Chlor-alkali Industry

Analytical Technology

&
On-line Monitoring Solutions

Chlorine
EDC
VC
PVC

Content

Analytical turnkey solutions for your plant and

your application, from product quality to control
over critical processes, in chlorine (membrane mercury - diaphragm type), ethylene dichloride
and (poly) vinyl chloride production plants:

Chlorine

Brine quality
Explosion protection
Membrane permeation
Drying processes
QC/QA of chlorine
Mercury processes
Environmental compliance

AppliTek is committed
to promoting, advising
and commissioning
analysis solutions for
assessing and controlling
production processes as
well as processes related
to production, in order to
assure quality control, to
protect the environment
and to enhance safety.
Corporate Objective

EDC
Control of chlorination reactor
Control of oxychlorination reactor
Moisture in EDC purification
QC/QA of liquid EDC
EDC drying processes
Corrosion prevention

VC

QC/QA of liquid VC
Corrosion prevention
Explosion protection

PVC

QC/QA of PVC powder

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 02

On-line Monitoring Systems Designed for

Safety, Efficiency, Quality and Compliance

AppliTek, your partner for critical parameter monitoring.

Responsible Care is a commitment to all of us, manufacturer, supplier or individual. The chemical industrys global initiative
to improve health, safety, environmental and security performance has had a significant influence on the achievements and
endeavors of manufacturers of process control technology. Newer technologies and higher standards pave the way to better
process understanding and, by consequence, to better process control.
Modern-day chemical production simply demands reliable, field-proven analytics. Deeply rooted into the chemical industry,
AppliTek has shown that these goals are entirely possible, by implementing on-line analyzers and on-line monitoring
systems into various processes and meeting ever growing demands in your particular industry.
Through continuous innovation and field experience AppliTek is able to provide you with the latest and most advanced
analyzer equipment designed for 24/7 measurements in your process. Profitable solutions are available for every production
process, sub process and application.
When critical processes depend on critical data, AppliTek has the answer on the screen, today and tomorrow.

Chlorine

Ethylene Dichloride

Vinyl Chloride

Poly Vinyl Chloride

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 03

Page 5

Chlorine Production Process

Page 12

EDC Production Process

Page 17

VC Production Process

Page 20

PVC Production Process

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 04

On-line monitoring Solutions for the

Ch lo ri n e In d us tr y

For more than 10 years, AppliTek on-line analyzer systems have been guaranteeing safety, production
efficiency and trouble-free operation In the chlor-alkali industry. AppliTek is your manufacturer of
dedicated analytics and one-stop-shop for highly advanced answers to the industrys needs,
implemented in all steps of the chlorine production process:

Brine preparation and purification

Chlorine electrolysis
Drying - Compressing - Liquefaction
Brine recovery
Bleach production

Safety & Control

AppliTek provides all the analytical solutions to do the job in function of the
process. Technical proposals include all necessary features to guarantee a proper
functioning of the on-line analyzer system in order to assure safety and process
control.

Best Available Technology

As a system integrator, AppliTek knows how to design and manufacture the right
solution. Our engineers have access to a large database of field-proven, resultdriven applications, while new techniques are used for the most demanding
applications and environments.

Start-up / Commissioning
As a single source supplier, AppliTek takes care of the commissioning of the
complete analyzer project, including start-up together with plant management
and operators. Local partners complement our service package, and can assist
you quickly in case of trouble shooting.

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 05

Process Overview

A p p l i Te k A n a l y t i c a l S o l u t i o n s f o r t h e C h l o r i n e P r o d u c t i o n P r o c e s s
Monitoring and controlling highly delicate production
processes is an equally delicate task, preserved for
specialists having extensive experience in the design,
manufacturing as well as commissioning of key analytics.
The AppliTek analyzer systems implemented in chloralkali processes are especially designed and field-tested
for more than 10 years for your peace of mind.
Technical proposals involve all the necessary
requirements to guarantee a proper functionality of the
on-line analyzer systems in order to monitor the safety
and control of the processes. Low maintenance and long
life-time is guaranteed by the specific design and the
choice of components, as well as the use of special
preconditioning systems.

TONI SPECIAL Total Nitrogen in brine

EZ-BRINE Calcium & Magnesium in brine (double system)

Oxygen in wet chlorine

Oxygen in dry chlorine (before and after Cl2 gas compressor)

EZ-NCL3 Nitrogen Trichloride in dry chlorine

Hydrogen in wet chlorine (double or triple system)

Hydrogen in dry chlorine (before and after Cl2 gas compressor)

Moisture in dry chlorine

EZ-CL2 Chlorine in ambient air

Typical Chlorine Production Process

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 06

Chlorine parameters - Overview

(1) Other ranges on request.

