CHLOR-ALKALI TECHNOLOGY

A Partnership for Life

Philip See (Business Development Manager)

Chartered Mechanical Engineer

26 Years in Chlor-Alkali with ICI/INEOS

Engineering Manager for

- 40 kte KOH Plant (ICI FM21 membrane electrolysers)
- 600 kte Chlorine Plant (ICI amalgam electrolysers)

Plant Design and Commissioning

- 430 kte Chlorine Plant (BICHLORTM Electrolysers)
- Technology benchmarking and operability studies

INEOS Overview

TURNOVER

$47

EMPLOYEES

PRODUCTION

15,000

BILLION

SITES

HERITAGE
AMOCO, BASF, BAYER,
BOREALIS, BP, DEGUSSA,
DOW, ENICHEM,
ERDOLCHEMIE, HOECHST,
ICI, INNOVENE, LANXESS,
MONSANTO,NORSK
HYDRO, SOLVAY

51 MANUFACTURING
PLANTS IN 11 COUNTRIES

GROWTH
HISTORY

15 Petrochemical/Chemical Businesses
Growth by acquisition since 1998
Worlds 4th largest independent chemical company

INEOS Technologies Portfolio and Heritage

LL/HD swing
Polyethylene
Acrylonitrile
Maleic
Anhydride
Expanded
Polystyrene

Polypropylene
Maleic
Anhydride

Chlorine
EDC
VCM
PVC

HD bi-modal slurry
Polyethylene

INEOS Technologies Locations

Lisle, IL
Nitriles/PP Catalyst

Grangemouth,
Scotland

Lima, OH
Naperville, IL

Nitriles Catalyst

Nitriles/PO/Olefins

Olefins
Lyndhurst, UK
PO

Chocolate
Bayou, TX
PP and Olefins

PO and
Performance
Chemicals

Runcorn, UK
Vinyls &
Electrochemical
Tech
Lavera, France

Green Lake, TX

Brussels,
Belgium

Venice, Italy

Rolle, Switzerland

Vinyls

Board

PO/PS

Nitriles

R&D/ Technical/ Manufacturing Centres

~400 people World-wide.
Extensive Intellectual Property and 6000 patents
Commercial Centres - Rolle (Switzerland), Lyndhurst and Runcorn
(UK), Lisle (USA), and Shanghai (China)

Shanghai,
China
Technologies
General

117 chlor-alkali projects over 30 years

Monopolar Cell rooms

BICHLOR Cell rooms

Americas Strong and Growing Presence

Company

Location

Year

HF Chlor-Alkali

USA

2014

Skymine

USA

2013

Fluoders

Paraguay

2013

Kuehne

USA

2001 / 2011

Olin

USA

2011 / 2014

FSTI/CSP

USA

2008

Allied

USA

2009

Lapsolite

Mexico

2006

Proquimsa

Ecuador

2005 / 2009

Proctor + Gamble

Guatemala

2003 / 2006

Successful Plant Lifespan Vital to INEOS ChlorVinyls

1800
1600
1400
1200
1000
800
600
400
200

BA
SF

lit
Vi
no

y
lva
So

n
lvi
So

m
a
Ar
ke

ye
r
Ba

zo
Ak

IN

EO
S

0
ow

A major European ChlorVinyls Manufacturer

2000

7 cell-rooms across Europe,

total capacity 1,600,000
MTPA Cl2

1000's metric tonnes of Chlorine per annum

A designer and operator of

chlorine plants for over 110
years

Successful Plant Lifespan Key Factors

Successful
Lifespan

Safe
Operation

Reliability

Efficiency

INEOS Runcorn Driving Continuous Improvement

430kte/yr chlorine

20 BiChlor electrolysers

Designed to Lifecycle Principles

INEOS Know-How applied

World Class Performance

Techniques A Structured Way of Working

1. Process
Description/
Purpose
Performance
of O Ring
carriers

2. Potential
Failure
Mode
Wrong
material
used in
manufacture

3. Potential
effect of
failure
Splits/cracks

4.
Sev
.
10

Dissolves/
Wear away
Chemical
Degrades

10

Thermal
Expansion
effect on
seal

10

Porous

10

Sticks to tup
tube

Cause
reaction
with other
materials/
products

10

5. Potential cause of
failure
Supplier changes RM
without informing ICL

6.
Occ
.
2

7. Current
Controls
None

Lifecycle Value Analysis

Critical Items Analysis

10. Recommended
actions

Change of BOM
Process Agreed
BOM integrating
into ETB systems

30

Change of supplier

Specification QA
systems &
registration

60

Generate approved
supplier list

Raw materials to
supplier changes
without their
knowledge

4/5

Specification
maybe not detailed
enough QA
systems &
registrations

450

Review
specification &
produce audit trial
& review
Specifications
agreed with
supplier.

