tk UCE leading chlorine production technologies

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1 tk UCE leading chlorine production technologies Euro Chlor th Technology Conference - Berlin May, 2017 Fulvio Federico thyssenkrupp Our Group Mission Uhde Chlorine Statement Engineers a reliable partner Building on a strong past looking into a bright future UHDENORA founded as JV 2001 between De Nora (founded 1923) and Uhde (founded 1921) Chlorine Engineers founded 1973, acquired in 2011 by Industrie De Nora S.p.A., the parent holding company of De Nora ThyssenKrupp Electrolysis GmbH (a carve-out of the former Uhde Product Unit Electrolysis, founded in 1960) + + Amounts to thyssenkrupp Uhde Chlorine Engineers 2 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 1

2 Our Vision The World Champion in electrochemical plant and technology service business 3 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico To ensure excellent support on a global scale thyssenkrupp Industrial Solutions and Industrie De Nora joined forces tk Industrial Solutions Support: Engineering, Procurement, Construction, Financing etc. Industrie De Nora Supplies: Coating and cell manufacture >60% <40% Technology, Plant Business (EPC), Services 4 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 2

3 The major focus of our business model will more and more shift to EP/EPC-business and to technology service EP business EPC business Service Business L = Licensor business Sales IP and R&D Technology Procurement Electrolyser Basic Engineering Detail Engineering Procurement Balance of Plant Construction Technology Service Shared services agreements Support by tk IS/DN sales offices DN: manufacture/ Coatings tk: lab/ energy storage DN Manufact. and coating tk IS (DE, IND) Support in Basic Eng. tk IS and its regional organisations support in all functions DN repair and coating JV thyssenkrupp Industrial Solutions Industrie De Nora 5 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico Our Our technologies Group Mission and Statement competencies have been attractive Accumulated contract awards Capacity NaCl electrolysis [mn. mtpy Cl 2 ] Capacity HCl electrolysis [mn. mtpy Cl 2 ] BM2.7 single element technology BiTAC technology tkuce HCl electrolysis technology 6 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 3

4 Continuity of the technologies is secured The portfolio includes all technologies that the joining parties offered BM Single Element Technology made in GERMANY BiTAC Filter Press Technology made in JAPAN 7 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico Membrane Chlor-Alkali technology development strategy Two best in class machines in the same family Both modules will remain to satisfy the equal market base SYNERGY Some technology are being harmonized EVOLUTION Unique Concept Electrolyzer BM - Single Element BM - Single Element BiTAC - Filter Press BiTAC - Filter Press UCE- Single Element UCE - Filter Press May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 4

5 We come from a strong heritage of technology improvements History of BiTAC series 1994 BiTAC 2005 n-bitac The very first to adopt Fine anode mesh & Coil cushion + 1 sheet cathode mesh 2,200 kwh/t (6 ka/m2) The world s first zero-gap cell which made 6kA/m 2 operation possible 2,060 kwh/t (6 ka/m 2 ) Adopted 0.15mm Fine cathode mesh ,010 2,025 kwh/t (6 ka/m 2 ) nx-bitac All compatible The same activated area of m 2 9 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico The BiTAC family: setting standards in low power consumption The latest BiTAC generation in our portfolio is based on more than two decades of expertise and experience in filter press nx-bitac benefits Fine anode mesh reduces cell voltage (minimized gas stagnation) Smooth anode surface with no dents, thanks to unique spot-welding tip Superior separation of gas and liquid Single piece of cathode mesh to fill gap losses and maximize active surface Elastic cushion with large number of contact points, to decrease IR drop and make homogeneous distribution of current density Superior inner circulation to ensure uniform concentration and brine supply Sample reference: BorsodChem, Hungary (commissioned in 2005, 2006 and 2012). NaOH capacity: 200,000 mt/year.two different generations of BiTACs in a single cell room; first-generation BiTACs replaced by the latest nx-bitac in autumn May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 5

6 The design of the nx-bitac elements brings the following benefits: Cathode Anode Woven mesh Coil cushion Gas-liquid separation Fine anode mesh with smooth surface Downcomer The filter press technology utilized in the BiTAC series has specific advantages: Low sealing force required for gaskets Fast remembraning of complete electrolyzer Smaller maintenance area required Lower power consumption through joining anode and cathode compartments by explosion bonding 11 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico We come from a strong heritage of technology improvements History of BM series Power consumption in kwh/ t NaOH 1) 2,170 BM 2.7 v3 2,130 BM 2.7 v4 2,070 BM 2.7 v5 2,055 BM 2.7 v5plus 2,020-2,035 BM 2.7 v6 Performance Technology development cycle technical performance limit technical performance limit v3 v4 v5plus v5 Partners are enabler v6 elastic electrode structure rigid electrode structure Effort ) 6 ka/m 2, 90 C, 32 % NaOH gap zero gap 12 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 6

