
50
151.987495
1415.946949
-675292.0791
0.185995
0.471376
0
0.000028
0.169628
0.092835
0.049303
0.014456
0.010647
0.005732
0
0
0
0
0
0
0
0

2
0
50
151.987495
76607.8318
-125436170
0.9913
0.00649
0
0.000394
0.000367
0.000095
0.000939
0.000051
0.000213
0.000151
0
0
0
0
0
0
0
0

CombinedFeed_2
1
50
151.987495
78023.54585
42235955.32
0
0.502491
0.489651
0
0.003726
0.001987
0.001491
0.000327
0.000327
0
0
0
0
0
0
0
0
0

3
0.2758
54.266594
151.987495
146608.117
-390625940
0.54282
0.126704
0
0.000136
0.013467
0.000033
0.057342
0.000248
0.000304
0.000057
0.258221
0
0
0.000402
0
0.000013
0
0.000253

4
1
47.455044
101.324997
0
0
0.223951
0.427515
0
0.000022
0.045896
0.000112
0.191262
0.000844
0.00102
0.000189
0.107212
0
0
0.001129
0
0
0
0.000848

5
0
47.455044
101.324997
109328.7531
-213042921
0.883565
0.002898
0
0.00024
0.00006
0
0.002484
0.000002
0.00001
0.000003
0.110572
0
0
0.000133
0
0.000025
0
0.000009

Ethylene
1
25
101.325
44875.69
83377990
0
0.9987
0
0
0
0
0
0.00065
0.00065
0
0
0
0
0
0
0
0
0

Ethylene_1
1
25
101.324997
22437.84315
41688995.19
0
0.9987
0
0
0
0
0
0.00065
0.00065
0
0
0
0
0
0
0
0
0

Ethylene_2
1
25
101.324997
22437.84315
41688995.19
0
0.9987
0
0
0
0
0
0.00065
0.00065
0
0
0
0
0
0
0
0
0

6
0
48.917685
3500
109328.7531
-212629318
0.883565
0.002898
0
0.00024
0.00006
0
0.002484
0.000002
0.00001
0.000003
0.110572
0
0
0.000133
0
0.000025
0
0.000009

HCl Recycle_2
0
-26.552983
1200
33172.24442
-98322446.48
0
0
0
0
0
0
0
0
0
0.998373
0
0
0
0.000999
0
0
0
0.000629

Oxygen
1
25
101.324997
14400
-4294.219232
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0

CombinedFeed_3
1
24.941762
101.324997
70010.08757
-42038576.71
0
0.370005
0
0
0.208399
0
0
0.000241
0.000241
0.420429
0
0
0
0.000421
0
0
0
0.000265

Vap. Frac
Temp (Celcius)
Pressure (Kpa)
Mass Flow (Kg/h)
Heat Flow (KJ/h)
Comp Mole Frac (12-ClC2)
Comp Mole Frac (Ethylene)
Comp Mole Frac (Cl2)
Comp Mole Frac (112-ClC2)
Comp Mole Frac (Oxygen)
Comp Mole Frac (Nitrogen)
Comp Mole Frac (CO2)
Comp Mole Frac (Methane)
Comp Mole Frac (Ethane)
Comp Mole Frac (HCl)
Comp Mole Frac (H2O)
Comp Mole Frac (CO)
Comp Mole Frac (n-Butane)
Comp Mole Frac (VinylCl)
Comp Mole Frac (NaCl*)
Comp Mole Frac (NaOH)
Comp Mole Frac (Propane)
Comp Mole Frac (Acetylene)

CombinedFeed_4
1
200
405.299986
70010.08757
-27856437.74
0
0.370005
0
0
0.208399
0
0
0.000241
0.000241
0.420429
0
0
0
0.000421
0
0
0
0.000265

11
1
220
405.299986
70009.59071
-219913302.1
0.306739
0.189991
0
0
0.020363
0
0.087035
0.000352
0.000352
0.000393
0.393775
0
0
0.000614
0
0
0
0.000386

12
0
220
405.299986
0
0
0.014477
0.00012
0
0
0.000241
0
0.00207
0
0
0.000025
0.983052
0
0
0.000014
0
0
0
0

7
1
715.517045
3120
141685.612
-73371186
0.996293
0
0
0.00272
0
0
0
0
0
0
0.000948
0
0
0
0
0.000039
0
0

FlueGasProduct
1
1188.262576
101.324997
85599.77041
-126689087.8
0
0
0
0
0
0.730961
0.119573
0
0
0
0.149466
0
0
0
0
0
0
0

Air
1
25
101.324997
80368.6104
-22795.6537
0
0
0
0
0.21
0.79
0
0
0
0
0
0
0
0
0
0
0
0

Fuel
1
25
101.324997
5231.160049
-11373939.49
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0

H2O
0
25
101.324997
3603.020099
-57244133.3
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0

