Hydrogen produced from chlor-alkali plants, typically through the chlor-alkali process, can be managed and utilized in several strategic ways depending on the facility’s configuration and operational goals.
One approach is direct utilization. Hydrogen can serve as a fuel for power generation or heating, either within the plant or at adjacent facilities. This includes using it in boilers or fuel cells to produce electricity. It can also act as a feedstock in chemical manufacturing processes, such as ammonia or methanol production.
Another method is storage. Hydrogen can be compressed and stored for future use, provided that adequate safety measures are in place. These include the use of pressure-resistant tanks and systems to monitor for and prevent leaks.
In some instances, hydrogen is vented to the atmosphere, although this is generally discouraged due to safety and environmental concerns. Venting should only be considered when safe capture or use is not feasible, and it must be done with stringent precautions to avoid flammability hazards.
Hydrogen can also be sold to third-party companies that require it for their operations. For this purpose, it must be purified and compressed to meet commercial-grade standards. Two common methods for hydrogen purification include pressure swing adsorption (PSA) and membrane separation. PSA effectively removes contaminants like oxygen, nitrogen, and water vapor, producing high-purity hydrogen suitable for specialized applications or premium sales. Membrane separation allows the selective extraction of hydrogen from mixed gas streams, facilitating further use or commercial distribution.
When neither venting nor storage is practical, flaring may be used. A controlled flare burns the hydrogen, converting it to water vapor. Though this mitigates the safety risks associated with hydrogen’s flammability, it results in energy loss and is considered a less desirable solution.
Hydrogen can also be used in hydrogenation reactions, which may occur within the plant or at nearby facilities. This includes applications like oil hydrogenation or other industrial chemical processes that depend on hydrogen.
From a business perspective, the most profitable strategies involve channeling high-purity hydrogen into lucrative markets, such as electronics, pharmaceuticals, and specialty gases, as well as the hydrogen fuel and energy storage sectors. It is especially beneficial to serve large-scale industrial users like refineries or ammonia producers. To supply such high-purity hydrogen, a chlor-alkali plant typically requires a PSA unit. The installation of PSA systems is becoming increasingly common as the commercial value of hydrogen rises and more companies seek integration with green hydrogen initiatives. As industries strive for decarbonization, chlor-alkali facilities may find it both environmentally and economically advantageous to capture and purify hydrogen—particularly if the plant is powered by renewable energy and located in regions with strict environmental regulations.