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

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Chapter 5 5.5 Energy consumption 5. In order to reduce energy consumption in the electrolysis process, BAT is to use high-performance bipolar membrane cells for new electrolysers. Description Membrane cells consist of an anolyte chamber with a coated titanium anode, a catholyte chamber with a coated nickel cathode and a separator consisting of a fluoropolymer grid with carbonate and sulphonate layers. In a bipolar configuration, individual membrane cells are electrically connected in series. High-performance cells make use of small gaps between the electrodes (Q 0.1 mm). Applicability Applicable to new electrolysers. The BAT-associated consumption levels for energy in the electrolysis process for new electrolysers are: Current density in kA/m 2 3 4 5 6 7 8 Electricity consumption in DC kWh/t NaOH (100 %) produced as yearly average values during the first year of operation ( 1 ) {tbd} {tbd} {tbd} 2060 – 2100 {tbd} {tbd} ( 1 ) Excluding electricity consumption for auxiliary processes. NB: {tbd} = to be determined after further data collection. [This BAT conclusion is based on information given in Section 4.3.2.3.2.] WORKING DRAFT IN PROGRESS 276 December 2011 TB/EIPPCB/CAK_Draft_1
Chapter 5 6. In order to reduce energy consumption in the electrolysis process, BAT is to use all of the techniques given below. a Technique Description Applicability Highperformance membranes b Asbestos-free diaphragms c Highperformance electrodes and coatings d High-purity brine e Nanofiltration f Iron(III) mesotartrate as anticaking agent g Brine acidification High-performance membranes consist of carbonate and sulphonate layers with fluoropolymer grid, sacrificial fibres and hydrophilic coatings. They show low voltage drops while ensuring mechanical and chemical stability. Asbestos-free diaphragms consist of a fluorocarbon polymer and fillers such as zirconium dioxide. These diaphragms show lower resistance overpotentials than asbestos diaphragms. Electrodes and coatings with improved gas release (low bubble overpotential), small gap between the electrodes (diaphragm cell technique: Q 3 mm; membrane cell technique: Q 0.1 mm) and low electrode overpotentials. The brine is purified to a level so that it strictly complies with the manufacturer's specifications of the electrolysis unit, in order to avoid contamination of electrodes and diaphragms/membranes which may increase energy consumption. A specific type of membrane filtration with membrane pore sizes of approximately 1 nm, used to concentrate sulphate in the brine purge, thereby avoiding the use of barium salts which may damage the membrane and increase energy consumption. Iron(III) meso-tartrate is used as an anti-caking agent, thereby avoiding the use of ferrocyanide whose decomposition products may damage the membrane and increase energy consumption. The brine is acidified prior to electrolysis to reduce the formation of chlorate and oxygen. Applicable to membrane cell plants on the occasion of a renewal of membranes at the end of their lifetime. Applicable to diaphragm cell plants. Applicable to diaphragm and membrane cell plants on the occasion of a renewal of coatings at the end of their lifetime. [Section on which BAT conclusion is based] [4.3.2.3.3] [4.2.2] [4.3.2.3.4] Generally applicable. [4.3.2.3.5] Applicable to membrane cell plants with brine recirculation. Applicable to membrane cell plants using solid salt with an anti-caking agent. [4.3.6.2.2] [4.3.2.3.6] Generally applicable. [4.3.6.4.2] WORKING DRAFT IN PROGRESS 7. In order to reduce energy consumption from the caustic concentration process, BAT is to use plate evaporators. Description Plate evaporators use metal plates to transfer heat from steam to dilute caustic in order to evaporate water. Applicability Applicable to new caustic concentrators in membrane cell plants. TB/EIPPCB/CAK_Draft_1 December 2011 277
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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
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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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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
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Page 259 and 260: Chapter 4 Example plants Thermal de
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Page 265 and 266: Example plants Solvin in Antwerp-Li
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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
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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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