Vent_1
1
47.45504
101.325
30477.03
-7.1E+07
0.223951
0.427515
0
0.000022
0.045896
0.000112
0.191262
0.000844
0.00102
0.000189
0.107212
0
0
0.001129
0
0
0
0.000848

CombinedEDC
0
47.455044
101.324997
109328.7531
-213042921.2
0.883565
0.002898
0
0.00024
0.00006
0
0.002484
0.000002
0.00001
0.000003
0.110572
0
0
0.000133
0
0.000025
0
0.000009

AqueousWaste
0
47.455044
101.324997
10405.3578
-164231573.5
0.000082
0
0
0
0
0
0.000059
0
0
0
0.999858
0
0
0
0
0
0
0

Vent_2
1
190.686955
3110
0.000659
-2.218782
0.282113
0.209826
0
0.000304
0.006469
0.000012
0.103438
0.00018
0.00064
0.000099
0.394065
0
0
0.002282
0
0
0
0.000573

Bot_1
0
251.633726
3120
141685.6119
-188127229.4
0.996293
0
0
0.00272
0
0
0
0
0
0
0.000948
0
0
0
0
0.000039
0
0

Light End
0
190.686955
3110
18834.75042
-59534569.54
0.534314
0.011593
0
0.000968
0.000239
0
0.009939
0.000006
0.000039
0.000013
0.442014
0
0
0.000829
0
0.000009
0
0.000037

8
1
364.950076
3120
141679.2807
-73371697.78
0.21941
0
0
0.001661
0
0
0
0
0
0.389283
0.000579
0
0
0.388801
0
0.000024
0
0.000241

Vent_3

HCL Recycle_1

10

Vent_4

VCM

HCl removed

EDC1

NaOH

EDC2

Recycled EDC_2

HCl in

0.38378
50
1480
-150837831.5
141679.2807
0.21941
0
0
0.001661
0
0
0
0
0
0.389283
0.000579
0
0
0.388801
0
0.000024
0
0.000241

1
-26.552949
1200
-2.203026
0.000851
0
0
0
0
0
0
0
0
0
0.999234
0
0
0
0.000079
0
0
0
0.000687

0
-26.552949
1200
-98651993.29
33282.59403
0
0
0
0
0
0
0
0
0
0.998382
0
0
0
0.000999
0
0
0
0.000619

0
91.856951
1210
-61969133
108396.686
0.35923
0
0
0.00272
0
0
0
0
0
0.001135
0.000948
0
0
0.635928
0
0.000039
0
0

1
30.702142
471
0.470721
0.000884
0
0
0
0
0
0
0
0
0
0.013822
0.000034
0
0
0.986139
0
0
0
0.000005

0
30.702142
471
14284363.5
56951.0437
0
0
0
0
0
0
0
0
0
0.001781
0.000102
0
0
0.998116
0
0
0
0.000001

0
476.28633
101.324997
-26300083.2
33.301773
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0

1
476.2863
101.325
-1.9E+08
70000.29
0.306733
0.189987
0
0
0.020362
0
0.087033
0.000352
0.000352
0.000008
0.394152
0
0
0.000614
0
0.00002
0
0.000386

0
25
101.324997
-102396.3768
23.998201
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0

0.446804
57.35
151.987495
-265189770
70000.28559
0.306733
0.189987
0
0
0.020362
0
0.087033
0.000352
0.000352
0.000008
0.394152
0
0
0.000614
0
0.00002
0
0.000386

0
145.091382
477
-77490625.89
51191.60993
0.989791
0
0
0.007537
0
0
0
0
0
0
0.002442
0
0
0.000175
0
0.000055
0
0

1
25
101.324997
-83723277.67
33172.24442
0
0
0
0
0
0
0
0
0
0.998373
0
0
0
0.000999
0
0
0
0.000629

Heated HCl to
reactor
1
25
101.324997
-83723277.67
33172.24442
0
0
0
0
0
0
0
0
0
0.998373
0
0
0
0.000999
0
0
0
0.000629

EDC recycle to
Light Column
0
147.319301
3500
-77293877.76
51191.60993
0.989791
0
0
0.007537
0
0
0
0
0
0
0.002442
0
0
0.000175
0
0.000055
0
0

Vap. Frac
Temp (Celcius)
Pressure (Kpa)
Heat Flow (KJ/h)
Mass Flow (Kg/h)
Comp Mole Frac (12-ClC2)
Comp Mole Frac (Ethylene)
Comp Mole Frac (Cl2)
Comp Mole Frac (112-ClC2)
Comp Mole Frac (Oxygen)
Comp Mole Frac (Nitrogen)
Comp Mole Frac (CO2)
Comp Mole Frac (Methane)
Comp Mole Frac (Ethane)
Comp Mole Frac (HCl)
Comp Mole Frac (H2O)
Comp Mole Frac (CO)
Comp Mole Frac (n-Butane)
Comp Mole Frac (VinylCl)
Comp Mole Frac (NaCl*)
Comp Mole Frac (NaOH)
Comp Mole Frac (Propane)
Comp Mole Frac (Acetylene)

