Commodity Production Costs Report
Sodium Hydroxide Flakes Production
Caustic Soda Operating Costs & Plant Construction Costs
This report presents the economics of solid caustic soda flakes production starting from a 50 wt% caustic soda solution in water. In this process, caustic soda is concentrated to about 99 wt% and the resulting melt is cooled and processed into flakes. 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.
Key reference(s): ?
The process under analysis comprises two major sections: (1) Evaporation; and (2) Flaker.
Evaporation. Sodium Hydroxide solution (50 wt%) is evaporated in three evaporation stages until molten Sodium Hydroxide is obtained. Initially, food grade sugar is dissolved with water to form a 5 wt% solution. This aqueous solution is mixed with the caustic soda solution before it is fed to the first stage. This Preconcentrator operates at mild temperatures (about 90 °C) under vacuum - a steam ejector is used to produce vacuum conditions. Steam generated in the Final Evaporator is used as heating medium. A caustic solution with 55-60% concentration is obtained and pumped to the Rising Film Evaporator, where it is evaporated to 75-85%. This evaporator operates under lower vacuum and higher temperatures (about 160 °C). The water vapors from the first two stages are condensed and discarded. The concentrated caustic solution is transferred to the final falling film evaporator, where 99% molten caustic. It operates at ambient pressure and very high temperature. Molten salt is used as heating medium.
Flaker. The hot liquid film of molten caustic is brought into contact with the cold surface of a horizontal rotating drum. As the drum rotates, the liquid film is cooled to below it melting point and solidifies. The solid caustic is removed from the drum surface by a knife, which is mounted in front of and across the whole length of the drum. The solid caustic is broken into flakes and packed.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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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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.
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