Sodium Hydroxide Production from Sodium Chloride (Membrane Process)
Caustic Soda Production Costs Report | Issue A | Q4 2024
| Report Details |
| 550 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 550 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Sodium Hydroxide production from sodium chloride in the United States, via a typical membrane process. In this process, sodium chloride is decomposed electrolytically, producing sodium hydroxide. Chlorine and hydrogen are generated as by-products in the process.
The report provides a comprehensive study of Caustic Soda production and related Caustic Soda production cost, covering three key aspects: a complete description of the Caustic Soda production process examined; an in-depth analysis of the related Caustic Soda plant capital cost (Capex); and an evaluation of the respective Caustic Soda plant operating costs (Opex).
The Caustic Soda production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Caustic Soda plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Caustic Soda plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Brine purification; (2) Electrolysis; and (3) Products Recovery.
Brine purification. Initially, recycled depleted brine is mixed with water and resaturated with fresh NaCl salt (sodium chloride). Heavy metal ions (e.g. Ca2+ and Mg2+) present in the brine would be harmful to the membranes. So the brine is treated with precipitants, in such a way the heavy metals precipitate forming a sludge, which is removed by settling in a clarifier. Subsequently, the clarified brine is filtered and then purified by ion exchange resins to remove residual hardness and achieve acceptable levels.
Electrolysis. The ultrapure brine and electricity are the main inputs to the electrolysis area. The brine is fed into the anolyte compartments of the cells, separated from the catholyte by cation-exchange membranes. Chlorine gas is generated at the anodes and sodium ions migrate through the membranes into the catholytes. The depleted brine from the anode compartments is dechlorinated downstream and then returned to brine saturation. On the catholyte side, water is electrolyzed generating hydrogen gas and hydroxyl ions. The membranes prevent the migration of such hydroxyl ions into the anolytes, in such a way that hydroxyl ions combine with the sodium ions forming caustic soda. The addition of demineralized water keeps the catholytes concentration at the desired level.
Products recovery. Hydrogen from electrolysis is compressed and directed to consumers. The caustic soda solution is concentrated to a saturated 50% NaOH solution – the commercialized form. The chlorine gas produced is sent to a drying system, consisting of drying towers where concentrated sulfuric acid circulates as dehydrating agent. The dry chlorine gas is compressed and then liquefied before being sent to storage.
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Production Process Information
Process Consumptions
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Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Caustic Soda production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Caustic Soda process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Caustic Soda production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Caustic Soda plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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