Confidential

Recycled
EDC_1
0.000002
145.09316
477
-77876378.24
51445.64124
0.98979
0
0
0.007493
0
0
0
0
0
0
0.002433
0
0
0.000177
0
0.000107
0
0

Appendix B Mass and Energy Balance

Confidential

Appendix C Heat Exchanger Network

CPH - CPC (MW/ C) Shifted T
Shifted T(C)

H (MW)Infeasible Heat Cascade

Feasible Heat Cascade
Hot Utility

720.5
C2

-0.069

249.2
111.3
102.9

-73

0.5
41.6

106.814

0.5
2.8

1.378

6.7
19.3

0.093

35.6

-11.823

0.6
52.6

-0.454

9.6
32.3
2.6

0.029

7.4

H6

93.487

0.5
14.5

-1.101

0.1
3.8

14.34

0.5
47.2

9.6

15.886

0.5

7.943

-31.2
H3

38.982

90.178

43.874

95.070

39.515

90.711

42.519

93.715

42.717

93.913

42.931

94.128

89.675

140.871

89.095

140.291

88.985

140.181

88.685

139.881

95.855

147.051

92.126

143.322

92.126

143.322

Surplus
Deficit
Surplus
Deficit
Surplus
Surplus
Surplus
Surplus
Deficit
Deficit
Deficit
Surplus

-3.7288

-21.6
C3

97.272

7.17

25.6

-0.079

46.076

Surplus

-0.3002

26.1
H5

93.961

-0.1101

29.9

-0.079

42.765

Surplus

-0.58

30

C4

67.790

46.7435

44.5

-0.04

16.594

Surplus

0.2146

45

H2

58.558

0.1976

52.4
H1

7.361

Surplus

3.0039

55

0.076

58.233

-4.3584

87.3

0.093

7.037

Surplus

4.8918

96.9
C5

4.826

-7.0938

149.5

0.093

-46.370

Deficit
PINCH

3.3108

150.1
C7

0.000

26.1708

185.7

H4

-51.196

Surplus

9.2326

205

1.356

36.500

0.3248

211.7
C1

-14.696

Deficit

53.407

214.5

0.116

31.664

4.8256

215
H7

-19.532

Deficit

-36.5

256.6

0.116

34.001

4.8363

257.1
C6

-17.195

Qh (min)

-2.3373

360

0.047

51.196

-17.1948

471.3

-0.021

Surplus /deficit

Deficit

Qc (min)

Surplus

-31.7

Cold Utility

Figure C1 :Problem Table Algorithm (PTA)

Pinch

ABOVE PINCH
CP (MW/C)
0.047
0.068

H (MW)
10.09
7.03

H1

H2
H2

261.6

476.3

H1

CP (MW/C)

167.4:

261.6

H2

0.069

32

715.5

252.1
73.056

C2

36.53

21.92 MW

10.3MW

10.09 MW

14.4

1.263

32.8

1.4418

7.2

15.886

7.9

93.526

46.8

106.698

53.3

25.6MW

C6
7.03 MW

0.068
190.7

H4

251.7:C

251.8:C

9.6

50.0
c

211:C
216.7

0.047

5.17MW

261.6

251.6
32 MW

H (MW)

57.4

201.3:C

261.6

365.0

BELOW PINCH
252.5:C

31.1

30.6

H5

7.2MW
251.6
-26.2

H3

-26.7

7.9MW
50.0

219.95:C

220.0

49.5

H6
46.8MW

219.5

H7
48.05MW
50.0

25.0

C4

0.017

0.43

C1

0.023

C3

0.079

4.1

C5

0.547

5.3

C7

11.917

7.2

0.43MW
200.0

25.0

91.9

24.9

4.0MW

-26.6

4.1MW

82.3
5.3MW

145.1

144.5

7.2MW

Figure C2 : Heat Exchanger Network (HEN) Design

Confidential

Appendix D Specifications of Major Utilities

Equipment

32

Reboiler for
Light Column
21.92

C2

C6

H1

H2

HP Steam

Refrigerant 2

Refrigerant 2

250
249
5.23

-40
-39
14805.56

-40
-39
16047.20

Furnace

Heat Duty (MW)

Stream in Heat Exchange
Network (HEN)

Fired Heat
(1000)
1000
400
39.36

Uility Consumption
Inlet Temperature (C)
Outlet Temperature (C)
Flowrate (kg/s)

To convert ethylene and oxygen into EDC with

a selectivity of 93 - 96% by recycling HCl from
VCM purification process.

Light Column
T-100

To separate water and unreacted reactants from

the product.

Thermal cracking of EDC into VCM and HCl.

