Asahi Kasei Corp. (Tokyo) announced that Portuguese chemical manufacturer Bondalti Chemicals has successfully started operation of its state-of-the-art chlor-alkali production facility in Estarreja, Portugal. Constructed by German engineering company CAC Engineering and using Asahi Kasei’s state-of-the-art chlor-alkali electrolysis technology, the improved plant will also be utilized for further reducing power consumption and optimizing the use of materials in the chlor-alkali industry.
Together with CAC Engineering (CAC), Asahi Kasei has installed nine chlor-alkali electrolyzers at Bondalti Chemicals’ (Bondalti) premises in Estarreja, Portugal. This project to convert the brine electrolysis unit, co-financed by the Portuguese Recovery and Resilience Plan, marks a new phase of modernization and will contribute to a significant increase in efficiency and reliability. It will also support the achievement of the ambitious decarbonization goals that are part of Bondalti’s strategy.
Joint Japan-Europe project team from Asahi Kasei, CAC, and Bondalti involved in the installation and operation of Bondalti’s demonstration electrolyzer (Source: Asahi Kasei)
With EU regulations on decarbonization constantly tightening, the industry is under pressure to reevaluate its power consumption and utilization of resources during the manufacturing process. At Bondalti’s new plant, one of the nine electrolyzers will also be utilized for trial runs with new components, aiming to enhance electrolyzers’ environmental performance, including power reduction and resource optimization. This electrolyzer uses Asahi Kasei’s newest ion exchange membranes and electrodes that feature improved performance compared to conventional products. Electrolyzers apply an electric current that separates brine (concentrated salt water) into chlorine, caustic soda, and hydrogen which are then used in a broad variety of chemical products in different industries. In line with Asahi Kasei’s efforts to establish a circular economy within the chlor-alkali industry, used cells and electrodes from these trials will be recycled into materials for reuse in new components.
“The start-up of our new, state-of-the-art chlor-alkali plant was made possible by the expertise of our partners and the dedication and skills of our people,” comments David Lopes, Director of Bondalti. “This achievement marks a strategic milestone in Bondalti’s commitment to sustainable innovation and operational excellence and strengthens our vision of leading the way in responsible chemical manufacturing.”
“We are happy to see Bondalti’s new plant starting operation on schedule,” adds Yoshifumi Kado, Senior General Manager of Asahi Kasei’s Ion Exchange Membrane & Electrolysis System Division. “By combining Asahi Kasei’s comprehensive system know-how with CAC’s advanced engineering technology and Bondalti’s onsite knowledge, these three key players will further expand the boundaries of the European chlor-alkali industry, contributing to a more sustainable approach to manufacturing.”
“The integration of nine new electrolyzers during a running production was an exceptional technical task and a further proof of the long-standing cooperation with Asahi Kasei for over 25 years and the trustful and constructive cooperation for more than 8 years in several projects with the experienced team of Bondalti,” concludes Mike Niederstadt, COO at CAC Engineering. “The project excellently shows the advantages of combining technological innovation, operational excellence and large-scale plant engineering expertise on a constructive and cooperative basis.”
As a one-stop solution provider for the chlor-alkali industry, Asahi Kasei combines its five decades of experience in developing, manufacturing, and operating electrolysis systems and components with the operation monitoring system and software analysis services provided by Canada-based Recherche 2000, an Asahi Kasei company, and—most recently—the establishment of a metal recycling ecosystem. The company manufactures and supplies ion-exchange membranes, electrolysis cells, electrodes, and operational expertise for electrolyzer plants.