China's advancement in the use of chlorine resources

On August 8, Huayi Group's Shanghai Chlor-Alkali Chemical Co., Ltd. announced a major breakthrough in its hydrogen chloride catalytic oxidation project using Deacon technology. The first batch of process parameters for the 1,000-ton capacity unit reached the target, marking China as the second country globally to master this advanced technology. This achievement places China at the forefront of global research and development in converting hydrogen chloride into chlorine, with significant implications for improving chlorine resource recycling and achieving energy efficiency and emission reduction goals. The pilot plant, developed independently by the company, features a fixed-bed tubular reactor and specialized catalysts. Since its commissioning on May 18, it has operated safely and steadily, with key process parameters meeting design specifications, particularly in terms of hydrogen chloride conversion rates. This success is a testament to the company’s technological capabilities and commitment to innovation. China is one of the world’s largest producers and consumers of chlorine, with annual consumption exceeding 20 million tons—about one-third of the global total. However, many chlorine-based products suffer from low chlorine atom utilization, with some processes converting 100% of chlorine into hydrogen chloride. Currently, over 5 million tons of by-product hydrogen chloride are produced annually, creating a pressing need for effective solutions. Zhang Wenlei, vice chairman of the China Chlor-Alkali Industry Association, emphasized the importance of enhancing chlorine utilization, promoting resource recycling, and optimizing industrial structures to address overcapacity and improve efficiency. Chlor-alkali production is an energy-intensive industry, consuming approximately 2,200 kWh per ton of chlorine gas. Utilizing by-product hydrogen chloride for chlorine production not only recycles resources but also significantly improves energy efficiency and reduces emissions. Recognizing this, Shanghai Chlor-Alkali has long pursued the independent development of Deacon technology. Since 2009, the company's Technology Center has invested heavily in R&D, working closely with Huayi Group. Through open collaboration, they successfully developed a cost-effective fixed-bed tubular reactor and a high-performance catalyst, which has been patented. Testing results show that the catalyst can operate continuously for more than 9,600 hours, demonstrating excellent stability and reliability. Looking ahead, Shanghai Chlor-Alkali is working on scaling up the Deacon process. A 100,000-ton hydrogen chloride catalytic oxidation plant is planned for the Shanghai Chemical Industry Park in 2016, aiming to meet future chlorine demand and support the full-cycle development of the chlorine industry. He Gang, the company’s general manager, stated, “Technological advancement and independent innovation are essential for corporate competitiveness. This pilot success is just the beginning. We will continue to push forward, overcome challenges, and achieve the industrialization of our Deacon technology as soon as possible.”

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