“bringing technology to life……” · 2011-11-24 · chlor-alkali membrane cell process...
TRANSCRIPT
KLORIGENKLORIGENKLORIGENKLORIGEN™™™™
On-site Generation of
Chlorine & Sodium Hypochlorite
“Bringing Technology to Life……”
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
Section I
Comparison of Chlorine Based Disinfection Practices
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
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
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
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
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™
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™
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)
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
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
Hypo Generating Costs
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
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
Section II
Klorigen™
Technical Overview
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
KLORIGEN™
Electrolyzer Module
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
KLORIGEN™ ELECTROLYZER
CL–
H+
Chlorine GasHydrogen Gas
Sodium Hydroxide
DC Power
Depleted Brine
OH–
H+
Anode
Membrane
CathodeNa+
OH–
BrineWater
KLORIGEN™ MODEL K6 (1500 gpd)
KLORIGEN™ MODEL K6
KLORIGEN™ MODEL K6
WATER & BRINE TREATMENT MODULE
KLORIGEN™ 40,000 ppd
Salt Handling System
Heated
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?
SODIUM HYPOCHLORITE FEED PUMPS
Remote Monitoring (WonderWare example)
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
Section III
Features & Benefits of the Klorigen™ System
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
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
ANSI/NSF 60
“Required for Drinking Water Chemicals”
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
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
Other Differences Between
0.8% vs. 12.5%
Danger of Un-separated CellsEmployed in 0.8% Systems
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%
• 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
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
Section IV
Chlor-Alkali Industry TrendsChlor-Alkali Industry Trends
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%
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
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
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.
Section V
Organization
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
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
PROCUREMENT OPTIONS
• Capital Purchase
• Project financing
• Third Party Lease / Purchase
• Chemical Product Supply (Build/Own/Operate)
• Maintenance Contract