Brine Preparation & Purification

TONISpecial onon - line determination of Total Nitrogen (TN) in Brine

Protect your plant against Nitrogen trichloride explosion

Upstream on-line control of Total Nitrogen (TN) in the BRINE allows you to take the necessary process actions to
prevent formation of Nitrogen Trichloride (NCl3 ) in the chlorine liquefaction. The on-line measurement of TN in
BRINE can be measured with the newly developed TONISpecial analyzer using a wet chemical oxidation technique with equimolar response.
Typical range: 0 2.5 mg/l TN (1)
EZ-BRINE onon - line Ca ++ & Mg ++ in BRINE

Control of BRINE quality in order to prevent membrane damage

By changing from mercury-type electrolysis to membrane electrolysis, the BRINE purity became very critical. A
malfunction of the BRINE purification process, causing a high concentration of Ca++ & Mg ++, can damage the
performance of the membranes. In case of membrane clogging by Ca++ & Mg ++, the electrical operation costs are
irreversibly increasing. At the end, replacement of the membranes can be necessary. The on-line concentration
of Ca++ & Mg ++ in BRINE can be measured with the newly developed EZ-BRINE analyzer using a high sensitive photometric technique.
Typical range: 1 20 or 1 100 g /l or ppm Ca2+ & Mg 2+ (1)

EZ-BRINEhigh onon - line Ca ++ & Mg ++ / Ca ++ / Mg ++ in brine

Control of BRINE quality

In Mercury type Chlorine plants a malfunction of the brine purification process, causing high concentrations of
Ca++, Mg ++, & SO4 -- , can damage the quality of the Mercury cathode or modifies the anode characteristics possible short circuit or high tension. In this way you get electrolysis of water instead of brine with local high production of Hydrogen (H2 ).
In Diaphragm type Chlorine plant a malfunction of the brine purification process, causing a high concentration
of Ca++ & Mg ++, can damage the performance of the diaphragm.
It is recommended to use EZ-BRINEhigh on-line Ca++ & Mg ++ in brine
Typical range: 1100-1000 mg/l Ca++ & Mg ++ / Ca++ / Mg ++ (1)

OnOn - line Hydroxides (NaOH) & Carbonates (Na 2 CO 3 ) in BRINE

control Caustic and Soda Ash quality of BRINE
Calcium purification:
Calcium carbonate (CaCO3 ) is precipitated by adding sodium carbonate (Na2 CO3 ). Flocculation reagent is added
and the solid calcium carbonate is decanted. The remaining solution is filtrated.
Ca2+ + Na2 CO3 CaCO3 + 2 Na+ (calcium precipitation)
Magnesium purification:
Magnesium hydroxide (Mg(OH)2 ) is precipitated by adding sodium hydroxide. Flocculent reagent is added and
the solid magnesium hydroxide is decanted. The remaining solution is filtrated. After the filtration the raw brine
is purified over ion-exchange resin.
Mg 2+ + 2 NaOH Mg(OH)2 + 2 Na+ (magnesium precipitation)
In order to control precipitation of calcium and magnesium, the optimal ration between carbonates and hydroxide must be controlled using an on-line analyzer system for the determination of Hydroxides and Carbonates in
BRINE.
Typical range: NaOH 0 1.0 g/l & Na2 CO3 0 1.5 g/l (1)

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 07

Chlorine Electrolysis

(1) Other ranges on request.

OnOn - line FAST determination of Hydrogen (H 2 ) in WET Chlorine (Cl 2 )

Protect your plant against Hydrogen explosion The HYDROGEN (H2 ) concentration in the WET Chlorine is
very critical, especially for MEMBRANE cell type production of Chlorine. A break trough of HYDROGEN (H2 )
in the Chlorine (Cl2 ) by membrane damage can occur within a few seconds. Depending of the concentration, a mixture of HYDROGEN (H2 ) and Chlorine (Cl2 ) gas can be flammable or explosive. For safety reasons it is recommended to install an on-line analyzer system for the fast determination of Hydrogen (H2 )
in WET Chlorine to keep the gas composition within the flammability limits.
RESPONSE TIME:
T90 from 15seconds
Mercury electrolysis:
Diaphragm electrolysis:
Membrane electrolysis:

Typical range:
on analyzer display 0 4% HCl 0 - 2% H2 by UV reactor (Cl2 + H2 --> 2HCl)(1)
on analyzer display 0 4% HCl 0 - 2% H2 by UV reactor (Cl2 + H2 --> 2HCl) (1)
on analyzer display 0 2% HCl 0 - 1% H2 by UV reactor (Cl2 + H2 --> 2HCl) (1)