Lack of detailed
agreed specification

10

Operator inspection
& operational
experience

900

10

100

Establish if there is
Shelf life
Develop Stock
rotation process
Develop robust spec

None
-

shelf life
not known
no stock
rotation

11.
Responsibility/
start date

12. Action Results

200

Dimensional
ly wrong

9.
RPN

Supplier changes RM
informs ICL

Shelf Life:
- Components

Performance
of O Ring
carriers

8.
Det
.
10

Too Narrow
Cant
Assemble

Supplier delivers
outside of spec

Drawings
Operator

48

Too Wide
Leaks in
service

10

Supplier delivers
outside of spec

Drawings
Operator
Cell room
measurements

720

Carry out QC Check

on tolerances
Sample test

Loss Elimination - FMECA

Risk Based Inspection

INEOS Technologies Team Chlorine Experienced

Design
Engineers

Project
Commissioning
Managers

Scientists

INEOS
TEAM

Technical
Managers

Plant Engineers

Plant Managers

Safe Operation

Successful
Lifespan

Safe
Operation

Reliability

Efficiency

Safe Operation Built In

Modular Technology AvoidsJ..

Interaction with live electrolysers
Leaks modules are bolted, sealed & pressure tested

Fully Wetted Membrane

Gas/Liquor interface above the membrane
Avoids damage and pin-holing of membrane
Prevents mixing of Cl2 / H2 to avoid explosions

Safety in Plant Design

Inherently safe design features
HAZOP

Reliability

Successful
Lifespan

Safe
Operation

Reliability

Efficiency

Reliability INEOS has the Knowledge

Accessible
Headers

High Integrity
Design

Stray
Currents

Optioneering

Rapid Module
Change

Dynamic
Modelling
Materials of
Construction

Robust electrode
coatings

Layout analysis

Reliability Avoiding Damaging Pressure Excursions

P02
(-20
mbarg)

PCV 01B

185 mbarg

Chlorine

SD1
PIC
01A

PIC
01B

V01
(10 BiChlor
Electrolysers)

205 mbarg

dP02
(Headers and
coolers)

Stream 01

SD1
dP03
(Headers,
dryer,
filter)

V02
(Headers
and coolers)

Stream 02

V03
(Headers,
dryer, filter)

P13
(165
mbarg)

Stream 11

dPIC
11B

dPCV 11B

dP = +15 mbar

dPIC
11A

V11
(10 BiChlor
Electrolysers)

P03
(xxx barg)

Stream 03
P12
(0 mbarg)

Hydrogen

PCV 01A

Dynamic model of the gas section downstream of electrolyser

Simulate transient events cellroom trip, electrolyser trip, load
changes

dP = + 25 mbar

dP12
(Headers and
cooler)

V12
(Headers
and cooler)

Stream 12

SD1

dP13
(Headers,
filter)

V13
(Headers,
filter)

dPCV 11A

PV 12

Stream 13

Model validated by comparing DP

predicted by model with plant data
Large negative DP excursion
improvement required

Model used to develop control scheme to avoid reverse DP

Excellent system response

Efficiency

Successful
Lifespan

Safe
Operation

Reliability

Efficiency

Power Efficiency At the Heart of BiChlor

Module low voltage dimple design

Max use of nickel post in cathode pan

Min use of titanium post in anode pan

Explosion bonded Ti/Ni discs for

excellent inter-module connection

Zero gap electrodes

Self aligning modules

Efficiency 30 Years of Coatings Development

Anode Coating
Lower power consumption
Greater resistance to Alkaline
wear

voltage
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

350

Cathode Coating
Highly resistant to upset
conditions
16 year warranty

Modern coating plant and

extensive refurbishment
centre

Potential (mV)

300
250
200
150

70
70
70
70
70
70
70
70
70
70
70
71
72
73
75
82
100
0

70
70
72
74
77
80
95
135
320
70
72
74
77
80
95
135
320

Comparision of Coating Performance

0
0
2
4
7
10
25
65
250
0
2
3
5
7
20
53
220

8
9
10
11
12
13
14
15
16

70
70
72
74
77
80
95
135
320

100
50
0
0

10

12

Years on line
INEOS COATING

COMPETITOR COATING

14

16

Efficiency Accessing our Operations Expertise

Designated Technical Service Manager

Experienced chlor-alkali specialist
Usually member of original commissioning team
Regular visits and contact

Getting the most from your plant

Performance evaluation
Operating and Technical support
Electrolyser maintenance planning

Customer forum every 2 years

Technical and Social content
Highly valued by clients

Efficiency Evolution not Revolution

Power Consumption (KWh/te

NaOH)

BICHLOR Start-up Power Consumption vs Current Density

2450
2350

2003

2250

2007

Incremental
improvement

2010

2150

2012

2050

2014

1950
1850
1750
1650
0

current density (KA/sq.m.)

INEOS A Partnership for Life

Unrivalled knowledge of chlor-alkali technology

and operations
Technology built to perform over the long term
A partnership for the long-term