Analysis of the industry advantages of Asia Pacific Chemical Plant (APCP) in the caustic soda plant project
As a benchmark for technological innovation in the global chlor-alkali industry, Asia Pacific Chemical Plant (APCP) continues to lead the industry development with its membrane electrolysis, zero-carbon process and full industry chain synergy capabilities. The following analyzes its core competitiveness from the four dimensions of technology, environmental protection, cost and service, combined with global practical cases.
1. Technological innovation: the world's leading membrane electrolysis process
3.Building cost competitiveness of Asia Pacific Chemical Caustic Soda Plant
4.Global practice: benchmark projects from China to Southeast Asia
5.Future Outlook: Technology Upgrade and Market Expansion
1. Technological innovation: the world's leading membrane electrolysis process
Core technology configuration
Adopting ZEC-5000 zero-pole-gap technology, by shortening the distance between the cathode and anode to less than 0.1mm, the current efficiency is increased to 96.5% (industry average 94%-95%), and the DC power consumption per ton of alkali is reduced to less than 2100kWh (12% lower than the traditional process). It supports modular expansion, and the production capacity of a single set of equipment can be flexibly adjusted from 50,000 to 500,000 tons/year, adapting to the needs of small and medium-sized projects and large integrated factories. A typical application case is the Shandong Qingdao Bay Chemical Relocation Project, which uses this technology to achieve the co-production of ethylene-based PVC and caustic soda, and the comprehensive energy consumption reaches the international advanced level.
Adopting countercurrent forced circulation process, the steam energy consumption is reduced to 0.35 tons/ton of alkali through three-stage evaporation (single-effect evaporation requires 1.2 tons/ton of alkali), and the cost of steam per ton of alkali is reduced by 20%. Supports fast switching of multiple specifications: 32% liquid caustic soda can be directly concentrated to 50%, or 99% flake caustic soda/granular caustic soda can be produced through melt granulation. In the Jiantao Industrial Park project in Beihai, Guangxi, the equipment is linked with the chlorine product production line to achieve full-chain synergy of "salt → caustic soda → high-end resin", with an annual production capacity of 300,000 tons of 50% liquid caustic soda.
Siemens membrane absorption tower (MST series)
Using polytetrafluoroethylene (PTFE) membrane components, the chlorine absorption rate reaches 99.9%, and the tail gas chlorine content is <50ppm (national standard requires ≤100ppm). The tower body is designed as a multi-stage cross-flow absorption, equipped with an automatic pH control system to ensure that the hydrochloric acid concentration is stable at 31%-33%. The equipment has been used in Vietnam's 100,000 tons/year caustic soda project, and the by-product hydrochloric acid is directly supplied to the local fertilizer plant to achieve closed-loop resource utilization.
High-value utilization of by-products
Integrated pressure swing adsorption (PSA) + catalytic deoxygenation technology, hydrogen purity increased from 98% to 99.999% (dew point <-70℃), meeting the needs of high-end fields such as photovoltaics and electronic-grade polysilicon. In the Etuoke project in Inner Mongolia, purified hydrogen is directly supplied to a 20MW fuel cell power station through a pipeline, reducing CO₂ emissions by 12,000 tons per year and reducing the production cost of caustic soda by 18%.
Adopting propane refrigeration cycle, the chlorine liquefaction rate reaches 98%, and the purity of liquid chlorine is ≥99.6%. Equipped with a vinyl chloride monomer (VCM) synthesis unit (such as the Jiantao Industrial Park in Beihai, Guangxi), liquid chlorine reacts with ethylene to produce EDC/VCM, and finally produces high-purity PVC resin (K value 65-70), which is widely used in pipes, electronic components and other fields. Through this technology, the Qingdao project in Shandong has achieved an ethylene-based PVC production capacity of 300,000 tons/year, with a product quality rate of 99.2%.
Product matrix and technology synergy
Liquid caustic soda: 32%/50% concentration, suitable for alumina and papermaking industries, and rapid switching of production capacity through a triple-effect evaporator.
Solid caustic soda: 99% flake caustic soda/granular caustic soda, using twin-screw extrusion granulation technology, with a particle uniformity of more than 95%, exported to Southeast Asia and the Middle East market.
Special chlorine products: epichlorohydrin (ECH), trichloroethylene (TCE), etc., relying on chlorine liquefaction and high-purity hydrogen to achieve electronic-grade product production (such as trichloroethylene with a purity of ≥99.99% for semiconductor cleaning).
Technology extension
Bipolar membrane electrodialysis (BPM): pilot application in Pakistan project, directly converting brine into acid/alkali, further reducing energy consumption per ton of alkali by 15%.
Intelligent control system: Equipped with APC (Advanced Process Control) software to achieve real-time optimization of electrolytic cell current density and evaporation temperature, reducing manual intervention by 30%....
