Report No. 61 CHLORINE. by YEN-CHEN. April A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA

Transcription

1 Report No. 61 CHLORINE by YEN-CHEN YEN April 1970 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION SUMMARY INDUSTRIAL STATUS In the United States Production Market Trends InCanada InEurope InJapan In Other Countries a 4 CHLORINE BY ELECTROLYSIS OF AQUEOUS SODIUM CHLORIDE Chemistry... Review of Processes... Diaphragm Cells... Mercury Cells... Dimensionally Stable Anode... Chlorine Treatment... Processes Using Unconventional Raw Materials or Making Unconventional Products... Chlorine by Salt Electrolysis Using a Diaphragm Cell.. Process Description... Process Discussion... Cost Estimates... Chlorine by Salt Electrolysis Using a Mercury Cell.,. Process Description... Process Discussion... Cost Estimates... Comparison of Costs of Diaphragm Cell Process and Mercury Cell Process CHLORINE BY ELECTROLYSIS OF HYDROGEN CHLORIDE Cells for Electrolysis of Hydrochloric Acid Process Description Process Discussion Cost Estimates Improvements in the Electrolysis of Hydrochloric Acid Other Processes for Electrolysis of Hydrogen Chloride V

3 CONTENTS 5 (continued) Westvaco Copper Chloride Process Schroeder Process Mercury Chloride Process CHLORINE BY OXIDATION OF HYDROGEN CHLORIDE USING A HETER- OGENEOUS CATALYST... Chemistry... Review of Processes... Process Description... Process Discussion... Cost Estimates... 7 CHLORINE BY OXIDATION OF HYDROGEN CHLORIDE USING NITRIC ACID... Chemistry... Review of Processes... Process Description... Process Discussion... Cost Estimates... 8 CHIQRINE FROM AMMONIUM CHLORIDE COPRODUCED IN A MODIFIED SOLVAY PROCESS... Process Review... Coproduction of Ammonium Chloride in Soda Manufacture... Ammonia and Hydrogen Chloride from Ammonium Chloride... Chlorine Directly from Ammonium Chloride... A Modified Solvay Process for Production of Soda Ash with Coproduction of Ammonium Chloride... Process Description... Process Discussion... Main Procedures... Crystallizer... Materials of Construction... Ammoniation... Calcination... Ammonia Still... Separation of Products... Purity of the Products... Cost Estimates... Use of Brine as a Raw Material vi

4 CONTENTS 8 (continued) A Process for the Manufacture of Chlorine from Ammonium Chloride... Process Description , Process Discussion Cost Estimates Integration of Modified Solvay Process and Chlorine Production from Ammonium Chloride Conversion of a Soda Ash Plant from the Conventional Solvay Process to the Modified Solvay Process CHLORINE AND SODA ASH BY ELECTROLYSIS... Carbonation of Cell Liquor... Integration of Electrolysis and Solvay Process... A Process for the Manufacture of Soda Ash and Chlorine by Electrolysis and Carbonation... Process Description... Process Discussion... Cost Estimates... A Process for Manufacture of Soda Ash and Chlorine by Solvay Process and Salt Electrolysis... Comparison of Various Processes for Production of Chlorine andsoda OTHER PROCESSES FOR CHLORINE MANUFACTURE Chlorine as a By-Product of Sodium Manufacture Chlorine as a By-Product of Magnesium Production Chlorine from Sodium Chloride Using Sulfur Trioxide..... Chlorine from Metallic Chlorides by Electrolysis Chlorine from Iron Chloride by Oxidation Chlorine from the Waste Liquor of a Solvay Soda Plant..,. Chlorine from Sodium Chloride Using Manganese Dioxide..,. Chlorine from Sodium Chloride Using Siliceous Materials... Chlorine from Sodium Chlorate Chlorine by Oxidation of Hydrogen Chloride in a Plasma... Chlorine by Thermal Dissociation of Hydrogen Chloride vii

5 CONTENTS APPENDIX A DESIGN AND COST BASIS APPENDIX B PHYSICAL DATA APPENDIX C HAZARDS AND SAFETY APPENDIX D SOURCES OF HYDROGEN CHLORIDE AS A RAW MATERIAL FOR CHLORINE PRODUCTION CITED REFERENCES PATENT REFERENCES BY COMPANY viii

6 ILLUSTRATIONS Chlorine from Salt by Electrolysis, Diaphram Cell Process Chlorine from Salt by Electrolysis, Diaphram Cell Process Production Costs at Different Production Levels, Chlorine from Salt by Electrolysis, Mercury Cell Process. 83 Chlorine from Salt by Electrolysis, hfercury Cell Process Production Costs at Different Production Levels Chlorine from Hydrochloric Acid by Electrolysis Chlorine from Hydrochloric Acid by Electrolysis Production Costs at Different Production Levels Chlorine from Hydorgen Chloride by Oxidation Chlorine from Hydrogen Chloride by Oxidation Comparison of Investment Estimates Chlorine from Hydrogen Chloride by Oxidation Using a Heterogeneous Catalyst Production Costs at Different Production Levels Chlorine from Hydrogen Chloride by Oxidation with Nitric Acid Chlorine from Hydrogen Chloride by Oxidation with Nitric Acid Production Costs at Different Production Levels Soda Ash by Modified Solvay Process Chlorine from Ammonium Chloride Chlorine by Modified Solvay Process and Ammonium Chloride Oxidation Production Costs at Different Production Levels...,,. 235 Conventional Solvay Process and Modified Solvay Process,. 237 Electrolysis of the Mother Liquor from Bicarbonate Separation in the Solvay Process Chlorine and Soda Ash by Electrolysis and Carbonation, Chlorine and Soda Ash by Solvay Process and Salt Electrolysis ix

