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KLORIGEN KLORIGEN KLORIGEN KLORIGEN On-site Generation of Chlorine & Sodium Hypochlorite “Bringing Technology to Life……”

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Page 1: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGENKLORIGENKLORIGENKLORIGEN™™™™

On-site Generation of

Chlorine & Sodium Hypochlorite

“Bringing Technology to Life……”

Page 2: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

DISCUSSION TOPICS

Section I Disinfection Practices Comparison

Section II Klorigen™ Technical Overview

Section III Advantages & BenefitsSection III Advantages & Benefits

Section IV Chlor-Alkali Industry Trends

Section V Organization

Page 3: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Section I

Comparison of Chlorine Based Disinfection Practices

Page 4: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

CHLORINE BASEDCHLORINE BASEDDISINFECTION OPTIONSDISINFECTION OPTIONS

• Pressurized Chlorine Gas

• Bulk Delivered Sodium Hypochlorite

• On-site Low-strength Hypo Production

• On-site Chlorine Gas Generation

• On-site High-strength Hypo Production

Page 5: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

PRESSURIZED CHLORINE GAS

• An effective and efficient broadband disinfectant

• Low operating cost

• 100 years of experience

• Generally accepted worldwide• Generally accepted worldwide

• Hazard to local community due to possibility of large scale toxic release

• Risk management requirements and insurance increasingly add to total operating costs

• Pending U. S. legislation is expected to restrict use and require specific training and licensing

• Chlorine cylinders subject to damage and theft

Page 6: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

BULK DELIVERED BULK DELIVERED SODIUM HYPOCHLORITESODIUM HYPOCHLORITE

• Safer alternative to pressurized chlorine gas

• Liquid is easier to contain & manage

• Higher and more volatile cost• Higher and more volatile cost

• Degrades with time and temperature

• Injection system different than chlorine gas

• Special transportation & storage concerns

• Reliance on third party suppliers

• Increasingly subject to supply interruptions

Page 7: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

LOW STRENGTH LOW STRENGTH ONON--SITE HYPO PRODUCTIONSITE HYPO PRODUCTION

• Less dependence on third party suppliers

• Weak concentration: 0.4 to 0.8% (household bleach is 5.25% )

• Lower degradation rate is better for long storage periods• Lower degradation rate is better for long storage periods

• Maintenance can be complex and frequent

• High capital and operating costs

• Outputs all un-reacted brine with the sodium hypochlorite

• Low grade salt results in impurities entering the water supply

• Excessive fouling of electrodes common and dangerous

• Requires significant product storage

• Metering equipment is specific to low-strength hypo

Page 8: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

ONON--SITE CHLORINE GAS SITE CHLORINE GAS GENERATIONGENERATION

• Elemental chlorine gas delivered on-demand

• System operates at or below atmospheric pressure

• Safe – no storage and no cylinder handling

• Cost effective – incorporates proven chlor-alkali technology

• Reliable - same process as used by major chlor-alkali

companies (PPG, Olin, Clorox, Dow, Pioneer, Monsanto)

• Addresses the “political cost” of keeping chlorine gas

• Exclusively KLORIGEN™

Page 9: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

HIGH STRENGTH HIGH STRENGTH ONON--SITE HYPO PRODUCTIONSITE HYPO PRODUCTION

• Reliable - same process used by major chlor- alkali companies

• Membranes eliminate routine anode fouling and acid washing• Membranes eliminate routine anode fouling and acid washing

• Hypo generated operator selectable 5% to 12.5% (trade)

• Eliminates need for bulk transport and excessive storage

• High purity sodium hypochlorite equal to or better than bulk

• Very stable cost structure, subject only to salt and electrical price

• Exclusively KLORIGEN™

Page 10: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

EFFICIENCY COMPARISON(per lb of equivalent chlorine generated)

15Klorigen

Low strength on-site hypo

0.951.75 1.65

3.0

2.2

Power

(kWh)

Salt

(lbs)

Water

(gallons)

Page 11: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Sodium Contribution Comparison - 12.5% Klorigen Hypo, 0.8% Hypo