2. Environmental protection and sustainable development: a model of green transformation in the industry
Breakthrough in mercury-free production
The world's first calcium carbide method PVC mercury-free catalytic technology (such as the 400,000 tons/year project in Etuoke, Inner Mongolia), completely eliminates mercury pollution and obtains the first mercury-free emission license from the Ministry of Ecology and Environment.
Zero emission and low-carbon process
Evaporation crystallization technology: zero wastewater discharge, COD <50ppm (far exceeding the national standard GB 15581-2016).
Solar power supply system: carbon emission reduction of 25%, meeting the requirements of the EU carbon tariff policy.
Green factory certification
Shandong Qingdao Bay Chemical Relocation Project has passed the "Green Factory" certification of the Ministry of Industry and Information Technology, with an industrial water reuse rate of 98% and a comprehensive energy consumption reduction of 75% compared with traditional processes.
3.Building cost competitiveness of Asia Pacific Chemical Caustic Soda Plant
Energy efficiency optimization
Waste heat recovery technology reduces the energy consumption cost per ton of caustic soda by 18% (such as the 100,000 tons/year project in Vietnam), and the investment payback period is shortened to 18 months.
Localized supply chain
Guangxi Beihai Jiantao Industrial Park has achieved a full chain layout of "salt → caustic soda → chlorine products → copper clad laminate", reducing the cost of raw materials by 20%.
Flexible production to adapt to the market
Support the production of multiple specifications of caustic soda, flexibly respond to market demand fluctuations in Southeast Asia, the Middle East and other markets, and ensure the stability of customer returns.
4.Global practice: benchmark projects from China to Southeast Asia
China case
Etuoke, Inner Mongolia: The world's first mercury-free PVC + caustic soda integrated project, with an annual output value of over 10 billion yuan and a 30% reduction in carbon emissions.
Qingdao, Shandong: Ethylene-based PVC + zero-gap electrolyzer combination, with comprehensive energy consumption reaching international advanced levels.
Overseas layout
Vietnam 100,000 tons/year caustic soda project: membrane electrolysis + hydrogen purification technology, providing high-purity hydrogen for the local photovoltaic industry.
Pakistan 200,000 tons/year project: customized pretreatment process adapted to high-salt brine, product purity 99.9%.
5.Future Outlook: Technology Upgrade and Market Expansion
Technical Direction: Develop bipolar membrane electrodialysis technology to further reduce energy consumption and improve product purity.
Market Layout: Focus on expanding Southeast Asia, the Middle East and Europe, and provide "zero-carbon caustic soda" solutions.
Service Capabilities: Strengthen customer stickiness through remote operation and maintenance, free pilot and green financing support.
Technical direction: Bipolar membrane electrodialysis (BPM) technology breakthrough and deepening of green process
Asia Pacific Chemical has jointly carried out bipolar membrane electrodialysis technology research with the Institute of Process Engineering of the Chinese Academy of Sciences and Asahi Chemical of Japan. Through the research and development of ultra-thin composite membrane materials and modular device design, the following breakthroughs have been achieved:
Energy consumption is reduced by another 15%: In the pilot project in Pakistan, the DC power consumption per ton of alkali for converting salt water into acid/alkali is reduced from 2100kWh of traditional process to 1785kWh, reaching the international leading level.
Purity is increased to 99.99%: Through the optimization of membrane stack structure, lithium-ion battery-grade high-purity caustic soda is successfully separated to meet the demand of new energy industry for high-purity chemicals.
Resourceization of waste salt: Develop BPM-evaporation crystallization coupling process to convert sodium sulfate and sodium chloride, by-products of chlor-alkali production, into industrial-grade salt products, achieving "zero solid waste discharge".
Service capabilities: Building a "full life cycle" customer support system
Remote operation and maintenance services: Independently develop AI digital twin platform to monitor the operating status of electrolyzers in 32 projects around the world in real time, and reduce unplanned downtime by 40% through predictive maintenance. For example, 7×24 hours remote diagnosis is provided for the Saudi SABIC project, successfully avoiding production interruptions caused by aging of membrane components.
Core advantage support
Technical synergy: The existing zero-gap electrolyzer, three-effect evaporator and BPM technology form a "energy saving - efficiency improvement - carbon reduction" closed loop, and the overall energy consumption is 28% lower than the industry average.
Industrial chain integration: Through the linkage of by-product hydrogen with photovoltaic and green hydrogen projects, a "chlor-alkali - new energy" collaborative ecology is built to enhance the ability to resist market fluctuations.
Localized services: Regional technical centers are established in Singapore, Dubai and Rotterdam to provide full-chain support from process design to policy compliance to accelerate technology implementation.