OnOn - line FAST determination of Oxygen (O 2 ) in WET Chlorine (Cl 2 )

verification & control of membrane oxygen permeation The oxygen concentration at the anode side of the electrolysis cell indicates the condition and performance of the membranes. The more the membranes are used, the
more change there is for blockage by impurities in the brine. In case of some blockage, the electrolysis tension on
the electrodes must be increased to get sufficient electrolysis of Cl2 at the anode. Above a certain value, H2 O is
decomposed by formation of O- . The on-line measurement of Oxygen in WET Chlorine creates optimum conditions of the electrolysis process and can also be used as preceding value for the Chlorine consumer such as the
EDC Ethylene Dichloride (C 2 H4 Cl2 ) plant to keep the explosion triangle Oxygen (O2 ) Chlorine (Cl2 ) - Ethylene
(C 2 H4 ) below explosion limits.
Typical range: 0 - 2% O2 (1)

Chlorine Drying / Compression / Liquefaction

onon - line Moisture (H 2 O) in DRY Chlorine (Cl 2 )
Monitor moisture level to control dryer process WET Chlorine (> 12mg/l H2 O) is corrosive for a lot of materials
used in the further Chlorine processing after the dryers. For this reason the Chlorine is dried to prevent corrosion.
Process dryers with limited drying capacity perform this drying process. Multiple dryers are used to allow regeneration in case of saturation. The drying process of the WET Chlorine needs to be controlled by an on-line measurement of moisture (H2 O) in Chlorine (Cl2 ) gas.
Typical range: 0-10 / 0-20 / 0-200 mg/l H2 O (1)

onon - line FAST determination of Hydrogen (H 2 ) in DRY Chlorine (Cl 2 )

Protect your plant against Hydrogen explosion By removing water out of the Chlorine in the drying process the
HYDROGEN (H2 ) concentration in the Chlorine is increasing. The dried Chlorine is often compressed or liquefied. During the liquefaction the HYDROGEN (H2 ) concentration in the Chlorine is also increasing. (Molecular
Weight of CHLORINE (Cl2 ) is very high compared with HYDROGEN (H2 )). For safety reasons it is recommended
to install a full redundant on-line analyzer system for the FAST determination of HYDROGEN (H2 ) in dry Chlorine
gas compressor and Liquefied Chlorine based on Multi Wavelength INFRARED technology to keep the gas
composition outside the flammability limits.
Typical range:
COMPRESSION
LIQUEFACTION
exceptional range:

on analyzer display 0 4% HCl 0 - 2% H2

on analyzer display 0 10% HCl 0 - 5% H2
on analyzer display 0 20% HCl 0 - 10% H2

by UV reactor (Cl2 + H2 --> 2HCl)(1)

by UV reactor (Cl2 + H2 --> 2HCl)(1)
by UV reactor (Cl2 + H2 --> 2HCl)(1)

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 08

Chlorine Drying / Compression / Liquefaction

(1) Other ranges on request.

OnOn - line FAST determination of Oxygen (O 2 ) in DRY Chlorine (Cl 2 )

verification & control of Chlorine oxygen specifications The oxygen concentration is very important for further Chlorine processes such as production of Ethylene dichloride (EDC) For safety reasons, the Oxygen concentration of the
Chlorination reactor is very important. So an on-line measurement of Oxygen in DRY Chlorine can be used as preceding value for the Chlorine consumer such as the EDC Ethylene Dichloride (C 2 H4Cl2 ) plant to keep the explosion triangle Oxygen (O2 ) Chlorine (Cl2 ) - Ethylene (C 2 H4 ) below explosion limits.
Typical range: 0 - 5% O2 (1)

EZ-NCL3 onon - line Nitrogen Trichloride (NCl 3 ) in DRY Chlorine (Cl 2 )

Protect your plant against Nitrogen trichloride explosion Most Chlorine (Cl2 ) is produced by electrolysis of BRINE
generated by dissolving Sodium Chloride (NaCl) or Potassium Chloride (KCl) in water (H2 O). Side reactions with
the Nitrogen impurities in the salt can lead to the formation of Nitrogen Trichloride (NCl3 )
in the Chlorine processing. Nitrogen compounds present in the BRINE are the main source for the formation of NCl3 .
In certain parts of the Chlorine production, the Chlorine is either liquefied or evaporated. The NCl3 tends to accumulate in liquid Chlorine. For this reason it is recommended to measure on-line the Nitrogen Trichloride (NCl3 ) and Ammonia (NH4 +) in Chlorine by the EZ-NCl3 analyzer system.
Typical range: 010 100 1,000 mg/l NCl3 (1)

Brine Recovery

(1) Other ranges on request.

onon - line Active Chlorine in Brine

Control of BRINE quality Purifying the BRINE for use in the membrane reactors for the production of brine is expensive, therefore the used brine is recycled. The recycled brine contains however high amounts of chlorine. By adding
hydrochloric acid to the brine, chlorine can be removed. The on-line Active Chlorine in Brine analyzer system can be
used to control this chlorine removal.
Typical range: 0 10 / 0 - 100 mg/l Cl2 (Active Chlorine) (1)
onon - line Chlorate (NaClO3 ) in Brine
Typical range: 0 10 mg/l NaClO3 (Chlorate)

