Workshop on Mercury Management Almaden 2013
Decommissioning planning and management in the chlorine- alkali industry
December 13, 2013Antonio CAPRINO
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INTRODUCTION
Commitment of the European chlor-alkali industry to shut down cell rooms using Hg cell technology by 2020 (at the latest)– Mercury based capacity represents today ~30% of the total
chlorine production capacity. – Beginning of 2013, still 31 chlorine cell rooms using mercury cell
technology in Europe.
In some of the EU countries, strong pressure to speed up the shut down :– National or regional legislations (interdiction of technology or
limitation of emissions)– Local permits
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Manufacturing Processes EUROCHLOR 1997 - 2011
% of total capacity
0%
10%
20%
30%
40%
50%
60%
70%
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
Mercury Diaphragm Membrane Other
INTRODUCTION
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Conversion mercury cells
Eurochlor document of reference– Conversion from Mercury to Alternative Technology in the Chlor-Alkali
Industry (updated June 2012) .– World chlorine production capacity in mercury plants (WCC 2002-10)
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Factors influencing conversion
Energy prices and efficiency– Membrane cells consuming less electrical energy, but consuming
steam for caustic concentration. Production capacity– If the market demand more production, membrane installation or
conversion can be the opportunity – Selection of current density : lower density requires more
electrolysersProduct quality– Membrane needs a higher quality of brine– Chlorine membrane has lower quality – Caustic need to be concentrate
Market conditions
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Investment and paybackIn 2008 Prochemics, an independent consultant company made a study for Eurochlor to evaluate the conversion costs, taking to account data of 2007.
Recently UNEP article about this theme :Story of the month - August 2012 :Converting to a Cost-Effective Mercury Free Technology in the Chlor-Alkali Industry
To convert an existent mercury plant into membrane– New electrolysers– Replacement or adapt rectifiers– Purification brine – Caustic concentration
Cost– Cost 550- 700 USd/ton capacity– Time schedule for conversion: 18 – 24 months– Pay back: 10 – 14 years
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SOLVAY EXPERIENCE
SOLVAY plants around the world (at 01.01.2013)– 13 plants, more than 2 Mt Cl2/y– 4 plants with mercury technology (2 in Spain + 1 in Belgium + 1 in Argentine)
SOLVAY Mercury plants conversion (2006 – 2011) :– 2006 - Rosignano (I)
1 cellroom – 120 ktCl2/y– 2007 : Bussi (I)
1 cellroom – 80 ktCl2/y– 2009 : Santo André (BR)
4 cellrooms – 106 ktCl2/y
SOLVAY Mercury plants conversion projects– Lillo (B) : 2012 (done 02/12/12)
1 cellroom – 180 ktCl2/y– Tavaux (F) : 2012 (in execution)
2 cellrooms – 240 ktCl2/y
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Manufacturing Processes SOLVAY 2003 - 2013
SOLVAY - % of total capacity
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Mercury Diaphragm Membrane
Conversion of Tavaux and Lillo Hg capacities
INTRODUCTION
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Focus of the presentationReference documents to be used for preparing the decommissioning
Management of decommissioning activities within Solvay– Central decommissioning project team (Hermes
Project)– Local management in the plants
Experience in Europe Rosignano plant to be transferred to Lillo and Tavaux plants. Experience in Brazil plant.
Main lessons & highlights
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Reference Documents
EUROCHLOR :– Env. Prot. 3 – Guideline for Decommissioning of Mercury
Chlor-Alkali Plants– Env. Prot. 19 – Guidelines for the preparation for permanent
storage of metallic mercury above ground or in underground mines.
LOCAL DOCUMENTS :– e.g. French S.H.D – “Protocole de démantèlement de salle
d’électrolyse à cathode de mercure”
COMPANY INTERNAL DOCUMENTS (if any)– Procedures– Chronogram, plans
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Management of the decommissioning
Solvay “Hermes Project”– Objectives :
Definition of the process to be followed for Hg cell rooms decommissioning in the Solvay GroupPreparing a technical database for Hg contaminated equipments.
– Project TeamProject Leader “Process” (former Hg Cell room production manager)Specialists of HSE and Corporate Purchasing DepartmentsLocal Team on site for management of the decommissioning
– Starting date : 2006
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Decommissioning Management on site
Early estimation of the different contaminated wastes to be disposed of, and definition of the equipments to be maintained in operation for Hg exposure concern.
– SOLVAY experience : 1.000 to 6.000 t of contaminated materials per unit.
