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

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