The report gives results of the initial phase of the development of a low-emissions ethylene oxyhydrochlorination process for producing 1,2-dichloroethane (ethylene dichloride). First, experimental work on an existing pilot-plant-scale, once-through process was used both to obtain baseline emission data in mass of hydrocarbon (HC) plus ethylene dichloride (EDC) per mass of HCl fed as a function of reactor temperature and percent excess ethylene to the reactor, and to resolve potential problems which may arise in a recycle operation. Second, the existing once-through pilot plant was converted to a recycle operation which then functioned successfully and yielded emission data in mass of HC plus EDC per mass of HCl fed as a function of reactor temperature and percent excess ethylene to the reactor. In particular, the project objective of reducing by 90% the HC plus EDC emissions from an ethylene oxyhydrochlorination process, through the recycling of reactor off-gases, was positively demonstrated. Third, various operating difficulties were assessed which would be important for future control applications and scale-up efforts. Economic analyses are presented to demonstrate the competitive position of the improved process.

"March 1976." Cover title. Prepared by Allied Chemical Corporation, Syracuse Technical Center, Solvay, New York, under contract no. 68-02-1835, ROAP no. 21AXM-020, program element no. 1AB015. Tables. Includes appendix. Includes bibliographical references (page 67).