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Journal of Chemical Engineering Research Progress, 2 (1) 2025, 14-18

Research Article

Improving 1,2-Ethylene Dichloride Yield and Purity with Reducing

Carbon Emissions from Ethylene through Waste Treatment
Method Modification
M. Syauqi Finardhy Saputra*, Rheka Fauzan Azhar, Try Ramadhani, Vares Dodi

Department of Chemical Engineering, Faculty of Engineering, Universitas Diponegoro, Semarang, Indonesia.

Received: 19th December 2024; Revised: 27th December 2024; Accepted: 27th December 2024
Available online: 8th January 2025; Published regularly: June 2025

Abstract
1,2-ethylenedichloride (EDC) is a chemical compound used widely in industry. This study aims to develop a modified
process for EDC production through direct chlorination and oxychlorination methods to improve mass efficiency,
establish an environmentally friendly plant, and produce high purity products. Conceptual process simulation was
conducted using Aspen HYSYS, with energy consumption and carbon emission analysis using Aspen Energy Analyzer.
Process modifications included a new separation system incorporating a flash drum separator, liquid-liquid extraction,
and reboiled absorber to achieve more high yield from 71796.84 kg/h to 71859.39 kg/h and purity from 94% to 99.05%
and. The results showed improved efficiency purity and yield with reduced carbon emissions from 67680 kg/h to 14170
kg/h, with the potential for industrial sustainability through feedstock optimization and reduced environmental
impact.

Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open
access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).

Keywords: 1,2-Ethylenedichloride; Carbon Emission; High Purity; Yield Maximizing

How to Cite: Saputra, M.S.F., Azhar, R.F., Ramadhani, T., & Dodi, V. (2025). Improving 1,2-Ethylene Dichloride
Yield and Purity with Reducing Carbon Emissions from Ethylene through Waste Treatment Method Modification.
Journal of Chemical Engineering Research Progress, 2 (1), 14-18 (doi: 10.9767/jcerp.20297)

Permalink/DOI: https://doi.org/10.9767/jcerp.20297

Supporting Information (SI): https://journal.bcrec.id/index.php/jcerp/article/downloadSuppFile/20297/5475

1. Introduction and tri- and tetrachloroethylene [2]. The

remainder is used in various processes, mainly for
1,2-ethylenedichloride (C2H4Cl2) is a
the synthesis of ethylenediamine [3]. By reviewing
chemical compound that has various industrial
the production of ethylene dichloride, innovation
uses. The world demand for EDC since 1975 has
in the design of ethylene dichloride plants while
increased by 5% per year. Therefore, it is
taking into account certain aspects such as mass
estimated that in the next 18 years, EDC demand
efficiency and total carbon emission efficiency.
will reach 137,771,329 tons [1]. About 85% of the
The two main methods for ethylene
total ethylene dichloride production is used to
dichloride (EDC) production are direct
produce vinyl chloride which is the main
chlorination and oxychlorination. Direct
ingredient in the production of polyvinyl chloride
chlorination, which reacts ethylene with chlorine,
(PVC), a multipurpose plastic used in various
offers higher conversion efficiency and easier
applications. In addition, about 10% of ethylene
process control, making it more cost-effective and
dichloride is also used in the production of
less energy-intensive [3]. However, this process
chlorinated solvents such as 1,1,1-trichloroethane
requires pure chlorine, which can pose safety and
handling issues. In contrast, oxychlorination,
* Corresponding Author. which uses ethylene, hydrogen chloride (HCl), and
Email: [email protected]
(M.S.F. Saputra)
oxygen or air, is advantageous in recycling HCl,

