PRODUCTION OF VINYL CHLORIDE MONOMER (VCM)

AMIRUL AIMAN BIN AHMAD FITRI

55201113696
NUR ASYIQIN ATIQAH BINTI ABDUL MALEK
55201113514
NOR FARAAIN BINTI AHMAD PUZI
55204113479
NIK AHMAD AMIRUDDIN BIN NIK NASRUDDIN
55201113687

UNIVERSITI KUALA LUMPUR

1
 PRODUCTION OF VINYL CHLORIDE MONOMER (VCM)

AMIRUL AIMAN BIN AHMAD FITRI

55201113696
NUR ASYIQIN ATIQAH BINTI ABDUL MALEK
55201113514
NOR FARAAIN BINTI AHMAD PUZI
55204113479
NIK AHMAD AMIRUDDIN BIN NIK NASRUDDIN
55201113687

Report submitted to fulfill the Partial Requirements for the Bachelor of

Engineering with Honours (Chemical)

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 AKNOWLEDGEMENT

This plant design written for the fulfilment of the Bachelor Degree
programme in Chemical Engineering at the Universiti Kuala Lumpur-
International College (UniKL-ICOLE). We would like to express our
gratitude to our supervisor, Mohd Solihin Bin Mohd Saidi for his
support, guidance, ideas and encouragement during the process of
writing this plant design. I am grateful to Ir. Zaimul Khalil Bin Md
Mustaffa for helping us in giving the rough ideas. Thanks to all
groupmates, friends and family.

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 Contents

DECLARATION .................................................................................... Error! Bookmark not defined.

AKNOWLEDGEMENT ........................................................................................................................ 3
CHAPTER 1 ........................................................................................................................................ 6
Project Overview .............................................................................................................................. 6
1.1. Production History............................................................................................................ 6
1.1. Ethane............................................................................................................................... 7
1.1.1. Introduction .............................................................................................................. 7
1.1.2. Process Overview ..................................................................................................... 7
1.1.3. Advantages & Disadvantages ................................................................................... 8
1.1.4. Ethane Properties ..................................................................................................... 8
1.2. Acetylene .......................................................................................................................... 8
1.2.1. Introduction .............................................................................................................. 8
1.2.2. Process Overview ..................................................................................................... 9
1.2.3. Cost Estimation ......................................................................................................... 9
1.2.4. Advantages & Disadvantages ................................................................................. 10
1.3. Ethylene .......................................................................................................................... 10
1.3.1. INTRODUCTION ...................................................................................................... 10
1.3.2. PROCESS OVERVIEW ............................................................................................... 11
1.3.3. ADVANTAGES AND DISADVANTAGES ..................................................................... 11
1.4. Properties and Applications ........................................................................................... 12
1.4.1. Product Properties.................................................................................................. 12
1.4.2. Applications ............................................................................................................ 13
1.4.3 Handling, Storage and Transportation ................................................................... 13
FEASIBILITY STUDY.......................................................................................................................... 15
2.1. Executive Summary ........................................................................................................ 15
2.2. Introduction .................................................................................................................... 15
2.3. Technical Requirement and Production Plan ................................................................. 17
2.3.1 Potential Site Locations .......................................................................................... 17
2.3.2 Site Selection .......................................................................................................... 19
2.3.1. Process Steps .......................................................................................................... 26
2.3.2. Economics and Proven Technology ........................................................................ 27

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 2.4. SWOT Analysis ................................................................................................................ 29
2.5. Market Survey ................................................................................................................ 30
2.6. Financial Analysis and Economics................................................................................... 31
2.6.1. Fixed Capital Investment (Capital Expenditure) ..................................................... 31
2.6.2. Operating Cost ........................................................................................................ 32
2.6.3. Approximating Selling Price .................................................................................... 32
2.6.4. The Cash Flow Analysis ........................................................................................... 34
2.6.5. Conclusion .............................................................................................................. 35
PROCESS SELECTION ....................................................................................................................... 36
3.1. Process Flow Diagram (PFD) .............................................. Error! Bookmark not defined.
3.1.1 Direct Chlorination ................................................................................................. 36
3.1.2 Simulation of Direct Chlorination ........................................................................... 36
3.1.3 EDC Purification ...................................................................................................... 37
3.1.4 Thermal Cracking (Pyrolysis) and Quenching ......................................................... 37
3.1.5 Purification of VCM ................................................................................................ 38
3.1.6 Waste treatment .................................................................................................... 38
3.1.7 Hydrochloric Acid Purification ................................................................................ 38
3.2. Piping and Instrumentation Diagram (P&ID).................................................................. 39
3.3. Equipment List ................................................................................................................ 39
MASS BALANCE............................................................................................................................... 42
4.1. Overall Balance .................................................................. Error! Bookmark not defined.
Chapter 5: Energy Balance ................................................................ Error! Bookmark not defined.
Manual Energy Balances ............................................................................................................ 48

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 CHAPTER 1: PROJECT OVERVIEW

Vinyl Chloride Monomer or also known as VCM is mainly use for the production of
Polyvinyl Chloride (PVC). Vinyl chloride is also the main building block for
hydrochlorocarbons (Wismer & America, 2001). There are three feedstock that can be
used in the production of VCM which is ethane, ethylene and acetylene. From the three
types of feedstock, the feed that use by the company is ethylene by direct chlorination.
The production of the VCM for the company is about 50,000 MT per annum. This
amount of production is based on the demand for the production of the PVC. Most of
the VCM buyer is from the China which is the main buyer. China’s willing to purchase
import VCM though it is high in cost. The estimated capital expenditure to build-up and
run the VCM plant is around RM 45,000,000. This estimation was a rough estimate
base on the existing VCM plant in certain country. The rate of investment for the
estimated plant is around 30% which roughly 3 – 4 years payback period.

1.1. Production History

Vinyl chloride was initially delivered economically in the 1900s through reaction of
HCL and acetylene inferred in calcium carbide. The high vitality prerequisite for
carbide generation was a genuine disadvantage to the proceeding with large scale
manufacturing of vinyl chloride by this strategy, particularly as the request
expanded after World War II. One reaction was to grow more efficient techniques
for delivering acetylene by the partial combustion of methane or naphtha.
Nonetheless, as ethylene turned out to be more ample in the mid-1950s,
particularly in the United States, business procedures were created to deliver vinyl
chloride from chlorine and ethylene by means of ethylene dichloride (EDC). After
decontamination, EDC was subjected to warm pyrolysis to deliver vinyl chloride.
The hydrogen chloride as a co-product was regularly financially utilized as a part
of response with acetylene if delivering offices existed.

These days, all present production plants for vinyl chloride rely on upon the
utilization of C2 hydrocarbons feedstock. The decisions are acetylene, ethylene
and ethane. Produce from acetylene is a moderately basic single-stage process,

6
 however the cost of acetylene is high. By difference, ethane is by a long shot the
slightest costly C2 hydrocarbon, however it can't at present be changed over to
vinyl chloride with high selectivity. In this manner, the joined strategy, which is
immediate chlorination and oxychlorination of ethylene, creates well more than
90% of the world's vinyl chloride.

1.1. Ethane

1.1.1. Introduction

The use of ethane in the feed stock is because it is cheaper which is one-
third of the ethylene. But, this process is still under R&D. Lot of companies
heavily invest in this research. This research is a gold investment since it
will reduce the processing step. Though it is a gold investment, there are
major problem associated with the use of ethane is its molecular symmetry
(Dry et al., 2003).

1.1.2. Process Overview

The process for ethane feed to VCM is still not available. Recently, the U.S.
Patent 5,763,710 have been some notable recent improvements on the use
of ethane as a feedstock (Wismer & America, 2001). Most of the company
that attempt in using the ethane to produce the VCM difficulties. Several
attempts failed during scale-up, stymied by a combination of poor
conversions, catalyst instability, and corrosion caused by high reaction
temperatures (“New VCM Plant Will Use Ethane,” n.d.).

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 1.1.3. Advantages & Disadvantages

Advantages Disadvantages
 Cheaper source of  There are no valid proven
feedstock
 Process step is reduce

1.1.4. Ethane Properties

Table 1 Properties of Ethane (“Physical Properties for Ethane,” n.d.)

Formula C2H6

Molecular Weight (lb/mol) 30.07

Critical Temperature (℉) 90.4

Critical Pressure (psia) 707.9

Boiling Point (℉) -127.5

Melting Point (℉) -297.9

Psat @ 70℉ (𝑝𝑠𝑖𝑎) 559.6

Liquid Density @ 70℉ (lb/ft3) 20.98

Gas Density @ 70℉ 1 atm (lb/ft3) 0.0784

Specific Volume @ 70℉ 1 atm (ft3/lb) 12.76

Specific Gravity 1.065

Specific Heat @ 70℉ (Btu/lbmol-℉) 12.67

1.2. Acetylene

1.2.1. Introduction

Production of VCM by using Acetylene is largest in China. The production

capacity of PVC started to increase in China due to lower cost of production

8
 of VCM. Since acetylene much cheaper in China, therefore it will become
advantage economically for the production of VCM in China.

1.2.2. Process Overview

Process of producing Vinyl Chloride Monomer (VCM) can be produced from

acetylene by reaction called hydrochlorination in gaseous phase. Acetylene
basically produced from Calcium Carbide in which Calcium Oxide (lime) is
reduced by carbon in electric furnace.

High
Temp.
CaO  3C  CaC 2  CO

In order to produce acetylene the calcium carbide is hydrolyzed.

CaC2  2H2O  C2H2  Ca(OH)2H

The acetylene that has been produces reacts with anhydrous hydrogen
chloride (HCl) over mercuric chloride (HgCl2) as catalyst supported on
activated carbon.

HgCl2
C2H2  HCl  CH 2CHCl
Carbon

The reaction between acetylene and hydrogen chloride cause a large

deposition of carbon.

The raw material involve in process of VCM using hydrochlorination of

acetylene are Acetylene ( C2H2 ) react with Hydrogen Chloride ( HCl ) using
Mercuric Chloride ( HgCl2 ) as catalyst. To produce VCM 99% of acetylene
and 98% of hydrogen chloride needed. Molar ratio of acetylene to hydrogen
chloride is 1:1.