To separate HCl from final product (VCM) and

unreacted EDC.

To separate final product (VCM) and

dichloroethane.(EDC)

VCM Column T-102

Confidential

Condenser for
HCl Column
7.9

H4

H5

HP Steam
Generation
249
250
14.55

MP Steam
Generation
174
175
3.64

5.17

Oxychlorinator
CSTR-101

HCl Column T-101

Condenser for
VCM Column
7.2

E-103

Appendix E Preliminary Equipment Schedule for Major Equipment

Type of Major
No. of
Function
Equipment
Units
Direct Chlorinator
To convert the raw material, ethylene into EDC
CSTR-100
1
with a selectivity over 99%.

Pyrolysis Reactor
PFR-100

10.3

Condenser for
Light Column
25.6

E-102

Operating Condition / Capacity / Size

Temperature / Pressure = 50
Volume = 162.3 m3
Diameter / Height = 5.165 m / 7.747 m
Temperature / Pressure = 220 / 405.3 kPa
Volume = 8.322 m3, Diameter = 1.919 m,
Height= 2.878 m
Condenser / Reboiler pressure = 3110 kPa /
3120 kPa
Diameter = 1.5m, Tray spacing = 0.55m,
Actual number of stages = 30
Feed stages = condenser
Temperature / Pressure =
Volume = 31.42m3, Length = 250.0 m,
Diameter = 0.10 m, Number of tubes = 16,
Wall thickness = 0.005m
Condenser / Reboiler pressure = 1200 kPa /
1210 kPa
Diameter = 1.5m, Tray spacing = 0.55m
Actual number of stages = 11
Feed stages = 6
Condenser pressure = 471 kPa
Reboiler pressure = 477 kPa
Diameter = 1.5m, Tray spacing = 0.55m,
Actual number of stages = 20
Feed stages = 8

Material of
Construction
Stainless Steel Type
304
Stainless Steel Type
316

CSTR-100

CSTR-101

46.8

48.05

H3

H6

H7

LP Steam
Generation
124
125
3.62

Cooling
Water
20
25
2235.83

HP Steam
Generation
249
250
31.33

Remarks(Special features)
Ferric chloride is used as catalyst to increase
selectivity of main reaction.
Conversion of EDC is more than 99%.
Copper (II) chloride is used as a catalyst.
Exothermic reaction.
Conversion of HCl is 94 97%.

Carbon Steel

Reflux ratio= 20.

Stainless Steel Type

304

Endothermic reaction.
Butane is used as the fuel.
Conversion of EDC is 55%.

Stainless Steel Type

304

Reflux ratio= 1.26.

Stainless Steel Type

304

Reflux ratio= 0.5.

Appendix F Pipe Sizing and Specifications

Temperature ( C)
Pressure (kPa) Stream Name
Material Calculated Di(Inch)
Ind. Di (Inch) Ind. Do (mm)
50
152
Combined feed2
SS304
71.37
19.25
508
50
152
To waste treatment
CS
12.38
13.12
355.6
50
152
2
CS
10.18
11.94
323.9
200
405
CombinedFeed4
SS304
63.59
22.64
610
220
405
11
CS
71.09
18.81
508
92
1210
10
CS
13.34
0.00
406.4
31
471
VCM
SS304
8.16
15.00
273.1
145
477
Recycled EDC_1
CS
8.71
10.02
273.1
49
3500
6
CS
12.19
10.02
355.6
191
3110
Vent_2
CS
0.0025
13.12
21.3
191
3110
Light End
CS
5.42
0.62
168.3
252
3120
Bot_1
CS
16.11
6.07
457
716
3120
7
SS304
38.29
16.87
101.6
365
3120
8
SS304
38.64
3.36
508
50
1480
9
SS304
28.22
19.25
406.4
-27
1200
Vent_3
SS304
0.0042
15.25
17.1
92
1210
10
SS304
11.03
0.54
323.9
Appendix G Preliminary Environmental Impact Assessment
Environmental
Impacts
Consequences
Factors
Mangrove species such as Rhizophora mucronata, Avicennia and Bruguiera the Kerteh site
might be affected when the site is clear for plant construction .Marine life will be
Flora and
endangered due to contamination of water through chemical spillage and wastewater
Biophysical
Fauna ,
discharge (The EcoCare Project 2013). Habitat of bird species such as crows and sparrow
Habitat , Land
are endangered due to clearing of land and inhalation of VCM and chlorine gas. The
construction leads to changes of landscape and soil erosion.
The discharge of chemicals (EDC , Chlorinated solvents and etc) which will results in
deterioration of quality Kerteh River. Construction work will produce more noise pollution
due to mobilization of vehicles, hammering and banging sound. The production processes
Water , Noise
cause noise pollution due to high operation of the machines and vessel. Quality of air is
Pollution
and Air
affected by haze produced from to hammering during construction process , releases of
chlorinated gas during the pyrolysis stage , global warming and greenhouse gas emissions
due to clearing of trees and empty land.
Limited of clean water available for residents due to high amount of water usage by the
Household
VCM production of about 3603 Kg/h. High exposure to VCM gas may lead the workers to
activities ,
deadly diseases such as cancer and other health problem. In the case of sudden explosion
Social
Health , and
and fire, local residents are highly affected and in high risk of death.
Risk
Decommisioning

Possibility of chemical spillage when piping is dissembled.

