Revamp Possibilities for Caustic Soda Plants For …...o Market leader in Membrane Cell Electrolysis – global market share in excess of 45% o Impressive global footprint for grassroots,

For Alkali Manufacturers Association of India

Revamp Possibilities for Caustic Soda Plants

06.09.2017 | AMAI Conference N.Ranga Rao - thyssenkrupp Industrial Solutions (India) Pvt. Ltd.

2 06.09.2017 | AMAI Conference | N.Ranga Rao, tkIS India

Topics

• thyssenkrupp Industrial Solutions (India) – tkIS India at a glance • thyssenkrupp Industrial Solutions – tkIS Electrolysis Technologies at a glance • Plant performance optimisation

o Optimisation by technological improvements of electrolysis cell house

o Optimisation by technological improvements apart from cell technology


Electrolysis @ tkIS India o Market leader in Membrane Cell with domestic market share in

excess of 75%

o Has worked as ‘partner of choice’ with almost all Indian Caustic Soda manufacturers for grassroots, expansion, conversion & technology upgradation projects

o Leveraging R&D set-up for various Electrolysis technologies yielding energy and other benefits to Customers

Over 150

projects


Life Cycle Services

Fertilisers Refinery Units Electrolysis & Polymers

Third Party Technologies (Petrochemicals, Cryogenic Storages,

Metallurgy, Inorganic Chemicals and Industrial Plants)

40 25 150 100

125 110

100

650 projects in India & Abroad

thyssenkrupp Industrial Solutions (India) Core Competencies


Chlor-Alkali HCl electrolysis H2O Electrolysis

HCl ODC NaCl ODC

Sodium Chlorate Chlorine Dioxide

Vanadium Redox Flow Batteries

• offers solutions with “Single Point Responsibility” from concept to commissioning for all electrolysis plants

• Only one partner for Technology Engineering Implementation Commissioning and 360o lifecycle services

thyssenkrupp Industrial Solutions (India) tkIS’s Electrolysis Technologies


• Commitment for achieving sustainability & enhancing plant performance through innovation

• Dedicated R&D team supported by strong engineering expertise at local office

• Experience in development activities spanning 2 decades, with demonstrable / proven results

• Comprehensive & systematic approach

o Assimilation of customer needs, o Literature survey to understand

stare of art, o Lab testing to generate proof of

concept (PoC) o Pilot scale testing for critical

process/ component o Generating data for Engineering

• Management of Intellectual Property Rights (IPR)

thyssenkrupp Industrial Solutions (India) Research & Development


Atul Ltd. -Valsad

Nirma –Bhavnagar

Punjab Alkalies– Punjab

Grasim Industries – Renukoot

Grasim Industries – Nagda

Reliance Industries – Dahej

Grasim Industries– Vilayat

GACL – Dahej

Aditya Birla Nuvo – Veraval

GACL– Baroda

United Phosphorus –Jhagadia Grasim Industries – Rehala

Grasim Industries – Ganjam

KPR Industries– Andhra Pradesh

Andhra Sugars– Andhra Pradesh

DCW– Tamilnadu

Travancore- Cochin Chemicals –Udyogamandal

Chemplast Sanmar– Karaikal

Sree Rayalaseema – Andhra Pradesh

Chemfab Alkalies – Pondicherry

Grasim Industries – Karwar

Direct Contracts

thyssenkrupp Industrial Solutions (India) Chlor-Alkali Electrolysis Footprint

• > 75% of market share in Caustic Soda industry in India • > 45% market share of Caustic Soda installed capacities worldwide


