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1 SURVEY OF CHEMICAL EMISSIONS According to the U.S. Manufacturing Energy Consumption Survey (USMECS), in 1994, the chlor-alkali industry consumed 136 PJ of total energy and used 62 PJ of electricity. These numbers are different from those used by Worrell [9]. This difference was due to the fact that the MECS excludes some chlorine production, which underestimates energy use. Table 35 provides our calculation for electricity needed to produce 11.1Mtons Cl2, along with the hydrogen evolved and its energy content. Table 35. Computation of Electricity Use for Electrolysis and Energy Content of Evolved Hydrogen Cl2 prod 11.1 (Mtons/yr) MW 70.7 (g/mole) Grams 1.11E+13 (g/year) Moles 1.57E+11 (year) Equivalents 3.14E+11 (equivalents) Coulombs 3.03E+16 (coulombs) Cell operation Volts 4.1 (V) Joules 1.24E+17 (J) 1.24E+02 (PJ) LHV H2 1.07E+13 (kcal) 4.49E+13 (kJ) 44.91 (PJ)* *1.57E11 moles H2*68.3 kCal/mole H2*4.1868 kJ/kCal*1PJ/1E12 kJ = 44.9 PJ Table 36 summarizes the results obtained by Worrell, USMECS, and Battelle using a chlorine production rate of 11.1 Mtons/year. Table 35 presents PNNL calculations, and Table 36 compares these results with those of Worrell et al. and U.S. Manufacturing Energy Consumption Survey (USMECS). PNNL calculated the electricity needed for electrolysis, which is more in line with Worrell’s results [9]. They also calculated the energy content of evolved hydrogen, which was 44.9 PJ (LHV). Worrell’s report indicated that only 3.4 PJ of the 44.9 PJ evolved hydrogen was captured. This indicates that there is a significant opportunity for energy capture with the chlorine production industry. At 50% efficiency, fuel cells can generate 20.8 PJ electricity from the additional hydrogen captured, and with good heat exchange, some of the evolved heat can be used for cogeneration. The total electricity generated from hydrogen capture (50% of 44.9 PJ) corresponds to about 20% of total electricity use during electrolysis. By using the waste heat from the fuel cell, the overall system efficiency can be further increased. Clearly, the evolved hydrogen from chlor-alkali cells provides a major opportunity to capture and utilize this currently wasted energy source. Since most chlor-alkali plants have an on-site cogeneration power plant, it is an ideal situation to use hydrogen as feed for a fuel cell. In order to fully utilize the heat from the power plant that generates the remaining power needed, it appears that SOFC or MCFC technology may be preferable. On the other hand, the temperature for the electrolysis cell more closely matches that of a PEM fuel cell. The pure hydrogen generated at the cathode can be used in any type of fuel cell. 31PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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