Confidential

Nominal Sizes (Inch )

20
14
12
24
20
16
10
10
14
0.5
6
18
3 1/2
20
16
0.375
12

Schedule No.
40S
40
40
40
40
40
40S
40
40
40
40
40
80S
40S
40S
10S
40S

Pipe thickness(Inch)
0.38
0.44
0.41
0.69
0.59
0.00
0.50
0.36
0.36
0.44
0.11
0.28
0.56
0.32
0.38
0.38
0.06

No.of pipes
4
1
1
3
4
1
1
1
1
1
1
1
13
2
2
1
1

Mitigation Measures
Rehabilition programme can be organized to replant and preserve mangrove in the
area. Unused area can be used as a growth site. The release of hydrochloric gas
should follow the guide and permitted amount which is 5-10ppm in most country
(Vinyl Chloride 2013). The gas could be pre-treated before being released to
air.The sites will have empty areas which can be used to plant green trees to reduce
the effect of soil salinity to take place.
Wastewater treatment implemented and amount of gas released will follows the
environmental regulation limits. Construction work will only be done during day
time and weekdays. The plant wall will be concealed to absorb industrial activity
sound. Trees will be planted in the empty areas site of the plant.

Dam or reservoir can be built to store water for future production or local usage.
Workers should attend safety and health training so that they are more alert and
aware of the usage of mask during the production. Proper emergency plan will be
conducted to ensure workers and residents are not in danger in the case of
emergency.
The pipelines should be monitored regularly to prevent leakage.

Appendix H Effluent Disposal Method

(Environmental Requirement: A Guide for Investors 2010 )
Type of Effluents

Source

Flue Gas Product

Amount
Flow rate : 85599.77
kg/h Nitrogen 0.7310
Carbon Dioxide 0.1196
Steam 0.1495

Fired Heater (FH-100)

Solid Waste ( Copper Chloride and Ferric Chloride) catalyst

Liquid / Aqueous Waste

CSTR Reactor ( Direct Chlorination and Oxychlorination

0.1 wt %
Water 0.9998
EDC 0.0001
Carbon Dioxide 0.001
Hydrochloric Acid 0.997

3-Phase Separator (V-102) , Distillation Column (T-100)

Standards
0.12 ppm

Treatments
The amount of flue gas release by fire heater is in small amount. Therefore no pre-treatment needed.

Copper 0.1
gm/Nm3
Ferric
0.2gm/Nm3

The catalyst life before disposal could be prolonged through regeneration and rejuvenation. The catalyst metal can be recovered
for other raw material before being disposed in an approved chemical landfill. The recovery of metal will reduce the amount of
waste being disposed. (Marafi , Stanislaus and Kam 2006)

0.2 gm of
HCL/Nm3

All liquid disposals will be sent to wastewater treatment unit. Chlorinated hydrocarbon waste will be removed through distillation
and Hydrogen chloride will be neutralized with the aid of caustic soda.
Dissolved solid carried by water will be filtered , flocculated and sedimentated

Appendix I Process Material Hazards

Process Material

Hazards Identification

Ethylene

Highly flammable gas. Rapid suffocation may

happen. (Airgas 2011)

Chlorine

Toxic and combustible gas. (Airgas 2010)

Ethylene
dichloride (EDC)
Hydrogen
chloride
Vinyl chloride
monomer (VCM)
Pure Oxygen

Flammable liquid. Irritation to respiratory tract,

skin and eyes. (Occidental 2005)
Toxic gas. Dangerous to inhalation. (Airgas 2013)
Flammable gas. (Airgas 2010)
Gas that ignites very easily. (Airgas 2011)

Health Effect
Harmful to target organ such as lungs, heart, muscle tissue.
Burns or frostbite effect to skin and eyes.
Inhalation of ethylene causing simple asphyxiant. (Airgas 2011)

Accidental Release Measures

Use spark-proof tools and explosion-proof equipment and stop the
leakage. (Airgas 2011)

Given carcinogenic effect to targeting organ.

