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CHLORINE ENGINEERING SERVICE MANUAL
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7/21/2019 Chlor Alkali Engineering Services
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Engineering Servicesfor the Optimisation ofChlor-Alkali Plants
Amanda Lancaster Process Technology Manager INEOS Technologies Electrochemical Technology Business
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This document is the property of INEOS Technologies (Vinyls) Limited and the information it contains is strictly confidentialand may not be copied, used or disclosed without the express permission of Ineos Technologies (Vinyls) Limited.2
Agenda
• The challenge of chlor-alkali
• INEOS experience and expertise
• Key areas for optimum cellroom design – Long term performance - power – Pressure – Brine purity and salt selection – Stray currents – Keeping the Plant Online – Keeping the Plant Safe
• Engineering services to meet the challenge
BICHLOR™ Cellroom
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The Challenge of Chlor-Alkali – Achieving Optimum Performance
Electrolysis
HydrogenTreatment
ChlorineTreatment
Pressure / DPcontrol
Catholytehandling and
dilution
Anolyte handling/ chlorate
destructionDechlorination
Sulphateremoval
Brineresaturation
Pure brinestorage and heat
conditioning
Catholyte heatconditioning
Primarypurification
Secondarypurification
NaOH
Cl2
H2
Key to successful, long term operation of a membrane cellroom, as well as goodtechnology selection, is the correct design of the unit operations surrounding theelectrolyser
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The Challenge of Chlor-Alkali - Why is it not so Easy
Explosive gases
Electrochemistry!
Stray currents
Exotic materials
Fragile components
Chemical sensitivityToxicity
Corrosive fluids
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For Big Challenges .
..... talk to someone who’s been there before
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Meeting the Challenge for Over a Century
INEOS have over 100 years experience ofoperating all chlor-alkali technologies
INEOS currently operate membrane technologyon 3 major European sites
INEOS have been at the forefront of membranecell technology since it’s inception
INEOS have installed chlor-alkali technology atover 100 sites worldwide
INEOS are experts in chlor-alkali design, engineering and operation
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Key Areas for Optimum Cellroom Design
• For optimum long term performance
– Minimise power consumption
– Maximise performance on day 1 – Ensure high performance maintained day 2+
• Key design areas to achieve optimum performance
– Cellroom pressure – Brine purity and salt selection
– Stray Currents
• Keeping the plant online
• Keeping the plant safe
BICHLOR™ Cellroom
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It’s all about Power – Ideal Power Consumption
Ideal power consumption Ideal power consumption Ideal power consumption Ideal power consumption
0 00 0 2 22 2 4 44 4 6 66 6 8 88 8 10 10 10 10
Years Years Years Years
P o w e r
P o w e r
P o w e r
P o w e r
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It’s all about Power – the Reality
Power consumption over time Power consumption over time Power consumption over time Power consumption over time
Time Time Time Time
P o w e r
P o w e r
P o w e r
P o w e r
Current efficiency Current efficiency Current efficiency Current efficiency
Pressure Pressure Pressure Pressure
Temperature Temperature Temperature Temperature Ohmic loss Ohmic loss Ohmic loss Ohmic loss
Overpotential Overpotential Overpotential Overpotential
dy dy dy dy dx dx dx dx
Quality of operation Quality of operation Quality of operation Quality of operation
Operability Operability Operability Operability
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It’s all about Power – a Marathon not a Sprint
Power consumption over time Power consumption over time Power consumption over time Power consumption over time
Time Time Time Time
P o w e r
P o w e r
P o w e r
P o w e r
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It’s all about Power – a Marathon not a Sprint
Power consumption over time Power consumption over time Power consumption over time Power consumption over time
Time Time Time Time
P o w e r
P o w e r
P o w e r
P o w e r
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Early Performance can be Easily Lost
20 mV start up voltage benefit
4mV/month voltage rise penalty
Saving = €0.1 million
Penalty = €0.9 million
100 ktpa plant 4 year cycleEuropean power price
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This document is the property of INEOS Technologies (Vinyls) Limited and the information it contains is strictly confidentialand may not be copied, used or disclosed without the express permission of Ineos Technologies (Vinyls) Limited.13
Keeping the Power Down - Pressure
High pressures can be beneficial .• Reduce day 1 power consumption• Reduce plant capital cost• Enable operation at altitude• Reduce utility usage
But they can also• Increase day 2+ power consumption if transients are not managed
Sometimes low pressure has other advantages .• Reuse of low pressure equipment (mercury or monopolar conversions)• Simple pressure control system• Less vulnerable to pressure / differential pressure excursions
Is high or low pressure right for you .?
