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CHLOR-ALKALI TECHNOLOGY
A Partnership for Life
Philip See (Business Development Manager)
• Chartered Mechanical Engineer
• 26 Years in Chlor-Alkali with ICI/INEOS
• Engineering Manager for
- 40 kte KOH Plant (ICI FM21 membrane electrolysers)
- 600 kte Chlorine Plant (ICI amalgam electrolysers)
• Plant Design and Commissioning
- 430 kte Chlorine Plant (BICHLORTM Electrolysers)
- Technology benchmarking and operability studies
TURNOVER
$47BILLION
EMPLOYEES
15,000
PRODUCTION HERITAGE
AMOCO, BASF, BAYER,
BOREALIS, BP, DEGUSSA,
DOW, ENICHEM,
ERDOLCHEMIE, HOECHST,
ICI, INNOVENE, LANXESS, MONSANTO,NORSK
HYDRO, SOLVAY
SITES
51 MANUFACTURING
PLANTS IN 11 COUNTRIES
GROWTH
• 15 Petrochemical/Chemical Businesses
• Growth by acquisition since 1998
• World’s 4th largest independent chemical company
HISTORY
INEOS Overview
INEOS Technologies Portfolio and Heritage
ChlorineEDCVCMPVC
•Polypropylene•Maleic Anhydride
•LL/HD swingPolyethylene•Acrylonitrile•Maleic Anhydride•ExpandedPolystyrene
•HD bi-modal slurryPolyethylene
Brussels, Belgium
PO and
Performance
Chemicals
Green Lake, TX
Nitriles
Lima, OH
Nitriles Catalyst
Lisle, IL
Nitriles/PP Catalyst Naperville, IL
Nitriles/PO/Olefins
Lyndhurst, UK
PO
Runcorn, UK
Vinyls &
Electrochemical
Tech
Grangemouth, Scotland
Olefins
Lavera, France
PO/PS
Venice, Italy
Vinyls
Chocolate Bayou, TX
PP and OlefinsRolle, Switzerland
Board
Commercial Centres - Rolle (Switzerland), Lyndhurst and Runcorn (UK), Lisle (USA), and Shanghai (China)
R&D/ Technical/ Manufacturing Centres~400 people World-wide.Extensive Intellectual Property and 6000 patents
Shanghai, China
Technologies
General
INEOS Technologies – Locations
BICHLOR™ Cell rooms
Monopolar Cell rooms
117 chlor-alkali projects over 30 years
Americas – Strong and Growing Presence
Company Location Year
HF Chlor-Alkali USA 2014
Skymine USA 2013
Fluoders Paraguay 2013
Kuehne USA 2001 / 2011
Olin USA 2011 / 2014
FSTI/CSP USA 2008
Allied USA 2009
Lapsolite Mexico 2006
Proquimsa Ecuador 2005 / 2009
Proctor + Gamble Guatemala 2003 / 2006
Successful Plant Lifespan – Vital to INEOS ChlorVinyls
• A designer and operator of
chlorine plants for over 110
years
• 7 cell-rooms across Europe,
total capacity 1,600,000
MTPA Cl2
• A major European Chlor-
Vinyls Manufacturer
0
200
400
600
800
1000
1200
1400
1600
1800
2000
10
00
's m
etr
ic t
on
ne
s o
f C
hlo
rin
e p
er
an
nu
m
Dow
INEOS
Akzo
Bayer
Arkema
Solvin
Solvay
Vinolit
BASF
Successful Plant Lifespan – Key Factors
SuccessfulLifespan
SafeOperation
Reliability Efficiency
INEOS Runcorn – Driving Continuous Improvement
• 430kte/yr chlorine
• 20 BiChlor electrolysers
• Designed to Lifecycle Principles
• INEOS Know-How applied
• World Class Performance
Techniques – A Structured Way of Working
1. Process
Description/
Purpose
2. Potential
Failure
Mode
3. Potential
effect of
failure
4.
Sev
.
5. Potential cause of
failure
6.
Occ
.
7. Current
Controls
8.
Det
.
9.
RPN
10. Recommended
actions
11.
Responsibility/
start date
12. Action Results
Performance
of O Ring
carriers
Wrong
material
used in
manufacture
Splits/cracks
Dissolves/
Wear away
Chemical
Degrades
Thermal
Expansion
effect on
seal
Porous
Sticks to tup
tube
Cause
reaction
with other
materials/
products
10
10
10
10
9
10
Supplier changes RM
without informing ICL
Supplier changes RM
informs ICL
Change of supplier
Raw materials to
supplier changes
without their
knowledge
Lack of detailed
agreed specification
Shelf Life:
- Components
2
1
2
4/5
10
1
None
Change of BOM
Process – Agreed
BOM integrating
into ETB systems
Specification – QA
systems &
registration
Specification –
maybe not detailed
enough QA
systems &
registrations
Operator inspection
& operational
experience
None
- shelf life
not known
- no stock
rotation
10
3
3
9
9
10
200
30
60
450
900
100
Generate approved
supplier list
Review
specification &
produce audit trial
& review
Specifications
agreed with
supplier.