Electrolysis @ tkIS o Market leader in Membrane Cell Electrolysis – global market

share in excess of 45%

o Impressive global footprint for grassroots, expansion, conversion & technology upgradation projects

o Only global consultant to offer under-one-roof solutions for the Electrolysis industry

o Continual R&D efforts spanning several decades have resulted in many innovations benefiting customers worldwide

o Closely associated with tkIS India for projects worldwide


Catholyte Circulation

Caustic Concentration

Chlorine Compression

Waste Gas De-chlorination

HCl Synthesis

98%

Hydrogen Treatment

DM H2O

a-Cellulose

NaOH

Caustic Flaking

Chlorine Liquefaction

Hypo Solution

48% Caustic

Hydrogen Compression for Bottling

Chlorine Tonner Filling

Transformer/ Rectifier

Membrane Electrolysis

Chlorine Treatment

Cl2

H2SO4 Concentration

H2

NaOH

H2O

78%

Clarification Precipitation

Brine Filtration

Brine Purification

Brine Saturation

Salt

Sludge

Anolyte De-chlorination

NaHSO3

Flocculant NaOH Na2CO3

BaCO3

Power Chlorate Destruction

HCl Synthesis

Main Raw Material : Salt, Power & Water

Conventional Membrane Chlor-Alkali Technology Process Overview


Plant Performance Optimisation – Cell House


Our spirit: “Know the potential for cheap but effective improvements?”

Key word: Revamp means

• Optimisation by technological improvements of electrolysis cell house

• Optimisation by technological improvements apart from cell technology

o Iterative process in close contact to the customer

o From basic study to execution of project

o Highly effective engineering, because of…

o …a large data base of engineering and service experiences

o …a separate, dedicated, well experienced Chlor-alkali engineering infrastructure for

project execution

Plant performance optimisation


BM2.7v6 nx-BiTAC

Optimisation by technological improvements of electrolysis cell house Electrolyser feature - options


Easy performance increase by retrofitting current elements or by replacing them with new elements of generation 6

No major change of periphery necessary

Higher efficiency and/or NaOH output

Your added value

• Improvements in BM 2.7 cell technology can pay off directly for you. We can either upgrade/retrofit your cells or simply exchange your old cells with new generation:

• Less width elements – more elements per stack

• Higher voltage efficiencies – more elements per trafo/rectifier

Better plant performance, less power consumption

v3-ZG

2055

v4-ZG

v3

2008

2070

2130

2055

2011 1997 2012

2020

2005

2170

v5plus

v6

v5

v4

2055

Power consumption in kWh/t NaOH100%*)

Pow

er c

onsu

mpt

ion

*) at 6 kA/m2 (90°C, 32 % NaOH)

Swap elements directly to v6

Retrofitting examples

Optimisation by technological improvements of electrolysis cell house for BM2.7


Multiple benefits Financial:

• Minimized investment

• Lowest power consumption

Operational:

• Improved safety level

• Increased current density operation

• Enhanced feed system

• Pure brine acidification possible

• No internal Δp fluctuations

Our approach Careful evaluation minimizes modifications to:

• Brine and Caustic feed system

• Electrical system

• Instrumentation

Our service package includes:

• Detailed replacement concept

• Definition of split of work

• Feasibility study and proposal

• Planning and implementation of modifications

• Assembly of new elements

• Installation, start-up and performance guarantee

BM2.7v2 BM2.7v6

Fast forward

to peak perfomance

Optimisation by technological improvements of electrolysis cell house for BM2.7 – Element Replacement Gen.V2/V3 to Gen.V6


Improvements in BiTAC cell technology can pay off directly for you. A few simple changes make a big difference:

Insert new high-performance membrane

Only cathode side is adjusted

Better plant performance, less power consumption

Easy efficiency increase, directly on-site

No major change of periphery necessary

Your added value

i-BiTAC

2005

2200

2060

1992 2014

2020

n-BiTAC

nx-BiTAC

BiTAC

2065 Po

wer

con

sum

ptio

n

Power consumption in kWh/t NaOH100%*)

Optimisation by technological improvements of electrolysis cell house for BiTAC

*) at 6 kA/m2 (90°C, 32 % NaOH)

