Commodity Production Costs Report
Chlorine from Gaseous Hydrogen Chloride (Electrolysis)
Chlorine Operating Costs & Plant Construction Costs
This report evaluates Chlorine production from HCl in the United States. The process examined in this report is similar to the Dupont hydrogen chloride dry electrolysis process. In this process, anhydrous hydrogen chloride is decomposed electrolytically in gaseous phase.
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.
Key reference(s): ?
Products
Chlorine. Chlorine figures among the most important chemical commodities. It is an indispensable intermediate in the chemical industry, employed in the manufacture of a multitude of end products (e.g. materials of construction, solvents, pesticides, etc). Most of chlorine produced on commercial scale is based on electrolysis of aqueous sodium chloride (brine), which also generates caustic soda and hydrogen as co-products (chlor-alkali processes).
Hydrogen. The hydrogen molecule, H2, is the normal state of pure hydrogen, even though hydrogen can be found in its atomic form under specific conditions. It is a very stable molecule, not usually reactive under normal conditions. Essentially, molecular hydrogen is produced industrially by three different methods: hydrocarbons steam reforming, hydrocarbons partial oxidation and water electrolysis. Hydrogen can also be obtained as a by-product recovered in processes such as the manufacture of styrene from ethylbenzene.
Raw Material
Hydrogen Chloride. Hydrogen Chloride (HCl), commonly found as hydrochloric acid (a.k.a. muriatic acid) when dissolved in water, is a highly important industrial chemical. Hydrochloric acid has widespread applications in various industries, with major uses in steel pickling, pH control, water treatment, and as a catalyst in chemical synthesis. It is also employed in the production of chlorides, fertilizers, dyes, and in food processing. Hydrogen chloride is primarily produced through the direct synthesis of hydrogen and chlorine, or as a by-product of chlorination reactions in various organic processes. The HCl gas can be absorbed in water to produce aqueous hydrochloric acid, which is the form most widely used industrially.
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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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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 Aqueous Hydrochloric Acid (Electrolysis)
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.
Details: 85 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
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Other Related Production Cost Reports
Hydrogen Chloride Production from Hydrogen and Chlorine
This study analysis the economics of Anhydrous Hydrogen Chloride (HCl) production from hydrogen and chlorine in the United States. The process examined is a typical synthesis of Hydrogen Chloride via the direct reaction of the elements.
Details: 25 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Vinyl Chloride from Ethylene and Chlorine (Balanced Process)
This study presents the economics of Vinyl Chloride (VCM) production from ethylene and chlorine in the United States. Initially, ethylene is chlorinated to produce ethylene dichloride (EDC). Then, EDC is thermally cracked yielding VCM and HCl. The HCl produced and ethylene are reacted with oxygen, yielding more EDC. This leads to a so called “balanced process”.
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Aluminum Chloride Production
This report presents the economics of Aluminum Chloride production from aluminum metal and chlorine in the United States. In the process, chlorine gas is passed through molten aluminum, producing Anhydrous Aluminum Chloride.
Details: 10 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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