1.2.3. Cost Estimation

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 The VCM production from acetylene estimated cost is calculated from
overall cost of the production involves. Starting from the raw material cost
which the main raw material used is acetylene is about RM 7.32 per kg.
While, for the hydrogen chloride used is around RM 8.5 per kg and other
catalyst and chemicals would be RM 5.00 per kg

1.2.4. Advantages & Disadvantages

Advantages Disadvantages
 Cheaper source of  Source further from Malaysia (
production (in China) problem to purchased)
 Easier process involves  Using catalyst mercuric chloride
is harmful for environment, and
health threat to human beings

1.3. Ethylene

1.3.1. INTRODUCTION

The goal of this project is to design environmentally friendly, safe, and

economically profitable vinyl chloride production plant. Environmental
friendliness requires that the design go beyond the minimum Environmental
Protection Agency (EPA) compliance regulation while maintaining plant
profitability. In this report, there will be discussed about production of Vinyl
Chloride Monomer (VCM) from ethylene which contain several pathways.
These report also present process and cost analysis of VCM. This process
combine two ethylene dichloride (EDC) production routes, direct
chlorination and oxychlorination to produce VCM. By doing so, hydrogen
by product produced in thermal cracking unit is used as a raw material ion
the oxychlorination unit for additional of EDC from ethylene

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1.3.2. PROCESS OVERVIEW

VCM is produced based on ethylene which is first reacted with chlorine to

produce EDC. There are two routes to make EDC; direct chlorination using
pure ethylene and chlorine, and oxychlorination in which the ethylene
reacts with chlorine in hydrogen chloride. In this case, direct chlorination
has been choose due to the costing. EDC is then converted into VCM by
thermal cracking and produced by product of hydrogen chloride. The
thermal cracking EDC is carried out at 500oC at pressure 4 atm. The exit
gases are cooled rapidly in a quench tower to limit formation of by product.
Hydrogen chloride is removed by distillation in the first column while the
VCM also obtained from the top stream of first distillation column.

1.3.3. ADVANTAGES AND DISADVANTAGES

 Lower investment costs

 Higher VCM quality
 Higher raw material efficiency
 A mercury free process
 Anhydrous operation
 Lower yield

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1.4. Properties and Applications

1.4.1. Product Properties

The Vinyl Chloride Monomer is a chemical that can be used in the PVC
manufacturing industry and copolymer. The other name for the vinyl
chloride monomer are 1-chloroethylene or chloroethene. The CAS number
for vinyl chloride is 75-01-4. The physical and the chemical properties of
the vinyl chloride monomer are:
 Physical State: Gas
 Colour: Colourless
 Change in Appearance: Compressed, Liquefied Gas
 Odour: faint odour, sweet odour
 Odour threshold: 260 ppm
 Molecular Weight: 62.50 g/mol
 Molecular Formula: CH2CHCl
 Freezing Point: -154°C
 Boiling Point: -13°C
 Flash Point: -78°C
 Lower Flammable Limit: 3.6%
 Upper Flammable Limit: 33.0%
 Evaporation rate: >15
 Vapour Pressure: 2980 mmHg @ 25°C
 Vapour Density: 2.15
 Specific Gravity: 0.9106
 Volatility: 100%
 Viscosity: 0.01702
 Water Solubility: 0.25%
 Auto Ignition: 472°C

Vinyl Chloride is a chemical that may polymerize easily. The chemical must be
stored above room temperature but cannot be exposed to light. The vinyl chloride
is incompatible with oxidizing materials, metals, aluminium, aluminium alloys,
copper, metal alkyl complexes and alkali metals. Vinyl Chloride monomer is a

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danger chemical that can cause health problem to human and can cause
environmental problem towards the aquatic organisms. There are exposure
controls that has been stated in the msds of vinyl chloride. The appropriate
engineering controls stated are ventilation equipment that are explosion proof if
explosive concentrations of material are present. The other control is to use closed
systems when possible but provide local exhaust or process enclosure ventilation
system. It must complied with the exposure limits. When handling the vinyl chloride
monomer, must wear eye protection, chemical suit, chemical resistant gloves and
respirators.

1.4.2. Applications

Poly Vinyl Chloride (PVC) was produce by the polymerization of Vinyl

Chloride Monomer (VCM). The demand of VCM is directly linked to the
demand for PVC (Vinyl et al., n.d.). PVC is used to make a variety of
products, including plastics, hoses, pipes and fittings for outdoor irrigation,
wire and cable coatings, packaging materials, furniture and automobile
upholstery, flooring, windows, credit or ATM cards, wall coverings,
housewares, outdoor furniture, plastic containers, wrapping film,
automotive parts and many others (“Vinyl Chloride Monomer (VCM) |
National Pollutant Inventory,” n.d.). PVC also used widely in building and
construction applications because of its excellent durability, easy
installation and cost effectiveness (The Dow Chemical Company, 2013).

1.4.3 Handling, Storage and Transportation

Vinyl chloride is otherwise called a cancer-causing agent and each

precautionary measure must be taken to avert human contact. As said
above, vinyl chloride is a combustible gas, which is heavier than air. It
polymerizes instantly when open to daylight, to warm or within the sight of
oxygen or air. At the point when vinyl chloride is to be put away or
transported, phenol or different stabilizers are sometimes added to keep its
polymerization.

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In little amounts, vinyl chloride is transported as the fluid under pressure in
steel chambers or drums. Road tank trucks are normally used to convey
vinyl chloride. Vinyl chloride is exchanged from tank trucks to capacity
vessels by pumping or blowing under a nitrogen air to maintain a strategic
distance from blast. Spillages from capacity vessels in the plant are
recognized by find cleanser arrangements. A halide light should never be
utilized to distinguish vinyl chloride because of the high combustibility of
vinyl chloride and its development of unstable blends with air. The
accompanying materials of development are regular for taking care of and
capacity for vinyl chloride:

Table 1: Construction materials for Vinyl Chloride storage and handling

Equipment Construction material

Tanks Steel or S30403

Tanks trucks Steel or S30403

Railroad cars Steel or S30403

Piping Steel or S30403

Valves Steel (N04400 trim) or CF8M

Pumps CF3M

Gaskets Spiral-wound PTFE/stainless steel

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 CHAPTER 2: FEASIBILITY STUDY

2.1. Executive Summary

This project presents the design of a vinyl chloride monomer (VCM) plant with a
capacity of 50,000 TPA located in Kerteh, Terengganu. The capacity of the plant
is based on comparing several different capacities. It also based on the investment
and net present worth. By looking for the historical demand data of raw material
and final product, it allowed us to make a prediction of the capacities. The purity
of vinyl chloride is around 99.9 mol% pure. This compositions allows the VCM to
undergo the polymerization for applications. The total capital investment to build
and run this plant is RM 210,974,088.74. The plant produces a total net profit of
RM 53,368,219.90 per year with an ROI 16.5%. The design build was focusing on
the maximization of safety and minimization of environmental impact while
maintaining profitability. The VCM plant produces a few by-products which will be
discharged to the stream. The Environmental Acts, enforced by Department of
Environmental (DOE), regulate the procedure on how to dispose the waste
streams. A common waste treatment system utilizing incineration, absorption,
caustic scrubbing and activated carbon adsorption is built in order to avoid
releasing any hazardous waste into environment.

2.2. Introduction

Nowadays, the population of human in this world is increasing rapidly with the
current population around 7.4 billion as in August 2016. It was estimates that this
population will increase year by year where it will reach around 11.2 billion in 2100.
With this gold opportunities, our company which is VCM Corporation will produce
a Vinyl Chloride Monomer (VCM). The product will be sold to the secondary
process where that company will produce Poly Vinyl Chloride (PVC). The product
mostly will be used for the production of PVC. The increase of population will
increase the needs of shelter to stay. This will urge the construction industry to
build many building which is the needs of using PVC is there. The demand of VCM
is directly linked to the demand for PVC (Vinyl et al., n.d.). This type of chain, make

15
the target market purchased our product constantly. In industry, there are two
factors that can give affect the purposed business which is positive or negative.
The positive affect that can be seen is the constant demand on the VCM in our
company. While the negative affect is where the company need to undergo many
procedure and inspection before opening the company. Besides that, the
inspection of the company also needs to be checked monthly to make sure that
there is no harmful effect to the people and environment nearby.

The product VCM is in a liquid form. This VCM will be transferred by the pipeline
to the secondary process company nearby and to the port for exporting. To
penetrate the market global, our company are producing the best quality of VCM.
Moreover, our production rate of VCM is higher than other company which will not
affect the demand of VCM from other company. During the process of the VCM,
the destructive features that can affect the competition of the product effectively is
the odor of the VCM. The common characteristic of VCM is sweet odor.
Since the statistics shows that they will be an increase in population, the market
evaluation also will give a positive signal to our company in future expansion. The
main of producing the VCM is to supply to all the secondary process company
which mainly allocated in the developing country. China and India is the major
country that purchased our VCM. This is because, their country has the majority
population in the world. Most of the customers are appeals by our VCM product
because we always assure that our product is in a good quality that will not affect
for further processing the PVC. The aspects that the product may be rejected or
disapproved is because the slow of production rate and less quality produce.

In this world, not everyone we can satisfied their interest. But, as a good and
understanding company, we try to overcome all the negative reaction from the
customers and the people nearby. If the negative reaction was about the product,
we will take note and try to improve it by doing a research. The market seems to
increase by year. This positive sign surely make the potential annual growth of the
total market increase.

In maintaining our company in the future, we need to compete with the well
establish companies. The competitors’ strength is most likely that they are well
known with their quality they give. To offsetting this strength, our company try to

16
 do a research on how to produce the VCM in a short production rate with a better
quality.
2.3. Technical Requirement and Production Plan
In outlining and building a plant, one of the angles that ought to be considered
appropriately is the choice of the area of the plant. A few components ought to be
considered, for example:
 Site characteristic
 Infrastructure
 Transportation facilities
 Suppliers/raw material availability
 Environment
 Labor
 Incentives, etc.