14

16

18

20

pp

m N

a i

n T

rea

ted

Wa

ter

Klorigen 12.5% Hypo

0.8% Hypo

Sodium Contribution Comparison

12.5% Klorigen™ Hypo vs. 0.8% Low Strength

0

2

4

6

8

10

12

14

1 2 3 4 5 6 7 8 9 10

mg/L Cl2 Dosage Per MGD Water

pp

m N

a i

n T

rea

ted

Wa

ter

Page 12: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

GENERATION COST COMPARISONS

Klorigen™

Material Cost Material Usage

Operating Cost

Salt 0.09 / lb 1.65 pounds 0.1485

Water 0.003/gallon 0.95 gallons 0.0285

Power 0.06 / kWhr 1.75AC kWhr 0.105$0.32 / pound

0.8%

Life-cycle 0.037/ lb various 0.037

Material Cost Material Usage

Operating Cost

Salt 0.09 / lb 3.0 lbs 0.27

Water 0.003/gallon 15 gallon 0.045

Power 0.06 / kWhr 2.5 kWhr 0.15

Life-cycle 0.020/ lb various 0.02

$0.49 / pound

Page 13: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Hypo Generating Costs

Page 14: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

DRIVING FORCES FORDRIVING FORCES FOR

ONON--SITE HYPO PRODUCTIONSITE HYPO PRODUCTION

•Safety - Reduce or eliminate truck traffic and large quantity storage of hazardous chemical

- Consistent with efforts to eliminate stored chlorine- Consistent with efforts to eliminate stored chlorine

• Good Community Relations- No off-site consequences- No worst case emergency planning- Reduced threat from accidents or terrorism

Secure, Low Cost Raw Material Supply- Salt instead of chlorine and caustic soda- Stable pricing

Page 15: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

DRIVING FORCES FORDRIVING FORCES FORONON--SITE HYPO PRODUCTIONSITE HYPO PRODUCTION

•Reduced Cost to the City - On-site high-strength generation costs less thanbulk delivered chemical

• Solution Flexibility- Hypo can be generated in one central facility or in distributed modular plants

- Generation can be by City personnel or private sector contract

- Various capital cost recovery options available

• On-Demand Facilitates “Steady-State” Process

- Hypo is always pure, and similar concentration

Page 16: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Section II

Klorigen™

Technical Overview

Page 17: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™ DEVELOPMENT

• Operating concept based on conventional chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today

• Process very similar to large scale chlor-alkali plants that typically produce in excess of 1000 tons of chlorine per day

• Equipment re-engineered by ETC for commercial and water utility markets using NSF-certified materials, robust membranes and advanced electrode technology (DSA) for on-site applications

Page 18: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™

Electrolyzer Module

Page 19: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™ PROCESS FLOW CHART

POSITIVEVENTILATION

HYPOCONVERSION

UNIT

Safely Diluted HydrogenDischarge To Atmosphere

EDUCTOR

EDUCTOR

Klorigen System Limits

Chlorine

Backup Eductor LineWater Supply

Sodium HypochloriteTo Storage

VENTILATIONUNIT

xxx CFM

MAKE-UPUNIT

50% NaOH

MAKE-UPUNIT

50% NaOH

UNIT

DCRECTIFIER

DCRECTIFIER TREATMENT

UNITTREATMENT

UNIT

ELECTROLYZERUNIT

ELECTROLYZERUNIT

480 VACPower

SALTDISSOLVER

SALTDISSOLVER

DCCurrent

Potable Water

Recirculating(Cooling)

Water

SoftenedWater

SoftenedWater

Food GradeSalt

Klorigen System Limits

PurifiedBrine

SaturatedBrine

DepletedBrine

Caustic

Page 20: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™ ELECTROLYZER

CL–

H+

Chlorine GasHydrogen Gas

Sodium Hydroxide

DC Power

Depleted Brine

OH–

H+

Anode

Membrane

CathodeNa+

OH–

BrineWater

Page 21: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™ MODEL K6 (1500 gpd)

Page 22: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™ MODEL K6

Page 23: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™ MODEL K6

Page 24: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

WATER & BRINE TREATMENT MODULE

Page 25: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN™ 40,000 ppd

Page 26: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Salt Handling System

Heated

Page 27: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Salt Supply Types

Type of salt NaCl Mg Ca SO4 BrAnticaking

AgentsInsolubles

wt% wt% wt% wt% ppm wt%

Morton Culinox 999 Morton Culinox 999

Food grade99.98 0.0001 0.002 (5 - 20 ppm) <0.02 50 ppm none trace

Pure Vacuum

Evaporated salt99.95 0.0001 0.002 (5 - 20 ppm) 0.04 50 - 500

SiO2, or

Sodium

Ferricyanide

trace

Solar salt* 96 - 99 0.01 - 0.17 0.04 - 0.30 0.11 - 2.0 100 - 2,000 1.0 - 4.0

Rock salt* 90 - 99 0.01 - 0.17 0.04 - 1.1 0.2 - 1.31000 -

10,0001.0 - 8.0

* Arsenic, copper, lead, mercury?