Corrosive to skin and eyes. (Airgas 2010)
Causes effect to central nervous system, damage of kidney and liver as
well as cancer risk if expose over long period.
Toxic by ingestion. (Occidental 2005)
Serious burn to eyes and skin.
Causing injury to respiratory system. (Airgas 2013)
Damaging particular organ such as skin, eyes, respiratory system and
central nervous system.
Not safe for ingestion. (Airgas 2010)
May causes frostbite if exposed to rapidly expanding gas.
Severe respiratory condition if overexposure to high concentration of
oxygen gas. (Airgas 2011)

Handling and Storage

Storage tank must store faraway from sources of ignition.
Using explosion-proof electrical equipment. (Airgas 2011)

The usage of spark-proof tools and explosion-proof equipment are

required and shut off the source of leakage. Eliminate all ignition
sources. (Airgas 2010)

Tanks should be separated from acids, alkalies, reducing agents and

combustibles. (Airgas 2010)

Using water spray curtain and stop the leak immediately. (Sciencelab
2013)

Store the tanks in refrigerated room and keep away from sources of
ignition. (Sciencelab 2013)

Use suitable protective equipment. (Airgas 2013)

Using spark-proof tools and explosion-proof equipment and turn off
gas supply. (Airgas 2010)
Shutdown of gas supply is priority in order to stop the leakage of gas.
(Airgas 2011)

Storage tank must be protected from physical damage. (Airgas

2013)
Requisite usage of explosion-proof electrical equipment.
Storage tank must be isolated from oxidizing materials. (Airgas
2010)
All materials that ignite easily should be separated out from the
storage tank. (Airgas 2011)

Appendix J Sustainable Development

Resources Utilisation
Heat Recovery from HCL
recycling
VCM byproducts consist of high
boiling and low boiling
compound. The heat produced by
the combustion of this waste can
be used to generate steam and
recovered as a valuable feed in
oxychlorination process
(ThyssenKrup 2013)

Economic
Recycle of effluent reduces cost of raw material
HCL is recycle back as raw material during oxy-chlorination process. This reduces the need to
further invest on the raw material
Reuse of By products for manufacturing of other industrial products
VCM process produced 112- trichloroethane and acetylene which as a byproduct are used in
chemical making, solvents, cleaning agent and etc. This will help to increase the profit of the
plant as the by product can be sold to other industry.
(Ethylene Dichloride (1,2-Dichloroethane) 2008)
Energy Saving
Usage of cracking gas heat and flue gas for
pre-evaporation and preheat of combustion air help to save energy consumption
(ThyssenKrup2013

Social
Job Opportunities
Construction stage will require workers for the road construction, vessel transportation
and etc.The VCM production will require more engineers to monitor and conduct the
production process.According to Azapagic and Verdan (2011) , a VCM plant will
requirefulltime employment of 20 operators , approximately 25 contractors during the
construction process that will take about 3 years.
More Housing Areas
More housing areas will be built to accommodate the workers.
Development of rural areas
The industrial area will be developed such that there will be more connecting roads ,
local markets and etc.

Environmental
Ferric Chloride and Copper Chloride as catalyst reduce toxic
generation
Use of this catalyst reduces formation of toxic and waste compared to usage
of mercury catalyst in acetylene based process ThyssenKrup (2013) states
that catalyst used in this process does not being discharge at the end of the
process. Therefore, minimal waste disposal.
Reduction of fresh water usage
The recycling of certain effluents from the process reduces the usage of
fresh water and pollution.This method is proven to reduce up to half of the
fresh water usage (Australian Vinyls Corporation Ltd. 2009)

Appendix K Contingency Plan

Event

Likelihood

Back-up Plan

Spillage of hazardous chemicals

Possible

Using spill pads backed with vapour barriers to remove flammable liquids. (ACS 2013)

Leakage of gas

Possible

Using emergency valves to turn off the source of leakage.

Power outages

Likely

Installation of uninterruptible power supply (UPS) system as standby power source (Solidstate 2013)

Explosion / fire gas ignition

Likely

Activate water sprinkles when fire ignition is occurred.

Installation of low-cost wireless smart skin sensors to monitor structures for strain, stress and early formation of
cracks by sensing through radio-frequency identification (RFID) chip component in the sensor. (Toon 2013)

Factory collapse

Unlikely

Release of chlorine gas

Likely

Leakage of ethyl dichloride (EDC)

Possible

Confidential

Installation of fume hood or exhaust fans for ventilation.

Using emergency valve to stop the release of chlorine gas.
Local exhaust fan are activated to keep surrounding ventilated.
Using emergency control to shut off the process.

Event Recovery
Checking and maintenance of equipment should be done regularly.
Knowledge of the use and handling of hazardous chemicals should be applied by each
worker.
Identify the causes of gas leakage and monitor the gas supply day by day.
Regular checking and maintenance of pipeline and vessel.
Conducting an annual inspection of any generators and possible upgrade of power
system.
Testing of back-up generator should be done regularly under load of 24 hours.
Find out the sources of ignition and checking of the current condition of plants.
Conduct inspection of factory structures regularly.
Robust and secure factory construction.
Detect the source of the release of chlorine by using chlorine gas detector. (wiseGeek
2013)
Regular checking and maintenance of pipeline and chlorine storage tank.
Identify the causes of EDC leakage by using gas detector to evaluate the airbourne
concentrations of EDC.