(1)

onon - line Sulphate (SO4 ) in Brine

Typical range: 0 60 ppm (SO4 )2- (1)
onon - line Silicium dioxide (SiO2 ) in Brine
Typical range: 0 10 mg/l SiO2 (1)

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 09

Bleach Production

A p p l i Te k A n a l y t i c a l S o l u t i o n s f o r t h e C h l o r i n e P r o d u c t i o n P r o c e s s
Description
Description: absorption of chlorine (Cl2 ) in sodium hydroxide (NaOH) for chlorine destruction and production of sodium
hypochlorite or bleach (NaOCl)
2 NaOH + Cl2
NaOCl + NaCl + H2 O
In case of excess sodium hydroxide consumption the sodium hypochlorite (NaOCl) will be decomposed:
@pH 8

NaOCl
NaCl + O2

@pH 9 10

3 NaClO
2 NaCl + NaClO3

DANGER Gas production P T

EZ-BLEACH onon - line analyzer system for the determination of sodium hypochlorite (NaOCl), sodium carbonate (Na 2 CO 3 ),
sodium hydroxide (NaOH) and sodium chloride (NaCl) in sodium hypochlorite (NaOCl)
Monitor reactor sodium hydroxide (NaOH) concentration:

starting from 20% - min. 4 to 6%

Monitor hypochlorite or bleach (NaOCl) concentration:

max. 170g/l NaOCl

Monitor sodium chloride (NaCl):

1 30g/kg NaCl

Monitor sodium carbonate (Na2 CO3 )

1 10g/kg Na2 CO3

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 10

Mercury Chlorine Plants

A p p l i Te k A n a l y t i c a l S o l u t i o n s f o r t h e C h l o r i n e P r o d u c t i o n P r o c e s s

Mercury facilities
Older production facilities such as mercury type plants can also
benefit from AppliTek engineered solutions. Environmental
compliance for emissions is a growing concern, both in waste
water and in ambient air. On-line monitoring of Mercury not only
enables you to detect calamities and take the necessary actions,
but also to improve the physico-chemical water treatment and
security of the working environment.

Mercury type chlorine production

(1) Other ranges on request.

OnOn- line determination of mercury (Hg) in water (H20)

Protects your Waste Water Treatment plant against mercury (Hg) upset
Waste water containing mercury (Hg) is typically treated by a Physico Chemical Waste Water Treatment Plant (WWTP).
Mercury is bounded as Mercury Sulphides (HgS) typically using Sodium Hydrogen Sulphide (NaHS). The precipitated HgS
is filtered out. The effluent is automatically controlled by the on-line Hg analyzer system using Cold Vapour Atomic Absorption Spectrometry (CVAAS) analysis method. The water is recycled back to the Physico Chemical Waste Water Treatment plant in case of an high mercury values.
Typical range: 0 50 g/l Hg (1)
OnOn - line determination of Mercury (Hg) in ambient air
In order to prevent pollution on-line monitoring of ambient air is a tool to protect the work floor.
The production room is automatically multi point controlled by the on-line Hg analyzer system using Cold Vapour Atomic
Absorption Spectrometry (CVAAS) analysis method.
Typical range: 0 50 g/l Hg (1)

OnOn - line determination of sodium hydrogen sulphide (NaHS) in water

Protects your Waste Water Treatment plant against mercury (Hg) upset
Waste water containing mercury (Hg) is typically treated by a Physico Chemical Waste Water Treatment Plant (WWTP).
Mercury is bounded as Mercury Sulphides (HgS) typically using Sodium Hydrogen Sulphide (NaHS). The precipitated HgS
is filtered out. The concentration of Sodium Hydrogen Sulphide (NaHS) in the WWTP is automatically controlled by the
on-line analyzer system.
Typical range: 0250/0500 mg/l NaHS (1)

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 11

On-line monitoring Solutions for the

Et h y l en e Di c hl or i de I n du st r y

As a specialist manufacturer of analytics, AppliTek is your one-stop-shop for highly advanced answers
to the specific needs of the chemical industry. Ethylene dichloride (EDC) is a chemical liquid that is
not found naturally in the environment, and classified as a hazardous chemical. Process control, as
implemented by AppliTek, will significantly increase output, product quality, and decrease production
hazards. Environmental compliance is another value-added benefit of the AppliTek technology.
AppliTek supplies solutions to all the types of EDC production:
Chlorination process
Oxychlorination process

From EDC to VCM

About 95% of EDC is used in the manufacture of vinyl chloride monomer (VCM),
nearly all of which goes into polyvinyl chloride (PVC) market. In addition, many
EDC plants are integrated with VCM production. Analytical solutions for this
specific production process can be found in the section Vinyl Chloride Industry.
demanding applications and environments.

