Simulation and Economic Evaluation of Methylene Chloride Production via Methane Chlorination

This study simulates and economically evaluates methylene chloride production via methane chlorination using Aspen HYSYS V۱۱. A plug flow reactor (PFR) model optimized reaction conditions to ۲۸۰°C and ۲ bar with a methane-to-chlorine ratio of ۱.۵, achieving ۵۱.۶۸% methane conversion and ۹۹% methylene chloride purity. Sensitivity analysis confirmed these parameters maximize yield while minimizing by-products (methyl chloride, chloroform, carbon tetrachloride). Sustainable design principles guided process integration, including sodium hydroxide/water absorption for HCl neutralization and distillation columns for product separation. By-product recovery enhanced profitability, yielding ۹۷%-purity methyl chloride. Economic feasibility was assessed via Total Annual Cost (TAC) methodology, combining capital and operating expenditures. For a ۱۷۰۰ ton per year capacity, the TAC was ۲۹۷۰۰۰ per year, with by-product credits significantly improving economic viability. The design reduced energy consumption and waste through heat integration and efficient separation. This work demonstrates a scalable, economically resilient methylene chloride production process, highlighting the synergy between operational optimization, sustainable engineering, and profitability in industrial chlorination systems.

کلیدواژه ها:

Conceptual design ، Process design ، Economic feasibility ، methane chlorination ، methylene chloride