Chlorine is a key feedstock for a wide range of chemicals and consumer products, and the major ingredient of polyvinyl chloride (PVC) plastic. The report includes details aboutthe production technologies used and markets served by 146 chlor-alkali plants (60 in Asia) and which of these plants supply chlorine to 113 PVC plants (52 in Asia). The report answers fundamental questions like: 

• Who is producing chlorine? 
• Who is producing PVC? 
• Where? How much? And with what technologies? 
• What products use the chlorine made in each plant? 

Key findings include:

• Over half of the world’s chlorine is consumed in the production of PVC. In China, we estimate that 74 percent of chlorine is used to make PVC.
• 94 percent of plants in Asia covered in this report use PFAS-coated membrane technology to generate chlorine.
• In Asia the PVC industry has traded one form of mercury use for another. While use of mercury cell in chlorine production is declining, the use of mercury catalysts in PVC production via the acetylene route is on the rise. 63 percent of PVC plants in Asia use the acetylene route. 
• 100 percent of the PVC supply chain depends upon at least one form of toxic technology. These include mercury cells, diaphragms coated with asbestos, or membranes coated with per- and polyfluoroalkyl substances (PFAS), used in chlorine production. In PVC production, especially in China, toxic technologies include the use of mercury catalysts.

Supplemental Documents:

• Spreadsheet: Chlorine & Building Materials Worldwide
• Map: HBN Map of Chlorine & PVC Resin Factories
• Chlorine and Building Materials Project: Phase 1

Chlorine is a key feedstock for a wide range of chemicals and consumer products, and the major ingredient of polyvinyl chloride (PVC) plastic. The report includes details about the largest 86 chlor-alkali facilities and reveals their connections to 56 PVC resin plants in the Americas, Africa and Europe. (The second phase of this project will inventory the industry in Asia.) A substantial number of these facilities, which are identified in the report, continue to use outmoded and highly polluting mercury or asbestos.

Demand from manufacturers of building and construction products now drives the production of chlorine, the key ingredient of PVC used in pipes, siding, roofing membranes, wall covering, flooring, and carpeting. It is also an essential feedstock for epoxies used in adhesives and flooring topcoats, and for polyurethane used in insulation and flooring.

Key findings include:

• In the United States, the chlor-alkali industry is the only industry that still uses asbestos, importing 480 tons per year on average for 11 chlor-alkali plants in the country (including 7 of the 12 largest plants).
• The only suppliers of asbestos to the chlor-alkali industry are Brazil (which banned its production, although exports continue for the moment) and Russia, whose Uralasbest mine is poised to become the sole source of asbestos once Brazil’s ban is in place.
• The US Gulf Coast is the world’s lowest-cost region for production of chlorine and its derivatives. It is home to 9 facilities that use asbestos technology, and some of the industry’s worst polluters including 5 of the 6 largest emitters of dioxin.
• One Gulf Coast facility has been found responsible for chronic releases of PVC plastic pellets into the Gulf of Mexico watershed.
• The US, Russia and Germany are the only countries in this report that allow the indefinite use of both mercury and asbestos in chlorine production.
• The world’s two largest chemical corporations – BASF and DowDuPont – have not announced any plans to phase out the use of mercury and asbestos, respectively, at their plants in Germany.
• Chlor-alkali facilities are major sources of rising levels of carbon tetrachloride, a potent global warming and ozone depleting gas, in the earth’s atmosphere.
• Far more chlorinated pollution, such as dioxins and vinyl chloride monomer, is released from chlor-alkali plants that produce feedstocks for the PVC industry than from plants that produce chlorine for other uses.

Supplemental Documents:

• Spreadsheet: Chlorine & Building Materials Worldwide
• Supplemental Table: Excess Chlorinated Pollutant Release Ratings (US and Canada)
• Map: HBN Map of Chlorine & PVC Resin Factories
• Chlorine and Building Materials Project: Phase 2

The report outlines strategies to protect public health and the environment by improving product transparency, eliminating dangerous chemicals from carpets, and increasing carpet recycling rates. It also reveals surprising efforts in the industry to remove many of these toxic substances from carpet design.