Start-up / Commissioning
As a single source supplier, AppliTek takes care of the commissioning of the
complete analyzer project. Protective corrosion resistant shelters will be
delivered to your site, prefabricated and equipped with all necessary equipment,
systems and utilities to start the monitoring tasks.

QC / QA
AppliTek also takes care of process quality control. Ethylene dichloride is
typically used for the production of of vinyl chloride. Liquid EDC is also used
as a commercial available product and transported by ship. All commercially
available EDC must be free of Hydrogen Chloride to prevent corrosion of the
storage and handling equipment.

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 12

Process Overview

A p p l i Te k A n a l y t i c a l S o l u t i o n s f o r t h e E D C P r o d u c t i o n P r o c e s s
Ty p e : E D C b y c h l o r i n a t i o n

Water in liquid phase EDC

Oxygen in vent gas of chlorination reactor

Impurities in liquid EDC

3
5
6
7
8

Ethylene in vent gas of chlorination reactor

HCl in liquid EDC

Chlorine in liquid EDC

FeCl3 in liquid EDC

Water in liquid phase EDC

8
6
7

Typical Ethylene Dichloride Production Process (by Chlorination)

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 13

EDC parameters - Overview

(1) Other ranges on request.

Chlorination process
Oxygen in Vent Gas CHLORINATION reactor
Keep your oxygen levels outside flammable limits
Control of Oxygen (O2 ) content in recycled gases & adjustment of O2 / C 2 H4 ratio in CHLORINATION reactor. On-line analyzer system uses Selective Oxygen (O2 ) measurement by Paramagnetic analyzer (fast response) with corrosive resistant
measuring chamber.
Typical range: 015%vol O2 (1)
Ethylene (C 2 H 4 ) in Vent Gas CHLORINATION reactor
Minimize Ethylene (C 2 H4 ) losses by feedback control of C 2 H4 / Cl2 ratio
Control of Ethylene (C 2 H4 ) content in recycled gases & adjustment of Cl2 / C 2 H4 ratio in CHLORINATION reactor. On-line
analyzer system uses Selective Ethylene (C 2 H4 ) measurement by Multi-Wavelength INFRARED analyzer with automatic
optical span possibility.
Typical range: 030%vol C 2 H4 (1)
Residual Chlorine in liquid phase EDC Ethylene Dichloride (C 2 H 4 Cl 2 )
Avoid risk of corrosion & severe damage to your installation
On-line analyzer system uses a scrubber system where nitrogen flow is bubbling through the liquid Ethylene Dichloride (EDC). The resulting vapor phase will contain mainly N2 , the stripped Chlorine (Cl2 ) and saturated Ethylene
Dichloride (EDC). A thermostatically controlled electrical cooler removes most of the Ethylene Dichloride (EDC),
and the remaining Chlorine (Cl2 ) is analyzed by the Multi-wavelength UV analyzer.
Typical range: 0 3,000 ppm Cl2 (1)
Ferric Chloride (FeCl 3 ) in liquid phase EDC Ethylene Dichloride (C 2 H 4 Cl 2 )
Avoid contamination of EDC and risk of corrosion damaging your installation
Ferric Chloride (FeCl3 ) is used as catalyst in the EDC reactor. The FeCl3 colors the EDC with a yellow / brown color
which is measured with an OPACIMETER.
Typical range: 0 300 ppm FeCl3 (1)
Quality (purity) of liquid phase EDC Ethylene Dichloride (C 2 H4 Cl 2 )
Avoid contamination of EDC and off spec product
On-line analyzer system uses Gas-chromatography
Ethylchloride - VC- CCl4 - C3 - C4 - Chloroform - CHCl3
Typical range: 0 5000 ppm (1)
Hydrogen Chloride in liquid phase EDC Ethylene Dichloride (C 2 H 4 Cl 2 )
Protect your EDC storage or transport against corrosion by HCl
All commercial available EDC must be free of Hydrogen Chloride (HCl) to prevent corrosion of the storage and handling equipment. For this reason it is advisable to monitor downstream of the purification column on-line the Hydrogen Chloride (HCl) concentration in Ethylene dichloride EDC (C 2H4 Cl2 ) by Ionic detection using Conductivity
Typical range: 0 10 ppm HCl (1)
Water in recycled EDC Ethylene Dichloride (C
(C 2 H 4 Cl 2 ) - feed Chlorination unit
Water in EDC Ethylene Dichloride (C 2H4 Cl2 ) - (EDC purification unit) top Light Column
Water in EDC Ethylene Dichloride (C 2H4 Cl2 ) - (EDC purification unit) top Heavies Column
Avoid risk of corrosion & severe damages
by on-line selective measurement of moisture (H2 O) in liquid phase EDC using Multi-Wavelength INFRARED
Typical range: 0 50 ppm H2 O (1)
| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 14