Such thought will give positive effect on the creation plant as far as gainfulness,
market and plant consumptions. Along these lines, the motivation behind this
review is to choose the most suitable area for the proposed 500,000 MTA of Vinyl
Chloride Monomer (VCM) generation plant.

2.3.1 Potential Site Locations

The production of Vinyl Chloride Monomer is delegated a petrochemical

industry. There are a few modern homes created by legislature of Malaysia
that is equipped for finding plants for this kind of industry. Such potential
areas are:

 Tanjung Langsat Industrial Estate, Pasir Gudang, Johor

 Gebeng ( II ) Industrial Estate, Kuantan, Pahang
 Teluk Kalong Industrial Estate, Kemaman, Terengganu

Comparison of short-listed locations is listed in Table 2

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 Table 2: Comparison between short-listed locations

Location Tanjung Langsat Gebeng ( II ) Teluk Kalong

Industrial Estate Industrial Estate Industrial Estate
Total area 1088.78 ha 48.34 ha 167.45 ha
available
Price per square 10.00 – 11.00 9.95 0.75 – 4.20
ft (RM/ft2)
Developer Johor State Pahang State Terengganu State
Economic Development Economic
Development Corporation Development
Corporation Corporation
Raw material Titan  Petronas & Union  Petronas & Union
supplier Petrochemical, Carside, Kerteh Carbide, Kerteh
Pasir Gudang  Ethylene Malaysia,  Ethylene Malaysia,
Kerteh Kerteh
Distance from 48 km from Johor 31 km from Kuantan 9.6 km from
nearest town bahru Kemaman
Transportation  Johor Port  Kuantan Port  Kemaman Port
facilities  Senai  Kemaman Port  Kertih Marine Port
International  Sultan Ahmad  Kuala Terengganu
Airport Shah Airport, Airport
 Main road to JB Kuantan  Kertih Airport
and Singapore  Kertih Airport  Sultan Ahmad
 Pasir Gudang –  Karak Highway to Shah Airport,
Tg Kupang – KL Kuantan
Tuas Highway  Main road to JB  Coastal highway
 North-South and Singapore links Kuala
Highway  Kuantan Port – Terengganu to
 North-South Gebeng – Kuantan, Kuala
Railway Kemaman Port Lumpur & JB
 Railway to Johor Railway  East Coast
Port Expressway
(proposed)
Water supply Syarikat Air Johor, Semambu Water Bukit Sah,
Sungai Layang Treatment Plant Seberang Tayor,
Reservoir Sungai Cherol,
Kemasik
Power supply Sultan Iskandar Tenaga Nasional  Tasik Kenyir
Power Plant (404 Berhad (800 MW) Hydroelectic Dam
MW) (400 MW)
 Paka Power Plant
(1200 MW)
 YTL Power
Generation Sdn
Bhd (600 MW)
Incentives  Pioneer status  Pioneer status  Low land premium
 Pioneer status

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  Investment Tax  Partial exemption  Investment Tax
Allowance (60% of income tax Allowance (80%
of expenditure) (15% income) of expenditure)
 Partial exemption  5 years tax  Partial exemption
of income tax exemption of income tax
(30% income)  Investment Tax (15% income)
 5 years tax Allowance (80% of  5 years tax
exemption expenditure) exemption
 Import duty  Infrastructure  Infrastructure
exemption allowance allowance
 Export, R&D and  Import duty  Import duty
manpower exemption exemption
training  Export, R&D and  Export, R&D and
 Free Zone manpower training manpower training

Residential area  Pasir Gudang  Kuantan  Kertih

 Kempas  Kemaman  Paka

2.3.2 Site Selection

In the wake of considering all the short-recorded areas, we have

chosen to manufacture the proposed 500,000 MTA vinyl chloride monomer
(VCM) plant at the Teluk Kalong Industrial Estate in Kemaman,
Terengganu.

Figure 1 demonstrates the guide of Terengganu. Terengganu Darul

Iman is arranged at the East Coast of Peninsular Malaysia confronting the
South China Sea. Teluk Kalong modern Area is situated in Kemaman, the
northern piece of Terengganu. The industrial estate has 167.45 hectares of
range still accessible for development. This industrial park which has
prepared fabricated modern land and plants can dispense medium and
substantial businesses, concoction and petrochemical ventures. The
offering cost of the land is very cheap which is around RM 0.75 to RM 4.20
for each square feet. The region is disengaged and isolated from most local
location. It is likewise near essential market and crude material source.

19
 Figure 1: Map of Terengganu

With every one of the foundations accessible in the territory, for example,
transportation offices, utilities supply and media transmission in addition to
the administration motivators, make Teluk Kalong an appealing area to set
up a plant. The following are the attributes and points of interest of Teluk
Kalong Industrial Estate as the chose area for the future plant.

i. Raw material suppliers

The production of vinyl chloride monomer uses ethylene and

hydrogen chlorine as the main raw material. Ethylene Malaysia and
Petronas & Union Carbide, Kertih have been recognized as the
main supplier of ethylene around that area. Meanwhile, hydrogen
chlorine can be obtained from Sitt Tatt, Kertih.

ii. Logistic

Distance to Kemaman : 9.6 km

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 Distance to Kuala Terengganu : 190 km
Custom and Excise office : 1 km from Kemaman Port
Nearest airport : Kertih Airport
Kuala Terengganu Airport
Sultan Ahmad Shah Airport,
Kuantan
Local Port: Kemaman Port, Tanjung
Berhala,
Kertih Port

iii. Climate
The weather in the northeast region is influenced by the monsoons
of North East. The monsoons usually commence in early November
and ends in March. The most severe wind can reach up to 30 knots
or more. Maximum rainfalls around the month of November,
December and January; and the driest months are around June and
July. It is generally warm and sunny throughout the year. The
temperature varies between 27°C and 32°C. At night, the
temperature is between 21°C and 24°C. Humidity is high at night
and early in the morning; and low around midday.

iv. Infrastructure
Terengganu has all the modes of transportation via land,
water and air. Through land, there are roads connecting major
towns in Terengganu and other states. Through water and air,
there are seaports and airport.
Roads
 Trunk federal road along the coast connecting all major
towns
 Trunk road traversing the hinterland
 Trunk road scheduled to be upgraded into East Coast
Expressway
 Road network linking Terengganu and neighbouring states

21
 Seaports
 Kemaman Deepwater Port managed by Kemaman Port
Authority with access to shipping routes all over the world
and as springboard for Asia Pacific market.
 Kertih Liquid Petrochemical Port managed by subsidiary of
Petronas is dedicated for liquid petrochemical products

Facilities
 Nine berths (at five major berth : East Wharf, LPR Export
Terminal, Kemaman Supply Base, Liquid Chemical Base
and West Wharf) with total capacity of 15.38 million tones
and total length of 1,328 metres, to cater for containers,
general cargo and dry bulk cargo at Kemaman Port. The
port entrance is 18 meters to handle vessels up to 150,000
DWT with a wide warehouse on the wharf for storage. Six
berths for accommodate a vessel with capacity between
7,000 to 40,000 DWT at Kertih Port.

Airport
 Served by 3 major airports, two in Terengganu, one in
Pahang, Kertih Airport, Kuala Terengganu Airport and
Kuantan Airport.
 Number of flights to Kuala Lumpur daily:
Kuala Terengganu Airport 4 – 5 flights per day
Kertih Airport 2 flights per day
Kuantan Airport 5 flights per day

v. Electric Power Supply

Suppliers : 1. Paka Power Plant Station TNB, 1200 MW

2. Paka IPP Station YTL, 600 MW
3. Kenyir Hydro Station TNB, 400 MW
Voltage : 220 – 240 V (max. available current = 132 kV)

22
 Reliability : Excellent

Table 3: Industrial tariff (for factories) categories and rates

Tariff Usage Sen/kWh

D Low voltage, less than 6.6kV supply (All units) 25.8
E1 Medium voltage general, 6.6 kV – 66 kV supply (All units) 19.8
For each kW of max. demand per month (RM 17.30)
E2 Medium voltage Peak/Off-peak, 6.6 kV – 66 kV supply
Peak period (0800 – 2200 hours) 20.8
Off-peak period (2200 – 0800 hours) 12.8
For each kW of max. demand per month during peak period
(RM 21.70)
E3 High voltage Peak/Off-peak. More than 132 kV supply
Peak period (0800 – 2200 hours) 19.8
Off-peak period (2200 – 0800 hours) 11.8
For each kW of max. demand per month during peak period
(RM 20.80)

Source : Tenaga Nasional Berhad

vi. Water Supply

Water source for Teluk Kalong Industrial Estate is from Bukit Sah,
Seberang Tayor, Sungai Cherol and Kemasik. The agency
responsible for water distribution in Terengganu, generally and
Teluk Kalong, particularly, is Terengganu Waterworks Department.
The rate of water supply varies from state to state. Currently, the
industrial water rate in Terengganu area are RM 1.15/m3 and
commercial rates are RM 0.95/m3 for first 700 m3 and RM 1.15/m3
for more than 700 m3 of usage. The reliability of water supply is
excellent.

23
vii. Telecommunications
The main telecommunication service company in Teluk Kalong is
Telekom Malaysia Berhad. Services provided including national
calls, international calls and Internet service. Besides that, there are
also cellular phone services provided by six service operators to
choose from. The state of Terengganu is also connected with a
backbone fibre optic line with a hub called ‘Terengganu-Net’. The
tariff introduced by the government for any fixed line, cellular
services are shown in Table 3, and Table 4 shows time per unit of
national call.

