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The catalytic oxychlorination of ethylene is widely used for the production of ethylene dichloride (EDC) which is an essential step for the production of poly-vinyl chloride (PVC). However, catalyst entrainment from the fluidization reactor has formed a problem and caused the loss of expensive catalyst powder with the outlet gas, hence less conversion in achieved. In this research we studied the catalytic oxychlorination of ethylene over the surface of geldart A powder with average particle size of 80 microns. Simulation was developed using Aspen plus and Mat Lab. It was validated against the industrial data and they were matching. Various operating conditions and variables were studied. The effect of fluidized gas velocity, bubble diameter, temperature and pressure on solid catalyst entrainment rate. In addition, the copper content from the quencher bottom was analyzed. It was found that the entrainment rate increased with the increase in fluidized gas velocity, bubble diameter, reactor temperature and pressure. While on the other hand increasing orifice diameter decreased the amount of entrained catalyst within the fluidized bed. It was found that the optimum superficial gas velocity is 2570.4 m/hr.and the optimum orifice diameter is 1 cm. At this condition the lowest rate of solids entrainment out of the bed will be reached. This will decrease the amount of lost catalyst and the process will be more economic with higher gas conversion.

Catalytic Oxychlorination Process Optimization for the Conversion of Ethylene to Ethylene Dichloride