Page 28: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

SODIUM HYPOCHLORITE FEED PUMPS

Page 29: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Remote Monitoring (WonderWare example)

Page 30: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Klorigen™ M-Series SystemHypochlorite Process Footprint

Process Unit – Electrolyzer

Chlorine and NaOH Generation

Water SoftenerPackage with Filters

24”L x 24”Wx48”H

50% NaOH Drum w/PumpApproximate Dimensions(200 lb/day Cl2 System pictured)

48” Dia x 45” tall

300 gal Salt TankHDPE

85” L x 48” W x 76” H

500 gal NaOH TankHDPE

48” Dia x 68”H

Control Cabinet withPLC & Power Supply

24”L x 24”W x 60”H

14 ft

19.5 ft

Page 31: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Section III

Features & Benefits of the Klorigen™ System

Page 32: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

FEATURES

• Automatic chlorine gas and/or hypo production

• Gas is generated on-demand at less than one

atmosphere (system is at negative pressure at all times)

• Adjustable output via local or remote SCADA control

• Low maintenance and operating costs with high NPVs

• Modularization facilitates future expansion as demand grows

• Operational turndown from 10 to 100 % of rated output capacity provides consistent operating efficiencies

Page 33: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

BENEFITS

• Retain your current disinfection practice – either

chlorine (gas) or sodium hypochlorite (liquid)

• Safest on-site chemical production method

• Fully automated – minimum operator intervention • Fully automated – minimum operator intervention

• Highest salt and power efficiency of any on-site generation process

• Cost competitive with most treatment practices

• Chlorine gas process can simultaneously supply valuable sodium hydroxide at no additional cost

Page 34: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

ANSI/NSF 60

“Required for Drinking Water Chemicals”

Page 35: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

SAFETY

• Never more than 3 lbs of chlorine gas in the system

• Chlorine is at atmospheric pressure eliminating potential

for significant toxic release as with conventional one ton

cylinders and tank cars

• System is equipped with numerous safety devices designed to

shut down system if a malfunction occurs

• Membrane grade (very pure) sodium hydroxide is produced

at 15% concentration and is safer for personnel handling

• Chlorine gas and sodium hypochlorite are produced on-demand

• Safest chlorine-based water disinfection alternative available

• Transport, storage & handling of chlorine and hypo are eliminated

Page 36: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

HYDROGEN BY-PRODUCT

• Naturally formed through electrolysis of brine

• Intrinsically safe moisture-laden H2 is further diluted through positive ventilation

• Less than 2% of Lower Explosive Limit (LEL) and safely vented to atmosphere

Page 37: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Other Differences Between

0.8% vs. 12.5%

Page 38: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large
Page 39: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Danger of Un-separated CellsEmployed in 0.8% Systems

Page 40: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Carbon FootprintComparing Low vs. High Strength Processes

Example: Equipment production capacity of 5 TPD of equivalent chlorine as sodium hypochlorite:

0.8% 12.5% Difference

Constituent Constituent (lbs CO2) (lbs CO2) (lbs CO2) %

_____________________________________________________________

Electricity 34,001 27,819 6,182 18%

Water 540 34 506 94%

Transport (salt 40 mi) 114 64 50 44%

Transport (salt 400 mi) 1,143 643 500 44%

Page 41: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

• On-site electrolytic production equals significant savings

• State-of-the-art membrane electrolyzer and process technology

• Highest quality bleach at production costs lower than market

• Eliminates hazards related to pressurized chlorine handling & use

KLORIGEN ADVANTAGES

• Eliminates hazards related to pressurized chlorine handling & use

• Costs are controlled and predictable – dependent primarily on prevailing prices of salt and electricity as raw materials

• The Klorigen process resolves bromate issues in drinking water

• High concentration bleach provides savings in transport, storage while increasing product shelf life

• Reliable supply of chlorine gas or hypo without depending on third-party suppliers of caustic soda and chlorine