Table 4: Fixed line and cellular services introduced by the

government

Monthly telephone rental (business) RM 35 for urban area

9 sen for first 3 min
Monthly telephone rental (business) RM 20 for rural area
Local area calls 3 sen for additional minute
National calls (trunk dialing) 13 sen per unit

Table 5: Time per unit of national calls

Distance Time per unit

Full rate Reduced rate
(0700 – 1900 (1900 – 0700
hours) hours)
Band A (not exceeding 50 km) 60 sec 90 sec
Band B (50 – 150 km) 20 sec 40 sec
Band C (150 – 550 km) 7.5 sec 15 sec
Band D (exceeding 550 km) 4 sec 8 sec
Band E (Sabah/Sarawak to 2 sec 4 sec
Singapore
Source: Telekom Malaysia Berhad

24
viii. Waste Disposal
Each individual plant has its own treatment plant according to the
standard and procedures outlined by the Department of
Environment. Water discharged has to be treated before it is being
channeled to any receiving body. A Scheduled Waste Recycling
Plant approved by the Department of Environment is expected to
begin its construction in Teluk Kalong Industrial Estate.

ix. Incentives
Manufacturing sectors has a lot of incentives provided by the
government in the Promotions of Investment Act 1986, Income Tax
Act 1967, Customs Act 1967, Sales Act 1972 and Excise Act 1976.
As for industrial estate in Terengganu which is designated as Easter
Corridor of Peninsular Malaysia, the incentives includes:

 Pioneer status (PS) which allow partial exemption from payment of

income tax. This incentive allows the company to pay tax on 15% of
statutory income for a period of 5 years, commencing from
Production Day.
 Investment Tax Allowance (ITA). Allowance of 80% in respect of
qualifying expenditure incurred within 5 years from the date of the
first expenditure in made.
 Infrastructure allowance of 100% on expenditure incurred for a
period 5 years
 Full Import Duty Exemption on raw materials/components if the
company is producing both for domestic and export market, if the
raw materials/components are not produced locally
 Second Round of Pioneer Status/Investment Tax Allowance
 Reinvestment Allowance (RA) for companies operated for at least
12 months. Allowance of 60% of capital expenditure incurred for 5
years from the year the first reinvestment is made.
 Tariff related incentives such as full exemption from import duty on
raw materials and components; exemption of import duty and sales
tax on machinery and equipment; drawback of excise duty, sales
tax and import duty paid.

25
  Incentives for export, R&D and manpower training

x. Labour

Basic wage rates vary according to location and industrial sector. In

addition to salaries, most companies also provide other benefits
such as medical treatment, personal accident and life insurance
coverage, free or subsidized transport, annual bonus, retirement
benefits and enhanced contributions. These benefits vary from
company to company.

Trained and untrained workers are easily available to fill in

vacancies in companies. There are also intellectual and skill
development centers including higher learning institutions among
others are University College of Terengganu, University Technology
of MARA, Sultan Zainal Abidin Religious College (KUSZA) and
Terengganu Advanced Technical Institute (TATI). Training
Institutions available such as Petronas Institute of Technology
(INSEP), Industrial Training Institute and Terengganu Safety
Training Centre (TSTC).

2.3.3 Process Steps

The process of vinyl chloride monomer (VCM) basically consists of

three main steps. The first reaction that takes place is a 1) direct
chlorination to convert ethylene to 1, 2-ethylenedichloride (EDC). The
process then followed by 2) thermal cracking or called pyrolysis process of
1, 2-ethylenedichloride (EDC) to vinyl chloride monomer (VCM). Last
process is purification of VCM and HCL.

FeCl3
1) C2H4  Cl 2  C2H4Cl 2

High
Temp.
2) C2H4Cl 2  C2H3Cl  HCl

26
 Direct chlorination commonly is a process use to produce EDC that involves
reaction between two gaseous which are ethylene and chlorine added in
liquid EDC phase under exothermal condition at moderate temperature.
The addition catalyst of Iron (III) chloride (FeCl3) causes the presence of
iron and together with dissolved oxygen act as inhibitors to helps the
substitution reaction.

The production of VCM is continued by undergoes thermal cracking or

pyrolysis of EDC produced from previous reaction. Theoretically, cracking
process is about breaking up the longer chain of hydrocarbon into much
smaller, and as linked to the words thermal it is vividly stated that there is
heating involve in the process. The EDC that produces from direct
chlorination will undergoes an endorthermic reaction for it to decompose
into desired product VCM and by-product HCl. The furnace will preheats
the reactant up; this is when the pyrolysis reaction rate becomes significant.
EDC need to be dried before undergoes cracking in furnace to removes
some impurities that are difficult to eliminate during VCM purification.

The hydrogen chloride (HCl) that being produces during this process is an
undesired product. The anhydrous HCL and aqueous HCL is combined and
purified in the HCL purification column. Last process of VCM production is
purification of VCM. This purification process is to separate VCM from EDC,
HCl and other remaining by-products.

2.3.4 Economics and Proven Technology

Manufacturing of VCM raised attention on pollution, safety and hazards.

The VCM technology has been improvised by years resulting in VCM plant
now as the cleanest and safest chemical process industries. The rapid
reaction of ethylene and chlorine shows that the reactor either boiling or
sub-cooled must be designed in order to provide sufficient residence time
for the gas resolution so that no liquid in excess brought over the gas
stream. In cracking part, residence time of the gases in the cracking reactor
and the material in reactor used at the area of the tube wall need to be
taken note. Assumption can be done by stating that depth of cracking is a
dominating parameter. To minimize the by-product formation, low depth

27
cracking are needed. Besides, carboneous substances that formed inside
reactor tubes would resulting a reduction of heat transfer and followed by
pressure drop increment to the point that the reactor need to be shut down
for about 72 hours due to decoking. Fixed cost for the plant is estimated
$400 per hour. Therefore, the minimization of the by-product formation is
one of contribution to the advance the process of production.

Basically, VCM production plant will produce sub-product contained

chlorine which is HCl. Usually; the sub-product will be recycled to undergo
the process of oxychlorination. Based from the process flow in diagram
below, by using oxychlorination the ethylene feed need to be divided into
two stream which one of it will go straight to the direct chlorination and the
other feed to pass through the oxychlorination process. The process will
give higher yield in production of VCM. However, the oxychlorination
process produces most of the chlorinated waste which is not beneficial for
environment. Therefore, to improvise the process, Deacons Process use
oxidation to recover the aqueous HCl from waste recovery and HCl from
sub-products, this way is much on benefit to the plant from the
environmental of view.

In advance, the production of VCM keep getting attention on improvising

the process to ensure more efficient and in the meantime the cost of the
production become lower, Kellog proposed the oxidation of HCl makes use
of nitrosyl-sulfuric acid (HNSO5) that contained in the hot sulfuric acid. This
process decreases the amount of byproduct results an overall yield to be
98%. While, the chlorinated waste produces from other processes can be
burned down to HCl and use back for the manufacturing of VCM. The
estimated cost reduction of this process is 15% lower compare to
oxychlorination.

28
 Figure 2: Oxychlorination process

Figure 3: Chlorine recovery by HCl Oxidation

Heat integrated network is a part of VCM plant process design technology.

It is to identify the required stream data and the temperature targets to find
out the minimum utilities needed in plant. This network is using pinch
design method.

2.4 SWOT Analysis

29
 Strength
- The product produce is 99.9% pure Weakness
VCM - The start-up company is to costing

SWOT
Analysis
Treats
Opportunity - The by-products consist of harmful
- No company that produce VCM in chemical that can affect human and
Malaysia greenhouse effect (GHG)

Figure 4: SWOT Analysis

2.5 Market Survey

The use of VCM is really vital in majority industries since it is use in the production
of PVC. In global, Asia Pacific was holding the major market share in vinyl chloride
monomer. Asia also known as the largest consumer of VCM where 50% of the total
consumption. Then, the market was followed by North America and Europe. The
global VCM market is expected to grow at a moderate rate with a single digit
compounded annual growth rate (CAGR) (“Vinyl Chloride Monomers (VCMs)
Market - Global Industry Analysis, Size, Share, Growth, Trends and Forecast 2012
- 2018,” n.d.). The growth rate of the VCM is depend on the buildup of the
infrastructure in the countries. The high growing in construction industry coupled
with piping industry over the period shows that the company with the production in
VCM will be stable in market. China along with India are major countries which are
expected to be the major market growth contributor in Asia Pacific region. VCM
supply in North East Asia and South East Asia remain tight throughout third quarter
of 2016 with the shows increase of price to RM 3113 per ton. As market PVC
increase dramatically in China, they are willing to import the VCM from other
country.

30
 2.6 Financial Analysis and Economics

2.6.1 Fixed Capital Investment (Capital Expenditure)

Table 6: Fixed Capital Investment

Total Fixed Capital Investment

Total Equipment Cost RM 77,628,193.26

Direct Cost Description Cost
Land Current land price RM 14,400,000.00
Equipment Installation 30% of TEC (Towler,2008) RM 23,288,457.98
Instrumentation & control 30% of TEC (Towler,2008) RM 23,288,457.98
Piping Installation 80% of TEC (Towler,2008) RM 62,102,554.61
Electrical Installation 20% of TEC (Towler, 2008) RM 15,525,638.65
Civil cost 30% of TEC (Towler,2008) RM 23,288,457.98
Structure & Building 20% of TEC (Towler, 2008) RM 15,525,638.65
Lagging & Paint 10% of TEC (Towler, 2008) RM 7,762,819.33
Total of Direct Cost RM 185,182,025.17

Indirect Cost Description Cost

Offsites 30% of TEC (Towler, 2008) RM 23,288,457.98
Design & Engineering 30% of TEC (Towler, 2008) RM 23,288,457.98
Contingency 10% of TEC (Towler, 2008) RM 7,762,819.33
Construction Expenses RM 11,874,476.15
Supervision RM 5,160,000.00
Total of Indirect Cost RM 71,374,211.43
Working Capital 86% of TEC (P&T) RM 66,760,246.20
Total of Fixed Capital Investment RM 323,316,482.81

The fixed capital investment is the most important part in any business. The capital
investment can be get from investor that are willing to invest in the business or in this case
the chemical plant. The amount of the sales and the amount of the capital cost that are
used to determine return of the investment. The investor will have their share on the plant
so they will have profit from their investment.