Process Overview

A p p l i Te k A n a l y t i c a l S o l u t i o n s f o r t h e E D C P r o d u c t i o n P r o c e s s
Ty p e : E D C b y o x y c h l o r i n a t i o n

Quality of liquid EDC

Oxygen in vent gas of oxychlorination reactor

Ethylene in vent gas of oxychlorination reactor

Chlorinated organics in water

5
7
8

CO/CO2 in vent gas of oxychlorination reactor

HCl from quench

HCl in liquid EDC

Water in liquid phase EDC

Typical Ethylene Dichloride Production Process (by Oxychlorination)

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 15

EDC parameters - Overview

(1) Other ranges on request.

Oxychlorination process
Oxygen in Vent Gas OXYCHLORINATION reactor
Keep your oxygen levels outside flammable limits
Control of Oxygen (O2 ) content in recycled gases & adjustment of O2 / C 2 H4 ratio in OXYCHLORINATION reactor. On-line
analyzer system uses Selective Oxygen (O2 ) measurement by Paramagnetic analyzer (fast response) with corrosive resistant measuring chamber.
Typical range: 05%vol O2 (1)
CO & CO 2 in Vent Gas in Vent Gas OXYCHLORINATION reactor
Optimize your process by optimizing the CO/ CO2 content
Control of CO/CO2 content in recycled gasses & adjustment of CO / CO2 ratio in OXYCHLORINATION reactor. On-line
analyzer system uses Selective CO/ CO2 measurement by Multi-Wavelenght INFRARED analyzer with automatic optical
span possibility.
Typical range: 010%vol CO / 050%vol CO2 (1)
Ethylene (C 2 H 4 ) in Vent Gas OXYCHLORINATION reactor
Control C 2 H4 content in recycled gas & adjustment of O2 /C 2 H4 ratio
Control of Ethylene (C 2 H4 ) content in recycled gases & adjustment of O2 /C 2H4 ratio in OXYCHLORINATION reactor. Online analyzer system uses Selective Ethylene (C 2 H4 ) measurement by Multi-Wavelength INFRARED analyzer with automatic optical span possibility.
Typical range: 010%vol C 2 H4 (1)
Chlorinated Organics in Water
Avoid contamination to protect environment.. On-line analyzer system uses a scrubber system where a carrier flow is
bubbling through the water. The vapor phase is measured by a Flame Ionization Detector (FID) and is a measure for
the Chlorinated Organics of the water.
Typical range: 0 15 mg/l CO units (1)
Water in liquid EDC Ethylene Dichloride (C 2 H 4 Cl 2 ) - from Drying Column
Avoid risk of corrosion & severe damages
by on-line selective measurement of moisture (H2 O) in liquid phase EDC using Multi-Wavelength INFRARED
Typical range: 0 50 ppm H2 O (1)
Hydrogen Chloride in liquid phase EDC Ethylene Dichloride (C 2 H 4 Cl 2 )
Protect your EDC storage or transport against corrosion by HCl
All commercial available EDC must be free of Hydrogen Chloride (HCl) to prevent corrosion of the storage and
handling equipment. For this reason it is advisable to monitor downstream of the purification column on-line the
Hydrogen Chloride (HCl) concentration in Ethylene dichloride EDC (C 2 H4Cl2 ) by Ionic detection using Conductivity
Typical range: 0 10 ppm HCl (1)
Composition vent gas OXYCHLORINATION by Gas Chromatograph
Typical range: 0 100%vol N2
0 20%vol CO
0 50%vol CO2
0 20%vol 1.2-EDC
0 5%vol Ethane

0 10%vol Ethylene
0 1%vol Methane
0 10%vol O2
0 5%vol H2

Quality (purity) of liquid phase EDC Ethylene Dichloride (C 2 H4 Cl 2 )

Avoid contamination of EDC and off spec product
Traces components disastrous for the quality of PVC. On-line analyzer system uses Gas-chromatography
VC - CCl4 - C3C4 - Chloroform - CHCl3 - Ethylchloride
Typical range: 0 5000 ppm (1)
| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 16

On-line monitoring Solutions for the

Vi n y l C hl or id e I n du st r y

Ethylene dichloride (EDC) serves as the primary feedstock for the vinyl chloride (VC/VCM) industry.
The EDC from the storage tank is cracked in the cracking furnace, resulting in the production of
vinyl chloride monomer, hydrogen chloride and other by-products. At this stage of he EDC-VC
chain, process monitoring is absolutely necessary to maintain control over the corrosive, hazardous
nature of the product, while achieving maximum output efficiency at this level AppliTek is also
your partner for critical parameter monitoring.