Page 42: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

KLORIGEN ADVANTAGES, continued

• Option to produce either sodium hypochlorite or chlorine gas

• Co-product NaOH can be employed to manage pH in chlorine gas applications

• Klorigen produced membrane-grade NaOH has less metal impurities and chloratesimpurities and chlorates

• Can produce up to 15% sodium hypochlorite concentration

• Materials of construction result in low chlorinated organics

• Utilization of food grade salt results in very low bromate levels

• Easily expandable, typically within original “footprint”

• Lowest carbon footprint of any chlorine-based alternative

Page 43: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Section IV

Chlor-Alkali Industry TrendsChlor-Alkali Industry Trends

Page 44: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

North America Chlorine Supply/Demand

TiO2 4%

Water Treatment 6%

Pulp & Paper 2%

HCl 3%

Epichlorohydrin 3%

Solvents 2%

Packaging 3%

Fluorocarbons 3%

Total Demand = 15 Million TonsSource: CMAI 2003 World Chlor-Alkali Analysis

PVC, EDC 39%

Propylene Oxide 11%

Inorganic/Organic 11%

MDI, TDI 13%

Page 45: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Chlorine Outlook for 2008 -2012

• Long Term chlorine DEMAND outlook growth of 2 – 2.5%

• Forecasted North American capacity will fail to keep the SUPPLY of chlorine in line with expected growth

• Dow recently ceased merchant sales – along with Formosa • Dow recently ceased merchant sales – along with Formosa Plastics, Shintech, Bayer, Westlake and GE - all 100% captive

• Only 3 suppliers including PPG & Oxy primarily dedicated to VCM – merchant supply mostly from Olin

• Chlorine (and hypo) re-packagers left to deal with higher costs, hazards, regulations, insurance and community relations issues to serve a shrinking market – it’s no surprise that some are exiting the business

Page 46: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Chlorine Shipping Issues

• Federally mandated plan to reroute trains with hazardous cargoes around densely populated areas

• Higher freight rates = 100-200% increase

• Lower speeds, longer delivery times

• New rail car design = $147,000+ per car

• Not all rail sidings will accommodate larger (90 ton) tank cars

• Increasing supply interruptions and force-majeures

Page 47: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Chlor-Alkali Industry Operating Rate and Hypo Prices

90%

92%

94%

96%

Glo

bal C

hlo

r -

Alk

ali O

pera

tin

g R

ate

$1.10

$1.30

$1.50

Bu

lk H

yp

och

lori

te P

rice -

$U

SD

Comparison of Bulk Sodium Hypochlorite Pricing Versus Klorigen System Costs

Bulk Hypo

Cost

Note: Hypo Price - Left hand scale, Operating Rate - Right

hand scaleSource: UBS Warburg, SRI for Hypo Price

76%

78%

80%

82%

84%

86%

88%

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

Year

Glo

bal C

hlo

r -

Alk

ali O

pera

tin

g R

ate

$0.30

$0.50

$0.70

$0.90

$1.10

Bu

lk H

yp

och

lori

te P

rice -

$U

SD

Source: UBS Warburg, SRI for Bulk Hypo Pricing

Klorigen System

Hypo Cost

Est.

Page 48: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

Section V

Organization

Page 49: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

ORGANIZATION

• Company founded in 2001 by current management to develop and commercialize on-site electrolytic chlorine generators for water treatment and commercial sodium hypochlorite production

• Initially funded by private investors and management; most employees are shareholders

• Only company in industry building small to medium sized chlorine gas and high strength generators specifically for on-site applications – up to 25 tons per day

• Product offerings span municipal, commercial, industrial, maritime and export markets

Page 50: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

MANUFACTURING

• All systems manufactured and assembled in U.S.

• 99% of components are American

• Thermo-welded plastic components

• Full machine and tool shop

• Customized electrical designs• Customized electrical designs

• FRP skid manufacture & assembly with 316 S/S fasteners

• Pre-delivery testing / certification

• ISO 9000-based quality control

• Installation support

• Operator Training

Page 51: “Bringing Technology to Life……” · 2011-11-24 · chlor-alkali membrane cell process technology, as used by major chlor-alkali companies today •Process very similar to large

PROCUREMENT OPTIONS

• Capital Purchase

• Project financing

• Third Party Lease / Purchase

• Chemical Product Supply (Build/Own/Operate)

• Maintenance Contract