Recent Development of Asahi Kasei Chemicals’ IM Technology to reduce Power consumption

Februay 25, 2009

Asahi Kasei Chemicals Corporation

Contents
1. About Asahi Kasei
2. Recent Activities in the Chlor-Alkali Business 3. Features of the Existing Electrolyzer 4. The Next Generation Cell (NCZ2) 4. Latest membrane 5. Summary

Number of employees (as of March 31. 2008) Net sales Income before taxes Net income Total assets 4.056 699 14. Financial highlights (For the year ended March 31. Asahi means 2.854 Sales composition for the year ended March 31.968 1. 2006) Total of AKC and its subsidiaries 5. Establishment of the company 3. 2008 52% 23% 6% 7% 7% 3% 2% 3 . Profile of Asahi Kasei Chemicals Corporation (AKC) 1. Engineering and others   “Rising Sun” 1931 16.254 Million of US $ Million of US $ Million of US $ Million of US $ 23.1. Business activities Chemicals Homes Pharma Fibers Electronics Materials & Devices Construction materials Services.

2005) Asahi Kasei Corporation Net Sales 13.879 M$ R&D Asahi Kasei Chemicals Net Sales 6.Profile of Asahi Kasei Chemicals Corporation (AKCC) (Split up at April. ----- Asahi Kasei EMD Asahi Kasei Construction Materials Asahi Kasei Life & Living Total 18 Divisions 4 . Asahi Kasei Fibers Energy Dev.432 M$ Asahi Kasei Homes Asahi Kasei Pharma Mizushima Works Kawasaki Works Ion Exchange Membrane Div.

Polyethylene Div. PC Div. PMMA sheets Synthetic rubbers. thermoplastic elastomers. Additives for Pharmaceuticals & foods.5 PVDC coatings Polycarbonate ( Chimei-Asahi Corporation ) Ion Exchange Membranes Div. electrolysis & electrodialysis systems Performance paper. acetonitrile. ammonia. Chlorine. PMMA. ABS & SB Latex Div. Purging compounds PP compound. industrial cleaning agents Industrial explosives. Adipic acid. Olefins.Business Configuration of Asahi Kasei Chemicals Basic Chemicals Div. Industrial Membranes Div. others AN. mPPE. others Nylon & Urethane Intermediates Div. Performance Plastics Div. epoxy resin. SAL ) . high styrene resins Ultrafiltration & microfiltration membranes. Methacrylates Div. others Photosensitive resins. fertilizers. SBL Functional Additives Div. others Acrylonitrile Div. POM. others Nylon66. Synthetic Rubber Div. high performance PE ABS. HDPE. Imaging Div. PS ( PS Japan. Performance Coating Materials Div. MMA monomer. Inorganic Chemicals Div. LDPE. detonators. engineering plastic compounds HDI. Energy Div. others Explosives Div. Plastic Compounds Div. SM. Others PS Coordination Div. fine porous membranes Ion-exchange membranes. others Power supply Caustic Soda. cyclohexanol. AS.

2008) 6 .AKCC Users’ Plant Location (Total 105 ) AKZO Nobel Chemicals B. BASF.V. Delfzijl Merseburg & Stade Rotterdam & Dow Chemical .778kT-NaOH/yr (as of Sep. Ludwigshafen Load Alkali Hindustan Organic Chem DSC Shriram Gujarat Fluorochemicals Grashim Industires Chemplast Sanumar Durgapur Chemical Megmani Fine chem Universal Russia Europe North America China 1 7 7 46 India Oceania Africa Japan Other Total 10 2 2 10 20 105 Total Capacity 17..

Overview of Electrolyzer Types Forced Circulation Power Consumption Natural Circulation (NCS.H.Z.compatible) Finite gap Zero gap NCH 19972038 kwh at 4kA/m2 FC 19752066 kwh at 4kA/m2 NCS 19912066 kwh at 4kA/m2 NCZ 20031934 kwh at 4kA/m2 2070 kwh at 6kA/m2 2226 kwh at 6kA/m2 Low 4.5kA/m2 6kA/m2 7 .

878kt/yr as of Feb 2008 .NCZ) 20034.NCS.803 kt/yr NCZ24% NCS17% 19978.NCH.979 kt/yr Note: FC : Forced circulation type cell NCS: Natural circulation type cell (standard) NCH: Natural circulation type cell (high current density) NCZ:Natural circulation type cell(zero gap) Total 15.742 kt/yr NCH49% 19912.Comparison of Cell Type (FC.257 kt/yr 1975FC10% 1.