16

anod

e

Anode side

Cathode side

• For retrofitting, no adjustments on anode side necessary • Re-meshing of anode electrode is optional

(only in our workshop)

• Installing of new coated cathode electrode as woven mesh (at client’s site or in our workshop)

Cell element

• Installation of high performance membrane and standard gasket

Retrofit of BiTAC can be done completely at client’s plant

cath

ode

Optimisation by technological improvements of electrolysis cell house for BiTAC – Simple and qualified modification of BiTAC to i-BiTAC

06.09.2017 | AMAI Conference | N.Ranga Rao, tkIS India


M

13th GEN-5 116

A

GEN-2 102

B

GEN-2 102

C

GEN-2 102

D

GEN-2 102

E

GEN-2 102

F

GEN-2 102

G

GEN-2 102

H

GEN-2 102

I

GEN-2 102

J

GEN-2 102

K

GEN-2 102

L

GEN-2 102

L

GEN-5 116

K

GEN-5 116

J

GEN-5 116

I

GEN-5 116

H

GEN-5 116

F

GEN-5 116

E

GEN-5 116

D

GEN-5 116

C

GEN-5 116

B

GEN-5 116

Optimisation by technological improvements of electrolysis cell house Example : Recap of cell house optimization project – execution philosophy adopted

RECT-1 RECT-2


A

GEN-2 102

B

GEN-2 102

M

13th GEN-5 111

L

GEN-5 111

K

GEN-5 111

J

GEN-5 111

I

GEN-5 111

B

GEN-5 111

H

GEN-5 111

F

GEN-5 111

E

GEN-5 111

D

GEN-5 111

C

GEN-5 111

-5 -5 -5 -5 -5 -5 -5 -5 -5 -5

RECT-1 RECT-2

G

GEN-2 102

-5

A

GEN-5 111

Optimisation by technological improvements of electrolysis cell house Example : Recap of cell house optimization project – execution philosophy adopted


Replacement by Gen 5b Plus

Recoating of Gen 2

Power Kwh/T

Invest. cost ₹ Million

Prod. loss of NaOH, matric ton

Savings from power ₹ Millon

Pay back years

2335

1952

470

1250

~ 2000

~ 2200

0

310

- 403 (*) 780 ~ 200 310 2.5

(*) Results in savings of 553 GWh of electricity in 8 yrs (*) Equivalent to 210,000 ton of CO2 reduction in 8 yrs (*) Client has benefitted the government scheme of “Perform, Achieve and Trade (PAT)”

Optimisation by technological improvements of electrolysis cell house Example : Recap of cell house optimization project - Greenhouse Gas Emission & Economics


2011

1,550

2013

3,000

1980

2,100

kWh / t NaOH

1900 2017

Market entry

Demo

3

1

Diaphragm / Mercury electrolysis

2

Standard membrane electrolysis

Optimisation by technological improvements of electrolysis cell house Alternative to standard conventional membrane technology - NaCl ODC

25% less power consumption compared to the standard conventional membrane technology - NaCl ODC offers the 3rd quantum leap in the history of Caustic production


1) Average over 5 years, picture copyright of company Covestro 2) guaranteed values

Covestro, Uerdingen Germany1)

Demonstration Full industrial scale

Grasim, Aditya Birla Nagda India

Demonstration Indian market

Befar Group, Binzhou, China.

