Methyl chloride is used as one of the main raw materials in the production of silicon-based polymers. Methyl chloride gas is reacted with powdered silicon metal in the presence of a copper catalyst. After reacting the products with water, methylsilicone polymer is formed.

Dow Corning implemented a major expansion at the Barry site in 1999, which more than doubled its production capacity. As part of this work, a new unit was installed to optimise the recovery and reuse of methyl chloride.

Waste gases from the production of silicone contain unreacted methyl chloride and silane compounds. The recovery unit allows these valuable raw materials to be captured and re-used. This saves emissions to the environment, minimises the use of raw materials and also provides energy for the generation of steam which is used on the site.

Re-use of methyl chloride has drastically reduced emissions to the atmosphere despite the increased production rates.