Chlorine from Aqueous Hydrochloric Acid (Electrolysis)
Chlorine Production Costs Report | Issue E | Q4 2024
| Report Details |
| 85 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 85 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This analysis presents the costs associated with Chlorine production in the United States. The process reviewed in this study is similar to the ThyssenKrupp Uhde hydrogen chloride electrolysis process. In this process, HCl aqueous solution is decomposed electrolytically in a diaphragm cell, producing Chlorine and hydrogen.
The report provides a comprehensive study of Chlorine production and related Chlorine production cost, covering three key aspects: a complete description of the Chlorine production process examined; an in-depth analysis of the related Chlorine plant capital cost (Capex); and an evaluation of the respective Chlorine plant operating costs (Opex).
The Chlorine production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Chlorine plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Chlorine plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises four major sections: (1) Medium Preparation; (2) Electrolysis; and (3) Hydrogen Recovery; and (4) Chlorine Recovery.
Medium Preparation. Initially, the waste HCl is purified from impurities that could harm electrolysis reaction. The HCl gas is absorbed as it flows counter-currently a circulating solution in a falling-film column, yielding a 28 wt.% HCl solution. This solution is filtered and split to be fed to the anolyte system and to the catholyte system, both with hydrochloric acid recycles. Depleted hydrochloric acid streams are also fed to two compartments, resulting in a hydrochloric acid at 23 wt.% in the anode compartment and at 21 wt.% in the cathode compartment.
Electrolysis. As the electrolysis proceeds in the cells, the anolyte acid and the catholyte acid flow through the respective chambers, yielding chlorine and hydrogen which are directed to purification steps downstream. Hydrochloric acid streams at 17 wt.%, from both cell compartments, are recycled to the respective system.
Hydrogen Recovery. The hydrogen from the cells a column in which most impurities are removed by hydrogen cooling, carried out by direct contact with a circulating dilute acid solution. Residual impurities in the hydrogen gas – namely residual HCl and chlorine – are removed in a tower, where the gas is scrubbed with a caustic solution. The purified hydrogen is compressed and then directed via pipeline to consumers.
Chlorine Recovery. The hot, saturated chlorine gas produced in the electrolyzers is cooled indirectly in titanium heat exchangers. he remaining water is removed by three drying towers where concentrated sulfuric acid circulates as dehydrating agent. The dry chlorine gas is compressed, liquefied.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Chlorine production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Chlorine process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Chlorine production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Chlorine plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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