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 Journal of Chemical Engineering Research Progress, 2 (1), 2025, 15

making it suitable for integrated operations that industry standards [9]. Process information for
produce chlorine as a by-product [4]. While this ethylene dichloride was sourced from the
method is more environmentally friendly because literature.
it recycles HCl, it also requires more complex The conceptual process simulation model
reactions, higher energy usage, and increased was developed specifically for the production of
risks associated with inside oxygen and heat ethylene dichloride through direct chlorination
management. and oxychlorination. Furthermore, the Aspen
Ethylene dichloride (EDC) purification is Energy Analyzer tool was used to analyze the
critical to ensuring the quality and efficiency of energy consumption and total carbon emissions in
downstream processes. High-purity EDC reduces all plant processes [10]. Aspen HYSYS was used
operational disruptions, extends the service life of to minimize total carbon emissions, and a
industrial equipment, and ensures compliance conversion study of ethylene dichloride
with product quality standards [5]. Impurities in production. Detailed simulation by incorporating
EDC, such as water, organic chlorides, and other measurement operations that reflect the real-time
by-products, can cause catalyst poisoning, concept of the plant's industrial processes..
equipment corrosion, and reduced product yield in In this research, an iterative simulation
subsequent reactions [6]. By enabling recycling of method was used to investigate, study, and
by-products and reducing emissions of harmful compare the basic and advanced processes for
substances such as carbon emissions, an effective ethylene dichloride production. The iterative
purification process also helps to reduce waste simulation method entails repeated iterations
and environmental impact. As a result, EDC using the software to adjust process parameters
purification is essential for maintaining process and observe their impact on the simulation
efficiency and supporting responsible and results. The process begins by building a
sustainable industrial practices [7]. simulation model using Aspen HYSYS, analyzing
To improve the production of ethylene the results with Aspen Energy Analyzer, and
dichloride in terms of economics and good iteratively modifying the process parameters until
conversion, this study will examine the design for the desired performance or results are achieved.
ethylene dichloride plant using HYSYS The process modification carried out in this study
simulation. The research study shows that is to adjust the process parameters and tools using
overcoming this problem can be done by the principles of the iterative simulation method.
implementing sustainable design procedures at Further explanation of the modifications made
various stages of the process. Optimizing can be seen in the next chapter.
conversion and minimizing carbon emissions by In addition, this study involves a comparison
selecting purification methods are in line with key between the initial ethylene dichloride purity and
targets in the industrial sector [8]. The objective the purity after modification. The mass of
of this research is to develop a modified process ethylene dichloride mass was obtained using
for producing ethylene dichloride by direct Aspen HYSYS. Furthermore, the %Purity was
chlorination and oxychlorination methods, aiming calculated as the ratio between the mass of
to achieve mass efficiency, set up a plant that ethylene dichloride product (kg/h) and the total
follows environmentally friendly principles, and mass of product (kg/h). The calculation of %Purity
maximizing yield with high purity of ethylene is expressed in Equation (1) [11]:
dichlorination products.
Mass of EDC product
%Purity= ×100% (1)
Total product mass
2. Methods
The basic process model of ethylene After obtaining energy demand data through
dichloride production via direct chlorination and Aspen Energy Analyzer and product purity, the
oxychlorination was designed using Aspen results were analyzed and compared between the
HYSYS, and the corresponding process flow sheet basic process system for producing ethylene
is depicted in Figures 1 and 2. This simulation dichloride and the modified ethylene dichloride
model serves to predict the process response of the process to assess the efficiency of each process.
plant through the application of mass and energy
balances, phase considerations, and chemical 3. Result and Discussion
equilibrium relationships. The model
3.1 Process Description Before Modification
incorporates relevant thermodynamic data, real-
time operating conditions, and rigorous In the ethylene dichloride (EDC) production
equipment models to mimic actual plant process, the materials used as raw materials are
processes. Aspen HYSYS process simulation tool chloride, ethane, water, and chloride acid. At the
was used to design a conceptual simulation model initial stage, the ethane stream is split into two,
for ethylene dichloride production, following one stream will be reacted with chloride (Direct

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 Journal of Chemical Engineering Research Progress, 2 (1), 2025, 16