– Contaminated materials (not exhaustive) :Steal, other metals (Copper, Aluminium)MercuryGraphite, carbonPVC, FRP, other plastics“Hard Rubber” from rubber-lined equipmentsGasketsSand, sludgeElectrical equipmentsConcrete, bricks…
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Decommissioning Management on siteDefinition of the treatment/disposal solutions for each contaminated equipment/waste, based on the techniques listed by the “Hermès team”.– Provision of the containers for metallic mercury
storage/transportation– Treatment/disposal solutions for each waste can depend on
national regulation.Early discussions and ITB with subcontractors for dismantling activities.– Technical solution proposed for each type of waste– Solutions for disposal
Well documented action plan for discussions with local authoritiesDefinition of people management during dismantling– Needs (local, external)– Medical and environmental monitoringCost control
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Decommissioning PhasesPhase 1 : Health and Safety preliminary actions– Emptying of the equipments (mercury, other fluids)– Cleaning of the different equipments, tightening, covering
with water if needed. – Dismantling of non-Hg equipments (incl. anodes, cell
covers,…)Skilled people from the plant (e.g. people in charge of the operation of the Hg cell room)
Phase 2 : Dismantling of the equipments– Dismantling of all the equipments, except equipments kept in
operation for HSE concernsCan be subcontracted if no skilled people available.
Phase 3 : Dismantling of all remaining equipments– Electrical equipments– Treatment units,…
Subcontracted in the most of cases.
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Rosignano - Main figures
Mercury Cell room– Chlorine capacity : 120 kt/y– Number of cells : 50 of 30 m2
Decommissioning activities– Shut down : May 2007– End of Safety Preliminary actions : March 2008– Dismantling plan accepted by local authorities in August
2008.– End of dismantling activities : end 2009
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Working area for safe handling of the contaminated equipments
Working area connected to Hg effluents treatment unit and regularly washed
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Santo Andre - Main figures
Mercury Cell room– Chlorine capacity : 106 kt/y– Number of cells : 52 of 12 m2 + 49 of 10 m2
Decommissioning activities– Shut down : February 2009– End of Safety Preliminary actions : December 2009– Dismantling plan accepted by local authorities:
December 2008.– End of dismantling activities : end 2011
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Cellroom dismantling phases
In process of Health & Safety action End of Health & Safety action
End of cells dismantling
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Material recuperation: example of tendency
Recuperação de material (acumulado)
1,0
10,0
100,0
1000,0
10000,0
ene-0
9mar-
09may
-09
jul-09
sep-0
9nov-0
9en
e-10
mar-10
may-10
jul-10
sep-1
0nov-1
0en
e-11
mar-11
may-11
jul-11
sep-1
1nov-1
1en
e-12
mar-12
mes
ton
TITANIO (e) COBRE (e) ALUMINIO (e)
FERRO (d) MERCÚRIO (e) OUTROS (e)
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Teams and time for dismantling
Horas trabalhadas
-
500
1.000
1.500
2.000
2.500
3.000
3.500
4.000
jan/09
fev/09
mar/09
abr/0
9
mai/09
jun/09jul
/09
ago/0
9se
t/09
out/0
9
nov/0
9
dez/0
9jan
/10
fev/10
mar/10
abr/1
0
mai/10
jun/10jul
/10
ago/1
0se
t/10
out/1
0
nov/1
0
dez/1
0jan
/11
fev/11
mar/11
abr/1
1
mai/11
jun/11jul
/11
ago/1
1se
t/11
out/1
1
nov/1
1
dez/1
1jan
/12
fev/12
mar/12
abr/1
2
mês
hs
-10.00020.00030.00040.00050.00060.00070.00080.00090.000100.000110.000120.000130.000140.000150.000
Mão Obra SOLVAY Mão de obra Contratada Externo
Total SLV (d) Total contratada (d) Total Acumulado (d)
Externo
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Main lessons & highlights
Decommissioning of a Hg cell room has to be managed as a specific project :
– Dedicated project team– Project to be structured carefully– Study to be started at an early step
the Hg cell room shut-down strategy can affect the conversion start-up schedule - in case of a conversion)Early definition of the equipments to be maintained in operation during decommissioningList of contaminated equipments/wastes and treatment solutions to be prepared for further discussions with subcontractors and local authorities.
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Main lessons & highlightsHealth of workers :– Has to be considered at an early step (definition of the
equipments to be maintained in operation for Health concerns)
– Work with skilled people (e.g. from Hg cell room operation team) when possible, at least for safety preliminary actions.
– Regular monitoring of Hg exposure (air and biomonitoring)
Key points :– People engaged: internal and external (contractors)– Creativity and Innovative solutions.– Controls: to have indicators of evolution