BICHLOR™ is designed to operate at high current density and low or highcellroom pressures and is robust to excursions
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Staying in Control of Pressure
INEOS operate plants at high pressures and can mitigate risks
•Easy to control pressure and differential pressure during steady operation
•Not so easy to control pressure during transient events (e.g. trips)
•Removal / re-instatement of a single electrolyser from a multi-electrolyser cellroom
•Pressure protection and relief systems to cover all sources of overpressure (and
underpressure) during all modes of operation
Risk of pressure and differential pressure excursions if the design of the pressurecontrol system isn’t right
Excessive pressure excursions canreduce electrolyser performance
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Staying in Control of Pressure - Typical System
Vent to chlorine absorption
Chlorine to compression
Hydrogen to plant
Vent to hydrogen stack
Electrolyser 1
Chlorinetreatment
PdIC
PIC
PIC
PIC PdIC
N2 purge
Catholyte header
Anolyte header
Vent tohydrogenstack
Anolyte tank
Catholytetank
XZ XZ
Hydrogen from other electrolysers
Chlorine from other electrolysers
Anolyte from other electrolysers
Catholyte from other electrolysers
Vent to chlorine header
Vent to hydrogen header
dP = 15mbar
dP = 25mbar
N2 or air purge
P = 185 mbar
P = 205 mbar
Brine feed
Caustic feed
B
A
A
B
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Staying in Control of Pressure – Getting it Right
Keys to good pressure and differential pressure control
• Correct valve sizing• Trip logic• Valve settings (stroke times)
• Tuning of valves
INEOS are experts in dynamic modelling of cellroom gas systems
• Simulate various transient events
• Optimise control valve selection• Develop the optimum logic and timed
responses• Achieve excellent pressure control in
all situations• Check response of system prior to
start-up
V01(10 BiChlor
Electrolysers)
V02(Headers
and coolers)
V03(Headers,
dryer, filter)
PIC01B
PIC01A
dP02(Headers and
coolers)
dP03(Headers,
dryer,filter)
P03(xxx barg)
P02(-20
mbarg)
P C V 0 1 B
PCV 01A
V11(10 BiChlor
Electrolysers)
V12(Headers
and cooler)
V13(Headers,
filter)
dPIC11B
dPIC11A
dP12(Headers and
cooler)
dP13(Headers,
filter)
P13(165
mbarg)
P12(0 mbarg)
d P C V 1 1 B
dPCV 11A PV 12
SD1
185 mbarg
205 mbargSD1
SD1
dP = +15 mbar
dP = + 25 mbar
Stream 02 Stream 03Stream 01
Stream 11 Stream 12 Stream 13
Chlorine
Hydrogen
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Staying in Control of Pressure – Dynamic Modelling
Model validated against a less than optimal pressure swing during a plant trip
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Staying in Control of Pressure – Dynamic Modelling
Model used to evaluate optimal valve stroke times, within the constraints of the installedvalves. Subsequent plant trip followed modelling results very well.
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Brine Purity and Salt Selection
Low cost brine plants can reduce capital ..
.but they can seriously increase day 2+ power increase due to impurity excursions
How will specific impurities behave in the brine loop and electrolyser?
• Precipitation within the membrane (increased voltage, reduced CE)• Plating on electrodes / attack of electrode coatings (increased over-potential)
1514131211
AnodeFace
CathodeFaceMembrane
+ _
Cation flow
Damaging cationsolubility (typical)
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Brine Purity and Salt Selection
What do we do in design to minimise damage due to brine impurities?
• Salt and brine selection
• Secondary purification design and resin specification
• Brine purge vs other brine loop purification techniques
• Hg residue for conversion projects
• Cost / benefit analysis of relaxation of specific impurities
• Full characterisation of brine
• Pilot trials for brine purification
INEOS are experienced in operating plants with different salt supplies andbrine purification strategies. We design to avoid the pitfalls
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Electrolyser Stray Currents
Relatively high voltages in membrane cells leads to current leakage via process fluids• Corrosion of electrolyser components• Corrosion of up and downstream metallic equipment
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Electrolyser Stray Currents
What do we do to alleviate the problems caused by stray currents?
• Inclusion of sacrificial stray current collectors in cell feeds
and exits• Positioning of process fluid supply and discharge lines
• High resistance fluid paths
• Grounding electrodes
– Protect up and downstream equipment – Positioned to minimise stray currents
to earth – Prolong life of the grounding electrode
• Stray current modelling
INEOS understand the issues of stray currents and know how goodcellroom design can minimise their effects
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Keeping the Plant On-Line
Capital cost saving decisions may impact long term availability and revenue
• Materials of constructionIt may cost less but how long will it
last?
• MaintainabilityIt may look neat but can you get at it?
• Maintenance windowHow long to repair/replace an item?
• Configuration and overcapacityIf one unit is off-line can another makeup?
• Buffering and redundancyStaying on line during upsets
• Refurbishment planningDoes technology supplier look afteryou?
As operators INEOS understand the importance of keeping the plant online. INEOS technology is designed to be robust and easily maintained.We help clients throughout the plant life cycle
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Keeping the Plant Safe
Maintenance outside of cellroom
Hydrogen in chlorine
Safety is paramount in the INEOS culture. Our technology is designed forinstallation into facilities demanding the highest safety standards in alloperating and maintenance situations
Isolations
Designing for inherent safety .
Working at height
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This document is the property of INEOS Technologies (Vinyls) Limited and the information it contains is strictly confidentialand may not be copied, used or disclosed without the express permission of Ineos Technologies (Vinyls) Limited.25
INEOS will Bring Deep Understanding of Chlor-Alkali to your Project
• Design of wider chlor-alkali plant, whether for a technology conversion or newinstallation is by now generally understood
• Deep understanding of the chemical engineering science around the electrolysissection of the plant is required to ensure optimal design
• Several key areas, identified here, require very careful consideration to ensureprolonged efficient operation of the plant
• Operating Experience + Technical Expertise Optimal Cellroom design
ContractorsINEOS
Client
Strengths Knowledge
CommunicateOptimise
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Where can INEOS add value?
Optioneering andfinancial analysis
Hazard studies andtechnical risk
Vendor analysis
and selection
Dynamic modelling
Plant performanceassessment Process Definition
Process Design
Detailed Engineering
Commissioning
Procurement and
Construction
Front End EngineeringExpert process
engineering
Operating skillsTechnology knowledge
Layout analysis
Feasibility studiesPlant capacity
assessment
Troubleshooting
SIL/LOPA
PDPs
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Where can we help you?
Thank you for your time and attention
Amanda Lancaster
Tel: + 44 1928 516677E-mail: [email protected]
www.ineostechnologies.com