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

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Figure 6.1: Schematic view of a three-compartment, finite-gap membrane cell with an oxygendepolarised cathode (Bayer/Uhde design)..........................................................................291 Figure 6.2: Simplified scheme of a proton-exchange membrane hydrogen-oxygen fuel cell...............295 WORKING DRAFT IN PROGRESS xii December 2011 TB/EIPPCB/CAK_Draft _1
SCOPE WORKING DRAFT IN PROGRESS Scope This BREF for the production of chlor-alkali concern the production of the following inorganic chemicals by means of the electrolysis of brine: chlorine, hydrogen, potassium hydroxide and sodium hydroxide. These activities fall under the scope of Annex I to Directive 2010/75/EU, namely under point 4.2: Production of inorganic chemicals, items (a) and (c). In particular, this document covers the following processes applied for those activities: The processes involved in the production of chlorine and caustic solution by the electrolysis of brine cover: the unloading and storage of salt; the preparation, purification and resaturation of brine; the electrolysis of brine the different electrolytic processes; the process engineering of caustic solution concentration, purification, storage and handling of caustic solution loading; the process engineering of chlorine cooling, drying, purification, compression, liquefaction, storage and handling of chlorine before storage and loading; the process engineering of hydrogen cooling, purification, and compression, storage and handling of hydrogen before storage and loading; the conversion of mercury cell plants to membrane cell plants; the decommissioning of mercury cell plants; the remediation of chlor-alkali production sites. This BREF does not address the following activities or processes: the electrolysis of hydrochloric acid for the production of chlorine (in 2011, there were only three installations in the EU-27); the electrolysis of brine for the production of sodium chlorate; this is covered by the reference document on Large Volume Inorganic Chemicals – Solids and Others Industry (LVIC-S); the electrolysis of molten salts for the production of alkali or alkaline earth metals and chlorine; this is covered by the reference document on Non-ferrous Metals Industry (NFM); the production of specialities such as alcoholates, dithionites and alkali metals by using alkali metal amalgam produced with the mercury cell technique (in 2011, there were only two installations in the EU-27); the production of chlorine, hydrogen or caustic solution by processes other than electrolysis (in 2011, there were very few installations in the EU-27); the treatment of waste water in a downstream central pre-treatment and/or treatment plant; this is covered by the reference document on Common Waste Water and Waste Gas Treatment/Management Systems in the Chemical Sector (CWW). TB/EIPPCB/CAK_Draft_1 December 2011 xiii
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 and 10: 4.3.6.3.3 Chemical reduction ......
Page 11 and 12: List of Tables Table 2.1: Main char
Page 13: List of Figures Figure 1.1: Share p
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
Page 65 and 66:
Chapter 2 The cooling water is gene
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Chapter 2 composition of the chlori
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2.6.11 Dealing with impurities 2.6.
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Chapter 2 amount of chlorine, and t
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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
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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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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
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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
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Driving force for implementation Th
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Chapter 4 4.2.3 Conversion of asbes
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Chapter 4 directly from the cells.
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4.3 All Diaphragm and membrane cell
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Chapter 4 non-standardised) will be
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Chapter 4 removal of conductive com
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Chapter 4 Cross-media effects Plant
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Environmental performance and opera
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Example plants Dow, Stade (Germany)
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Chapter 4 current density resulting
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Chapter 4 modifications to auxiliar
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Table 4.14: Cost calculation for th
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Chapter 4 membrane lifetimes range
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Chapter 4 Cross-media effects Some
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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
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Chapter 4 was the solution at that
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differential pressure at inlet and
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Chapter 4 chlorine scrubber, immedi
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Chapter 4 Achieved environmental be
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{Please TWG provide more informatio
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environmental legislation; generati
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Chapter 4 Table 4.21: Examples of o
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Chapter 4 Driving force for impleme
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4.3.6.3.4 Catalytic decomposition r
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Chapter 4 In both cases, the spent
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Chapter 4 Example plants Thermal de
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Chapter 4 migration of hydroxide io
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eduction of chlorate emissions; red
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Example plants Solvin in Antwerp-Li
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eduction of costs related to equipm
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Chapter 4 Off-site reconcentration
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Chapter 4 b) closing of doors and w
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4.4 Membrane cell plants 4.4.1 High
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4.5.3 Containment Chapter 4 Descrip
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Chapter 4 Sections 4.5.4.2 and 4.5.
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Chapter 4 At this site, mercury con
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Chapter 4 However, the soil washing
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5 BEST AVAILABLE TECHNIQUES Scope
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General considerations In these BAT
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5.2 Decommissioning of mercury cell
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5.3 Environmental management system
Page 291 and 292:
Chapter 5 The BAT-associated enviro
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Chapter 5 6. In order to reduce ene
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5.6 Monitoring of emissions Chapter
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[This BAT conclusion is based on in
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5.9 Generation of waste Chapter 5 1
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5.11 Site remediation Chapter 5 20.
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Chapter 5 inorganic chloramines, di
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6 EMERGING TECHNIQUES 6.1 Introduct
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Chapter 6 cooperation with the Japa
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Chapter 6 In December 1998 a test w
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6.3 Use of fuel cells in chlor-alka
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Chapter 6 hydrogen that is burnt to
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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
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References [112] Santorelli et al.,
Page 323 and 324:
References [161] Germany, 'Verordnu
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[212] Florkiewicz, Long life diaphr
Page 327 and 328:
References [259] Rappe et al., 'Lev
Page 329 and 330:
GLOSSARY OF TERMS AND ABBREVIATIONS
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V. Units · VI. Chemical elements T
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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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