Workshop on Mercury Management Almaden 2013

Decommissioning planning and management in the chlorine- alkali industry

December 13, 2013Antonio CAPRINO

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INTRODUCTION

Commitment of the European chlor-alkali industry to shut down cell rooms using Hg cell technology by 2020 (at the latest)– Mercury based capacity represents today ~30% of the total

chlorine production capacity. – Beginning of 2013, still 31 chlorine cell rooms using mercury cell

technology in Europe.

In some of the EU countries, strong pressure to speed up the shut down :– National or regional legislations (interdiction of technology or

limitation of emissions)– Local permits

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Manufacturing Processes EUROCHLOR 1997 - 2011

% of total capacity

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Mercury Diaphragm Membrane Other

INTRODUCTION

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Conversion mercury cells

Eurochlor document of reference– Conversion from Mercury to Alternative Technology in the Chlor-Alkali

Industry (updated June 2012) .– World chlorine production capacity in mercury plants (WCC 2002-10)

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Factors influencing conversion

Energy prices and efficiency– Membrane cells consuming less electrical energy, but consuming

steam for caustic concentration. Production capacity– If the market demand more production, membrane installation or

conversion can be the opportunity – Selection of current density : lower density requires more

electrolysersProduct quality– Membrane needs a higher quality of brine– Chlorine membrane has lower quality – Caustic need to be concentrate

Market conditions

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Investment and paybackIn 2008 Prochemics, an independent consultant company made a study for Eurochlor to evaluate the conversion costs, taking to account data of 2007.

Recently UNEP article about this theme :Story of the month - August 2012 :Converting to a Cost-Effective Mercury Free Technology in the Chlor-Alkali Industry

To convert an existent mercury plant into membrane– New electrolysers– Replacement or adapt rectifiers– Purification brine – Caustic concentration

Cost– Cost 550- 700 USd/ton capacity– Time schedule for conversion: 18 – 24 months– Pay back: 10 – 14 years

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SOLVAY EXPERIENCE

SOLVAY plants around the world (at 01.01.2013)– 13 plants, more than 2 Mt Cl2/y– 4 plants with mercury technology (2 in Spain + 1 in Belgium + 1 in Argentine)

SOLVAY Mercury plants conversion (2006 – 2011) :– 2006 - Rosignano (I)

1 cellroom – 120 ktCl2/y– 2007 : Bussi (I)

1 cellroom – 80 ktCl2/y– 2009 : Santo André (BR)

4 cellrooms – 106 ktCl2/y

SOLVAY Mercury plants conversion projects– Lillo (B) : 2012 (done 02/12/12)

1 cellroom – 180 ktCl2/y– Tavaux (F) : 2012 (in execution)

2 cellrooms – 240 ktCl2/y

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Manufacturing Processes SOLVAY 2003 - 2013

SOLVAY - % of total capacity

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Mercury Diaphragm Membrane

Conversion of Tavaux and Lillo Hg capacities

INTRODUCTION

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Focus of the presentationReference documents to be used for preparing the decommissioning

Management of decommissioning activities within Solvay– Central decommissioning project team (Hermes

Project)– Local management in the plants

Experience in Europe Rosignano plant to be transferred to Lillo and Tavaux plants. Experience in Brazil plant.

Main lessons & highlights

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Reference Documents

EUROCHLOR :– Env. Prot. 3 – Guideline for Decommissioning of Mercury

Chlor-Alkali Plants– Env. Prot. 19 – Guidelines for the preparation for permanent

storage of metallic mercury above ground or in underground mines.

LOCAL DOCUMENTS :– e.g. French S.H.D – “Protocole de démantèlement de salle

d’électrolyse à cathode de mercure”

COMPANY INTERNAL DOCUMENTS (if any)– Procedures– Chronogram, plans

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Management of the decommissioning

Solvay “Hermes Project”– Objectives :

Definition of the process to be followed for Hg cell rooms decommissioning in the Solvay GroupPreparing a technical database for Hg contaminated equipments.

– Project TeamProject Leader “Process” (former Hg Cell room production manager)Specialists of HSE and Corporate Purchasing DepartmentsLocal Team on site for management of the decommissioning

– Starting date : 2006

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Decommissioning Management on site

Early estimation of the different contaminated wastes to be disposed of, and definition of the equipments to be maintained in operation for Hg exposure concern.