31
 2.6.2 Operating Cost

Table 7: Operating Cost for the Plant

List
Description
Raw Materials Flow sheet
Operating Labour
2000 kWh per day
Utilities
20000 m3 per month
Miscellaneous Materials 10% from Maintenance
Maintenance 5-10% of fixed capital
Supervision 20% of Operating Labour
Insurance 50% of Operating Labour
Laboratory Cost 20% of Operating Labour
Taxes 2% of fixed capital
Plant Overheads 50% of Operating Labour
Royalties 1% of fixed capital
Capital Charges 10% of fixed capital
Total
Price (RM)
RM 117,766,214.72
RM 7,056,000.00
RM 690,000.00
RM 276,000.00
RM 1,616,582.41
RM 16,165,824.14
RM 1,411,200.00
RM 3,528,000.00
RM 1,411,200.00
RM 6,466,329.66
RM 3,528,000.00
RM 3,233,164.83
RM 32,331,648.28
RM 195,480,164.04

2.6.3 Approximating Selling Price

The production price for the Vinyl Chloride Monomer is RM 3909.60 per one ton
from the production cost divide with production capacity. The selling price for the
Vinyl Chloride Monomer is RM 3913.51 per one ton which are 0.1% increment from
the production price. The other product produce and sell by the company is
Hydrogen Chloride with selling price RM 4039.36 per ton with increment of 0.05%
from RM 4037.35. The total price gain from the total capacity of 50,000 TPA VCM
and also 29,615 TPA HCL can be determined.

Rate of Investment = (Net Earnings / Total Capital Investment) x 100%

= (RM 53,368,219.90 / RM 323,316,482.81) x 100%
= 16.5%

Payback Period
Payback period = Fixed Capital Investment / Net Profit
= RM 323,316,482.81 / RM 53,368,219.90/year

32
 = 6 years and 1 month

Profitability Measures

The Investor's Rate of Return for this Project: 14.04%

The Net Present Value (NPV) at 14.04% for this

Project: RM 17,618,993.22

ROI
Analysis

Annual Sales: RM 282,131,715.27

Annual Costs: RM (210,974,088.74)
Income Tax: RM (17,789,406.63)
Net Earnings: RM 53,368,219.90
Total Capital Investment: RM 323,316,482.81
ROI: 16.5%

33
 2.6.4 The Cash Flow Analysis
Table 8: Cash Flow Analysis
interest rate = 14.42%
Percentage
N Year of Design Sales Capital Costs Variable Cost Fixed Cost Taxable Income Income Tax Net Earnings Annual Cash Flow Present Value
Capacity
0 2017 0% Construction RM (185,182,025.17) RM (185,182,025.17) RM (185,182,025.17)
0 2018 0% Construction RM (138,134,457.64) RM (138,134,457.64) RM (138,134,457.64)
1 2019 45% RM 141,067,675.35 RM (60,006,958.71) RM (34,031,381.22) RM 47,029,335.42 RM (11,757,333.85) RM 35,272,001.56 RM 35,272,001.56 RM 30,826,779.90
2 2020 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 41,909,934.65
3 2021 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 36,628,154.74
4 2022 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 32,012,021.27
5 2023 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 27,977,644.88
6 2024 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 24,451,708.51
7 2025 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 21,370,135.04
8 2026 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 18,676,922.77
9 2027 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 16,323,127.75
10 2028 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 14,265,974.26
11 2029 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 12,468,077.49
12 2030 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 10,896,764.11
13 2031 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 9,523,478.51
14 2032 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 8,323,263.86
15 2033 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 7,274,308.56
16 2034 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 6,357,549.87
17 2035 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 5,556,327.45
18 2036 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 4,856,080.63
19 2037 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 4,244,083.75
20 2038 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 3,709,214.95
21 2039 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 3,241,754.02
22 2040 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 2,833,205.75
23 2041 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 2,476,145.56
24 2042 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 2,164,084.57
25 2043 90% RM 282,131,715.27 RM (133,348,797.13) RM (75,625,291.61) RM 73,157,626.53 RM (18,289,406.63) RM 54,868,219.90 RM 54,868,219.90 RM 1,891,351.66

NPV RM 26,941,611.71
RM 26,941,611.71
IRR 14.43%

34
2.6.5 Conclusion

In making the decision on which one is the best and suitable in build up the
plant, various method was calculated and done. These include the average rate of
return on investment or equity, payable period, discounted cash flow methods and
the profitability index. Based on the financial and economic analysis, the
profitability that can be gain by the company is around RM 53,368,219.90 per
annum. This business is a joined venture among four engineer. To build up the
plant, it takes a billion dollar for startup. So, the loan is the solution in open up this
business. The current creditors does not have any obligations in giving the loan
since most of us still young and strong in running the business. On other hand,
most of us have many connections between other companies and know how to
penetrate the market.

On calculations of all the important data needed before start up the

business, the rough year that the company will gain back the initial cash investment
is around 3 years. Meanwhile, the cost-benefit ratio of the ventures is 2% each
after the company gain back the initial cash investment. In a few years of startup
the business, the present value of net cash flow will be negative. But, the present
value of net cash flow will slowly be positive with the current market. The NPV of
the plant RM 17,618,993.22.

This company is highly demanded and give a lot of contribution to other

company in producing the PVC that will be used in many industries especially in
construction industry. The running of this VCM business gave many employment
opportunities.

35
 CHAPTER 3: PROCESS SELECTION

3.1 Direct Chlorination

Direct chlorination is a process between gaseous reactants of ethylene and chlorine

in homogenous catalytic reaction. Dichloroethane or known as EDC will form due to
this reaction. Ferric chloride is a catalyst chosen for chlorination of ethylene. The
reaction controlled by absorption of ethylene which is as the limiting factor. The
process happens in the fluidized bed reactors, where the ethylene and chlorine
gaseous are introduced at the bed of Ferric Chloride catalyst particles. The gas then
flows to the above of the reactor passing through the solid catalyst particles. The
friction of the solid catalyst and the gaseous reactant allows more absorption of
ethylene to happen which to provide higher conversion to happen. The solids moving
freely causes the heat transfer sufficient for exothermic gas-solid reactions. The
reactor will be operate at low-temperature chlorination (LTC) which at the range of 50-
90⁰C. This lower temperature technique results in higher selectivity. Since this is the
exothermic reaction, thus heat needs to be removing by heat exchanger as the
external heat transfer device.

3.1.1 Simulation of Direct Chlorination

The EDC product from previous reaction will enter the acid wash tank to
discard the undesired or liquid waste that contains hydrogen chloride (HCl)
and Chlorine (Cl2). This is called a simulation of direct chlorination. The
aqueous effluent from reactor enters the vertical packed bed fume scrubber
that filled with sodium hydroxide (NaOH). The sodium hydroxide have reactive
agent and act as a scrubbing liquid that neutralizes the HCl and emits the non-
harmful gases that form which by disposing it into the atmosphere. This
process however needs to send to the settling tank to separate the NaOH
spent and the crude EDC. Note that the catalyst also removes from the

36
 remaining product. The remaining EDC then will further process into
distillation column for purification.

3.2 EDC Purification

The EDC is then purified in a distillation column. This process removes moisture in the
stream that can cause corrosion in the equipment due to HCl and to achieve highest purity
of EDC by separating it from any other impurities. The top product will consist of a high
purity EDC. While the bottom product produces byproduct of heavy ends that contain
trichloroethane, hydrogen chloride, ethylene and chlorine which will be send to the waste
recovery for further treatment. The EDC produce from here is highly purified and will be
stored in a storage tank before undergoes the production of vinyl chloride monomer
(VCM).

3.3 Thermal Cracking (Pyrolysis) and Quenching

The EDC use dryer to removes any water molecules before enter the furnace to avoid
corrosion in the equipment. After that, furnace will play the main role to convert EDC into
VCM and by –product HCl at high temperature operation. The furnace will be operate at
temperature around 480⁰C -550⁰C with pressure of 3 to 30 bar, this is an endothermic
reaction therefore long tubular coil is install in the furnace. The reaction start when the
convection happens at the bottom part of the furnace to heat the reactant till the
temperature is significant to support the pyrolysis reaction. The high temperatures can
cause breakage of the longer molecular chain into much smaller molecular chain which
in this process EDC into VCM. The rapid of movement of particles in high temperature
condition will break the carbon-carbon bond and leaves the heavy residue. The EDC
vapor is then leaves the furnace and send to the quencher immediately to avoid any coke
or tar form. The by-product HCl will send to the HCl recovery.

37
3.4 Purification of VCM

The VCM produce during thermal cracking need further refine to produce high selectivity
final product. Therefore, another distillation column need to be installed in order to
removes unreacted EDC and remaining by-products which is polychlorides during the
previous process. The VCM column made of 20 trays and operating condition on the top
tray is 65 psig pressures with 10 psig column pressure drop. The VCM produce and leaves
the column as an overhead product of VCM column. The by-products are then sending to
another column. The distillation column is to separate the EDC remaining and the
polychlorides. Which the EDC remain can be recycling back to the thermal cracking
process in order to achieve desired VCM production. While the polychlorides, will undergo
further treatment together with heavy ends in a waste treatment process.

3.5 Waste treatment

The vapor and liquid by product send into the incinerator. The incinerator is allows to
operate at 1127⁰C of temperature which is high enough for the combustion of halogen
element and waste that contain chlorine. The inlet stream also supply by oxygen for
the combustion process. the element inside the waste react together and add extra
products for combustion forming carbon dioxide (CO2), water(H2O) , hydrochloric acid
(HCl), chlorine gas(Cl2), and nitrous oxides(NOx). These elements will then send to
the absorption column which water use as a solvent in the column to removes HCl and
H2O from the bottom stream send right away towards the HCl recovery system. The
top products of remaining element send into the scrubber by using NaOh as the
solvent. The process produces off gasses that less harmful and can be eliminate into
the atmosphere. The bottom product in the HCl removes from the scrubber and mixes
with the absorption column bottom product send to the HCl recovery system.

3.6 Hydrochloric Acid Purification

38
 The anhydrous HCL and aqueous HCL are combine and purified by purification column
becoming the HCL acid. This HCL will be sold.

