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

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Chapter 4 Source: [ 63, Euro Chlor 2010 ] Figure 4.4: Impact of technological development of the membrane cell technique on specific electricity consumption and maximum current densities Data on the electricity consumption of the latest bipolar membrane cell electrolysers from different equipment suppliers are summarised in Table 4.12. Table 4.12: Electricity consumption of bipolar membrane cell electrolysers using the latest technique as a function of current density Equipment provider Unit Current density in kA/m 2 3 4 5 6 7 8 Electricity consumption Chlorine Engineers 1890 1950 2000 2060 2110 2170 INEOS Uhde DC kWh/t NaOH (100 %) ND 1885 ND 1925 ND 1995 2100 2060 ND 2130 ND ND Asahi Kasei ND 1955 ND 2094 ND ND Chlorine Engineers 2130 2200 2260 2320 2380 2450 INEOS Uhde DC kWh/t Cl2 ( ND 2125 ND 2170 ND 2250 2370 2325 ND 2405 ND ND Asahi Kasei 1 ) ND 2205 ND 2362 ND ND ( 1 ) Assuming a production of 1.128 t NaOH (100 %)/t Cl2 produced. NB: ND = no data available. Source: [ 22, Uhde 2009 ], [ 133, Chlorine Engineers 2011 ], [ 134, INEOS 2011 ], [ 135, Asahi Kasei 2011 ] WORKING DRAFT IN PROGRESS Typically, the electricity consumption of a membrane cell unit increases by approximately 3 – 4 % after three years due to the accumulation of impurities in the membrane and the aging of the electrode coatings [ 1, Ullmann's 2006 ], [ 63, Euro Chlor 2010 ]. Cross-media effects Raw materials and energy are consumed for the manufacture of the electrolysers and the auxiliary equipment. Technical considerations relevant to applicability Generally, there are no technical restrictions to the applicability of this technique for new electrolysis units. In the case of an enlargement of an existing membrane cell unit, some 196 December 2011 TB/EIPPCB/CAK_Draft_1
Chapter 4 modifications to auxiliary equipment might be necessary. However, in the case of a replacement of an older membrane cell unit, not only the electrolysers but also some of the auxiliary equipment requires replacement, especially when changing from a monopolar to a bipolar configuration. In the latter case, transformers, rectifiers and electrical facilities such as busbars cannot be reused and must be replaced. Many more adaptations are usually necessary in the case of a conversion of an existing mercury or diaphragm cell plant (see Sections 4.1.2 and 4.2.3) [ 63, Euro Chlor 2010 ]. Economics Electricity accounts for about 50 % of the total cash production costs which is the sum of of the costs for raw materials, labour, maintenance, overhead and taxes [ 7, Euro Chlor 2010 ]. Typical production costs are shown in Table 4.13. Further information on investment costs can be found in Section 4.1.2. Table 4.13: Typical production costs for a membrane cell chlor-alkali plant with a chlorine production capacity of 500 kt/yr Cost object Unit Unit/t Cl2 EUR/unit EUR/t Cl2 Salt t 1.7 30 51 20 Membranes ND ND ND {Please TWG advise: This value seems very high compare to Section 4.3.2.3.3.} Other raw materials ND ND ND 32 Steam t 2.08 18 37 Other utilities ND ND ND 6 Electricity AC kWh 3000 0.07 210 Variable costs NA NA NA 356 Operating costs NA NA NA 6 Maintenance costs NA NA NA 31 Plant overhead NA NA NA 11 Taxes and insurances NA NA NA 24 Fixed direct costs NA NA NA 72 Total direct costs NA NA NA 428 Corporate costs NA NA NA 14 Total cash costs NA NA NA 442 Depreciation NA NA NA 121 Total production costs NA NA NA 563 NB: NA = not applicable; ND = no data available. Source: [ 137, Euro Chlor 2010 ], [ 138, Prochemics 2007 ] At the planning and design stage of a new membrane cell unit, the economic optimum is sought by balancing investment and operational costs. The final result may be different due to variations of energy prices and investment costs in Member States and companies [ 63, Euro Chlor 2010 ]. For example, electricity prices for an industrial consumption of 20 GWh/yr in EU WORKING DRAFT IN PROGRESS Member States with chlor-alkali plants ranged from EUR 64.5/MWh in France to EUR 131.8/MWh in Italy in April 2011 (end-user prices excluding VAT) [ 139, Europe's Energy Portal 2011 ]. These figures are indicative because individual contracts with big consumers containing contract clauses on interruptibility and load-shedding could lead to lower prices. The choice of the design regarding the optimum current density in terms of capital costs and electricity prices is shown in Figure 4.5. A current density of 4 kA/m 2 is the economic optimum for low relative capital costs and high electricity prices, while a current density of 6 kA/m 2 is the optimum for high relative capital costs and low electricity prices [ 63, Euro Chlor 2010 ]. TB/EIPPCB/CAK_Draft_1 December 2011 197
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EUROPEAN COMMISSION JOINT RESEARCH
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PREFACE 1. Status of this document
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Reference Document on Best Availabl
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3.4.7 Emissions of noise ..........
