16th Chlorine Symposium

Retrofitting technologies for the best cost-value-ratio

15th – 17th June, 2016 D. Donst and T. Hamada
thyssenkrupp Uhde Chlorine Engineers GmbH
Key Statements

Purpose

Modification of existing cell elements from finite gap to Zero Gap technology

Benefit

• technology based on the latest developments in Zero Gap Technology

Performance
• significantly reduced power consumption to 2,055 kWh/t NaOH100%

• 5+21 clients around the world successfully tested v3/v4-ZG and i-BiTAC
Lifetime
• 3+4 years qualification of retrofitted elements in an industrial scale achieved

• customized solutions result in ROI with less than 2 years

Life cycle costs
• 20 years of experience and a wide supplier and manufacturing partner network

Customized solutions for the best cost-value-ratio

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

2 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Agenda

• Key statements

• Retrofit of BM2.7 gen. v3 & v4 to Zero Gap Technology

• Retrofit of i-BiTAC to Zero Gap Technology

• Project execution

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

3 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Significantly reduced power consumption by retrofitting

Technology development cycle Power consumption in kWh/t NaOH100%*)

*) at 6 kA/m2 (90°C, 32 % NaOH)

2170
technical performance limit

Power consumption
v3
Performance

v6 2130
technical performance limit v4
v5plus 2070
v3/4-ZG v5
v5 2055 2055 2055
v4 v3-ZG v4-ZG v5plus
2020-2035
v3
v6

Effort 1997 2005 2008 2011 2012

elastic electrode structure
rigid electrode structure

Performance improves after retrofit by 5% (compared to new v3 elements)

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

4 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
190 kWh/t benefit in power consumption for v3/v4-ZG vs. recoated v3
std. power consumption on 6 kA/m2

v3 recoated
v3/v4-ZG
[ kWh/t NaOH 100% ]

end of test

-190 kWh/t NaOH100%

Days on line

Power consumption reduced by 9% after retrofit (compared to recoated v3 elements)

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

5 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Qualified modification of BM2.7 gen. v3/v4 to BM2.7 v3/v4-ZG

Anode halfshell
• Removing of anode distance strips (not needed anymore, zero gap!)

• Welding of new mesh electrode, (coated) onto existing louver electrode

Cathode halfshell
cathode halfshell

• Removing of cathode distance strips (not needed anymore, zero gap!)

anode halfshell

• Mechanical treatment of the cathode halfshell and installation of elastic

element (after modification also at client’s site or in UCE/DeNora workshop)

• Installing of new coated cathode electrode as woven mesh

(at client’s site or in UCE/DeNora workshop)

Cell element
• Installation of special frame gasket and high performance membrane

• Installation of anode and cathode flange on wheels

Installation/exchange of elastic element and cathode electrode can be done at client’s plant
16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016
6 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Impressions of v3/v4 retrofitting

Reliable manufacturing procedure with high quality standards

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

7 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Wide range of operating experience with v3-ZG / v4-ZG: overview

No. of Days
Generation elements online Country
BM2.7 gen. v3-ZG 284 700 China, plant A
China, plant B,
4 170 test finished

6 1,000 Germany, test facility

BM2.7 gen. v4-ZG 4 500 China, plant C

4 290 India, plant D

4 70 India, plant E

4 10 Germany, plant F

6 1,000 Germany, test facility

Successful qualification of v3/v4-ZG in client’s plant around the world

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

8 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Agenda

• Key statements

• Retrofit of BM gen. v3 & v4

• Retrofit of i-BiTAC

• Project execution

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

9 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Reduction of power consumption for different BiTAC types by i-BiTAC

Technology development cycle Power consumption in kWh/t NaOH100%*)

technical performance limit 2200

Power consumption
Performance

nx-BiTAC BiTAC
technical performance limit n-BiTAC

i-BiTAC 2060 2065

n-BiTAC i-BiTAC
BiTAC
2010-2025
nx-BiTAC

Effort 1992 2005 2014

elastic electrode structure
rigid electrode structure

Performance improves after retrofit by approx. 6% (compared to new original BiTAC )