3.7 Piping and Instrumentation Diagram (P&ID)

The use of P&ID is to make sure that the temperature, level, flow and pressure is in
a good condition that will not affect the process production and explosion if something
wrong happened with the equipment. All the indicator and controller are place at
proper place where it can detect everything. The process control that have here is
feed-forward and feed-back control system.

3.8 Equipment List

Table 9: Chemical List

Process Inlet Outlet Remarks Equipment
Direct Ethylene Crude Catalyst FBR
Chlorination Chlorine EDC (FeCl3)
(Reactor) HCl
(Acid Wash) EDC crude Crude Washing
From Liq HCl EDC Tank
product of Dilute
FBR NaOH
Caustic HCl (g) Offgas Recycle Vertical
Scrubber NaOH (l) (H2, CH4, NaOH into Packed Bed
(from vapor C2H4, the Fume
product of C2H6) scrubbing Scrubber/
FBR system Vertical
Packed
Tower Air
Scrubber

39
Separation Crude Crude Recycle Settling tank
of acid wash EDC EDC NaOH into
NaOH scrubbing
(wash) system
Purification Crude EDC Remove Wash Tower
of EDC EDC
Absorption Contain of
Column FeCl3
(Activated
Carbon)
Distillation EDC + Pure Plate Column
Column Lower EDC
boiling
point
impurities
Bottom
product
recycle
Thermal EDC + EDC Dryer
Cracking traces H2O vapor
and molecules
Pyrolysis
Hot flue 4 atm, Furnace
gas 500°C
EDC vapor
Incineration Heavy 1127°C Incinerator
ends,
polychlorid
es, O2

40
Absorption CO2, H2O, CO2,H2O, Absorption
HCL, CL2 HCL,CL2, Column
Neutralizatio CO2,H2O, HCL and Scrubber
n HCL,CL2, Off-gases
NaOH
Purification HCL HCL Acid Purification
Column Column

41
 CHAPTER 4: MASS BALANCE & ENERGY BALANCE

4.1 Mass Balance

𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛𝑠
Basis production of VCM 50 000 𝑎𝑛𝑛𝑢𝑚

𝐶2 𝐻4 + 𝐶𝑙2 → 𝐶2 𝐻4 𝐶𝑙2
𝐶2 𝐻4 𝐶𝑙2 → 𝐶2 𝐻3 𝐶𝑙 + 𝐻𝐶𝑙
𝐶2 𝐻4 + 𝐶𝑙2 → 𝐶2 𝐻3 𝐶𝑙 + 𝐻𝐶𝑙 ( Balance Equation )

𝑔
Molecular weight 𝐶2 𝐻4 : 28.05
𝑚𝑜𝑙
𝑔
Molecular weight 𝐶𝑙2 ∶ 70.91 𝑚𝑜𝑙
𝑔
Molecular weight 𝐶2 𝐻3 𝐶𝑙 ∶ 62.50 𝑚𝑜𝑙
𝑔
Molecular weight 𝐻𝐶𝑙 ∶ 36.46 𝑚𝑜𝑙

𝐶2 𝐻4 + 𝐶𝑙2 → 𝐶2 𝐻3 𝐶𝑙 + 𝐻𝐶𝑙

Mol 1 1 1 1

Molecular weight 28.05 70.91 62.50 36.46

Mass 28.05 70.91 62.50 36.46

Mass Composition 0.449 1.134 1 0.583

𝐶2 𝐻4 , 𝑚̇ 1
𝐶2 𝐻3 𝐶𝑙 , 𝑚̇ 3
OVERALL BALANCES
𝐻𝐶𝑙 , 𝑚̇ 4
𝐶𝑙2 , 𝑚̇ 2

42
 kg
m 3  146000
day

kg kg
m 1  0.449  146000  65554
day day

kg kg
 2  1.134  146000
m  165564
day day

kg kg
m 4  0.583  146000  85118
day day

EDC
𝐶2 𝐻4 , 𝑚̇ 1
𝑚̇ 6
DIRECT EDC , EDC
𝐶𝑙2 , 𝑚̇ 2 𝑚̇ 5
CHLORINATION PURIFICATION

Heavyends
𝑚̇ 7
For Direct Chlorination process, inlet = outlet
𝑚̇ 1 + 𝑚2̇ = 𝑚̇ 5
65 554 kg/day + 165 564 kg/day = 231 118 kg/day of EDC.
Upper stream of EDC purification is 98% while heavyend is 2%

kg kg
m 6  0.98  231118  226495.64
day day
kg
m 7  0.02m 5  0.02  231118
day
kg
m 7  4622.36
day

43
 𝐸𝐷𝐶
𝑚̇ 3 𝑉𝐶𝑀
𝑉𝐶𝑀
THERMAL VCM
CRACKING PURIFICATION
𝑚̇ 6 𝑚10
̇
8
m
̇
𝐸𝐷𝐶 𝑟𝑒𝑐𝑦𝑐𝑙𝑒 𝑚11

𝑚̇ 9 HCL =
87% of 𝑚̇ 4

kg kg
m 9  0.87  85118  74052.66
day day
m 11  0.4  226495.64 kg  90598.26 kg
day day
m10  m3  m11  146000 kg  90598.26 kg
day day
m10  236598.26 kg
day
m8  m11  m6  90598.26 kg  226495.64 kg
day day
m8  317093.9 kg
day

44
𝑚̇ 7 Heavy Ends m14 CO2
INCINERATION m15 H2O
m16 HCl
𝑚13
̇ O2 m17 Cl2

Composition of chemical in Heavy ends

Components Composition Mass flowrate
𝐶2 𝐻3 𝐶𝑙3 0.15 𝑘𝑔
693.36 ⁄𝑑𝑎𝑦

𝐻𝐶𝑙 0.1 𝑘𝑔
462.24 ⁄𝑑𝑎𝑦

𝐶2 𝐻4 0.5 𝑘𝑔
2311.18 ⁄𝑑𝑎𝑦

𝐶𝑙2 0.25 𝑘𝑔
1155.59 ⁄𝑑𝑎𝑦

C Balance

 kgC2 H 3Cl3 2kgC   kgC2 H 4 2kgC   kgCO2 1kgC 

 693.36     2311.18     m
 14  
 day 1kgC H
2 3Cl3   day 1kgC 2 H 4   day 1kgCO 2 

kgC
m 14  6009.12
day

Cl Balance

 kgC2 H 3Cl3 3kgCl   kgHCl 1kgCl 

 693.36     462.24  
 day 1kgC2 H 3Cl3   day 1kgHCl 
 kgCl2 2kgCl   kgHCl 1kgCl   kgCl2 2kgCl 
 1155.56     m 16     m 17  
 day 1kgCl2   day 1kgHCL   day 1kgCl2 
kg kg kg
4853.44  m 16  2m 17 1
day day day

45
In the incineration, oxygen will be needed to breakdown the carbon, hydrogen and
chlorine. This cracking process will produce carbon dioxide, water, hydrogen chloride.
The incineration need mass flow rates of oxygen that are more than the amount of
carbon dioxide produce. Base on the statement above we need at least 8000kg/day
of oxygen inlet into the incineration.

O Balance

kgO2 2kgO  kgCO2 2kgO   kgH2O 1kgO 

8000    6009.12     m 15  
day 1kgO2  day 1kgCO2   day 1kgH2O 
kgO
3981.76  m 15
day

H Balance

 kgC2 H 3 Cl3 3kgH   kgC2 H 4 4kgH 

 693.36     2311.2  
 day 1kgC 2 H 3 Cl 3   day 1 kgC 2 H 4 

 kgHCl 1kgH   kgH 2 O 2kgH   kgHCl 1kgH 

  462.24     3981.76     m 16  
 day 1kgHCl   day 1kgH 2 O   day 1kgHCl 
kgH
3823.6  m 16
day

subs m16 int o eq1

kg kg
4853.44  3823.6  2m17
day day
kgCl2
m17  514.92
day

m18 H 2O

46
 m19CO2

m14 CO2
m15 H 2 O ABSORPTION 𝑚4 𝐻𝐶𝑙 𝑇𝑜𝑡𝑎𝑙
m16 HCl COLUMN
m17 Cl 2 m20

Anhydrous 𝐻𝐶𝑙 m8

m20  m4  m8  85118 kg  74052.68 kg

day day
m20  11065.32 kgHCl
day

H Balance

4.2 Material Balance Summary

Stream no.
Process Component 𝒎̇, (kg day)
In Out
𝑚̇1 - C2H4 65554.00
Direct 𝑚̇2 - Cl2 165564.00
Chlorination C2H4 Cl2, C2H3 Cl3,
- 𝑚̇5 231118.00
HCl, C2H4, Cl2
C2H4 Cl2, C2H3 Cl3,
EDC 𝑚̇5 - 231118.00
HCl, C2H4, Cl2
Purification
- 𝑚̇6 C2H4 Cl2 226495.64

47
 C2H3 Cl3, HCl,
- 𝑚̇7 4622.36
C2H4, Cl2
𝑚̇6 - C2H4 Cl2 226495.64
𝑚̇8 - C2H4 Cl2 317093.88
Pyrolysis
- 𝑚̇9 HCl 74052.68
- 𝑚̇10 C2H3 Cl, C2H4 Cl2 236598.24
𝑚̇10 - C2H3 Cl, C2H4 Cl2 236598.24
VCM
- 𝑚̇3 C2H3 Cl 146000.00
Purification
- 𝑚̇11 C2H4 Cl2 90598.24
C2H3 Cl3, HCl,
𝑚̇7 - 4622.46
C2H4, Cl2
𝑚̇13 - O2 8000.00
Incineration - 𝑚̇14 CO2 6009.12
- 𝑚̇15 H2O 3981.76
- 𝑚̇16 HCl 3823.60
- 𝑚̇17 Cl2 514.92
𝑚̇14 - CO2 6009.12
𝑚̇15 - H2O 3981.76
𝑚̇16 - HCl 3823.60
HCl
𝑚̇17 - Cl2 514.92
Purification
𝑚̇18 - H2O 73330.88
- 𝑚̇19 CO2 6009.12
- 𝑚̇20 HCl 11065.32
𝑚̇8 - HCl 74052.68
Mixer 𝑚̇20 - HCl 11065.32
- 𝑚̇4 HCl 85118.00

4.3 Manual Energy Balances

Energy balances are important to determine the energy requirements of the process:
the heating, cooling and power required in the process design. The shortcut methods
suggested by Biegler and Grossmann (1997) have been used to calculate the energy
balances of the process. Energy of each streams as well as energy consumption of every
unit was also calculated. In this project some assumptions are made for the energy
balances calculation:

48
  The processes follow the law of conservation of energy where:
Energy out = Energy in + Generation – Consumption –Accumulation

 Steady- state condition in all equipment.

