Today’s Russian Chlor-Alkali Industry
Boris Yagud
Executive Director
Association “RusChlor”
RusChlor Membership
The full members in Association “Ruschlor”
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Volgograd Open Joint-Stock Company "Kaustik"
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Sterlitamak Open Joint-Stock Company “SODA”
Sayansk Open Joint-Stock Company “Sayanskkhimplast”,
Sayansk, the Russian Federation;
Kemerovo Limited Liability Company “Khimprom”
Moscow Closed Joint-Stock Company "Russian Centre
'Chlorine Safety"
Novocheboksarsk
Open
Joint-Stock
Company
"Khimprom"
Berezniki Limited Liability Company “Soda-Khlorat”;
Closed Joint-Stock Company "Ilimkhimprom", Bratsk, the
Russian Federation;
Novomoskovsk
Limited
Liability
Company
“Novomoskovskij Khlor”;
Kirovo-Chepetsk
Limited
Liability
Company
“Halopolimer”, Kirovo-Chepetsk, the Russian Federation;
Solikamsk Open Joint-Stock Company “Magnievyij zavod”
Volgograd Open Joint-Stock Company "Khimprom"
Skoropuskovsk Limited Liability Company “Sintez”,
Moscow Region
Open Joint-Stock Company “WTE Yugo-Vostok”
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Associate members in Association “RusChlor”
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Moscow Limited Liability Company "Sintez"
Irkutsk Limited Liability Company "Giprokhlor"
Izhevsk Limited Liability Company “Gidroproekt”
Dzerzhinsk Limited Liability Company "Uhde"
Moscow Closed Joint-Stock Company “GMZ ‘Khimmash”
Moscow Limited Liability Company “Khlorkompleks”
Moscow Limited Liability Company “Universal”;
Dzerzhinsk Limited Liability Company “Group of Companies
‘Spetsmash”;
Ekaterinburg Closed Joint-Stock Company “Scientific and
Productive Enterprise ‘Mashprom”;
Moscow Limited Liability Company “GLYNWED ‘Russia”;
"Chemieanlagenbau Chemnitz GmbH", Germany;
Descote, France
"Midland Manufacturing Inc.", USA;
"Uhde GmbH", Germany;
“Industrie De Nora S.p.A.”, Italy
Phoenix Armaturen Werke Bregel Gmbh, Germany;
Thaletec GmbH, Germany
“Bluestar Beijing Chemical Machinery Co., Ltd”, China;
ISGEC Heavy Engineering Ltd, India
Chem-Tech Engineering srl, Italy
BS&B Safety Systems Ltd., Ireland
RusChlor Projects 2011 – 2013
 formulation of the Russian proposals for the
Minamata Convention text;
 formulation of the National Development Strategy
for the Chlor-alkali Industry for the period from
the year 2014 through 2030;
 membership in World Chlorine Council (WCC);
 participation in formulation of the WCC
documents on the industrial safety;
 participation in development by the government
of the Russian Federation of the new Federal Laws
and Rules on the Industrial Safety.
Distribution of the production capacity of the
Russian chlor-alkali industry over the production
methods
18%
52%
Diaphragm
electrolysis
Membrane
electrolysis
30%
Mercury-cathode
electrolysis
THE KEY-TASKS STEMMING FROM THE CURRENT
SITUATION OF THE CHLOR-ALKALI INDUSTRY
1. MODERNIZATION OF THE INDUSTRY SECTOR, WHICH INCLUDES MODERNIZATION OF
THE BASIC EQUIPMENT AT THE FACILITIES OPERATING THE DIAPHRAGM AND
MERCURY-CATHODE ELECTROLYSIS.
2. PUTTING INTO COMMERCIAL OPERATION OF ONLY SUCH NEW PRODUCTION FACILITIES
THAT ONLY OPERATE THE MEMBRANE ELECTROLYSIS.
3. IMPROVEMENT IN THE ENVIRONMENTAL CONDITIONS:
– REDUCTION IN THE MERСURY EMISSION;
– REDUCTION IN THE USE OF ASBESTOS;
– REDUCTION IN THE GREENHOUSE GASES EMISSION AS A RESULT FROM THE REDUCED
ENERGY CONSUMPTION.
4. GRADUAL BOTH ECONOMICALLY AND ECOLOGICALLY FEASIBLE CONVERSION OF THE
STILL FUNCTIONING PRODUCTION FACILITIES OF THOSE THAT ARE STILL OPERATING
THE MERCURY CATHODE ELECTROLYSIS OR THE DIAPHRAGM ONE OR BOTH INTO THE
MEMBRANE ELECTROLYSIS TECHNOLOGY.
RusChlor Suggestions Accepted by
Federal Acts of the Russian Federation
• Federal Law “On Industrial Safety of Hazardous Production Facilities”
(came into the legal force on March 04, 2013);
• National Standards “Safety Rules for Production of Chlorine and
Chlorine-containing Substances” (approved by Federal Service for
Ecological, Technological, and Nuclear Supervision and duly registered
by the Ministry of Justice of the Russian Federation on December 30,
2013);
• National Standards “Safety Rules for the Chemically Hazardous
Production Facility” (approved by Federal Service for Ecological,
Technological, and Nuclear Supervision and duly registered by the
Ministry of Justice of the Russian Federation on December 30, 2013).
