Simulation and Economic Evaluation of Methylene Chloride Production via Methane Chlorination

Document Type : Research Article

Authors

Faculty of Chemical engineering, Tabriz (Sahand) university of technology, Sahand new town, Tabriz, Iran.

Abstract

This study simulates and economically evaluates methylene chloride production via methane chlorination using Aspen HYSYS V11. A plug flow reactor (PFR) model optimized reaction conditions to 280°C and 2 bar with a methane-to-chlorine ratio of 1.5, achieving 51.68% methane conversion and 99% 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 97%-purity methyl chloride. Economic feasibility was assessed via Total Annual Cost (TAC) methodology, combining capital and operating expenditures. For a 1700 ton per year capacity, the TAC was $297000 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.

Highlights

  • Methane Chlorination Process: Developed an optimized methane chlorination route for methylene chloride production using Aspen HYSYS V11, achieving 99% product purity.
  • Key Parameter Optimization: Identified optimal reactor conditions (280°C, 200 kPa) and CH₄/Cl₂ ratio through sensitivity analysis, maximizing conversion to 51.68%.
  • By-Product Valorization Strategy: Integrated recovery of high-value by-products (methyl chloride, chloroform, carbon tetrachloride), enhancing overall process profitability.
  • Economic Feasibility: Demonstrated viable production at $297000 annual cost for 1700-ton capacity, with potential for rapid ROI through by-product sales.
  • Sustainable Design: Proposed energy-efficient heat integration and NaOH-based HCl neutralization, reducing the environmental impact of chlorinated hydrocarbon production.

Keywords

References

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Chemical Process Design
Volume 4, Issue 2
December 2025
Pages 12-23

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