 Kinetic energy, potential energy and shaft work change for these streams will be
neglected and only enthalpy changes take place. Hence the enrgy balance equation
equal to  Q = H
 Ideal properties for evaluating the energy balances of the process streams. This
means the pressure effect can be neglected.
 No heat of mixing and pressure effect on H.
 Reference temperature for all the calculation is 25°C or 298.15K.

Calculation of vapor heat capacity is based on ideal gas heat capacity:

T
H v (T, y)  H f  H T   k n k H f ,k (T1 )   n k  2 C 0p,k (T)dT
T1
k

where nk = molar flow rate for component k, kmol/h

Hf,k = heat of formation for component k at standard reference state,

C°p,k (T) = temperature dependent heat capacities for component k

C p B(T 2  Tref
2
) C p C(T 3  Tref
3
) C p D(T 4  Tref
4
)
 CpdT Cp A(T  Tref )  2

3

4

where CpA, CpB, CpC and CpD = heat capacities equation constants for component –k.

Whereas, enthalphy for liquid mixtures of specific stream is estimated by:

T
H L (T)   k n k H f ,k   n k  C 0p,k (T)dT   k n k H k
To vap
k

where Hkvap (T) is heat of vaporization at specific temperature.

49
 The dependent of heat of vaporization on temperature can be found through the
Watson correlation:
Hvap (T) = Hkvap (Tbk) [ (Tc - T)/( Tc - Tb)]0.38

where Tck = critical temperature,

Tbk = the atmospheric boiling point for component k,
Hkvap (Tbk) = heat of vaporization at this temperature

4.4 Energy Balance of Vinyl Chloride Monomer Production

Since there is no temperature changes, ∆T = 25⁰C -25⁰C=0, Therefore; for inlet

stream (reactant)

25
̂𝐶 𝐻 = ∆𝐻𝑓° + ∫ 𝐶𝑝. 𝑑𝑇
𝐻 2 4
25

𝑘𝐽⁄ 𝑘𝐽⁄
= 52.3 𝑚𝑜𝑙 + 0 𝑚𝑜𝑙

= 52.3 𝑘𝐽⁄𝑚𝑜𝑙

While Chorine (Cl2) gas no heat formation and no change of temperature resulting in
̂𝐶𝑙 = 0.In the Outlet stream (Reactant);
𝐻 2

̂𝐶 𝐻 𝐶𝑙 = −169.7 + 0.1294 (87 − 25)

𝐻 ̂𝐶 𝐻 𝐶𝑙 = −177 + 0.1444 (87 − 25)
𝐻
2 4 2 3 3
𝑘𝐽
= −161.677
𝑘𝐽⁄ = −168.047 ⁄𝑚𝑜𝑙
𝑚𝑜𝑙

̂𝐻𝐶𝑙 = −167.4 + 0.075 (87 − 25) ̂𝐶𝑙 𝐻 = 52.28 + 2.7415

𝐻
𝐻 2 4
𝑘𝐽
= 55.0215 ⁄𝑚𝑜𝑙
= 162.35 𝑘𝐽⁄𝑚𝑜𝑙

̂𝐶𝑙 = 0 + 2.108
𝐻 2

= 2.108 𝑘𝐽⁄𝑚𝑜𝑙

50
 ̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 − ∑ 𝑛̇ 𝐻
𝑄 = ∆𝐻 = ∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡

= −3.659 × 108 − 1.2138 × 108

108 𝑘𝐽 1 𝑑𝑎𝑦
= −4.8728 × ×
𝑑𝑎𝑦 86400𝑠
= −5639.81 𝑘𝑊

Direct Chlorination
Component Product Reactant Q(kW)
𝑛̇ (mol/day) ̂ (kJ/mol)
𝐻 𝑛̇ (mol/day) ̂ (kJ/mol)
𝐻
𝐶2 𝐻3 𝐶𝑙3 2273310 -161.677 - -
𝐶2 𝐻4 81980 55.0215 2321030 52.36
𝐶𝑙2 16660 2.108 2318850 0
𝐶2 𝐻4 𝐶𝑙3 51.60 -168.045 - -
𝐻𝐶𝑙 12590 -162.75 - -

̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = −3.659
∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = 1.2138
∑ 𝑛̇ 𝐻 −5639.81

× 108 × 108
EDC Purification 1
EDC 2273310 -167.2 2273310 -159.366
𝐶2 𝐻3 𝐶𝑙3 5160 -17.7 5160 -160.99
HCl 12590 -167.4 12590 -139.085
𝐶2 𝐻4 81980 52.28 81980 57.47
𝐶𝑙2 16660 0 16660 3.802

̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = −3.780
∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = −3.601
∑ 𝑛̇ 𝐻 −207.18

× 108 × 108
Pyrolysis
𝐸𝐷𝐶𝑚6 63200.71 -112.205 2273.31 -162.2
𝑈 − 𝐸𝐷𝐶𝑚10 - - 63200.71 -17.7
HCl 2.013 × 106 −162.89 - -

51
 VCM 2320070 51.1124 - -
Polychloride 51.2 15.156 - -

̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = −2.164
∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = −1.487
∑ 𝑛̇ 𝐻 −2487.42

× 108 × 106
VCM Purification
VCM 2320070 51.1124 2320070 32.288
Polychloride 51.2 15.156 51.2 2.419
EDC 63200.71 -112.205 63200.71 -157.88

̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = 1.115 × 108

∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = 6.493
∑ 𝑛̇ 𝐻 539.00

× 107
EDC Purification 2
EDC 63200.71 -159.936 63200.71 -152.06
PC 51.2 3.597 51.2 4.016

̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = −1.011
∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = −9.610
∑ 𝑛̇ 𝐻 −5.787

× 107 × 106
Incineration
PC - - 51.2 3.597
𝐶2 𝐻3 𝐶𝑙3 - - 5160 -177
𝐻𝐶𝑙 260360.494 -86.775 12590 -167.4
𝐶2 𝐻4 - - 81980 52.28
𝐶𝑙2 8010.719 39.525 16660 0
𝑂2 - - 203804 -5.836
𝐶𝑂2 135629.546 -342.18 - -
𝐻2 𝑂 61560 -199.936 - -
̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = −8.058
∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = 7.581
∑ 𝑛̇ 𝐻 −95.826

× 106 × 103
HCl Purification
𝐶𝑂2 - - 135629.546 -391.260

52
 𝐻2 𝑂 (𝑔) - - 61560 -239.809
𝐻𝐶𝑙 3.015 × 105 -165.15 260360.494 -162.9
𝐶𝑙2 - - 8010.719 2.039
𝐻2 𝑂 (𝑙) - - 19909.722 -

̂𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 4.979
∑ 𝑛̇ 𝐻 ̂𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = −1.102
∑ 𝑛̇ 𝐻 699.53

× 108 × 108

CHAPTER 5: EQUIPMENT DESIGN

5.1 Major Equipment

The major equipment of the plant is design base on the formula and information gather on the
mass balance, and the energy balance part. The information are then to be used as the basis
to calculate the design of the equipment.

53
 5.1.1 Reactor

5.1.2 Scrubber

5.1.3 Distillation of EDC

5.1.4 Dryer

The dryer that require in this process is dryer for compressed air. The type of the
compressed air dryer that are selected for this processes is membrane air dryer. The
membrane type dryer is for gas separation. This type of dryer is using membrane to
filter the water vapour that available in the ethylene dichloride gas. The membrane
structure is a semi-permeable membrane that allow the water to pass through the
membrane pores faster. The membrane will reduce the amount of water vapour in the
air stream at the outlet.

The advantages of the membrane dryer are it has low installation cost, low operating
cost. The dryer also can be installed outdoors and can be used in hazardous
atmospheres. The dryer also has no moving parts. The disadvantages of the
membrane dryer are limited to low capacity systems, it has high purge air loss (15 to
20%) to achieve required pressure dew points. The membrane may be fouled by oil
or other contaminants from the gas. The membrane dryer also has high initial capital
cost. According to the (http://www.cagi.org/pdfs/cagiairdryingselectionguide.pdf) the dryer
standard conditions is according to ADF 100, Refrigerated Compressed Air Dryers –
Methods for Testing and Rating.

The temperature of the dryer is 200°C. Ethylene dichloride in 200°C is in vapour state
because the boiling temperature is 83.5°C. The operating pressure for the dryer is 100
psig. The water vapour will be separated by the membrane and the 1, 2-
dichloroethane (EDC) will be collected as the EDC will not pass through the
membrane and also will be dried from the moisture that available in EDC. The EDC

54
need to be dried as the EDC will be cracked in the thermal cracking. This is to ensure
that the EDC that are cracked into VCM is pure and contain less moisture.

The membrane that is selected to separate the water vapour from the gas is sulfonated
polyetheretherketon (SPEEK) because this membrane possess a high selectivity and
permeability for water vapour removal from the gas streams
(http://doc.utwente.nl/40766/1/thesis_Metz.pdf).

EDC that will flow into the dryer is 226,495.64 kg/day. The volumetric flow rate of the
EDC is 2.092 m3/s that enter the dryer with velocity of 0.2 m/s. The velocity of the
dryer is determine based on the flow rates of the volume of the EDC that enter the
dryer per second. The volumetric flow rates and the velocity of the EDC enter the dryer
determine the dimension of the dryer. The dryer is basically a cylinder, the dimension
that are calculated based on the information gather is the height of the dryer which is
0.5 m. The radius of the dryer is determine based on the area of the dryer get from
the calculation.