Portfolio of solutions
Worldwide AppliTek has installed numerous analyzer systems for the chemical
and petrochemical industry. Most of our analytical solutions are field-proven and
recommended by industry specialists and industry associations. For the VC
industry, AppliTek provides solutions to increase lifetime and safety of the
production environment, and to increase QC/QA.

Impurities monitoring
Compliance with product specs is necessary to commercial ends. Knowing trace
impurities in polymer grade VCM is of utmost importance in the manufacturing
of PVC. Similar to the EDC production process, on-line gas chromatography is
used to monitor impurities in the VC end product (gas phase).

Single source supplier

Choosing AppliTek means decreasing project management, for either grassroot
installations or revamping. From the chlorine electrolysis until the VC storage
tank, AppliTek remains your single partner for the whole analyzer project.

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 17

Process Overview

A p p l i Te k A n a l y t i c a l S o l u t i o n s f o r t h e V C P r o d u c t i o n P r o c e s s

1
2

Water in gas phase EDC

Impurities in gas phase VC

UPA Acidity in VC

Oxygen in VC (from PVC)

Water in liquid phase VC

4
5

Typical Vinyl Chloride Production Process

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 18

VC parameters - Overview
(1) Other ranges on request.

Water in gas phase EDC Ethylene Dichloride (C 2 H 4 Cl 2 ) - feed Cracking Furnace

Avoid risk of corrosion & severe damages
by on-line selective measurement of moisture (H2 O) in liquid phase EDC using Multi-Wavelength INFRARED
Typical range: 0 50 ppm H2 O (1)

Water in liquid phase VC Vinyl Chloride 2(C 2 H 3 Cl)

Avoid risk of corrosion, leakage of VC & severe damages
by on-line selective measurement of moisture (H2 O) in liquid phase EDC using Multi-Wavelength INFRARED
Typical range: 0 50 ppm H2 O (1)

OnOn - line analyzer system for Acidity (HCl) in Vinyl Chloride (VC) 2(C 2 H 3 Cl)
Protect VC storage or transport against corrosion.
All commercial available VC must be free of Hydrogen Chloride (HCl) to prevent corrosion of the storage and handling
equipment. For this reason it is advisable to monitor on-line the Hydrogen Chloride (HCl) by means of UPA Universal
Process Analyzer technology.
Typical range: 0 100 ppm HCl
Impurities in gas phase VC
Typical range: 0 100 ppm methyl chloride
0 20 ppm butadiene
0 500 ppm vinylacetylene

0 100 ppm ethylchloride
0 20 ppm 1,1 EDC
0 100 ppm 1,2 EDC

Oxygen in VC return from PVC

Keep your oxygen levels outside flammable limits of the safety triangle.
Control of Oxygen (O2 ) content in VC return. On-line analyzer system uses Selective Oxygen (O2 ) measurement by Paramagnetic analyzer (fast response) with corrosive resistant measuring chamber.
Typical range: 05 %vol O2 (1)

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 19

On-line monitoring Solutions for the

Po l y Vi n y l C hl or i de I n du st r y

Polymer powders can be burned during the drying process causing black, brown, pink or yellow
powder particles (called specks) in the finished product. The AppliTek EZ-PowderScan is an
on-line quality control system based on optical scanning, designed to be implemented as a
powerful QC/QA tool in the polymerization stage.

The EZ-PowderScan quality control measurement consists of a

discontinuous non-intrusive sampling system that doses a fixed volume
of PVC powder from the PVC transport line (PVC powder is transported
from the dryer to the storage silos by means of air displacement trough a
typical 4 pipe at 2 bar) to the vibration plate of the analyzer system. The
complete analyzer system is placed, along with its sampling system,
inside a ventilated and air-conditioned analyzer shelter. Typical analysis
time is 5 minutes.

PVC parameters - Overview

EZ-PowderScan OnOn - line measurement of black specks, defects and contaminants in PVC powder

Avoid off-spec product quality.

The image of the bulk material is evaluated by field-proven optical scanning according to contamination, false
colors or foreign bodies. Their characteristics can be detected precisely and detailed with the help of dedicated
software. Irregularities are sorted into class sizes which are user definable.
Typical range: size classes from 40 microns upwards

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 20

Process Overview

A p p l i Te k A n a l y t i c a l S o l u t i o n s f o r t h e P V C P r o d u c t i o n P r o c e s s

Polymer production & Quality Control

The PVC production process today comprises the following steps:
Step 1:

Chlorine Production

Step 2:

Ethylene Production

Step 3:

Ethylene Dichloride Production

Step 4:

Vinyl Chloride Production

The basic fine white PVC powder, produced by polymerization is then mixed with one or more additives. There are two
main types: 'stabilizers', which allow the PVC to be processed without degradation during moulding or extrusion, and
'plasticizers', which give it flexibility. Additives can also give PVC great strength, make it colored or confer whichever
qualities are desired in the end product. Finally, the PVC granules or ready-to-use powders, are converted into final products
via numerous specific techniques.
After polymerization reaction the PVC powder is dried. During the drying process the PVC powder can be burned causing
black or brown spots in the end product. (defined as BB100). The produced PVC powder must have a minimum quality
(maximum amount of black or brown spots). This is exactly what the EZ-PowderScan monitors, on a 24/7 basis.

