The synthesis of cthyl chloride is accomplished by reacting ethylene with
hydrogen chloride in the presence of an aluminum chloride catalyst:
$$\mathrm{C}_{2} \mathrm{H}_{4}(\mathrm{g})+\mathrm{HCl}(\mathrm{g})
\stackrel{\text { catallyst }}{\longrightarrow} \mathrm{C}_{2} \mathrm{H}_{5}
\mathrm{Cl}(\mathrm{g}) ; \quad \Delta H_{\mathrm{r}}\left(0^{\circ}
\mathrm{C}\right)=-64.5 \mathrm{kJ}$$
Process data and a simplified schematic flowchart are given here.
Data
Reactor: adiabatic, outlet temperature \(=50^{\circ} \mathrm{C}\) Feed A: \(100
\% \mathrm{HCl}(\mathrm{g}), 0^{\circ} \mathrm{C}\)
Feed \(\mathrm{B}: 93\) mole \(\% \mathrm{C}_{2} \mathrm{H}_{4}, 7 \%
\mathrm{C}_{2} \mathrm{H}_{6}, 0^{\circ} \mathrm{C}\)
Reactor: adiabatic, outlet temperature \(=50^{\circ} \mathrm{C}\) Feed A: 100\%
HCl(g), 0"C Feed B: 93 mole\% C_H_4, 7\% C_H_0, 0"C Product C: Consists of
1.5\% of the HCl, 1.5\% of the C_2 \(\mathrm{H}_{4}\), and all of the
\(\mathrm{C}_{2} \mathrm{H}_{6}\) that enter the reactor Product D: \(1600
\mathrm{kg} \mathrm{C}_{2} \mathrm{H}_{5} \mathrm{Cl}(\mathrm{l}) /
\mathrm{h}, 0^{\circ} \mathrm{C}\)
Recycle to reactor: \(\mathbf{C}_{2} \mathrm{H}_{5} \mathrm{Cl}(\mathrm{l}),
0^{\circ} \mathrm{C}\)
\(\mathrm{C}_{2} \mathrm{H}_{5} \mathrm{Cl}: \Delta \hat{H}_{\mathrm{y}}=24.7
\mathrm{kJ} / \mathrm{mol}\) (assume independent of \(T\) )
\(\left(C_{p}\right)_{C_{2} H_{3} C(v)}\left[\mathrm{kJ} /\left(\mathrm{mol}
\cdot^{\circ} \mathrm{C}\right)\right]=0.052+8.7 \times 10^{-5}
T\left(^{\circ} \mathrm{C}\right)\)
The reaction is exothermic, and if the heat of reaction is not removed in some
way, the reactor temperature could increase to an undesirably high level. To
avoid this occurrence, the reaction is carried out with the catalyst suspended
in liquid cthyl chloride. As the reaction proceeds, most of the heat liberated
goes to vaporize the liquid, making it possible to keep the reaction
temperature at or below 50^'C.
The stream leaving the reactor contains cthyl chloride formed by reaction and
that vaporized in the reactor. This stream passes through a heat exchanger
where it is cooled to \(0^{\circ} \mathrm{C},\) condensing essentially all of
the cthyl chloride and leaving only unreacted \(\mathrm{C}_{2} \mathrm{H}_{4},
\mathrm{HCl}\), and \(\mathrm{C}_{2} \mathrm{H}_{6}\) in the gas phase. A portion
of the liquid condensate is recycled to the reactor at a rate equal to the
rate at which ethyl chloride is vaporized, and the rest is taken off as
product. At the process conditions, heats of mixing and the influence of
pressure on enthalpy may be neglected.
(a) At what rates (kmol/h) do the two feed streams enter the process?
(b) Calculate the composition (component mole fractions) and molar flow rate
of product stream \(\mathrm{C}\).
(c) Write an energy balance around the reactor and use it to determine the
rate at which ethyl chloride must be recycled.
(d) A number of simplifying assumptions were made in the process description
and the analysis of this process system, so the results obtained using a more
realistic simulation would differ considerably from those you should have
obtained in Parts (a)-(c). List as many of these assumptions as you can think
of.
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