Chlorination) and the other stream will be mixed before modification can be seen at Figure 1 and
with chloride acid and water (Oxychlorination). Figure 2.
Ethane and chloride will be reacted (Direct
Chlorination) which begins with mixing in a 3.2 Properties and Reaction During Process
mixer (MIX-100) with a pressure of 1.5 atm at a
The physical properties of the compounds
temperature of 25 °C. The mixture is flowed to the
involved, such as boiling point, vapor pressure,
heater (E-100) to be heated to a temperature of 60
density, and solubility, are very important in the
°C before being inserted into the reactor. The
ethylene dichloride (EDC) formation reaction
heater output temperature is adjusted using a
(Table 1). Understanding these characteristics
controller (SET-1) so that the reactor output
helps to control the reaction, separate the
temperature is 60 °C. The reactor used is a stirred
products, and implement safety procedures
tank reactor (CSTR) with kinetic reaction. On the
throughout the process [13].
other hand, the other ethane stream will be
Aside from the importance of understanding
reacted with air and chloride acid
the physical properties of the compounds
(Oxychlorination) in a flow pipe reactor (PFR).
involved, reviewing the enthalpy of formation in
Ethane, air, and hydrochloric acid are mixed in a
ethylene dichloride (EDC) production reactions is
mixer (MIX-101) at 25 °C and 1.5 atm pressure.
crucial to understanding the energy requirements
After that, the mixture is flowed to the
and thermodynamic efficiency of the process by
compressor (K-100) until the pressure becomes 4
knowing the nature of the reaction (endothermic
atm and the temperature increases to 137 °C.
or exothermic) [15]. Knowing the nature of the
Before entering the PFR reactor, the mixture is
reaction can help determine the amount of energy
passed through a heater (E-101) to increase the
required from outside, regulate the temperature,
temperature to 225 °C. The outputs of the CSTR
and make the right reactor design to achieve.
and PFR reactors are mixed using a mixer (M-
Chemical reaction of direct chlorination (DC)
102). Furthermore, it is cooled using a cooler with
and oxychlorination (OX) [12], calculation of
an output temperature of 15 °C. Next, the flash
kinetic reaction [17] and calculation of ∆H
drum separator produces vapor product and
reaction [18]:
liquid product. Liquid product is then put into
three-phase distillation and will produce
C2H(4) ((g)) + Cl(2) ((g))→ C2H4Cl(2) ((l))
nitrogen, water, and ethylene dichloride. Also, -r1 = k1 [C2H4] [Cl(2)]
heavy product is produced [12]. The simulation k1 = 11493 exp (-2156.8/T) m3.mol-1.s-1

Figure 1. Basic process flow diagram of EDC production using Aspen HYSYS

Figure 2. Process flow diagram of basic process of EDC production

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 Journal of Chemical Engineering Research Progress, 2 (1), 2025, 17

∆Hdc = ∆HProduct - ∆HReactant a temperature of 298 K, the result shows a

∆Hdc = ∆HC2 H4Cl2 - ∆HC2 H4 + ∆HCl2 negative ∆H value. Therefore, it can be concluded
∆Hdc = -129.7 - (52.30 + 0) that the ongoing reaction is an exothermic
∆Hdc = -182 kJ/mol
reaction that releases heat [19]. The ∆G f data for
∆Hdc = -182000 J/mol
1 each component at a temperature of 298 K can be
C2H(4) ((g)) + 2HCl (g)+ O(2) ((g))→ C(2)H4Cl(2) ((l)) seen in Table 2 [18].
2
269 Ka [C2 H4 ][Cl2 ] exp[-37800 RT]
-r2 =
1 + k2 [C2 H4 ]
168284 [C2 H4 ][Cl2 ] exp[-37800 RT] Calculation of ∆Gf reaction for direct chlorination
-r2 = (dc):
1 + 630[C2 H4 ]
∆Hox = ∆HProduct - ∆HReactant ∆Gf (dc) = ∆Gf (Product) - ∆Gf (Reactant)
∆Hox = ∆HC2 H4 Cl2 - ∆HC2 H4 + ∆HHCl +∆HO2 ∆Gf (dc) = ∆Gf (C2H4 Cl2) - (∆Gf (C2 H4 ) + ∆Gf (Cl2 ) )
1 ∆Gf (dc) = ∆Gf (C2H4 Cl2 ) - (∆Gf (C2H4 ) + ∆Gf (Cl2 ) )
∆Hox = -129.7 - (52.30 - 92.3 + 0)
2 ∆Gf (dc) = -73.85 - (68.12 + 0)
∆Hox = -239.2 kJ/mol
∆Gf (dc) = -141.97 kJ/mol
∆Hox = -239200 J/mol
Based on the calculation of the direct ∆Gf (dc) = -141970 J/mol
chlorination and oxychlorination enthalpy (∆H) at ∆Gf 298 = -R T ln K298

