Analysis of the hazards for the molten cuprous chloride pouring operation in an industrial hydrogen production facility

An analysis is reported of a design for a local exhaust ventilation system for the molten cuprous chloride pouring station in an industrial plant. Heat recovery from molten cuprous chloride is a key process within the copper–chlorine (Cu–Cl) cycle of thermochemical water splitting for hydrogen production. Because of particulate matter, dust, and vapors emitted by the molten salt, an effective and safe design is crucial. The design process involves calculating duct diameters to provide the desired duct air velocity through the system. The static pressure is evaluated so that the fan size can be determined. An adequate supply of makeup air must be provided to replace the air exhausted through the ventilation system. The economics of the ventilation system and ways to protect employee health, as well as minimize the costs associated with exhaust ventilation, are also described.