Commodity Production Costs Report
Sodium Chlorate Production
Sodium Chlorate Operating Costs & Plant Construction Costs
This report presents the economics of a typical Sodium Chlorate production process from sodium chloride via electrolysis. The economic analysis approaches a plant located in the United States.
The report provides a comprehensive study of Sodium Chlorate production and related Sodium Chlorate production cost, covering three key aspects: a complete description of the Sodium Chlorate production process examined; an in-depth analysis of the related Sodium Chlorate plant capital cost (Capex); and an evaluation of the respective Sodium Chlorate plant operating costs (Opex).
The Sodium Chlorate 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 Sodium Chlorate 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 Sodium Chlorate 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 two major sections: (1) Electrolysis and (2) Sodium Chlorate Recovery.
Electrolysis. In a salt dissolver, a brine solution is prepared from sodium chloride raw material and process water. After purification, the solution receives hydrochloric acid and sodium dichromate, which, respectively, increase cell efficiency and protect electrodes from corrosion. The purified, acidified solution is then subjected to electrolysis. At the cathodes, hydrogen gas is generated and released along with impregnated chlorine. The released gas is collected in a column that prevents chlorine emissions through caustic scrubbing. At the anodes, chlorine atoms generated combine with water and free ions forming hypochlorous acid and sodium hypochlorite. Hypochlorous acid and sodium hypochlorite then react forming sodium chlorate. Reaction tanks downstream the electrolytic cells provide a longer residence time for the chemical reaction between hypochlorous acid and sodium hypochlorite to take place. The cells liquor is finally transferred to the crystallizer in the Sodium Chlorate Recovery section.
Sodium Chlorate Recovery. Prior to crystallization, residual hypochlorites are eliminated through heating and addition of chemicals. The cells liquor, virtually free of hypochlorites, is heated, subjected to vacuum evaporation and finally crystallized under vacuum. The Sodium Chlorate crystals are recovered by centrifugation, washed, and fed to a dryer. Dry sodium chlorate is conveyed to silos before being packed into big bags.
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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 Sodium Chlorate 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 Sodium Chlorate 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 Sodium Chlorate 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 Sodium Chlorate 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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