Commodity Production Costs Report

Sodium Hydroxide from Sodium Chloride (HCl as Co-Product)

Caustic Soda Operating Costs & Plant Construction Costs

500 kta United States-based plant | 107 Pages | Issue F | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

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): ?

Caustic Soda Production Cost Report 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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Table of Contents


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  • Operating Cost Summary
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • 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
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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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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