Sodium Hydroxide from Sodium Chloride (HCl as Co-Product)
Caustic Soda Production Costs Report | Issue F | Q3 2024
Report Details |
500 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 500 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 a Sodium Hydroxide production via a typical membrane process integrated with the production of hydrochloric acid. In this process, sodium chloride is decomposed electrolytically producing sodium hydroxide, chlorine and hydrogen. Hydrogen and chlorine are reacted forming hydrogen chloride, which is subsequently absorbed in water to produce an aqueous hydrochloric acid solution. The analysis is based on plant located in the United States.
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 four major sections: (1) Brine purification; (2) Electrolysis; (3) Sodium Hydroxide recovery; and (4) Hydrochloric acid production.
Brine purification. Initially, recycled depleted brine is resaturated with fresh sodium chloride. The brine is treated with precipitants, in such a way the heavy metals (harmful to the membranes) precipitate forming a sludge, which is removed by settling in a clarifier. Subsequently, the clarified solution is filtered and then purified by ion exchange resins to remove residual hardness until acceptable levels are achieved.
Electrolysis. 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.
Sodium Hydroxide recovery. The Caustic Soda solution is concentrated to a saturated 50% NaOH solution, the commercialized form, before being sent to storage. The evaporation of the Caustic Soda solution is carried out in a triple effect evaporator, having nickel as the material of construction.
Hydrochloric acid production. Chlorine and hydrogen are reacted to produce hydrogen chloride. A slight excess of hydrogen is used to assure a chlorine-free product (an additional amount of hydrogen is purchased from an external supplier). The reaction takes place in a combustion chamber. The hydrogen chloride formed is fed to a falling film absorber where it is absorbed in a weak acid stream to produce 35 wt% hydrochloric acid. The gas from the absorber is sent to a tails tower, where the remaining hydrogen chloride is absorbed in demineralized water, forming a weak acid stream, which is recycled to the absorber.
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Production Process Information
Process Consumptions
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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
Other Caustic Soda Production Cost Reports
Sodium Hydroxide Production from Sodium Chloride (Membrane Process)
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.
Details: 550 kta United States-based plant | Q3 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 550 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Sodium Hydroxide Production from Sodium Chloride (Diaphragm Process)
It presents the economics of Sodium Hydroxide production from brine in the United States. The process examined in this report is a typical diaphragm process. Chlorine and hydrogen are also generated as by-products in the process.
Details: 600 kta United States-based plant | Q3 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 600 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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