Chlorine Dioxide Production from Chlorine
Chlorine Dioxide Production Costs Report | Issue B | Q3 2024
| Report Details |
| 10 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 10 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study presents the costs associated with the construction of a plant for Chlorine Dioxide production from chlorine in the United States. Initially, sodium chlorate is produced from caustic soda and hydrochloric acid solution via electrolysis. Hydrogen and chlorine are reacted in a furnace to form the pure hydrogen chloride. The sodium chlorate formed is then reduced with the hydrogen chloride to chlorine dioxide.
The report provides a comprehensive study of Chlorine Dioxide production and related Chlorine Dioxide production cost, covering three key aspects: a complete description of the Chlorine Dioxide production process examined; an in-depth analysis of the related Chlorine Dioxide plant capital cost (Capex); and an evaluation of the respective Chlorine Dioxide plant operating costs (Opex).
The Chlorine Dioxide production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Chlorine Dioxide plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Chlorine Dioxide plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises two major sections: (1) sodium chlorate synthesis; and (2) sodium chlorate reduction.
Sodium Chlorate Synthesis. A brine solution recycled from the Sodium Chlorate Reduction section is subjected to electrolysis, forming sodium chlorite and hydrogen. Sodium chlorite is converted into sodium chlorate through a chemical reaction, that begins to occur in the electrolyzers and is only completed in the retention tank downstream. The hydrogen formed leaves the electrolyzers as a gaseous stream and is passed through two scrubbing stages before being routed to the hydrogen chloride furnace in the sodium chlorate reduction section.
Sodium Chlorate Reduction. The hydrogen gas is fed to a furnace together with a fresh chlorine feed for production of hydrogen chloride. The hydrogen chloride generated is cooled and sent to the Chlorine Dioxide Generators, where it is used in the reduction reaction of the sodium chlorate sent from the retention tank. The reduction reaction generates Chlorine Dioxide, sodium chloride, water and chlorine. Sodium chloride is recovered and recycled as a brine solution to the sodium chlorate synthesis section. Chlorine Dioxide, in turn, leaves the reactor as a gaseous stream along with chlorine. That gaseous stream is fed into absorber columns, from which a Chlorine Dioxide solution is obtained. Unabsorbed chlorine is washed with a dilute sodium hydroxide stream, thus forming a sodium hypochlorite solution.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Chlorine Dioxide production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Chlorine Dioxide process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Chlorine Dioxide production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Chlorine Dioxide plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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