Appendix L HAZOP of Major Equipment

Selected Equipment
CSTR-100 and
CSTR-101
Continuous Stirred
Tank Reactor (Direct
Chlorination and
Oxychlorination)

Guide word /
Deviation
No flow
Low flow

Flow rate fluctuation in feed stream inlet

Temperature indicator failure
Insufficient supply of feed

High temperature

Runaway reaction.
Insufficient cooling of reaction.
High concentration of catalyst.

Low pressure

Insufficient feed supplu

Faulty pressure control valve
Low feed flow to the reactor.
Pressure control failure..
Uncontrolled high reaction temperature (Reactor Problem 2013).

No flow

Flow control valve faulty.

Low flow

High viscosity in liquid reactants.

Low efficiency in pump due to high viscosity effect

High flow

Increase of the reboiler heat duty.

Low temperature

Fluctuation of inlet temperature.

High temperature

High reboiler duty.

high vapour flow cause pressure rise

Low pressure

High duty of condenser.

Low flow of reactants to the column.
Inefficiency of pump due to high viscosity
Uncontrolled high inlet stream flow.
Pump failures.
Heat duty of reboiler is increasing.
Differential flow measurement circuit defect (Cause and
Countermeasures 2013).
Impurities present in the feed.

High pressure

PFR-101
Plug Flow Reactor
(EDC pyrolysis)

Tubes blockage due to impurities in feed.

Flow control valve failures.
Formation of coke and catalyst surfaces fouling.

High flow
Low temperature

High pressure

T-100, T-101 and T106

Distillation column
(EDC and VCM
purification column)

Possible Causes

No flow
Low flow
High flow

Fluctuation of inlet flow stream.

Feed variations (Reactor Problem 2013).

Low temperature

High temperature
Low pressure
High pressure

Consequences

Safeguard

Action Required

Installation of flow detector to detect the rate of flow

to the reactor.
Regeneration of catalyst to avoid coke formation

Cleaning of reactor or pipeline must be done once a month.

Installation of flow controller.

Install temperature controller.
Pumping of feed is being kept under normal
observation.
Install temperature indicator
External cooling to avoid overheating
Decrease the flow of catalyst.

Monitor the flow rate frequently.

Avoid feed vaporization by storing storage tank in ventilated
place.

Fix pressure detector

Pumping feed to the reactor through alternative
sources (Reactor Problem 2013).
Install pressure controller and high flow detector.

Maintenance to the pressure control valve.

Installation of flow indicator.

Normal checking and maintenance should be conducted.

Flow indicator should be installed.

Turn off the supply of reactant to the distillation
column.
Installation of flow controller.

Restart the distillation column when excessive weeping happens

(Tham 2009).

Temperature detector and controller should be

installed.
Install temperature controller
Remove the trace of impurities that leftover in the
column.
Install pressure indicator and controller

Regular monitoring and checking of temperature.

Installation of pressure controller and high pressure

detector.

Monitor pressure regularly.

Checking and maintenance of pump and vessel regularly.

Install flow indicator.

Shutdown of reactor to remove impurities.
Install low flow detector

Clean the reactor and pipeline monthly.

Reactor may overpressure.

Product overflow and low production rate
High pressure drop.
Off-specification happens in product.
Circulation becomes uneven. (Reactor Problem 2013)
Product overflow
Low conversion achieved.
Low production.

The reaction is speeding up and goes out of the limits

of the cooling system.
Pressure rise in reactor
Rupture of reactor and vessel.
Rupture reactor
Overpressurised
Low products rate
Occurrence of flash fire.
Reactor will reach or exceed the maximum allowable
pressure and causes degradation.
Overflow of product may occur.
Attain of low product due to low conversion of reactant
in low flow.
Insufficient pressure to have liquid hold up on the tray.
Excessive weeping occurs and decreases the efficiency
of separation.
Increases vapor flow rate that exceeds a critical
threshold and triggers flooding.
Low product obtained.
Low conversion of feed.
Distillation column will be ruptured and overheated.
Product overflow.
Pressure is not enough to hold up the liquids on the
trays.
Separation efficiency is reduced. (Tham 2009)
Explosion may happen.
Overflow of product.
Reactor is overpressure.
Reactor exceeds the pressure limit.
Product overflow or less product rate
Low conversion of feed.
Change of feed composition (Reactor Problem 2013).
Changes of composition and properties of feed may
occur (Reactor Problem 2013).
Product overflow.
Low conversion of reactants.
Low product achieved.
Reactants cannot be heated up
Explosion may happen.
Reactor is overheated.
Overpressurised
Low conversion of products.
Pressure of reactor rise above the safe limit.
Overflow of product.

