Reducing HCl Release to the Environment by Eliminating Methyl Chloride at Reactors End of Run

Study of unreacted MeCl clearing from CSTR reactors at the end of run: It is a unique set up with CSTR reactors in cascade, used to produce salt-based product, esters and methanol from this unit operations. This study involves chemical reaction Engineering and process improvement experiments along with control logics to perform the steps to eliminating MeCl to the environment either in vapor or liquid form. pH and agitation speed are critical criterion to determine the presence of MeCl in the final drained liquid after the end of run. Process trends have been depicted in the study to verify the authenticity of the steps followed. Practical methods have been run through the lab analysis as well as studies done through the real unit operations environment. Reaction calculation was also part of methods used to conclude some portion of the study. Most literatures were referred through MeCl thermal and physical property data through published safety data sheets and pending patents on scrubbing methods of MeCl. Data was also collected through lab analysis on GC spectrometry with both gas and liquid methods, collected reading from unit operations at different ranges of pressure profile. This discussion would involve the use of water and caustic wash to react most of the MeCl out. The point in question is to minimize or eliminate of HCl emissions generated through unreacted MeCl when reactors are at the end of run and eventually getting washed off. Study concludes by giving quantity of MeCl (eventually HCl) sent to flare or thermal oxidizer to eventually burn-out. Recommendations were made with respect to number of cycles of wash to minimize the inert levels, thermal efficiency improvement to crack down the MeCl down that will be burned as well as changes in handling the unit operations. Conclusions are based on flash calculations, chemical reaction between Caustic, Water and MeCl + heat through steam jackets with combinations of pressure and temperature changes. Results published with the successful run of the process that is being recommended through the study.