Feasibility analysis of a hydrogen cogeneration system in a chloralkali electrolysis plant

Abstract

There is currently a growing global focus on sustainability and energy efficiency, which has driven increased interest in innovative solutions designed to transform industrial processes and address these urgent challenges. The sector has made notable progress with decentralized wind and photovoltaic energy systems, but there is still significant untapped potential in closing economic cycles and maximizing the use of industrial by-products. One such by-product is hydrogen, a valuable energy resource generated during chlor-alkali electrolysis processes, which is often released into the atmosphere, resulting in energy loss and missed opportunities for resource optimization. This study focuses on the feasibility analysis of integrating a hydrogen cogeneration system into a chlor-alkali electrolysis plant. The research assesses the technical and economic viability of implementing such a system to optimize the use of hydrogen by-product, addressing both operational efficiency and environmental impact. To this end, a detailed technical evaluation is conducted, exploring system design, integration challenges, and performance indicators. In parallel, a comprehensive economic analysis is carried out, examining investment costs, potential savings, and return on investment under different market scenarios. This techno-economic assessment, conducted in collaboration with Welysis, a Spanish company specialized in chlor-alkali electrolysis plants, uses a Welysis operational plant in Santa Cruz de Tenerife as the reference for implementing the developed model. The results indicate that hydrogen cogeneration in chlor-alkali plants has great potential to improve energy efficiency. However, economic viability is sensitive to factors such as energy prices and initial investment costs. This work contributes to a deeper understanding of sustainable energy solutions in industrial processes and offers a framework for evaluating the adoption of hydrogen cogeneration systems.