7 ILLUSTRATIONS 9.4 Total Capital Investment for Different Processes for Producing Chlorine and Soda......,, Production Cost of Chlorine with Coproduction of Soda by Different Processes..,......,

8 TABLES Comparison of Various Processes for Producing Chlorine with Coproduction of Soda Comparison of Processes for Producing Chlorine from Hydrogen Chloride Comparison of Diaphragm Cell and Mercury Cell for Chlorine-Alkali Production Chlorine Producers in the United States Chlorine Producers in Canada Chlorine Producers in Europe Chlorine Producers in Japan Characteristics of Diaphragm Cells Available for License. 37 Diaphragm Cell Process Patent Summary Characteristics of Mercury Cells Available for License.. 43 Mercury Cell Process Patent Summary Dimensionally Stable Anodes Patent Summary Liquefaction of Chlorine Patent Summary Recovery or Removal of Chlorine from a Dilute Chlorine Stream Patent Summary Treatment of Chlorine-Containing Gases Patent Summary Chlorine from Seawater by Electrolysis Patent Summary Chlorine by Salt Electrolysis, Diaphragm Cell Process Major Process Equipment Chlorine by Salt Electrolysis, Diaphragm Cell Process Stream Flows Chlorine by Salt Electrolysis, Diaphragm Cell Process Total Capital Investment xi

9 TABLES Chlorine by Salt Electrolysis, Diaphragm Cell Process Production Costs.., Chlorine by Salt Electrolysis, Mercury Cell Process Major Process Equipment and Utilities Summary..., Chlorine by Salt Electrolysis, Mercury Cell Process Stream Flows Chlorine by Salt Electrolysis, Mercury Cell Process Total Capital Investment Chlorine by Salt Electrolysis, Mercury Cell Process Production Costs.., Cells for Electrolysis of Hydrochloric Acid Patent Summary..., Chlorine by Electrolysis of Hydrochloric Acid Major Process Equipment and Utilities Summary Chlorine by Electrolysis of Hydrochloric Acid Stream Flows Chlorine by Electrolysis of Hydrochloric Acid Total Capital Investment Chlorine by Electrolysis of Hydrochloric Acid Production Costs , Devices for Reducing Voltage for Hydrochloric Acid Electrolysis Patent Summary..., Chlorine by Hydrogen Chloride Oxidation Using a Heterogeneous Catalyst Patent Summary..., Chlorine by Hydrogen Chloride Oxidation Using a Heterogeneous Catalyst Major Process Equipment and Utilities Summary.,, Chlorine by Hydrogen Chloride Oxidation Using a Heterogeneous Catalyst Stream Flows. : Comparison of Processes Using Air and Oxygen for Oxidation of Hydrogen Chloride Major Process Equipment and Utilities Summary xii

10 TABLES Chlorine by Hydrogen Chloride Oxidation Using a Heterogeneous Catalyst Total Capital Investment Chlorine by Hydrogen Chloride Oxidation Using a Heterogeneous Catalyst Production Costs Chlorine by Hydrogen Chloride Oxidation Using Oxygen Production Costs Chlorine from Hydrogen Chloride or Alkali Chloride by Oxidation with Nitric Acid or Related Compounds Patent Summary Chlorine from Nitrosyl Chloride Patent Summary Chlorine from Hydrogen Chloride by Oxidation with Nitric Acid Major Process Equipment and Utilities Summary Chlorine from Hydrogen Chloride by Oxidation with Nitric Acid Stream Flows Chlorine from Hydrogen Chloride by Oxidation with Nitric Acid Total Capital Investment Chlorine from Hydrogen Chloride by Oxidation with Nitric Acid Production Costs Production of Ammonium Chloride as a Coproduction of Soda Ash Manufacture by the Solvay Process Patent Summary Ammonia and Hydrochloric Acid from Ammonium Chloride Patent Summary Chlorine from Ammonium Chloride Patent Summary Soda Ash by Modified Solvay Process with Coproduction of Ammonium Chloride Major Process Equipment and Utilities Summary xiii

11 TABLES 8.5 Soda Ash by Modified Solvay Process with Coproduction of Ammonium Chloride Stream Flows Soda Ash by Modified Solvay Process Total Capital Investment., Soda Ash by Modified Solvay Process Production Costs Chlorine from Ammonium Chloride Major Process Equipment and Utilities Summary Chlorine from Ammonium Chloride Stream Flows Chlorine from Ammonium Chloride Total Capital Investment Chlorine from Ammonium Chloride Production Costs Soda Ash Production Cost Changes by Converting an Existing Conventional Solvay Process to a Modified Process..... Payout in Converting a Conventional Solvay Soda Ash Process to a Modified Solvay Process.., Sodium Carbonate from Electrolytic Cell Liquor Patent Summary Integration of Salt Electrolysis and Solvay Process Patent Summary Chlorine with Coproduction of Soda Ash by Electrolysis and Carbonation Major Process Equipment and Utilities Summary Chlorine with Coproduction of Soda Ash by Electrolysis and Carbonation Stream Flows Chlorine with Coproduction of Soda Ash by Electrolysis and Carbonation Battery Limits and Utilities Cost of Carbonation Section. 259 Chlorine with Coproduction of Soda Ash by Electrolysis and Carbonation Total Capital Investment xiv

12 TABLES 9.7 Chlorine with Coproduction of Soda Ash by Electrolysis and Carbonation Production Costs Chlorine by Integrated Solvay Process and Salt Electrolysis Total Capital Investment Chlorine by Integrated Solvay Process and Salt Electrolysis Production Cost , Comparison of Payoff Period of Different Processes at Various Rates of Chlorine Production xv