Bondalti Completes Major Chlor-Alkali Plant Modernization in Portugal with Asahi Kasei Technology
- Site
- Estarreja
- Message Category
-
Plant Startup Marks End of Three-Year Conversion Project
ESTARREJA, Portugal - September 2, 2025 - Portuguese chemical manufacturer Bondalti Chemicals has successfully commenced operations at its modernized chlor-alkali production facility in Estarreja, completing a comprehensive three-year conversion project that represents one of the most significant industrial modernizations in the Portuguese chemical sector.
The upgraded facility, constructed by German engineering company CAC Engineering and incorporating Asahi Kasei's state-of-the-art AlkaNexus electrolysis technology, features nine advanced bipolar electrolyzers designed to significantly enhance energy efficiency and production reliability.
#chloralkali #electrolyzer #portugal #asahikasei #bondalti
|
Kokel, Nicolas
9/13/2025 6:56 AM
Production Capacity Analysis Current Post-Modernization Capacity Following the modernization project, Bondalti's Estarreja site now operates with a confirmed annual production capacity of 105,000 tonnes each of chlorine and caustic soda, alongside hydrogen as a co-product through the membrane electrolysis process. Historical Technology Comparison Research reveals that Bondalti was an early adopter of clean technology in the European chlor-alkali industry. The company transitioned from mercury cell technology to membrane technology as early as 2002, approximately 15 years before the EU mercury ban deadline. Prior to the 2025 modernization, Bondalti's Estarreja facility operated 23 electrolyzers consisting of nine AZEC-B1 units and 14 MGC23 electrolyzers. The AZEC-B1 electrolyzers, which began operation in 2002, utilized bipolar technology with each unit containing 62 cells. These systems were electrically connected in parallel and operated at controlled constant direct current rates. Capacity Evolution Estimate While exact pre-modernization capacity figures were not explicitly disclosed, industry analysis suggests the facility's capacity has been optimized rather than dramatically expanded. The replacement of 23 older electrolyzers with nine state-of-the-art units indicates a significant improvement in efficiency per unit, with the new systems likely delivering the same or enhanced output with considerably lower energy consumption. Advanced Technology Implementation The new facility represents a technological leap forward in chlor-alkali production. One of the nine electrolyzers serves as a dedicated test unit for next-generation components, focusing on further reducing electricity consumption and optimizing resource utilization. This test electrolyzer incorporates Asahi Kasei's latest ion exchange membranes and electrodes, which deliver superior performance compared to conventional products. Strategic and Environmental Impact The modernization project, co-financed by Portugal's Recovery and Resilience Plan, directly supports Bondalti's ambitious decarbonization strategy. The company targets a 50% reduction in scope 1 emissions and 100% scope 2 emission reduction by 2030 (compared to 2005 baseline levels). |
