(BAT) Reference Document for the Production of Chlor-alkali ...

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VI. Chemical elements ..........................................................................................................................315 VII. Chemical formulae commonly used in this document....................................................................316 VIII. Acronyms and definitions .............................................................................................................317 ANNEX....................................................................................................................................................323 WORKING DRAFT IN PROGRESS viii December 2011 TB/EIPPCB/CAK_Draft_1
List of Tables Table 2.1: Main characteristics of the different electrolysis techniques processes............................... 21 Table 2.2: Typical configurations of a monopolar and a bipolar membrane cell plant......................... 37 Table 2.3: Typical compositions of various types of salt...................................................................... 39 Table 2.4: Typical impurities with sources and effects on the membrane cell technique as well as typical brine specifications Example of brine specifications for the membrane process operating at a current density up to 4 kA/m 2 ....................................................................... 44 Table 2.5: Possible Trade-offs in chlorine gas liquefaction.................................................................. 52 Table 3.1: Overview of emission and consumption levels inputs and outputs of the three chloralkali manufacturing techniques processes.......................................................................... 65 Table 3.2: Salt consumption in chlor-alkali plants with brine recirculation in EU-27 and EFTA countries in 2008/2009 ........................................................................................................ 67 Table 3.3: Consumption of water as solvent for caustic production..................................................... 68 Table 3.4: Consumption and use of main chemical auxiliaries in chlor-alkali plants using a brine recirculation process ............................................................................................................ 70 Table 3.5: Operating conditions and electricity consumption of the chlor-alkali electrolysis cells in EU-27 and EFTA countries ................................................................................................. 74 Table 3.6: Operating conditions and electricity consumption of monopolar and bipolar chlor-alkali membrane electrolysis cells in EU-27 and EFTA countries ................................................ 76 Table 3.7: Caustic concentration at outlet cell and steam consumption for caustic concentration in chlor-alkali installations in EU-27 and EFTA countries...................................................... 77 Table 3.8: Energy consumption for auxiliary processes of chlor-alkali installations in EU-27 and EFTA countries.................................................................................................................... 78 Table 3.9: Total energy consumption of chlor-alkali installations in EU-27 and EFTA countries....... 79 Table 3.10: Emissions of sulphate to water from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009............................................................................................................................ 85 Table 3.11: Emissions of chloride to water from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009............................................................................................................................ 86 Table 3.12: Emissions of free oxidants to water from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009 ........................................................................................................ 87 Table 3.13: Emissions of chlorate to water from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009............................................................................................................................ 89 Table 3.14: Emissions of bromate to water from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009............................................................................................................................ 89 Table 3.15: Emissions of heavy metals to water from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009. ....................................................................................................... 91 Table 3.16: Emissions of halogenated organic compounds to water from chlor-alkali plants in EU- 27 and EFTA countries in 2008/2009.................................................................................. 92 Table 3.17: Generation of brine filtration sludges in chlor-alkali plants in EU-27 and EFTA countries in 2008/2009 ........................................................................................................ 94 Table 3.18: Emissions of chlorine to air from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009............................................................................................................................ 96 Table 3.19: Generation of spent sulphuric acid in chlor-alkali plants in EU-27 and EFTA countries in 2008/2009........................................................................................................................ 99 Table 3.20: Share of hydrogen emitted by chlor-alkali plants in EU-27 and EFTA countries in 2010 101 Table 3.21: Emissions of noise from chlor-alkali plants in EU-27 and EFTA countries in 2008/2009 103 Table 3.22: Amount of mercury in cells per annual chlorine production capacity in mercury cell chlor-alkali plants in EU-27 countries in 2010 .................................................................. 104 Table 3.23: Mercury emissions from individual chlor-alkali installations in 2010 as reported by Euro Chlor ......................................................................................................................... 107 Table 3.24: Mercury emission data from the EMECAP project and Euro Chlor for three mercury cell chlor-alkali plants........................................................................................................ 111 Table 3.25: Emissions of mercury to air from the cell room from chlor-alkali plants in EU-27/EFTA countries in 2008/2009 ...................................................................................................... 113 Table 3.26: Fugitive mercury emissions from the cell room from three mercury cell chlor-alkali plants in the United States in 2005/2006 ........................................................................... 114 Table 3.27: Emission factors of mercury to air from process exhausts from chlor-alkali plants in OSPAR countries in 2009.................................................................................................. 116 Table 3.28: Emissions of mercury to water from mercury cell chlor-alkali plants in EU-27 and EFTA countries in 2008/2009............................................................................................ 121 WORKING DRAFT IN PROGRESS TB/EIPPCB/CAK_Draft_1 December 2011 ix
Page 1 and 2: EUROPEAN COMMISSION JOINT RESEARCH
Page 3 and 4: PREFACE 1. Status of this document
Page 5 and 6: Reference Document on Best Availabl
Page 7 and 8: 3.4.7 Emissions of noise ..........
