Commodity Production Costs Report
Sodium Hydroxide from Sodium Chloride (HCl as Co-Product)
Caustic Soda Operating Costs & Plant Construction Costs
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.
Key reference(s): ?

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.
Report in PDF Format
Download & Explore Anytime
Access in Various Devices
Print & Read Comfortably
Share With Co-workers
Up-to-date Report
Professional report based on Q3 2024 economic data, ensuring timely evaluations.
Multiple Use Cases
Ideal for investment screening, feasibility studies, cost estimates, and research planning.
Proven Methodology
Developed using a consistent methodology honed over a decade, ensuring reliable cost analyses.
Report Editions
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 (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

Sodium Hydroxide Production from Lime and Sodium Carbonate
This report presents the economics of Sodium Hydroxide production from lime and sodium carbonate in the United States, via a conventional lime-soda process. In this process, calcium hydroxide is generated by treating lime with water. Then, calcium hydroxide reacts with soda ash. Besides Sodium Hydroxide, Precipitated Calcium Carbonate is also obtained as product.
Details: 100 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD

Sodium Hydroxide Flakes Production
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.
Details: 60 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
Could Not Find the Report You Need?
Obtain a Bespoke Report
Get a report targeting the process in which you are interested
See Offer Details
Understand Bespoke Reports and how you can easily order them
Check Editions & Pricing
Complete a brief form and see a quotation for your Bespoke Report
Other Related Production Cost Reports

Hydrogen Production from Natural Gas (Partial Oxidation Process)
This study provides a techno-economic study of Hydrogen production from natural gas in the United States. In this analysis, natural gas is submitted to a thermal partial oxidation process, producing syngas, which is passed through a shift converter to enrich the Hydrogen output.
Details: 25 MM Nm3/y United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD

Advanced Natural Gas Combined Cycle Power Plant
This study also provides a techno-economic analysis about Electricity generation from natural gas in the USA. In this study, high efficiency H-class combustion turbines (CT) supplemented with heat recovery steam generators (HRSG) and steam turbines (ST) are employed to Electricity generation.
Details: 3500 GWh/y United States-based plant | Q3 2024 | 107 pages | Issue D | From

Hydrogen Production from Natural Gas (Steam Reforming)
This report provides an economic analysis of Hydrogen production from natural gas in the United States using a steam reforming process. Initially, methane present in natural gas is cracked with steam generating syngas. Then, the carbon monoxide from syngas is reacted with steam, producing carbon dioxide and additional hydrogen.
Details: 1000 MM Nm3/y United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD

Nitrobenzene Production from Benzene (NORAM)
This report presents the economics of Nitrobenzene production from benzene and nitric acid in the United States. The process analyzed in this report is similar to NORAM's adiabatic benzene nitration process, which uses a plug-flow nitrator containing jet-impingement elements.
Details: 530 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD

Conventional Natural Gas Combined Cycle Power Plant
This report examines the costs associated to Electricity generation from natural gas in the USA via conventional natural gas combined cycle. In this process F-class combustion turbines (CT) supplemented with heat recovery steam generators (HRSG) and steam turbines (ST) are employed to Electricity generation.
Details: 5200 GWh/y United States-based plant | Q3 2024 | 107 pages | Issue C | From

Aluminum Chloride Production
This report presents the economics of Aluminum Chloride production from aluminum metal and chlorine in the United States. In the process, chlorine gas is passed through molten aluminum, producing Anhydrous Aluminum Chloride.
Details: 10 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
+800 Reports Developed, Targeting +250 Commodities
Vast Report Library
858 independent and up-to-date reports examining embryonic and established production processes.
Free Sample Reports
Quickly understand the structure and depth of content of our professional reports.