Chemical Engineering Project: Chloroform Production Plant Design

This project report details the design of a plant for the production of chloroform from methane, a crucial chemical compound used in various applications. The project, undertaken as a Bachelor's degree requirement, focuses on the objectives of designing an efficient plant and contributing to society through chloroform production. The report outlines the author's responsibilities, including process design, safety considerations, and project documentation, emphasizing the application of chemical engineering principles and problem-solving skills. It describes the production process, including methane chlorination, photochemical chlorination, and oxychlorination, highlighting the importance of reaction conditions, reactor design, and material balance. The project also addresses challenges such as safety protocols and reaction optimization, offering solutions implemented to ensure the project's success. The report emphasizes the importance of collaborative work, safety measures, and innovative approaches in achieving the project's goals. The project also explores the thermodynamics, production capacity, and the economic benefits of establishing chloroform manufacturing plants.

CE 3.1 Project Information
Name of the project: Plant Design for the Production of Chloroform from Methane
Location of the project: Please fill
Project Duration: Please fill
Organization: Please fill
Role and Designation during the time: Team Member of the project
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
The project of Plant Design for the Production of Chloroform from Methane was
developed for providing advantages to the society by the plant designing. It was done for
proper production of Chloroform from methane. Chloroform is the organic compound that
has the formula of CHCl3. It finds its way into analgesic ointments, cough syrup preparation
and toothpaste. This project was my first major project in bachelor’s degree and hence I was
extra conscious about the project outcome.
CE 3.2.2 Objectives developed for the project
This particular project has various significant objectives. They are as follows:
 To design plant for producing chloroform from methane
 To help the society with the various advantages of chloroform.
CE 3.2.3 My area of work
The project of Plant Design for the Production of Chloroform from Methane was one
of the most important projects in my career. Being a chemical engineer, I made sure that the

project was executed properly, without any type of complexities. I was responsible for
making the project successful without any type of problem. I was under the supervision of my
project supervisor and the entire project was completed under the control of our Head of the
Department. Since, this was my first project; I had various doubts regarding the completion
of the project.
CE 3.2.4 Project Group
Figure 1: People involved in the project
CE 3.2.5 My responsibilities throughout the project
I was an important part of the project. I had various and several roles and
responsibilities throughout this project and I was successful in executing all of them. My first
responsibility was to know about chemical engineering properly and had to learn about the
basic concepts of chemical engineering. As, this was my first project, I made the project
report properly and thus was responsible for documenting the project records. My next
responsibility was to assist my project supervisor in the entire project and I was happy that I
was successful in doing so. Another important responsibility that I had to execute in this

project was providing guidance to my juniors. I gained significant knowledge and experience
in the entire phenomenon.
CE 3.3 Distinctive Activity
CE 3.3.1 Engineering knowledge and skills applied in the project
I have utilized my chemical engineering skills and knowledge for the success of the
project. I knew that if I will apply my skills and knowledge in the project properly, it is
evident that the project will be a huge success. I am a hardworking person and have excellent
problem solving skills. Since I was a quick learner, I utilized my experience in this particular
project. I had also used my computer proficiency in the project, which included MS Office,
MS Project and many more. My power of critical thinking is also applied here.
CE 3.3.3 Comprehending the Theory of Project
The process to produce chloroform from methane could be described easily. Thermal
chlorination of natural gas was accomplished with the help of various cycles that are
dependent on the preferred product ratio as well as the state of byproduct HCl. Chlorination
was eventually carried out within an adiabatic furnace where the exothermic reaction heat
evolved was eradicated for the purpose of preheating the inlet gas to the temperature of
280°C. This particular temperature was kept within the range of 370°C and 410°C, as per the
selected cycle. The CH4/Cl2 ratio was fixed by the product ratio expected.
HCl was recovered in an absorption column of water spray, hence providing around
30 to 32% aqueous HCl directly. When dry gas was desired, the mixture of HCl and H2O was
circulated within the tower. Several chlorinated gases were scrubbed from the absorber with
the solution of caustic soda for removal of CO2 and HCl. Compression and drying with H2SO4
was followed by the processes of condensation and rectification for producing products of