– SOLVAY experience : 1.000 to 6.000 t of contaminated materials per unit.

– Contaminated materials (not exhaustive) :Steal, other metals (Copper, Aluminium)MercuryGraphite, carbonPVC, FRP, other plastics“Hard Rubber” from rubber-lined equipmentsGasketsSand, sludgeElectrical equipmentsConcrete, bricks…

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Decommissioning Management on siteDefinition of the treatment/disposal solutions for each contaminated equipment/waste, based on the techniques listed by the “Hermès team”.– Provision of the containers for metallic mercury

storage/transportation– Treatment/disposal solutions for each waste can depend on

national regulation.Early discussions and ITB with subcontractors for dismantling activities.– Technical solution proposed for each type of waste– Solutions for disposal

Well documented action plan for discussions with local authoritiesDefinition of people management during dismantling– Needs (local, external)– Medical and environmental monitoringCost control

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Decommissioning PhasesPhase 1 : Health and Safety preliminary actions– Emptying of the equipments (mercury, other fluids)– Cleaning of the different equipments, tightening, covering

with water if needed. – Dismantling of non-Hg equipments (incl. anodes, cell

covers,…)Skilled people from the plant (e.g. people in charge of the operation of the Hg cell room)

Phase 2 : Dismantling of the equipments– Dismantling of all the equipments, except equipments kept in

operation for HSE concernsCan be subcontracted if no skilled people available.

Phase 3 : Dismantling of all remaining equipments– Electrical equipments– Treatment units,…

Subcontracted in the most of cases.

SOLVAY Rosignano (Italy)SOLVAY Santo Andre (Brazil)

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Rosignano - Main figures

Mercury Cell room– Chlorine capacity : 120 kt/y– Number of cells : 50 of 30 m2

Decommissioning activities– Shut down : May 2007– End of Safety Preliminary actions : March 2008– Dismantling plan accepted by local authorities in August

2008.– End of dismantling activities : end 2009

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Rosignano – Plant overview

Cell room

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Cellroom after the Health & Safety preliminary actions

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Cells dismantling

Cell « confinement » for dismantling

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Cells dismantling

Cell « confinement » for dismantling (connected to air treatment unit)

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Working area for safe handling of the contaminated equipments

Working area connected to Hg effluents treatment unit and regularly washed

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Specific zone (connected to air treatment) for some Hg equipments dismantling

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Floor of the cell room regularly washed

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Santo Andre - Main figures

Mercury Cell room– Chlorine capacity : 106 kt/y– Number of cells : 52 of 12 m2 + 49 of 10 m2

Decommissioning activities– Shut down : February 2009– End of Safety Preliminary actions : December 2009– Dismantling plan accepted by local authorities:

December 2008.– End of dismantling activities : end 2011

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Cellroom dismantling phases

In process of Health & Safety action End of Health & Safety action

End of cells dismantling

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Cell room after the Health & Safety preliminary actions

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Material recuperation: example of tendency

Recuperação de material (acumulado)

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TITANIO (e) COBRE (e) ALUMINIO (e)

FERRO (d) MERCÚRIO (e) OUTROS (e)

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Teams and time for dismantling

Horas trabalhadas

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Mão Obra SOLVAY Mão de obra Contratada Externo

Total SLV (d) Total contratada (d) Total Acumulado (d)

Externo

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Main lessons & highlights

Decommissioning of a Hg cell room has to be managed as a specific project :

– Dedicated project team– Project to be structured carefully– Study to be started at an early step

the Hg cell room shut-down strategy can affect the conversion start-up schedule - in case of a conversion)Early definition of the equipments to be maintained in operation during decommissioningList of contaminated equipments/wastes and treatment solutions to be prepared for further discussions with subcontractors and local authorities.

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Main lessons & highlightsHealth of workers :– Has to be considered at an early step (definition of the

equipments to be maintained in operation for Health concerns)

– Work with skilled people (e.g. from Hg cell room operation team) when possible, at least for safety preliminary actions.

– Regular monitoring of Hg exposure (air and biomonitoring)

Key points :– People engaged: internal and external (contractors)– Creativity and Innovative solutions.– Controls: to have indicators of evolution

Thank you for your attentionAntonio CAPRINO

www.solvay.com