فهرست نشریات علمی دسترسی آزاد ایران

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.