Establish if there is
Shelf life
Develop Stock
rotation process
Performance
of O Ring
carriers
Dimensional
ly wrong
Too Narrow
– Can’t
Assemble
Too Wide –
Leaks in
service
2
10
Supplier delivers
outside of spec
Supplier delivers
outside of spec
8
8
Drawings
Operator
Drawings
Operator
Cell room
measurements
3
9
48
720
Develop robust spec
Carry out QC Check
on tolerances
Sample test
Lifecycle Value Analysis
Critical Items Analysis
Loss Elimination - FMECA
Risk Based Inspection
INEOS Technologies Team – Chlorine Experienced
ProjectCommissioning
Managers
Technical Managers
Plant Managers
Plant Engineers
Scientists
DesignEngineers
INEOSTEAM
Safe Operation
Successful
Lifespan
SafeOperation
Reliability Efficiency
Safe Operation – Built In
• Modular Technology AvoidsJ..– Interaction with live electrolysers
– Leaks – modules are bolted, sealed & pressure tested
• Fully Wetted Membrane– Gas/Liquor interface above the membrane
– Avoids damage and pin-holing of membrane
– Prevents mixing of Cl2 / H2 to avoid explosions
• Safety in Plant Design– Inherently safe design features
– HAZOP
Reliability
Successful
Lifespan
Safe
OperationReliability Efficiency
Reliability – INEOS has the Knowledge
Layout analysis
Optioneering
Dynamic Modelling
Materials of Construction
Stray Currents
Accessible Headers
Rapid ModuleChange
High Integrity Design
Robust electrodecoatings
Reliability – Avoiding Damaging Pressure Excursions
V01
(10 BiChlor
Electrolysers)
V02
(Headers
and coolers)
V03
(Headers,
dryer, filter)
PIC
01B
PIC
01A
dP02
(Headers and
coolers)
dP03
(Headers,
dryer,
filter)
P03
(xxx barg)
P02
(-20
mbarg)
PCV 01B
PCV 01A
V11
(10 BiChlor
Electrolysers)
V12
(Headers
and cooler)
V13
(Headers,
filter)
dPIC
11B
dPIC
11A
dP12
(Headers and
cooler)
dP13
(Headers,
filter)
P13
(165
mbarg)
P12
(0 mbarg)dPCV 11B
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
• Dynamic model of the gas section downstream of electrolyser• Simulate transient events – cellroom trip, electrolyser trip, load
changes
• Model validated by comparing DP predicted by model with plant data
• Large negative DP excursion –improvement required
• Model used to develop control scheme to avoid reverse DP• Excellent system response
Efficiency
Successful
Lifespan
Safe
OperationReliability Efficiency
Power Efficiency – At the Heart of BiChlor
� Module low voltage dimple design
• Max use of nickel post in cathode pan
• Min use of titanium post in anode pan
� Explosion bonded Ti/Ni discs for
excellent inter-module connection
� Zero gap electrodes
� Self aligning modules
Efficiency – 30 Years of Coatings Development
• Anode Coating– Lower power consumption
– Greater resistance to Alkaline wear
• Cathode Coating– Highly resistant to upset
conditions
– 16 year warranty
• Modern coating plant and extensive refurbishment centre
voltage
0 70 70 0
1 70 70 0
2 70 72 2
3 70 74 4
4 70 77 7
5 70 80 10
6 70 95 25
7 70 135 65
8 70 320 250 8 70
9 70 70 0 9 70
10 70 72 2 10 72
11 71 74 3 11 74
12 72 77 5 12 77
13 73 80 7 13 80
14 75 95 20 14 95
15 82 135 53 15 135
16 100 320 220 16 320
0
Comparision of Coating Performance
0
50
100
150
200
250
300
350
0 2 4 6 8 10 12 14 16
Years on line
Po
ten
tial
(mV
)
INEOS COATING COMPETITOR COATING
Efficiency – Accessing our Operations Expertise
• Designated Technical Service Manager– Experienced chlor-alkali specialist
– Usually member of original commissioning team
– Regular visits and contact
• Getting the most from your plant– Performance evaluation
– Operating and Technical support
– Electrolyser maintenance planning
• Customer forum every 2 years– Technical and Social content
– Highly valued by clients
Efficiency – Evolution not Revolution
BICHLOR™ Start-up Power Consumption vs Current Density
1650
1750
1850
1950
2050
2150
2250
2350
2450
0 1 2 3 4 5 6 7
current density (KA/sq.m.)
Po
wer
Co
nsu
mp
tio
n (
KW
h/t
e
NaO
H)
2003
2007
2010
2012
2014
Incremental improvement
INEOS – A Partnership for Life
• Unrivalled knowledge of chlor-alkali technology and operations
• Technology built to perform over the long term
• A partnership for the long-term