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4.3.6.3.3 Chemical reduction ......
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List of Tables Table 2.1: Main char
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List of Figures Figure 1.1: Share p
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SCOPE WORKING DRAFT IN PROGRESS Sco
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1 GENERAL INFORMATION 1.1 Industria
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Chlorine production in Mt/yr 12 11
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Chapter 1 Figure 1.4 shows the annu
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Share of total capacity in % 70 70%
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1.4 Chlor-alkali products and their
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Total consumption: 9 801 kt Miscell
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1.4.5 Consumption of hydrogen Chapt
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Chapter 1 and hazardous waste incin
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2 APPLIED PROCESSES AND TECHNIQUES
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Chapter 2 WORKING DRAFT IN PROGRESS
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Chapter 2 The main characteristics
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2.2 The mercury cell technique proc
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Chapter 2 Characteristics of the ca
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2.3 The diaphragm cell technique pr
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Source: [ 2, Le Chlore 2002 ] [USEP
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2.4 The membrane cell technique pro
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Chapter 2 (carcinogenic) [ 76, Regu
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Chapter 2 The membranes used in the
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Table 2.2: Typical configurations o
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2.5 Brine supply 2.5.1 Sources, qua
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Chapter 2 centrifuges before dispos
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Source: [ 29, Asahi Glass 1998 ] (p
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Impurity Source Upper limit of brin
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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
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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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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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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
Page 161 and 162: Heading within the sections Cross-m
Page 163 and 164: 4.1 Mercury cell plants 4.1.1 Overv
Page 165 and 166: Chapter 4 plants at comparable capa
Page 167 and 168: Chapter 4 Table 4.2: Data from the
Page 169 and 170: Chapter 4 environment can be expect
Page 171 and 172: 4. Plant size Chapter 4 An increase
Page 173 and 174: Table 4.6: Comparison of reported c
Page 175 and 176: Chapter 4 Generally, conversion cos
Page 177 and 178: 4.1.3 Decommissioning 4.1.3.1 Decom
Page 179 and 180: 3. Emptying of the cells and handli
Page 181 and 182: Chapter 4 Table 4.7: Overview of co
Page 183 and 184: Table 4.8: Techniques for monitorin
Page 185 and 186: Chapter 4 Table 4.10: Decommissioni
Page 187 and 188: 4.2 Diaphragm cell plants 4.2.1 Aba
Page 189 and 190: Source: [ 146, Arkema 2009 ] Figure
Page 191 and 192: 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
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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: Chapter 4 current density resulting
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
Page 223 and 224: Chapter 4 evaporation unit integrat
Page 225 and 226: Chapter 4 Environmental performance
Page 227 and 228: Chapter 4 Technical description The
Page 229 and 230: Chapter 4 Table 4.17: Monitoring te
Page 231 and 232: Chapter 4 Environmental performance
Page 233 and 234: Environmental performance and opera
Page 235 and 236: Chapter 4 Prevention of chlorine re
Page 237 and 238: Chapter 4 Good pipework design to m
Page 239 and 240: Chapter 4 was the solution at that
Page 241 and 242: differential pressure at inlet and
Page 243 and 244: Chapter 4 chlorine scrubber, immedi
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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
Page 261 and 262: 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
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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
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REFERENCES References [1] Ullmann's
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References [63] Euro Chlor, Euro Ch
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References [112] Santorelli et al.,
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References [161] Germany, 'Verordnu
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[212] Florkiewicz, Long life diaphr
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References [259] Rappe et al., 'Lev
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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
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EOX Extractable Organically-bound H
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Glossary Technique Ensemble of both
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ANNEX Annex {The CAK plant capaciti
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Euro Chlor No. Country code Company
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