Commodity Production Costs Report
Sodium Hydroxide Production from Sodium Chloride (Mercury Process)
Caustic Soda Operating Costs & Plant Construction Costs
This report analyses the economics of Sodium Hydroxide production from brine in Germany, via a typical mercury cell process. In this process, sodium chloride is decomposed electrolytically, producing sodium hydroxide. Chlorine and hydrogen are 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): ?
Products
Caustic Soda. Causic soda (NaOH), also known as sodium hydroxide, is a major inorganic used in several industries. Most of caustic soda production is used in the manufacture of chemicals, such as propylene oxide and sodium salts. Electrolysis of sodium chloride accounts for most of today’s installed capacity for caustic soda production, which also generates chlorine.
Hydrogen. The hydrogen molecule, H2, is the normal state of pure hydrogen, even though hydrogen can be found in its atomic form under specific conditions. It is a very stable molecule, not usually reactive under normal conditions. Essentially, molecular hydrogen is produced industrially by three different methods: hydrocarbons steam reforming, hydrocarbons partial oxidation and water electrolysis. Hydrogen can also be obtained as a by-product recovered in processes such as the manufacture of styrene from ethylbenzene.
Chlorine. Chlorine figures among the most important chemical commodities. It is an indispensable intermediate in the chemical industry, employed in the manufacture of a multitude of end products (e.g. materials of construction, solvents, pesticides, etc). Most of chlorine produced on commercial scale is based on electrolysis of aqueous sodium chloride (brine), which also generates caustic soda and hydrogen as co-products (chlor-alkali processes).
Raw Material
Sodium Chloride. Sodium chloride (NaCl) is the salt naturally occurring in sea water. Sodium chloride (as aqueous solution, i.e., brine or solid) is widely used in the chemical industry as a feedstock for the production of chlorine, sodium hydroxide, and other sodium-based compounds through electrolysis.
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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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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
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