Table 1. Physical properties of the main components [14]

Name Ethylee Chlorine HCL EDC Unit

Molecular Formula C2H4 CL2 HCl C2H4Cl2 -
Molecular Weight 28.05 70.906 36.46 98.96 kg/kmol
Nomal boiling point -103.8 -34.5 -85.1 83.4 ºC
Critical temperature 282.4 417 324.6 561 K
Critical pressure 50.4 77 83.1 57.3 Bar
Critical volume 129 124 81 220 cm3/mol
Liquid density 577 (-110) 1563 (-34) 1193 (-85) 1250 (16) kg/m3 (ºC)
∆Hvap at nbp 13.553 20.432 16.161 32.029 kJ/mol
Explosion limit in air 2-36 - - 6-16 %

Figure 3. Modified process flow diagram of EDC production using Aspen HYSYS

Figure 4. Figure 4. Flow diagram of modified process of EDC production

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 Journal of Chemical Engineering Research Progress, 2 (1), 2025, 18
∆Gf 298 3.3 Process Modification
ln K298 =
-R T
J
-141970 The simulation process after modification
ln K298 = mol
-(8.314
J
)(298 K) can be seen from Figure 3 or Figure 4. for the
mol. K
ln K298 = 57.3020 result can be seen in Table 1 or Table S1
K298= 7.6908× 1024 (Supporting Information). After the modification
At operating temperature of 60 ºC (333 K): of the ethylene dichloride (EDC) formation
KT ∆Hf 298 1 1 process, cooling is carried out using a cooler that
ln =- ( - ) cools the output material from the process before
K298 R T T298
J modification which has a pre-cooled temperature
K333 -182000 1 1 of 71.8 °C to 15 °C. This process releases
ln =- mol ( - )
K298 J 333 K 298 K 48,030,000 kJ/h of heat energy. After being cooled
8.314
mol. K by the cooler, separation is carried out, the
K333
ln 24 = 57.3020 separation system tool used by using three
7.6908 × 10
K358 = 3.4105× 1019 separators, namely the separator, liquid-liquid
extractor, and reboiled absorber.
Because of the value of K333 > 1, thus, the reaction The waste treatment using separation
of direct chlorination is irreversible [20]. The ΔGf system shown in the figure above includes the use
value of each component can be seen from Table of a flash drum separator (V-100), liquid-liquid
2. Calculation of ∆Gf reaction for oxychlorination extractor (T-101), and reboiled absorber (T-103).
(ox): The flash drum separator functions to separate
the gas and liquid mixture by utilizing the phase
∆Gf (ox) = ∆Gf (Product) - ∆Gf (Reactant) difference, which will produce vapour product and
∆Gf (ox) = ∆Gf (C2 H4Cl2 ) - (∆Gf (C2 H4) + ∆Gf (HCl) +∆Hf (O2) ) liquid product from the flash drum [21]. The
1 liquid that comes out of the separator is then sent
∆Gf (ox) = -73.85 - ( - (68.12 - 95.3 + 0) to the advanced process in the liquid-liquid
2
∆Gf (ox) = -179.97 kJ/mol extractor.
∆Gf (ox) = -179970 J/mol Liquid-liquid extractor (T-101) is used to
∆Gf 298 = -R T ln K298 separate liquid mixtures based on differences in
∆G
ln K298 = f 298 solubility in certain solvents [22]. In this process,
-R T
-179970
J water is used to assist the separation of
ln K298 = J
mol
components, the water used is 100 kgmol/h with
-(8.314 )(298 K)
mol. K
ln K298 = 72.6397 an initial temperature of 15 °C and a pressure of
K298 = 3.5238× 1031 1 atm and pumped to produce a pressure of 4 atm
and a temperature of 15.02 °C which will be
At operating temperature of 225 ºC (498 K): inserted into the liquid-liquid extractor. The
result is two products, Product 1 of Extractor,
KT ∆Hf 298 1 1 which is a liquid with components that are more
ln =- ( - ) soluble in the solvent, and Product 2 of Extractor,
K298 R T T298
J a liquid with insoluble components. These
K498 -239200 1 1
ln =- mol ( - ) products are separated based on the dissolved
K298 J 498 K 298 K liquid phase.
8.314
mol. K The reboiled absorber (T-103) then separates
K498
ln 24 = -38.7735 the gas and liquid components further using the
7.6908 × 10
K498 = 5.1035 × 1014 absorption principle assisted by reboiling. The
liquid containing heavy components is separated
Because of the value of K498 > 1, thus, the reaction at the bottom as Liquid Product of Reboiled
of direct chlorination is irreversible [20]. Absorber, while the lighter components, in the
form of gas, are removed as Vapor Product of