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

10 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Lowering of power consumption by 200 kWh/t:
original BiTAC vs. i-BiTAC
std. power consumption on 6 kA/m2
[ kWh/t NaOH 100% ]

-200 kWh/t NaOH100%

Days on line

Power consumption reduced by approx. 9% after retrofit (compared to original BiTAC)

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

11 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Simple and qualified modification of BiTAC to i-BiTAC

Anode side
• For retrofitting, no adjustments on anode side necessary
• Re-meshing of anode electrode is optional
(only in UCE/DeNora workshop)

Cathode side
cathode
anode

• Mechanical treatment of existing cathode electrode and cathode springs

(at client’s site or in UCE/DeNora workshop)

• Installation of coil cushion element

(at client’s site or in UCE/DeNora workshop)

• Installing of new coated cathode electrode as woven mesh

(at client’s or in UCE/DeNora workshop)

Cell element
• Installation of high performance membrane and standard gasket

Retrofit of BiTAC can be done completely at client’s plant

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

12 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Impressions of i-BiTAC

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

13 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Significant base for i-BiTAC operating experience: overview
No. of elements Days online Country No. of elements Days online Country
336 1,923 China, plant A 3,024 2,400 Far east, plant P
212 1,804 China, plant B 375 1,800 Far east, plant Q
761 1,786 China, plant C 114 700 Middle east, plant R
323 1,651 China, plant D 348 1,800 Oceania, plant S
1,312 1,524 China, plant E 19 1,000 Europe, plant T
315 1,426 China, plant F 183 900 Europe, plant U
364 1,380 China, plant G Total 9,534 elements
272 1,324 China, plant H
180 957 China, plant I
272 915 China, plant J
398 847 China, plant K
88 738 China, plant L
77 693 China, plant M
25 674 China, plant N
536 529 China, plant O

Successful qualification of i-BiTAC in client’s plant

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

14 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Agenda

• Key statements

• Retrofit of BM gen. v3 & v4

• Retrofit of i-BiTAC

• Project execution

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

15 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Beneficial NPV calculation for an actual case with sensitivity analysis
Based on the energy cost savings in comparison to recoated* v4

Sensitivity for Current Density (CD) Sensitivity for Electricity Cost [in €]
electricity cost: 5 €ct./kWh current density: 5 kA/m² CD

400 T€ 400 T€

300 T€ 300 T€

200 T€ 200 T€
capital value

capital value
100 T€ 100 T€

T€ T€

-100 T€ -100 T€

-200 T€ -200 T€

-300 T€ -300 T€
0 1 2 3 4 0 1 2 3 4
Time [a] Time [a]

Basic conditions:
Elements: 180 BM2.7 v4 / Investment: 1 Mio.€ / Interest rate: 10%

Attractive ROI periods due to customized solutions for the best cost-value-ratio
*excl. costs for accessories & membrane
16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016
16 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Experienced execution network with focus on client’s demand

Disassembly
of electrolyzer
and elements

Assembly of Shipping of
retrofitted halfshells
electrolyzer to the
workshop

S
S
S customer
Shipping of
halfshells Incoming
to the inspection
customer and repair of
halfshells

Retrofit of
anode and
cathode
halfshells

thyssenkrupp UCE network has a lot of experience to apply necessary steps in a high quality

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

17 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Reference summary for Retrofitting projects

• tk UCE has about 10 years experience in retrofitting

• 26 clients have tested the retrofitting of tk UCE

• Amount of retrofitted elements: 9,846 pcs.

• Retrofitting Technology of BM and BiTAC is a part of our Full Service Concept

• Plant conversion concept should be discussed case by case

Upgrade/Retrofit - because change remains the only constant

16th Chlorine Symposium – Dortmund, Germany- 15th – 17th June 2016

18 | 4:40 pm / June 16, 2016 | Retrofitting technologies | D. Donst and T. Hamada
Thank you
for
your attention