1. Basically chlorine is used as chlorinating agent during chlorination. As chlorine is stored in liquid form under pressure, it is need to evaporate before passing it to reactor. 2. Chlorination reactions are highly exothermic where Hr ranges between 25 to 30 kcal/gmol. 3. During chlorination, HCl gas is obtained as the by-product and it is highly corrosive in nature, hence in environmental and safety point of view, HCl gas cant be vented directly in atmosphere. So proper absorption system for HCl should be designed.
4. HCl leaving the reactor is saturated with
organics. So after condensation, these condensed organic contents should be recovered and recycled back to reactor. 5. The organic phase from reactor contains traces of HCl. This HCl is stripped off from reaction mass i.e. HCl stripping is done using stripper. 6. Recovery of organics from HCl absorption system is necessary. CHOLOROBENZENE
Benzene reacts with chlorine in an
electrophilic substitution reaction, but only in the presence of a catalyst. The catalyst is either aluminium chloride or iron chloride.
C6H6 + Cl2 C6H5Cl + HCl
Although reaction rate of benzene to chlorobenzene is approximately 8.5 times more than dichlorobenzene but ortho and para dichlorobenzene is also formed during this reaction. Para dichlorobenzene is more valuable (used as insecticide, moth repellent, deodorant) and is twice as much as ortho dichlorobenzene in the final product. The final composition of the charge will vary somewhat depending upon temperature, catalyst and rate & degree of chlorination, Approximate composition is usually
shows the required density has reached, benzene circulation is stopped. The required density is about 1.280 at 15 C. The time consumed is about 6 hrs. Special type of reactor used for chlorination Bubble Column Reactor with external Heat exchanger. Bubble column reactors Bubble column reactors
Bubble columns are devices in which gas, in
the form of bubbles, comes in contact with liquid. The purpose may be simply to mix the liquid phase. Substances are transferred from one phase to the other Bubble column reactors -Simple vertical cylindrical vessels with intense contact between the two phases.
-The gas phase is dispersed into the liquid phase
using specific gas distributors at the bottom of the column.
-The net liquid flow may be co-current or counter-
current to the gas flow direction. Gas is sparged at the bottom of the liquid pool contained by the column. (sparging is a technique which involves bubbling a gas, through a liquid. Sparging increases the gas-liquid interface.)
Spargers, like porous plates, generate uniform
size bubbles and distribute the gas uniformly at the bottom of the liquid pool. Bubble Column
Co- Counter- current current Static Gas Spargers Dip tube Perforated plate
Perforated ring Porous plate
Bubble column reactors 1. Chlorine from storage tank is passed to chlorine evaporator to evaporate the chlorine and then this gaseous chlorine is passed to reactor. 2. Benzene (in liquid form) from Benzene day tank (DT) is passed to reactor (chlorinator). 3. Reaction between chlorine and benzene takes place in chlorinator and organic phase mostly containing mono-chloro-benzene (MCB) along with few amount of di- and tri- chloro-benzene (DCB and TCB) is produced; also HCl gas is produced as by-product. 4. Gaseous phase (mainly containing HCl gas and few amount of organics saturated with HCl) from reactor is passed to series of condensers (2 or 3 condensers), where, organics get condensed which are recycled back to chlorinator while HCl gas stream is further passed to HCl absorption system. 5. Organic phase from chlorinator contains traces of HCl. Therefore this organic phase before passing to further separation system, it is passed to stripper where HCl traces get stripped off from organic phase. 6. Organic phase now free from HCl is passed to further purification i.e. to series of distillation column, where main product MCB gets separated from traces of DCB, TCB and unconverted Benzene if any. FLOW CHART SHOWING DIFFERENT STEPS 1. Bubble Column Reactor with external Heat exchanger To show this bubble column reactor, draw reactor (cylindrical, vertical arrangement), show the liquid and bubbles inside it. Liquid (Benzene) is fed from top or from side inlet of reactor. Here, as it is gas-liquid type reaction, Cl2 gas (evaporated in Cl2 evaporator) is passed in reactor from bottom using sparger. Cl2 gas is sparged in benzene liquid so that it bubbles in liquid and good contact between gas and liquid takes place for reaction to occur. As reaction is exothermic, we need to continuously remove this heat of reaction, for which external heat exchanger is used. The whole reaction mixture (gas+liquid) is continuously circulated from reactor to heat exchanger to reactor. For this circulation, pump is used. Once the reaction is completed, the reaction mixture (product) is removed from reactor through bypass line provided on circulation line somewhere at the top of reactor. Draw heat exchanger as vertical shell and tube type heat exchanger beside the bubble column reactor. 2. HCl Absorption system: As HCl gas is by-product of chlorination process and as it is being corrosive in nature, it is needed to absorb this HCl gas using suitable solvent like water or any other. The gas free from HCl then further can be vented in atmosphere. HCl gas from condensers and stripper, is sent to a series of towers. The water is passed to these gas tower, which will absorb HCl. After certain time, HCl solution is removed from its bottom and passed to settler cum separator. In this settler cum separator, HCl acid gets separated from traces of organic phase if any. HCl acid is sent to storage tank (ST). Tail gases free from HCl gas, are taken out from top of 1st tower and sent to the top of second tower. Tail gases from last tower are absorbed in alkali solution contained in alkali solution tank to remove the traces of HCl 3. Separation of Organic Phase from stripper We need to separate main product MCB from traces of other by-products like DCB or TCB and unconverted benzene, from organic phase coming out from stripper. Three distillation columns are used to separate different products. Benzene is separated at the top of first column from other products and sent to settling tank. Remaining organic phase is taken out from bottom of 1st column and sent to 2nd distillation column. Second separates MCB from top, which is further sent to settling tank. Bottoms of second column are sent to 3dr distillation column. Traces of DCB gets separated from top of 3rd and sent to ST, however bottoms of 3rd is residue stream.