Table 2. Data of ∆Gf for each component at temperature 298 K

Component Name Molecular Formula Gf 298 K (kJ/mol)
Ethylene C2H4 68.12
Chlorine Cl2 0
Hydrochloric Acid HCl -95.3
Oxygen O2 0
Water H2O -228.6
Ethylene Dichloride C2H4Cl2 -73.85

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 Journal of Chemical Engineering Research Progress, 2 (1), 2025, 19

Reboiled Absorber. The system as a whole is 3.4 Emission of Carbon Analysis of Separation
designed to improve the separation efficiency of Operating System
multicomponent mixtures in the process industry
Carbon emission analysis is carried out by
[23].
varying the separator, which initially before
In this separation system, the output
modification uses a flash drum separator and
product from the reboiled absorber (T-103)
three-phase distillation, while after modification
consisting of liquid product and vapor product will
uses a flash drum separator, liquid-liquid
undergo further processing before being recycled.
extraction, and reboiled absorber. This is done
The vapor product from T-103 will be cooled from
with the aim of minimizing the occurrence of
126.6 °C to 60 °C using a cooler (E-103) to reduce
carbon emissions by using the Case Study tool.
its temperature so that it is ready for use or
The case study was conducted by changing the
further processing. After cooling, this product is
type of separation device. Figure 5 presents a
flowed to the recycle system, which is then
comparison of carbon emissions using the system
returned to the mixer (MIX-103).
before modification with the system after
At the mixer (MIX-103), the recycle product
modification.
stream joins the new feed from the main process.
The results of the case study show that the
This mixture is then cooled in the cooler (E-102)
process before modification produces greater
before entering the separator flash drum (V-100).
carbon emissions than those produced by the
The process is designed to improve separation
process after modification. The resulting process
efficiency and ensure the reuse of valuable
before modification produces carbon emissions of
components, while reducing waste and operating
67680 kg/h of carbon emissions. This amount is
costs. With this recycle system, the separation
more than the process after modification which
process becomes more economical and sustainable
only produces carbon emissions of 14170 kg/h
as it maximizes the utilization of materials that
carbon emissions. The results of the modification
have not been fully separated in the previous
process can produce products that have higher
cycle. This process will continue to repeat,
purity and produce smaller carbon emissions, this
starting from separation in the flash drum,
can be seen at Figure 5 and Table 3.
extraction in T-101, to absorption in T-103,
The post-modification process produces less
resulting in an efficient and optimized separation
carbon emissions than the pre-modification
cycle.
process due to improved flow circulation and

Figure 5. Comparison of carbon emissions

Table 3. Comparison basic process and modified process

Process 12-ethylene dichloride yield (kg/h) 12-ethylene dichloride purity (%)

Basic 71796.8362 94
Modified 71859.3916 99.05

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 Journal of Chemical Engineering Research Progress, 2 (1), 2025, 20

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