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

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