CAUSTIC SODA (SODIUM HYDROXIDE (NaoH) BY ELECTROLYTIC PROCESS
[CODE NO.3776]
Alkali chemical constitutes the oldest segment of the chemical industry. These chemicals serve as key inputs for a number of industries such as aluminium, soap, detergent, glass, tyre, rubber, pulp and paper, pharmaceutical, water treatment, textiles, leather, fiber etc. The key chemicals in the chlor-alkali industry are
• Caustic Soda
• Chlorine (including liquid chlorine)
• Soda Ash
Caustic Soda (chemically known as Sodium Hydroxide) and Chlorine are produced
together through the electrolysis of common salt solution (Sodium Chloride or Brine).
Caustic Soda and Chlorine are generated in the ratio of 1:0.89. Demand for chlorine drives caustic soda production globally, but in India the industry has developed in line with the demand-supply balance of caustic soda.
There are three alternative technologies used to manufacture caustic soda from brine. These are membrane cell; diaphragm and mercury cell technologies.
1. The membrane cell technology involves lower power costs compared to the other two. It is also the most environmental friendly as it does not use any hazardous materials as compared to mercury cell and diaphragm technologies which use mercury and asbestos respectively.
COST ESTIMATION
Plant Capacity 100 Ton/Day
Land & Building (10 Acres) Rs. 24.09 Cr
Plant & Machinery Rs. 89.80 Cr
Working Capital for 2 Month Rs. 10.97 Cr
Total Capital Investment Rs. 136.56 Cr
Rate of Return 26%
Break Even Point 60%
INTRODUCTION
USES
USES OF CHORINE
B.I.S. SPECIFICATION
MARKET OVERVIEW OF CAUSTIC SODA CHLORINE
INSTALLED CAPACITY & PRODUCTION IN LAST 10 YEARS
IMPORTS
EXPORTS
SECTORWISE CAUSTIC SODA CONSUMPTION IN INDIA DURING 2017-18
INSTALLED CAPACITY & PRODUCTION OF CAUSTIC SODA
INSTALLED CAPACITY & PRODUCTION OF CHLORINE
CONSUMPTION OF CAUSTIC SODA & LIQUID CHLORINE
EXPORT OF CAUSTIC SODA
EXPORT OF LIQUID CHLORINE
IMPORT OF CAUSTIC SODA
IMPORT OF LIQUID CHLORINE
TOP FIVE EXPORT DESTINATION OF CAUSTIC SODA & LIQUID
CHLORINE (2016-17)
GLOBAL MARKET OVERVIEW OF CAUSTIC SODA
PROCESS OVERVIEW
DIAPHRAGM CELL
MEMBRANE CELL
PROCESS FLOW SHEET
CHLORINE PRODUCTION FROM MEMBRANE CELLS
PROCESS FLOW DIAGRAM FOR CAUSTIC SODA MANUACTURE
PROCESS OF MANUFACTURE
PROCESS DESCRIPTION
ELECTROLYTIC PROCESS FOR CHLORINE AND CAUSTIC SODA
OPERATIONAL OF MEMBRANE CELL PLANTS
BACKGROUND OF THE FIRST MEMBRANE CELL PLANT IN INDIA
SPECIAL FEATURES OF THE PLANT
WATER SEAL CLARIFIER
FILTERS
SECONDARY BRINE UNIT
CELL ROOM
POWER CONSUMPTION
PERFORMANCE
PRIMARY BRINE
FEED BRINE QUALITY
DEPLETED BRINE
QUALITY OF CAUSTIC SODA
HYDROCHLORIC ACID
LIQUID CHLORINE
COMPRESSED HYDROGEN GAS
CELL VOLTAGE AND POWER CONSUMPTION
ADVANTAGE OF MEMBRANCE CELLS COMPARED TO MERCURY CELLS BRINE
RESULTS IS, CASE OF A MEMBRANE CELL PLANT:
CONSUMPTION FIGURES
POWER CONSUMPTION
CATHODE GAS
CHLORIE LIQUEFACTION
HYDROGEN TREATMENT
CELL HOUSE OPERATION
CELL MAINTENANCE
MOVING EQUIREMENT IN CELL HOUSE
ELECTROLYSIS OF BRINE
THE NET RESULT OF THE REACTION CAN BE WRITTEN AS:
PRINCIPAL AMONGST THESE ARE:
CHLORINE AND CAUSTIC PRODUCTION
THE DIAPHRAGM CELL PROCESS
TYPES OF CHLORALKALI CELL PROCESSES
THE MERCURY CELL PROCESS
THE MEMBRANE CELL PROCESS
DETAILS OF MEMBRANE CELL
CHLOR-ALKALI ELECTROLYSIS PROCESS
PROCESS DESCRIPTION
DIAPHRAGM CELL -
MERCURY CELL -
SAFETY AND HEALTH HAZARDS
TREATMENT OF EFFLUENTS RELEASING FROM CHLORO ALKALI PLANT
BLOCK DIAGRAM TO MANUFACTURE CAUSTIC SODA (MEMBRANCE
CELL TECHNOLOGY)
TECHNOLOGY AND ENERGY CONSERVING POTENTIAL
PRODUCTION PROCESS AND ENERGY SAVING TECHNOLOGY
RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
SUPPLIERS OF CAUSTIC SODA PLANT & EQUIPMENTS ON TURNKEY BASIS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF SALT
SUPPLIERS OF SODIUM CARBONATE
SUPPLIERS OF SULPHURIC ACID
SUPPLIERS OF LIME
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF BOILERS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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