simulation and economic evaluation of methylene chloride production via methane chlorination

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.