Page 9: 4.3.6.3.3 Chemical reduction ......
Page 13 and 14: List of Figures Figure 1.1: Share p
Page 15 and 16: SCOPE WORKING DRAFT IN PROGRESS Sco
Page 17 and 18: 1 GENERAL INFORMATION 1.1 Industria
Page 19 and 20: Chlorine production in Mt/yr 12 11
Page 21 and 22: Chapter 1 Figure 1.4 shows the annu
Page 23 and 24: Share of total capacity in % 70 70%
Page 25 and 26: 1.4 Chlor-alkali products and their
Page 27 and 28: Total consumption: 9 801 kt Miscell
Page 29 and 30: 1.4.5 Consumption of hydrogen Chapt
Page 31 and 32: Chapter 1 and hazardous waste incin
Page 33 and 34: 2 APPLIED PROCESSES AND TECHNIQUES
Page 35 and 36: Chapter 2 WORKING DRAFT IN PROGRESS
Page 37 and 38: Chapter 2 The main characteristics
Page 39 and 40: 2.2 The mercury cell technique proc
Page 41 and 42: Chapter 2 Characteristics of the ca
Page 43 and 44: 2.3 The diaphragm cell technique pr
Page 45 and 46: Source: [ 2, Le Chlore 2002 ] [USEP
Page 47 and 48: 2.4 The membrane cell technique pro
Page 49 and 50: Chapter 2 (carcinogenic) [ 76, Regu
Page 51 and 52: Chapter 2 The membranes used in the
Page 53 and 54: Table 2.2: Typical configurations o
Page 55 and 56: 2.5 Brine supply 2.5.1 Sources, qua
Page 57 and 58: Chapter 2 centrifuges before dispos
Page 59 and 60: Source: [ 29, Asahi Glass 1998 ] (p
Page 61 and 62:
Impurity Source Upper limit of brin
Page 63 and 64:
Chapter 2 No such dechlorination tr
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Chapter 2 The cooling water is gene
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Chapter 2 composition of the chlori
Page 69 and 70:
2.6.11 Dealing with impurities 2.6.
Page 71 and 72:
Chapter 2 amount of chlorine, and t
Page 73 and 74:
2.6.12.2 Chemical reactions Chapter
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2.7 Caustic processing production,
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Chapter 2 2.8 Hydrogen processing p
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3 CURRENT PRESENT EMISSION AND CONS
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Chapter 3 Table 3.1: Overview of em
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3.3 Consumption levels of all cell
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3.3.3 Ancillary materials Ancillary
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Further materials and/or further us
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Chapter 3 current) and the efficien
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Chapter 3 distance means a higher f
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3.3.4.3.6 Production of caustic pot
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Chapter 3 hydrogen at low pressure
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28 kg of hydrogen is produced {Thes
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Chapter 3 depleted brine is recircu
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Chapter 3 Table 3.10: Emissions of
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Chapter 3 When measuring chlorine i
Page 105 and 106:
Page 107 and 108:
Page 109 and 110:
Chapter 3 concentrations of organic
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Chapter 3 3.4.3 Emissions and waste
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Chapter 3 {Please TWG provide infor
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Chapter 3 in process and waste wate
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Chapter 3 produced per year has bee
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Page 121 and 122:
Chapter 3 of chlorine capacity. The
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Table 3.23: Mercury emissions from
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Mercury emissions in g Hg/t Cl capa
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Chapter 3 Table 3.24: Mercury emiss
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Page 131 and 132:
Chapter 3 KCl are higher than from
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Chapter 3 When concentrated solid c
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Chapter 3 Generally, storage of con
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Chapter 3 recycled brine systems si
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Process Maintenance To solid treatm
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3.5.9.5 Graphite and activated Acti
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Chapter 3 Table 3.31: Yearly waste
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Chapter 3 The fact that the differe
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Chapter 3 3.6 Emissions Emission an
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Reported asbestos concentrations ar
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Chapter 3 3.7 Emissions Emission an
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{A list of techniques used on full
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3.8.3 PCDDs/PCDFs, PCBs, PCNs and P
Page 157 and 158:
Chapter 3 The ‘dioxin’ pattern
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Chapter 4 4 TECHNIQUES TO CONSIDER
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Heading within the sections Cross-m
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4.1 Mercury cell plants 4.1.1 Overv
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Chapter 4 plants at comparable capa
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Chapter 4 Table 4.2: Data from the
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Chapter 4 environment can be expect
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4. Plant size Chapter 4 An increase
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Table 4.6: Comparison of reported c
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Chapter 4 Generally, conversion cos
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4.1.3 Decommissioning 4.1.3.1 Decom
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3. Emptying of the cells and handli
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Chapter 4 Table 4.7: Overview of co
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Table 4.8: Techniques for monitorin
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Chapter 4 Table 4.10: Decommissioni
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4.2 Diaphragm cell plants 4.2.1 Aba
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Source: [ 146, Arkema 2009 ] Figure
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Chapter 4 diaphragms [ 31, Euro Chl
Page 193 and 194:
Driving force for implementation Th
Page 195 and 196:
Chapter 4 4.2.3 Conversion of asbes
Page 197 and 198:
Chapter 4 directly from the cells.
