Commodity Production Costs Report

Sodium Hydroxide Production from Sodium Chloride (Diaphragm Process)

Caustic Soda Operating Costs & Plant Construction Costs

600 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $799 USD | See Report Editions Prices

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.

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 three major sections: (1) Brine preparation; (2) Electrolysis ; and (3) Products recovery.

Brine preparation. Initially, brine is treated with precipitants, in such a way the heavy metals precipitate forming a sludge, which is removed by settling in a clarifier and subsequent filtration.

Electrolysis. The treated brine is sent to the electrolysis section, where hydrogen gas, chlorine gas, sodium ions and hydroxyl ions are generated. The ions combine forming caustic soda, which is sent to evaporation, downstream. The the gases are also routed to product recovery.

Products recovery. Hydrogen from electrolysis is compressed and directed to consumers. The caustic soda solution is fed to an evaporator, where it is concentrated to a saturated 50% NaOH solution – the commercialized form. Part of the concentrated solution is recycled. The chlorine gas produced is dried, compressed and then liquefied before being sent to storage.

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Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 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
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 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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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
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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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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