Characteristics & benefits

Unique Characteristics
Up-time > 99%
NO insertion piece at Sample Take Off Point
NON INTRUSIVE system
Insulation valves on Sample Take Off and Return Points
Field Proven technology
Fast measurement
BB100 is free definable
Short payback time
Fast Loop Sample return to process

Benefits
High reliability
Low maintenance
NO restriction in process line
NO pollution of PVC powder
Manipulation EZ - PowderScan possible without process stop (PVC
process usually never stops)
EZEZ - PowderScan is a real on-line measurement
BB100 Result every 5 minutes
Guarantees PVC powder quality
Reduce give-away
EZEZ - PowderScan is flexible in use (any PVC type)
Contaminant color can be free defined
Preventing 1 contamination incident is enough to fund for the EZEZ PowderScan on-line analyzer system
Fast measurement, very limited PVC powder waste

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 21

Single
Source
Responsibility
Program

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 22

Single Source Responsibility Program

So lu ti o ns a n d S e r v ic es
AppliTek supplies you with the ideal formula for all your needs in process control/monitoring.
From the feasibility to the basic engineering until the implementation of the analyzer system,
AppliTek is and remains your single partner. The Single Source Responsibility Program is the
AppliTek symbiosis between analytical expertise and system integration, finalized in-house until
the delivery to the plant. Service and maintenance complete our task as a single source supplier
and are carefully planned during the implementation of the system and the on-site training of
management and operators.

Advice of best analysis method for customer needs

In-house feasibility studies
Application development.
Danger Assessment Studies
In-house customer & product training

Application laboratory

Engineering
In-house CAD ExPert team
In-house Ex Proof (ATEX/NEC)
ExPert team
In-house Software/PLC expert team
In-house Preconditioning ExPert team
Cost planning
Basic & Detail engineering

ConstructionIntegration

Commissioning - Servicing

Site Acceptance Test (SAT)

Start up / Test runs
Operator / Product training
Maintenance (contracts)
Periodic preventive checks

In-house quality & safety control

Flexibility in changes of scope of supply
Project & Site Management
Factory Acceptance Test (FAT) prior to shipment
Fully equipped workshop

| APPLITEK On-line Monitoring Solutions for the Chlor-alkali Industry | 23

About the company AppliTek

Since 1985 AppliTek delivers complete on-line analyzer systems and
offers consultancy on existing or new on-line analyzer systems,
preventive maintenance programs and training for the Chlor-alkali
industry. The delicate production processes of this industry require
reliable and state of the art process control the assets of AppliTeks field
proven analytics, many times considered as Best Available Technology. Besides
superior value, AppliTek aims to provide single source responsibility as well as
global availability to its customers.
M embersh i p AppliTek is member of the Chlorine Institute and Clorosur, and
technical correspondent for EuroChlor.

Global spread & Local support

AppliTeks universal solutions can be found around the Globe. As a solution
provider, the company provides several services to complement the analytical
part of its value proposition. Local representatives assist in start-up and
commissioning, while assuring a personal follow-up with the customer.
AppliTek shares a joint strategy with specialized companies for local advice and
promotion. From its head office in Belgium, the company is represented in all
corners of the world, with regional hubs in the Americas, Pacific Asia, China and
the Middle East. Please contact us for more details.

AppliTek

AppliTek NV/SA

Industrial Zone De Prijkels

Venecoweg 19

B-9810 Nazareth
Belgium

Tel.: +32 9 386 34 02

For USA call: +1-866-417-5887 (toll free)

Mob. +32 475 963402

Fax.: +32 9 386 72 97

E-mail: team@applitek.com

Alternatively: c.du.bois@applitek.com

Visit us on www.applitek.com

2010 AppliTek NV Printed in Belgium

In accordance with its policy of continued product improvement, AppliTek reserves the right to change specifications without
further notice.
The content of this page/document is entirely a non-binding external opinion. Neither AppliTek NV nor any of its employees
can be held liable for damages to people, third parties, goods and assets, that may result from implementing the content
EZ-BRINE , EZ-NCL3 , UPA , TONI , EZ-BLEACH , EZ-PowderScan and EZ-CL2 are registered trademarks and
property of AppliTek NV.
Our company is registered under Reg. Nr.: BE 0427.086.347 RPR Gent