Brine acidification 4. Gas pressurization 5.Features of Asahi Kasei Electrolyzers 1. Quick. Filter press design and rigid structure with metal header 2. easy maintenance and membrane replacement 3. Easy update modification of a cell (NCS&NCH →NCZ cell) 9 .

Features of Asahi Kasei Electrolyzers 1 Filter press design and rigid structure with metal header 10 .

easy maintenance and membrane replacement 11 .Features of Asahi Kasei Electrolyzers 2 Quick.

Features of Asahi Kasei Electrolyzers 3&4 Acidification and Gas Pressurization 12 .

0 O2/Cl2 % 2.0 3.5 3.0 0.0 1.5 1.5 Injection of HCl 0 88 90 92 94 96 98 100 Current Efficiency % 13 .5 No injection of HCl 2.Features of Asahi Kasei Electrolyzers 3&4 Acidification and Gas Pressurization 4.

Features of Asahi Kasei Electrolyzers 5 Easy modification to zero-gap cell Overview New Cathode Used Cathode (Current Cell bottom collector) Anode Mattress Rib Membrane 14 .

99V 2070kwh NCZ2 2010 (Expected) 8kA/m2 2.Next Generation Cell NCZ Market Entry Normal Operation Performance at 6kA/m2 2003 6kA/m2 2.90V 2004kwh 15 .

NCZ2 Concept Design • Lower Cell Voltage & Reliability 1) Mattress compression optimization 2) New catalyst and configuration of electrodes ・ minimization of gas influence ・ lower overvoltage and longer durability • Higher Current Density Operation 1) More uniform concentration distribution with inner part design 2) Better separation of gas & liquid 16 .

00 0.Cell Voltage Components at 6kA/m2 Electrolyzer Decomposition Voltage Anode Overvoltage Membrane Resistance + Donnan Potential NCH NCZ NCZ2 2.02 0.25V 2.21 0.08 0.90V 17 .23 0.51 0.07 0.02 2.99V 0.14 0.) 0.09 Total (expected) 0.07 3.06 Cell Structure Catholyte Loss Cathode Overvoltage Others (Gas influence etc.02 0.

0V/0. Membrane) 3.7 1.3 3.7 2.1 2.9 2.5 3.2*1.7 3.97*18Mt/yr=1.000kt-CO2/yr 18 .CV Improvement in AKC Technology (Cell.1 1.9 1.1*1013wh/y=6.5 6kA/㎡ 4kA/㎡ Cell Voltage (V) FC 1975- NCS 1991- NCH 1997- NCZ 2003- NCZ2 2010GDE 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 670.5 2. Electrode.3 2.9 3.

Try New ‘Aciplex F6801’ Membrane ■ Save Power Costs Help the Environment Make More Profit 19 ■ ■ .

2) AciplexTM-F membrane can be used for KOH production.Overview of Membrane types No Sacrificial threads channels Sacrificial threads channels Low Cell Voltage For high current density with low Cell Voltage Power Consumption Mechanical Strength F4600 Series F4200 Series F4400 Series Low Latest version Superior properties F6800 Series 1) AciplexTM-F membranes has F2200 series for low concentration caustic (20~24% NaOH) production. Please consult with Asahi personnel. 20 .

Key Technology of New ‘Aciplex F-6801’ ■ Low Power Consumption High Mechanical Strength High Durability against Impurities 21 ■ ■ .

5mm gap.5 2007 97. 1. 22 .95 F4403D 2. COH=32%. Temp.Point 1: Low Power Consumption Items Cell Voltage (V) Current Efficiency (% ) Power Consumption (kWh/t-NaOH) F6801 2.0 2038 Conditions : CD=4kA/m2.5 2027 97.92 F4404 2. CCl=205g/l.=90℃. AK Lab  Low PC will contribute to save power costs.95 97.

CEC. UHDE. AGC etc.Why Don’t You Try New ‘Aciplex F-6801’ ? ■ Fit to Any Technologies & Any Gaps (AKCC.) Fit to Middle-High Current Density (4-8kA/m2 in Commercial Plant) Supplied more than 220.000m2 23 ■ ■ .

2) AKCC developed 4 types of electrolyzer.Summary 1) AKCC has developed IM electrolysis technology for more than 34 years. 4) AKCC will continue to improve IM membranes. 24 . 3) AKCC will continue to improve Electrolysis Technology such as NCZ2 & GDE (Gas Diffusion Electrode) with lower power consumption and reliability.