Commodity Production Costs Report
Chlorine from Aqueous Hydrochloric Acid (Electrolysis)
Chlorine Operating Costs & Plant Construction Costs
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.
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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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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
Other Chlorine Production Cost Reports

Chlorine Production from Sodium Chloride (Diaphragm Process)
This study presents the economics of Chlorine production from sodium chloride via a diaphragm plant located in the United States. In the process under analysis, an aqueous solution of sodium chloride (brine) is decomposed electrolytically in a diaphragm cell, producing Chlorine, sodium hydroxide and hydrogen.
Details: 550 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD

Chlorine Production from Sodium Chloride (Mercury Cell Process)
This study presents the economics of Chlorine production from sodium chloride via a mercury cell process. The plant is assumed to be located in the United States. In the process under analysis, an aqueous solution of sodium chloride (brine) is decomposed electrolytically in a mercury cell, producing Chlorine, sodium hydroxide and hydrogen.
Details: 250 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD

Chlorine from Gaseous Hydrogen Chloride (Oxidation)
This report presents the economics of secondary Chlorine production from hydrogen chloride. The analysis approaches a plant in the United States using a process similar to the Kel-Chlor process, technology based on the Deacon process. In this process, anhydrous hydrogen chloride is subjected to an oxidation reaction in the presence of catalysts producing Chlorine.
Details: 65 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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