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5. The Chlorine Industry This chapter reflects an in-depth analysis of the chlorine and alkaline industry. The chlorine and alkalines production is closely connected, due to the feedstock used (salt). This sub-sector is one of the most energy and electricity intensive industries. The U.S. is the world’s largest chlorine manufacturer. The major markets for chlorine are PVC (37%), inorganic chemicals (22%), other organic chemicals (17%), propylene oxide (7%), pulp and paper (6%), water treatment (6%), solvents (5%). The major markets for caustic are: pulp and paper (26%), soaps and detergents (9%), propylene oxide (9%), petroleum (8%), water treatment (6%), other organic chemicals (13%), inorganic chemicals (12%) (Florkeiwicz, 1998). These areas are expected to continue to grow, but below the historical rate of growth (CMA, 1996). In part, the slower growth is attributable the collapse of the Asian economies and to environmental concern about the use of chlorine in industrial processes (Hileman et al., l994). In this chapter we first discuss the major process used to make chlorine (section 5.1), followed by a discussion of the U.S. chlorine industry (section 5.2) and energy consumption and intensity (section 5.3). 5.1 Chlorine manufacturing Processes The production of chlorine gas is an energy intensive chemical process requiring between 25-40 GJ (worldwide average) primary energy per tonne chlorine produced (Phylipsen et al., 1998a). In the process a brine solution is converted into two co-products through electrolysis: chlorine gas and sodium hydroxide (caustic soda). The three main electrolysis cell types that are used to separate and produce the chlorine gas and caustic are the mercury flow, diaphragm, or ion- selective membrane. In the diaphragm and membrane cells the caustic soda requires an additional step of concentrating the solution so that it can meet market specifications for most products. Of the three cell types the membrane cell requires the least energy to operate and is currently considered the state-of-the-art technology. Figure 7 shows the main process stages for chlorine production. AC Power Brine Waste Impure Brine Figure 7. Simplified Chlorine Production Flow Chart Chlorine Hydrogen Caustic Caustic Water Product Caustic Rectifier Brine Preparation Electrolytic Cell 22 1PDF Image | Energy use and energy intensity
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