Requirements to the
Processes
Federal Law No. 116-FZ
“On Industrial Safety of
Hazardous Production
Facilities” as amended on
March 04, 2013
Federal Acts of the Russian
Federation
Requirements to the
Equipment
Federal Law No. 184-FZ
“On Technical
Regulation” as amended
on December 28, 2013
Federal Rules and Regulations
for Industrial Safety
(FRRIS)
FRRIS
“Safety Rules for
Production of Chlorine
and Chlorine-containing
Substances” of December
30, 2013
FRRIS
“Safety Rules for the
Chemically Hazardous
Production Facility” of
December 30, 2013
Regulatory Instruments
applicable on a Voluntary
Basis
RusChlor Technical
Recommendations
Instrumental Guidance
provided by Federal
Service for Environmental,
Technological, and Nuclear
Supervision (RTN
Instrumental Guidance)
Technical Regulations of
the Custom Union
(TRCU)
TRCU “On safety of the
machinery and
equipment” No. 010/2011
TRCU “On Safety of
Equipment under the
Explosive Environments”
No. 012/2011
TRCU “On Safety of the
Gas-fired Machines” No.
016/2011
TRCU “On Safety of the
Pressurized Equipment”
No. 032/2013"
Regulatory Instruments
applicable on a Voluntary
Basis
The standards that should
assure that all the
requirements of the
Technical Regulations are
fulfilled
Design Specifications
The standards that specify all
the procedures to be followed
and technique to be applied in
studying, testing, or measuring
under the Technical
Regulations.
Commissioning and admission to service at the
Hazardous Industrial Facility
Confirmation of conformity of the device with the
requirements of the Technical Regulation
Only such a legal entity or self-employed entrepreneur
that falls into either of the following two categories and is
duly registered as a resident legal person for the Custom
Union's territory can lawfully apply for the certificate:
• Manufacturer or contractor fulfilling the manufacturer's
obligations;
• Supplier (under a certain schema).
Set of documentation:
• Safety Assessment Report;
• Operational Requirements Documents;
• The Contract (Delivery Contract) or consignment details
for either a consignment or one-off item;
• Management System Certificate;
• Report on the Studies Undertaken;
• Test reports;
• Conformity Certificates for the Materials and Parts;
Performance of the Expert Examination as to the
Industrial Safety of the device or installation
• prior to the beginning of its operational use at the
hazardous production facility;
• at the end of its operational lifetime as determined by
the legislation or manufacturer;
• in the absence of any exact endurance data in the
technical documentation linked to the device or
installation on the condition that the actual operational
life of the device or installation has exceeded 20 years;
• upon completion of the works on changing the design,
replacement of the construction material for the bearing
elements of the device or installation or upon
completion of the works on the reconstructive
maintenance that have followed such an accident at the
hazardous production facility that resulted in a damage
caused to the device or installation.
SAFETY ASSESSMENT REPORT
• Safety Assessment Report
Safety Assessment Report is a single document comprising
the risk analysis and certain data on the minimum essential
safety measures. The data on the safety measures is
supposed to have been initially excerpted from the design,
operational, and process control documentation. Safety
assessment report is required to be accompanying the
machinery or equipment at all the stages of its lifecycle so that
the risk assessment data calculated in operational stage upon
completion of works on capital repair of the machinery or
equipment should be added to the report.
• GOST R “Safety of the Machinery and Equipment.
Requirements as to the Safety Analysis Report” No. 541222010
SAFETY ASSESSMENT REPORT
FOR THE TECHNICAL DEVICES
CONTENTS
The key parameters and records of performance
The general approach to providing for safety in the design process
Reliability requirements
Personnel/ user skills requirements
Analysis of the risk of the commercial use
Safety requirements necessary to fulfill in commissioning
Requirements to safety management in the commercial run
Requirements to quality management in the commercial run
Requirements to management over the environment protection in commissioning, commercial run, and disposal of
Requirements to collection and analysis of the safety information in commissioning, commercial run, and disposal of
Safety requirements to be fulfilled in decommissioning
PRODUCTION OF THE CHLORORGANIC PRODUCTS IN THE
RUSSIAN FEDERATION IN THE 2010–2013 TIMEFRAME
• The organochlorine synthesis industry is clearly underperforming
both the qualitatively and quantitatively, which should be mostly
accounted for by the poor demand for the products in the market
with a possible exception of PVC.
• Without a considerable economic revival one can hardly expect that
the chlororganic products output can rise to any substantial extent in
both the short- and mid-term perspective.
• The rise in the PVC output is hampered by the lack of ethylene in
the domestic market.
IMPORT CONTENT OF THE RUSSIAN
DOMESTIC PVC MARKET
2006-2007 гг.
2010-2013 гг.
33-42%
~50%
Consumers: construction, housing and public utilities,mechanical engineering,
packing and wrapping materials, and some other industries.
THE DEMAND FOR PVC HAS EXCEEDED 1 MILLION
TONS A YEAR IN THE RUSSIAN FEDERATION
The demand for PVC rose by hefty 34 percent in 2010 compared to the same
indicator's previous year’s value. The demand curve has been almost flat since
then.
The caustic soda Consumption Segment
Apparent
Consumption of
the caustic soda
(as of 2013)
Customer
Share (%)
Chemical industry
Production of cellulose, pulp, paper, and cartonboard
405663
273337
39%
26%
Metals industry, including both the extraction and
downstream operations
Electric-power industry
Oil and gas extraction
Food processing
Mechanical engineering industry
Other
Final total
134540
83742
41972
35096
11845
47944
1034139
13%
8%
4%
3%
1%
5%
100%
Apparent Consumption of the caustic soda (as of 2013)
Mechanical
engineering
industry
Food processing
1%
3%
Oil and gas
extraction
4%
Electric-power
industry
8%
Metals industry,
including both
the extraction
and downstream
operations
13%
Other
5%
Chemical
industry
39%
Production of
cellulose, pulp,
paper, and
cartonboard
27%
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