The materials use for the dryer is 316 stainless steel. This materials is use to prevent
corrosion from the water vapour and chloride that are present in the ethylene
dichloride.

55
 kg
m  226495.64
day
kg
  1253
m3

1day 1h
226495.64 kg  
m day 24h 3600 s
V  
 1253 kg 3
m
3
V  2.092 m
s

  0.2 m s

3
V 2.092 m
Area   s
 0 .2 m
s
Area  10.46m 2

Area  2r 2  2rh

r  0.5m

10.46m 2  2 (0.5) 2  2 (0.5)h

10.46m 2  0.063m 2  0.63h
h  2.83m
5.1.5 Furnace

5.1.6 Quencher

5.1.7 Distillation of VCM

The distillation column that is design is the binary distillation column for the two
mixtures which is ethylene dichloride or 1, 2- dichloroethane (EDC) and vinyl
chloride that are form for the cracking of the EDC. The mixtures of the liquid
will enter the distillation column from the quencher.

56
The stages or the tray of the distillation column is calculated by using the Mc-
Cabe Thiele method which use the vapour liquid equilibrium (VLE) data and
the reflux ration to plot the number of tray for the distillation column. The VLE
data for the distillation of vinyl chloride and EDC is got from the VLE-calc that
is from (http://vle-
calc.com/phase_diagram.html?numOfC=2&compnames=1&Comp1=171&Comp2=169&Com
p3=2&VLEMode=isobaric&VLEType=xy&numberForVLE=1).

x1 (vinyl y1 (vinyl
TEMPERATURE
chloride) chloride)
°C mol/mol mol/mol
83.0945 0 0
76.0045 0.01 0.202706
69.4613 0.02 0.357054
63.832 0.03 0.474225
58.9408 0.04 0.563807
50.8406 0.06 0.687521
44.3699 0.08 0.765745
39.0472 0.1 0.817899
29.0003 0.15 0.891214
21.8252 0.2 0.927474
16.3655 0.25 0.948138
12.029 0.3 0.961112
8.47549 0.35 0.969851
5.4926 0.4 0.976062
2.93917 0.45 0.980671
0.716502 0.5 0.984214
-1.24742 0.55 0.987023
-3.00713 0.6 0.989313
-4.60534 0.65 0.991226
-6.07665 0.7 0.992865
-7.45004 0.75 0.9943
-8.7506 0.8 0.995587
-10.0009 0.85 0.996769
-11.2218 0.9 0.997879

57
 -11.7065 0.92 0.998309
-12.1911 0.94 0.998735
-12.6769 0.96 0.999158
-12.9206 0.97 0.999368
-13.1651 0.98 0.999579
-13.4106 0.99 0.999789
-14.1347 1 1

The data obtain for vapour (y) and liquid (x) are then plot in the graph paper to
obtain the equilibrium line for the process of vinyl chloride purification. The
graph plot of vapour (y) against liquid (x) will have the result for the number of
the theoretical stages and theoretical tray.

mole fraction (y) vs mole fraction (x)

1.2
y = 0.4999x + 0.6032
1

0.8

0.6

0.4

0.2

0
0 0.2 0.4 0.6 0.8 1 1.2

There are another graph that are drawn on graph paper to draw the 45° line, q
line, operating line, stripping line and theoretical stages. The mole vinyl chloride
feed into the distillation column is calculated using this equation:

58
Fx f  Dx D  WxW

kg kg kg
F  236598.24 D  146000 W  90598.24
day day day
xD  0.99 xW  0.05
kg  kg   kg 
236598.24  xF  146000  0.99    90598.24  0.05 
day  day   day 
xF  0.63

The q line are calculated by using this equation:

HV  H F
q , HV  H L  molar latent heat of vaporization
HV  H L
kJ kJ
HV  H L VCM  370 , HV  H L EDC  320
kgmol kgmol
kJ
HV  H L a var age  355
kgmol
H  H F HV  H L  CpL (TBoiling  TFeed )
q V 
HV  H L HV  H L
kJ kJ
Cp EDC  1.31465 , Cp VCM  1.16812
kgC kgC
kJ
Cpav  1.241
kgC

355
kJ
 1.214
kJ
83.09  50C
kgmol kgC
q  1.116
kJ
355
kgmol

The calculated q line must be drawn into the graph, the equation to draw the q
line is:

59
 q 1.116
slope    9.62
q  1 1.116  1
y  y0 y  0.5
9.62  1  1
x1  x0 0.55  0.5
y1  0.981

After the q line is drawn. The operating line and stripping line must be drawn to
obtain the theoretical number of stages. To draw the operating line must have
the value for reflux ratio. The value of reflux ratio is 10% more than the value
of minimum reflux ratio. To know the reflux ratio, the minimum reflux ratio must
be calculated first.

Rm x  y ' 0.99  0.987

 D   0.00682
Rm  1 xD  x' 0.99  0.55
Rm
 0.00682
Rm  1
Rm  0.00682 Rm  0.00682
Rm  0.0069

R  10% more than Rm

110
R  0.0069  0.00759
100

R x 0.00759 0.99
yn 1  xn  D  xn 
R 1 R  1 0.00759  1 0.00759  1
yn 1  0.0075 xn  0.9825

By using the equation above, all the line are drawn and the number of stages
can be define. By drawing the line, 4 stages is obtain from the equilibrium data
of vinyl chloride and ethylene dichloride.

The actual number of trays are obtain by dividing the theoretical number of
trays with the efficiency of the tray.

60
Tray Efficiency
y  yn 1
EM  n
y *n  yn 1
yn 1  0.0075(0.7)  0.9825  0.98775
yn  0.989313
y *n  0.992865
0.989313  0.98775
EM   0. 3
0.992865  0.98775

log 1  EM (mV / L  1)

EO  , m  0.4999, EM  0.3
log mV / L 
  0.4999  146000 
log 1  0.3  1 
  90598.24  log 0.943
EO    0.27
 0.4999  146000  log 0.806
log  
 90598.24 

ideal tray number

EO 
actual tray number
3
Actual Tray number   11
0.27

The spacing of the tray between each other is determine by the comfort of the
people when doing the maintenance. The comfortable height for the space
between the trays is 24 inches to 30 inches. The chosen height for the space
between the trays is 24 inches. The height of the column can be determine by
the height of the space and the number of trays as it is equilibrium to each
other. The tower height is 7.3 meter.

11 tray  1 reboiler 12

12  24"  288"
1m
288"  7.3m
39.37"

61
The diameter of the tray can be determine by using the flooding method. The
diameter of the tray is use to estimate the diameter of the column. The
calculated diameter of the tray in the tower is 0.48 m, but the design diameter
is usually 50% more than the calculated value which is 0.72 m. The diameter
of the tower is estimated to be around 1 m.

1/ 2
    L  V 
0.2

Vmax  KV    
 20   V 

first ,
62.50 kg 273.2 K  447.5kPa kg
V  mol   10.416 3
22.4 m
3
(273.2  50) K  101.325kPa m
mol
kg
 L  1253
m3
kg kg
L  90598.24 ,V  146000
day day
90598.24 kg  kg 
day  10.416 m3 
0.5
L  V 
      0.057
V   L  kg kg
day  
146000 1253
m3 

The KV is obtain form a graph based on the value of plate spacing (24”) and
0.057. The KV value obtain is 0.37 ft/s

  25 dyn cm , Kv  0.37 ft / s
1253  10.416
0.2
 25 
Vmax  0.37 ft / s   4.04 ft / s
 20  10.416

The design velocity has downspout area around 9% and it must 20% below
flooding.

Vdesign  4.04 ft / s  0.91  0.80  2.94 ft / s

0.3048m
Vdesign  2.94 ft / s   0.896m / s
1 ft

62
The tower cross section can be calculate by using the velocity design and
density of gas.

146000 kg 1 1
day
Area     0.181m 2
86400 s 10.416 kg 0.896 m
day m3 s
D 2
Area   0.181m 2
4
D  0.48m

Ddesign  50%more
150
Ddesign   0.48m  0.72m
100

The valve chosen to be installed in the column is valve tray. This is due to the
mechanism of the valve tray. Valve Tray is using valve which is rise as vapour
rate increase and then reduce as vapour rate fails, this stop the liquid from
weeping. Valve can be round or rectangular, with or without caging structured.
Valve disk rise as vapour rate increase. Valve tray has minimum capacity
approximately 60%. The pressure of the column is 65 psig with a pressure drop
of 10 psig per tray. The materials chosen for the distillation column is 316
stainless steel. Temperature of the feed is 50°C, the outlet temperature for top
product which is VCM is 30°C and bottom which is EDC is 70°C.

5.1.8 Incineration

5.1.9 Absorption Column

5.1.10 Mixer

63
REFERENCES

Dry, J., Lawson, B., Le, P., Osisanya, I., Patel, D., & Shelton, A. (2003). Vinyl Chloride
Production. Marcel Dekker, Inc., Encyclopedia of PVC., 1–9.
New VCM Plant Will Use Ethane. (n.d.). Retrieved from
http://www.chemicalonline.com/doc/new-vcm-plant-will-use-ethane-0001
Physical Properties for Ethane. (n.d.). Retrieved from
http://www.airproducts.com/products/Gases/gas-facts/physical-properties/physical-
properties-ethane.aspx
The Dow Chemical Company. (2013). Product Safety Assessment: Vinyl Chloride Monomer,
1–6.
Vinyl, V. C. M., Monomer, C., Cl, C. H., Chloride, P. V., Processess, T., Pyrolysis, E. D. C.,
& Process, K. (n.d.). Executive summary 1.
Vinyl Chloride Monomer (VCM) | National Pollutant Inventory. (n.d.). Retrieved from
http://www.npi.gov.au/resource/vinyl-chloride-monomer-vcm
Vinyl Chloride Monomers (VCMs) Market - Global Industry Analysis, Size, Share, Growth,
Trends and Forecast 2012 - 2018. (n.d.). Retrieved from
http://www.transparencymarketresearch.com/vinyl-chloride-monomers.html
Wismer, J., & America, A. N. (2001). Vinyl Chloride from Ethane, (Vcm).

64
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