7 The BM2.7 single-element series: major energy savings from zero-gap technology Nearly 30 years after the first Uhde single-element, the highly successful BM2.7 series is now in its 6 th generation. Key benefits: Energy saving:increased utilizable area of membrane in full zero-gap Enhanced efficiency:uniform current distribution and release of gas bubbles No leaks: throughout service life, by unique sealing and hose systems Contact pressure independently controlled: direct forces on elastic element and membrane, irrespective of torque forces applied on bolts for the sealing system Extended membrane service life: optimal pressure window to ensure zero gap and minimize electrical contact losses Sample reference: Vestolit Marl, Germany (commissioned 2007). Capacity: 236,900 t/year of NaOH; 210,000 t/year of Cl2 13 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico Every BM2.7 single-element is fully assembled and tested before inserting it into the electrolyzer Cathode Anode Woven mesh Elastic element Current distributor Inner collecting channels Anode expanded mesh Downcomer BM2.7v6 advantages Unique sealing and hose system, 100% leakproof up to 4.7 bar g (operating pressure: < 0.5 bar g ) Roller suspension of each single-element ensures precise adjustment of stack compression Hard, long-wearing PTFE gaskets Assembly and testing of elements in clean area outside cell house. Elements can be stored for months. Fast and simple replacement. Only one type of element in electrolyzer (no end elements) 14 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 7

8 UCE will be the integration of technologies Unique Concept Electrolyzer 15 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico by integration of people and competencies: ONE team Unique technology tk UCE test facility HLT3 at CABB, Gersthofen tk UCE test facility OCT at CABB, Gersthofen tk UCE test facility 1dm 2 at Okayama tk UCE test facility 16dm 2 at Okayama Development path UCE Bench cells: already running since 2015 Full size prototypes: online 2016 Demonstration/qualification: 2017/18 Ready-to-market: May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 8

9 Unique Concept Electrolyzer Our targets: we strive to deliver best solutions for our customers and with our customers best performance PC < 2000 kwh/t NaOH (at 6 ka/m 2 ) operability up to highest current densities (8 ka/m 2 ) efficiency and products quality durability/reliability by sharing platform and common architecture, selecting and utilizing best available design solutions by working close with our partners for coatings, manufacturing, membranes, components, operation keep compatible for filter press (BiTAC) replacement as well as for single element (BM) previous generations platform will be extended in future also to other applications as NaCl-ODC, HCl-ODC, Alkali Water Electrolysis 17 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico Oxygen-depolarized cathode: quantum leap in sustainability NaCl-ODC electrolysis developed in collaboration with Covestro and IDN offers distinct advantages. ODC benefits: O 2 fed to the cathode compartment suppresses the formation of H 2, resulting in a reduction of cell voltage from around 3 V to 2 V Up to 25% less energy consumption than conventional technology Ecologically valuable: lower CO 2 emissions BM2.7 and ODC technologies combinable in a single plant Reliable, proven technology Higher degree of site flexibility 18 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 9

10 HCl Electrolysis: Chlorine recovery for greater sustainability HCl Electrolysis: Ecological responsible Business independent of Cl 2 and HCl prices Avoids traditional chlor-alkali plants, with higher capital expenditure Interesting for regions with high Cl 2 demand or excess NaOH Eliminates risks of transporting Cl 2 No costs for HCl neutralization or disposal With ODC: Energy savings up to 30 % compared to diaphragm electrolysis No H 2 production Wide and flexible plant operation Electrolyzer design ensures maintenance flexibility and potential capacity increases Proven and reliable technology HCl recycling can be implemented in many Cl 2 consuming processes Is your HCl feed suitable? Test it and see! (1) Deploy our lab cells (2) See for yourself: our mobile HCl ODC test skid (3) New full-scale facility high-load electrolyzer ( HLT4 ): up to 7 ka/m²; two separate anolyte circuits; test and qualify pretreatment steps May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico Skid-mounted technology: solutions for cost-effective chlorine production Several innovations in our contract-execution concepts are specifically designed to make cost-effective, space-saving chlorine production possible. Compact cell house design Benefits of skid-mounted plants Standardized engineering for optimized costs Process simplification to reduce costs Fewer civil and erection works on site Lower capital expenditure risks Much faster project schedule than conventional plants 20 May 16, 2017 Euro Chlor tk UCE leading chlorine production technologies Fulvio Federico 10

11 Thank you 11