high purity. Chloroform used as an anesthetic and a non-polar solvent in laboratories or by
industries.
There are various types of procedures that helps to produce chloroform. They are as
follows:
i) Methane Chlorination: In methane chlorination reactions can produce yield ranges
from 90 to 95%, but use of fixed bed reactors requires that the cantilever construction made is
strong enough to support the catalyst.
ii) Photochemical Chlorination: Yield will be produce are 90% and this reactions can
reduce impurities in the resulting chloromethane, but the capacity per reactor is low so very
slow reactions.
Chloroform production process by making a reaction between acetone and chlorine in
principle consists of some stages, i.e., raw materials preparation stage, reaction stage, product
purification stage. The product produced from batch reactor is in the form of side products
and chloroform which are then flown into or H-110 to separate chloroform and side products
based on the size of particle and density. The low result of decanter is in the form of calcium
acetate, calcium hydroxide, calcium chloride which is flown to waste processing unit. The
result of decanter in the form of chloroform is flown into distillation column for purification.
Upper product which is produced from distillation column is in the form of chloroform with
the purification of 99%.

The chemical reactions of chloroform are given above. HCl was recovered in an
absorption column of water spray, hence providing around 30 to 32% aqueous HCl directly.
When dry gas was desired, the mixture of HCl and H2O was circulated within the tower.
Several chlorinated gases were scrubbed from the absorber with the solution of caustic soda
for removal of CO2 and HCl. Compression and drying with H2SO4 was followed by the
processes of condensation and rectification for producing products of high purity.
The process of Oxychlorination of methane was the most important step in our
project. The Deacon process was most frequently suggested. This process of oxychlorination
helped the Deacon Process in consuming the produced HCl and this reaction was easily
controlled.
The description of the oxychlorination process is as follows:

This process effectively utilized the benefits of oxychlorination process that is
coupled with the catalyst action for providing 100% chloroform purity. HCl was sent into the
reactors for regenerating catalyst. The material balance of the process was extremely vital for
this project.
The two major components of this project were neutralizer and condenser.
Figure 2: Condenser

Figure 3: Neutralizer
The main purpose of utilizing a neutralizer within the project was to neutralize HCl
produced in the reactions that would otherwise involve in further processing of the product
and might cause damage to the containing equipment and pipes, because of its corrosive
nature.
For any gas phased reaction, a fixed procedure needs to be adopted. Then the reactor
height required to be divided into an optimum no of reactor units in series which provided the
same residence time for the gas phased reactants, thereby attaining the expected reaction.
The establishment of chloroform manufacturers in the world will reduce imports and
diversify products with high economic values which add to state revenues and provide
employment.

The maximum amount of production done within a particular unit of time is called
production capacity. There are many factors that influence to determine production capacity
is as follows:
a) Availability of Raw Materials
b) Minimum Design Capacity
The review of thermodynamics aims at finding out the properties of a reaction,
including exothermic or endothermic as well as the direction of its reaction including
reversible or irreversible.
CE 3.3.4 Identified issues and their solutions
3.3.4.1 Issues
The most significant issue that I faced in the project was regarding the safety
measures that were needed during chemical reactions. We were dealing with various
hazardous acids and chemicals and hence safety was the first priority. Moreover, the team
member, who was given the responsibility to make the chemical reactions, was not able to
make them perfectly and hence erroneous results were coming in the project. These particular
issues were causing major delay in our project and thus we were facing serious problems.
3.3.4.2 Solutions
For solving this particular problem, I suggested for taking up all necessary safety
measures and hence was successful in making the project perfect and proper. For the issue of
chemical reactions, I myself made them and thus was able to remove the errors to a greater
extent. I was well appreciated by my project supervisor and other team members for being
able to solve the issues quickly and perfectly. This even helped in reducing the project delays
to a greater level.

CE 3.3.5 Plan to produce creative and innovative work
My plan was to produce innovative and creative work by working collaboratively. I
segregated my entire work properly and each task was executed properly and with utmost
sincerity. Moreover, regular follow-ups were taken, so that the project does not face any type
of problem.