Detailed Project Report on Caustic Soda [Sodium Hydroxide (NaoH)] By Electrolytic Process

CAUSTIC SODA [SODIUM HYDROXIDE (NaoH)] BY ELECTROLYTIC PROCESS

[EIRI/EDPR/1626] J.C.430

INTRODUCTION

Alkali chemical constitutes the oldest segment of the chemical industry. These chemicals serve as key inputs for a number of industries such as aluminium, soap, detergent, glass, tyre, rubber, pulp and paper, pharmaceutical, water treatment, textiles, leather, fiber etc. The key chemicals in the chlor-alkali industry are 

• Caustic Soda 

• Chlorine (including liquid chlorine) 

• Soda Ash

Caustic Soda (chemically known as Sodium Hydroxide) and Chlorine are produced together through the electrolysis of common salt solution (Sodium Chloride or Brine).

Caustic Soda and Chlorine are generated in the ratio of 1:0.89. Demand for chlorine drives caustic soda production globally, but in India the industry has developed in line with the demand-supply balance of caustic soda.

There are three alternative technologies used to manufacture caustic soda from brine. These are membrane cell; diaphragm and mercury cell technologies.

1. The membrane cell technology involves lower power costs compared to the other two. It is also the most environmental friendly as it does not use any hazardous materials as compared to mercury cell and diaphragm technologies which use mercury and asbestos respectively.

2. The diaphragm technology involves higher capital and power costs. The quality of caustic soda is also of inferior quality. However, it is popular as the purity of chlorine from this method is highest and chlorine demand is major driver for caustic soda production globally.

3. Mercury cell technology involves lower capital costs compared to membrane and diaphragm technologies. However, it is not so popular because of related pollution hazards due to use of mercury.

Globally the diaphragm technology is the most widely used while in India the membrane cell technology accounts for more than 90% of the total capacity.

Caustic soda is available in both solid and liquid form. It is deliquescent, absorbing water vapour and carbon dioxide from the air. It is also extremely corrosive and should be handled with great care. Adequate protection from bodly contact with the solid form or concentrated solutions should be provided. It is also a fire hazard compound as it heats spontaneously and may ignite combustible materials that are nearly.

COST ESTIMATION

Plant Capacity            100 MT/Day

Land & Building (40,000 sq.mt.)    Rs. 29.50 Cr

Plant & Machinery                    Rs. 97.84 Cr

Working Capital for 3 Months    Rs. 21.11 Cr

Total Capital Investment          Rs. 174.86 Cr

Rate of Return                          23%

Break Even Point                      62%

CONTENTS

INTRODUCTION

USES

BIS SPECIFICATION

MARKET SURVEY

MANUFACTURERS/SUPPLIERS/EXPORTERS OF CAUSTIC SODA

PROCESS OVERVIEW

DIAPHRAGM CELL

MEMBRANE CELL

PROCESS FLOW SHEET

PROCESS FLOW DIAGRAM FOR CAUSTIC SODA MANUACTURE

PROCESS OF MANUFACTURE

RAW MATERIAL REQUIRMENTS

PROCESS DESCRIPTION

ELECTROLYTIC PROCESS FOR CHLORINE AND CAUSTIC SODA

PROCESS DETAILS, EMISSION AND ITS CONTROLS

OPERATIONAL OF MEMBRANE CELL PLANTS

SPECIAL FEATURES OF THE PLANT

TREATMENT OF EFFLUENTS RELEASING FROM CHLORO ALKALI PLANT

BLOCK DIAGRAM TO MANUFACTURE CAUSTIC SODA (MEMBRANCE CELL TECHNOLOGY)

TECHNOLOGY AND ENERGY CONSERVING POTENTIAL

PRODUCTION PROCESS AND ENERGY SAVING TECHNOLOGY

SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)

SUPPLIERS OF CAUSTIC SODA PLANT AND EQUIPMENTS ON TURNKEY BASIS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERY SUPPLIERS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)