Loss of heating from the tube.

Fouling
Temperature control valve failures. (Reactor Problem 2013)
Inlet temperature fluctuation.
Thermometer failure.
Low flow of feed due to insufficient of feed supply.
Faulty of pressure control valve.
Pressure control failure.
Fluctuation of flow rate of inlet stream.

Installation of flow indicator and flow controller.

Ensure flow rate supplies are in normal circumstances.

Removal of impurities from feed (Reactor Problem 2013)

Heat supply to the reactor is shutting off to reduce the

temperature of reactor.

Often check and monitor the pressure of reactor.

Regular reactor maintenance

Monitor the flow rate regularly.

Observe operating temperature

Regular maintenance and cleaning of distillation column
Monitor column pressure
Pump maintenance.

Monitoring of flow rate

Remove impurities from the feed (Reactor Problem 2013).
Check and monitor the flow of reactants is in normal
circumstances. (Reactor Problem 2013)

Install temperature indicator.

Replace the broken temperature control valve

Ensure the heating medium is lined up to reactor.

Install temperature sensor and temperature controller

Monitoring of temperature.
Perform maintenance frequently.
Observe and alert to the operating pressure of reactor to ensure
the pressure is beyond safe limit.
Regular checking and maintenance.
Monitor the flow rate of inlet stream frequently.

Install low pressure and low flow detector.

Installation of high flow and high pressure detector.

References
Airgas Inc. 2013. Hydrogen Chloride. Material Safety Data Sheet. http://www.airgas.com/documents/pdf/001028.pdf.
Australian Vinyls Corporation Pty Ltd.2009. Sustainability Report.http://www.av.com.au/Assets/228/1/SR0809publish.pdf

Atlas Steels.2012. Pressure Rating Table for Stainless Steel Pipe. http://www.atlassteels.com.au/documents/St_St_Pipe_Pressure_Rating_Charts_rev_Sep_2010.pdf
Atlas Steels.2012. Pressure Rating Table Carbon Steel Pipe. http://www.atlassteels.com.au/documents/C_St_A106_GrB_Pipe_Pressure_Rating_Charts_rev_Dec_2012.pdf
Azapagic, Adisa., Slobodan Perdan, and Roland Clift. 2004. Sustainable Development in Practice. John Wiley & Sons, Ltd.
Cause and Countermeasures to Reactor Manual Shutdown during Startup at Hamaoka No. 4. 2013. Accessed September 11, http://www.chuden.co.jp/english/corporate/press2007/pdf/pre1130_1_1.pdf.
Department of Environment.2010. Environmental Requirement : A Guide for Investors. http://www.doe.gov.my/portal/wp-content/uploads/2010/12/A-Guide-For-Investors1.pdf
DUTTA, B.K. 2007. Principles of Mass Transfer and Seperation Processes: PHI Learning.
Fogler, H.S. 2006. Elements of Chemical Reaction Engineering: Pearson Education Internat.
Himmelblau, D., and J. Riggs. 2012. Basic Principles and Calculations in Chemical Engineering: Pearson Education Land Clearing and Its Impacts.2013.Bush Land
Clearing and Its Impacts.2013.Bush Land Clearing and Its Impacts.2013.Bush Heritage Australia. http://www.bushheritage.org.au/natural_world/natural_world_land_clearing
Occidental Chemical Corporation. 2005. Ethylene Dichloride Finished Grade. Material Safety Data Sheet. http://www.nfc.umn.edu/assets/pdf/msds/ethylene_dichloride_finished_grade.p
Reactor Problem. 2013. Monitor and Control the Reaction Process. Accessed September 2, http://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC302/PROC302-020200- Technology Transfer Network Air Toxics Web Site.2007. Ethylene Dichloride (1,2-Dichloroethane). http://www.epa.gov/ttnatw01/hlthef/di-ethan.html
Tham, M.T. 2009. Factors Affecting Distillation Column Operation. Distillation an Introduction. Accessed September 3, http://lorien.ncl.ac.uk/ming/distil/distilop.htm.
The ecoCate Project.2013.Petronas Chemicals Olefin Sdn Bhd.. http://www.optimal.com.my/ecoCare.aspx
ThyssenKrup. 2013. Vinyl chloride and polyvinyl chloride.Accessed August 15, http://www.thyssenkruppuhde.de/fileadmin/documents/brochures/uhde_brochures_pdf_en_8.pdf

Perry, Robert H., and D.W. Green. 2008. Perry's Chemical Engineers' Handbook, Eighth Edition: McGraw-Hill.
Smith, J.M., H.C. Van Ness, and M.M. Abbott. 2005. Introduction to Chemical Engineering Thermodynamics: McGraw-Hill Book Company. Vinyl Chloride.2013.Accessed September 2. http://monographs.iarc.fr/ENG/Monographs/vol97/mono97-8A.pdf

Confidential

10