Commercial plant Chinese market

2011 2013

2015

Market entry

Capacity 20,000 t/year Cl2 Current density 4-4.5 kA/m² Power consump. 1,504 kWh/t NaOH1)

Capacity 35,500 t/year Cl2

Current density 4kA/m² Power consump.1,480kWh/t NaOH2)

More than five years of reliable operation in industrial plant scale

Optimisation by technological improvements of electrolysis cell house Successful market entry of NaCl-ODC technology


2008

2,130

2,070

2,020

2013

1,550

2005 2012

BM 2.7 v4

BM 2.7 v5

BM 2.7 v6

ODC

1) At 6 kA/m2, 90°C, 32 % NaOH

Power Consumption in kWh/ t NaOH1)

June 2013

“Quantum leap”

Demo

Optimisation by technological improvements of electrolysis cell house Successful market entry of NaCl-ODC technology

2011

2,055 BM 2.7 V5 plus


Feed Brine Flow Auto control

Feed Caustic Flow Auto control Automatic Anolyte & Catholyte Header - Bypass valves

Optimisation by technological improvements of electrolysis cell house Electrolyser Automation


mmWC

Advantages : Minimize aux. power consumption

Effective utilization of downstream equipment

3500 2000

Optimisation by technological improvements of electrolysis cell house High pressure operation of Electrolysers


Plant Performance Optimisation – Outside Cell Hosue


Membrane Electrolyser

Salt Brine Saturation

Water

Anolyte Dechlorination

Clarification Precipitation

Brine Filtration

Brine Purification

Bisulfite

Nanofiltration (SRS Skid)

Pretreatment

Sulfate Precipitation/ Gypsum Filtration

Gypsum

Permeate

Concentrate

CaCl2 solution

Filtrate

Purge

Purge

High investment costs

Lean Brine

Cost effective sulfate removal especially for small plants

Limitation : - High CaCl2 excess in primary brine plant? - Quality of Gypsum?

Optimisation by technological improvements apart from cell technology Avoiding brine purge at low investment costs: SRS and/or Gypsum precipitation

27 | June 2017 | thyssenkrupp Industrial Solutions

Insert photo of

product, service in action or technical illustration

Resolution:

- min: 760x512 pixel,

- best: 1500x1100 pixel

Reduced cost for steam

Optimized to your local setup and surrounding conditions

ROI acc. your conditions at site

Your added value

Steam price is a decisive factor for the cost of caustic concentration – so you directly push your margin by cutting these costs. Reduction of steam consumption depends on a number of effects:

2 effect concentration: 710 -750 kg / t NaOH 100%



Combination of shell & tube and plate heat exchangers

Medium steam pressure necessary (10-12 barg)

Cost reduction for caustic concentration

Optimisation by technological improvements apart from cell technology Adaption to steam price

28 | June 2017 | thyssenkrupp Industrial Solutions

Insert photo of

product, service in action or technical illustration

Resolution:

- min: 760x512 pixel,

- best: 1500x1100 pixel

Cost-optimized - thanks to standardized engineering & skids

Process simplification to reduce operating costs

Easy delivery, fewer civil & erection works on site

Much faster project schedule

Your added value

tkIS offers you standardized, pre-assembled modules in steel skids, which come in a standard container size for ease of transportation. Individual skids can be installed in existing plants for modernization / debottlenecking purposes, for example:

Brine filtration

NaCl electrolysers

Chlorine Cooling / Drying / Liquefaction

Waste gas dechlorination

Sulfate Removal System (SRS)

Sodium hypochlorite production skids

Our process and technology expertise in complete plants is also ideal for cost-effective, small-scale plants.

Skid-mounted plants : Capacity of 5,000 to 15,000 mt/a of NaOH

Skid modules for cost-effective debottlenecking

Optimisation by technological improvements apart from cell technology Integration of skid-mounted units


Contact thyssenkrupp Industrial Solutions (India) Private Limited (formerly Uhde India Private Limited)

Uhde House, LBS Marg, Vikhroli (W), Mumbai 400 083, India

Tel : +91 22 4047 8020 / Fax : +91 22 2578 6187

e-Mail : [email protected]

Website : www.thyssenkrupp-industrial-solutions-india.com

Thank You for your attention !

Documents

Revamp Possibilities for Caustic Soda Plants For …...o Market leader in Membrane Cell Electrolysis – global market share in excess of 45% o Impressive global footprint for grassroots,