Commodity Production Costs Report
Chlorine Production from Sodium Chloride (Diaphragm Process)
Chlorine Operating Costs & Plant Construction Costs
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.
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): ?
The process under analysis comprises five major sections: (1) Brine Purification; (2) Electrolysis; (3) Hydrogen Compression; (4) Chlorine Purification; and (5) Caustic Soda Concentration.
Brine Purification. Saturated brine is treated for separation of impurities that may be harmful to the electrolysis. After such treatment (with sodium carbonate and caustic soda), the precipitates form a sludge, removed by settling in a clarifier. The clarifier overflow, containing a few tens of ppm of solids, is then filtered in a sand filter. The resulting filtrate is acidified by means of hydrochloric acid addition, so as to neutralize residual hydroxide and carbonate. Such acidification improves electrolysis performance.
Electrolysis. The brine is fed into the anode compartments of the cells and subsequently through the asbestos diaphragm to the cathode compartment. Chlorine is generated at the anodes and sodium ions migrate through the diaphragm into the cathode chamber. On the cathode side, water is electrolyzed generating hydrogen gas and hydroxyl ions. The flow of brine across the diaphragm inhibits the migration of such hydroxyl ions into the anode chamber, in such a way that hydroxyl ions combine with the sodium ions forming caustic soda.
Hydrogen Compression. Hydrogen obtained from the electrolysis is cooled and compressed before being discharged to consumers.
Chlorine Purification. The hot, saturated Chlorine gas is forwarded to an appropriate treatment involving cooling and drying steps. It is compressed in a multi-stage centrifugal compressor, and then liquefied.
Cuastic Soda Concentration. The 10-15 wt% caustic liquor produced, also containing unreacted sodium chloride, goes to evaporation and final centrifugation. A saturated 50% NaOH solution is obtained. As the solution is concentrated, precipitated salt is removed from the solution. Part of the salt recovered contains significant amounts of sodium sulfate impurity and must be treated before being reused in the process.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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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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
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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