Commodity Production Costs Report
Sodium Hydroxide Production from Lime and Sodium Carbonate
Caustic Soda Operating Costs & Plant Construction Costs
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.
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 three major sections: (1) Causticization; (2) Sodium Hydroxide Purification; and (3) Calcium Carbonate Separation.
Causticization. Initially, soda ash is conveyed to a dissolution tank, also fed with a wash liquor recovered from a thickening step downstream. Here a strong soda solution is prepared, containing 18-20 wt% of sodium carbonate. In a rotary lime slaker, solid lime is slaked to a dry hydrate using wash liquor recovered from a thickening step downstream. The milk of lime is fed to a mechanical classifier for the removal of unburnt stone, overburnt lime and grit. The purified lime suspension produced is directed to the Causticizer, where a large amount of purified lime causticizes the sodium carbonate solution under agitation, yielding Sodium Hydroxide and calcium carbonate. The lye suspension, containing the sodium hydroxide produced, overflows to the 1st thickener, where the calcium carbonate settles and is separated as a sludge, generating a clear lye containing most of the Sodium Hydroxide.
Sodium Hydroxide Purification. The clear lye is concentrated in an evaporator, yielding a 50 wt% caustic soda solution. The suspension is then allowed to settle, recovering the soda solution.
Calcium Carbonate Separation. The cake from the 1st thickener is fed to two other thickeners, along with wash water, for further separation of remaining caustic soda from the sludge. The precipitated calcium carbonate obtained is partly dried, deagglomerated to the desired particle size and sold as by-product. The remainder is sent to a kiln, in which calcium carbonate is converted back to calcium oxide and carbon dioxide is generated. The calcium oxide obtained is reused in the process.
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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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