Page 199 and 200:
4.3 All Diaphragm and membrane cell
Page 201 and 202:
Chapter 4 non-standardised) will be
Page 203 and 204:
Chapter 4 removal of conductive com
Page 205 and 206:
Chapter 4 Cross-media effects Plant
Page 207 and 208:
Environmental performance and opera
Page 209 and 210:
Example plants Dow, Stade (Germany)
Page 211 and 212:
Chapter 4 current density resulting
Page 213 and 214:
Chapter 4 modifications to auxiliar
Page 215 and 216:
Table 4.14: Cost calculation for th
Page 217 and 218:
Chapter 4 membrane lifetimes range
Page 219 and 220:
Chapter 4 Cross-media effects Some
Page 221 and 222:
Chapter 4 The drawback of using fer
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Chapter 4 evaporation unit integrat
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Chapter 4 Environmental performance
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Chapter 4 Technical description The
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Chapter 4 Table 4.17: Monitoring te
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Chapter 4 Environmental performance
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Environmental performance and opera
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Chapter 4 Prevention of chlorine re
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Chapter 4 Good pipework design to m
Page 239 and 240:
Chapter 4 was the solution at that
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differential pressure at inlet and
Page 243 and 244:
Chapter 4 chlorine scrubber, immedi
Page 245 and 246:
Chapter 4 Achieved environmental be
Page 247 and 248:
{Please TWG provide more informatio
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environmental legislation; generati
Page 251 and 252:
Chapter 4 Table 4.21: Examples of o
Page 253 and 254:
Chapter 4 Driving force for impleme
Page 255 and 256:
4.3.6.3.4 Catalytic decomposition r
Page 257 and 258:
Chapter 4 In both cases, the spent
Page 259 and 260:
Chapter 4 Example plants Thermal de
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Chapter 4 migration of hydroxide io
Page 263 and 264:
eduction of chlorate emissions; red
Page 265 and 266:
Example plants Solvin in Antwerp-Li
Page 267 and 268:
eduction of costs related to equipm
Page 269 and 270:
Chapter 4 Off-site reconcentration
Page 271 and 272:
Chapter 4 b) closing of doors and w
Page 273 and 274:
4.4 Membrane cell plants 4.4.1 High
Page 275 and 276:
4.5.3 Containment Chapter 4 Descrip
Page 277 and 278:
Chapter 4 Sections 4.5.4.2 and 4.5.
Page 279 and 280:
Chapter 4 At this site, mercury con
Page 281 and 282:
Chapter 4 However, the soil washing
Page 283 and 284:
5 BEST AVAILABLE TECHNIQUES Scope
Page 285 and 286:
General considerations In these BAT
Page 287 and 288:
5.2 Decommissioning of mercury cell
Page 289 and 290:
5.3 Environmental management system
Page 291 and 292:
Chapter 5 The BAT-associated enviro
Page 293 and 294:
Chapter 5 6. In order to reduce ene
Page 295 and 296:
5.6 Monitoring of emissions Chapter
Page 297 and 298:
[This BAT conclusion is based on in
Page 299 and 300:
5.9 Generation of waste Chapter 5 1
Page 301 and 302:
5.11 Site remediation Chapter 5 20.
Page 303 and 304:
Chapter 5 inorganic chloramines, di
Page 305 and 306:
6 EMERGING TECHNIQUES 6.1 Introduct
Page 307 and 308:
Chapter 6 cooperation with the Japa
Page 309 and 310:
Chapter 6 In December 1998 a test w
Page 311 and 312:
6.3 Use of fuel cells in chlor-alka
Page 313 and 314:
Chapter 6 hydrogen that is burnt to
Page 315 and 316:
Chapter 7 7 CONCLUDING REMARKS AND
Page 317 and 318:
REFERENCES References [1] Ullmann's
Page 319 and 320:
References [63] Euro Chlor, Euro Ch
Page 321 and 322:
References [112] Santorelli et al.,
Page 323 and 324:
References [161] Germany, 'Verordnu
Page 325 and 326:
[212] Florkiewicz, Long life diaphr
Page 327 and 328:
References [259] Rappe et al., 'Lev
Page 329 and 330:
GLOSSARY OF TERMS AND ABBREVIATIONS
Page 331 and 332:
V. Units · VI. Chemical elements T
Page 333 and 334:
VIII. Acronyms and definitions AC A
Page 335 and 336:
EOX Extractable Organically-bound H
Page 337 and 338:
Glossary Technique Ensemble of both
Page 339 and 340:
ANNEX Annex {The CAK plant capaciti
Page 341 and 342:
Euro Chlor No. Country code Company
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