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    Caustic Soda ChE 308

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    gcavagli
    The document discusses the chlor-alkali industry and the manufacture of caustic soda, chlorine, and soda ash. It describes the electrolytic process used to produce caustic soda and chlorine from sodium chloride. Specifically, sodium chloride solution is electrolytically decomposed into chlorine, sodium hydroxide, and hydrogen. It also discusses the three main electrochemical methods - the diaphragm cell, mercury cell, and membrane cell processes. The membrane cell process is highlighted as the most efficient with the lowest energy consumption. The document also provides details on products derived from caustic soda and chlorine like hydrochloric acid, sodium hypochlorite, and bleaching powder.

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    Caustic Soda ChE 308

    Uploaded by

    gcavagli
    150 views24 pages
    The document discusses the chlor-alkali industry and the manufacture of caustic soda, chlorine, and soda ash. It describes the electrolytic process used to produce caustic soda and chlorine from sodium chloride. Specifically, sodium chloride solution is electrolytically decomposed into chlorine, sodium hydroxide, and hydrogen. It also discusses the three main electrochemical methods - the diaphragm cell, mercury cell, and membrane cell processes. The membrane cell process is highlighted as the most efficient with the lowest energy consumption. The document also provides details on products derived from caustic soda and chlorine like hydrochloric acid, sodium hypochlorite, and bleaching powder.

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    The document discusses the chlor-alkali industry and the manufacture of caustic soda, chlorine, and soda ash. It describes the electrolytic process used to produce caustic soda and chlorine from sodium chloride. Specifically, sodium chloride solution is electrolytically decomposed into chlorine, sodium hydroxide, and hydrogen. It also discusses the three main electrochemical methods - the diaphragm cell, mercury cell, and membrane cell processes. The membrane cell process is highlighted as the most efficient with the lowest energy consumption. The document also provides details on products derived from caustic soda and chlorine like hydrochloric acid, sodium hypochlorite, and bleaching powder.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    150 views24 pages

    Caustic Soda ChE 308

    Uploaded by

    gcavagli
    The document discusses the chlor-alkali industry and the manufacture of caustic soda, chlorine, and soda ash. It describes the electrolytic process used to produce caustic soda and chlorine from sodium chloride. Specifically, sodium chloride solution is electrolytically decomposed into chlorine, sodium hydroxide, and hydrogen. It also discusses the three main electrochemical methods - the diaphragm cell, mercury cell, and membrane cell processes. The membrane cell process is highlighted as the most efficient with the lowest energy consumption. The document also provides details on products derived from caustic soda and chlorine like hydrochloric acid, sodium hypochlorite, and bleaching powder.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 24

    1

    ChE 308 Lecture 3 Chlor-Alkali Industries: Caustic soda, Chlorine, Soda Ash

    Chlor-Alkali Industry
    Lime stone and Fuel Carbon dioxide Ammonia Sodium Chloride

    Electrolyte Process

    Soda Ash

    Sodium bicarbonate

    Chlorine Pulp and Paper Solvents Pesticides Plastics Sanitation Refrigeration Fluid

    Caustic Soda Soap, Rayon, Dyes, Paper, Foods, rubber, Textiles, Chemicals, Bleaching, Petroleum, Metallurgy Soap Glass Drugs Paper Ceramics Sugar Photography Leather Drugs Beverages Baking Powder Food products Fire extinguisher

    Manufacture of Chlorine and Caustic Soda


    Sodium Hydroxide:
    White, solid material that picks up moisture from air. If put in water, it produces a large amount of heat. Very corrosive and can cause severe burns

    Caustic Soda and Chlorine Processes


    Sodium Chloride solution (brine)is electrolytically decomposed to elemental chlorine (in the anode compartment), and sodium hydroxide solution and elemental hydrogen (in the cathode compartment) in all the processes The overall reaction for the electrolytic production of caustic soda and chlorine is: 2 NaCl (aq) + 2 H2O = Cl2 (gas) + H 2 (gas) + 2 NaOH (aq) Anode Cathode

    Manufacture of Chlorine and Caustic Soda contd


    Reactions: Decomposition Voltage and voltage efficiency:

    Where, E= Theoretical decomposition voltage H= enthalpy change of reaction J= electrical equivalent of heat T= absolute temperature F= Faraday constant n= number of equivalents involved

    Manufacture of Chlorine and Caustic Soda contd


    Decomposition Voltage and voltage efficiency (contd):
    The ratio of theoretical voltage to that actually used is the Voltage efficiency of the cell(ranges from 60-75%). The ratio of the theoretical to the actual current consumed is defined as the Current efficiency(ranges from 95-97%). The product of voltage efficiency and current efficiency is the energy efficiency of the cell.

    Manufacture of Chlorine and Caustic Soda contd

    Methods of manufacture
    1. Chemical: Lime soda Process 2. Electrochemical: Chloro Alkali Process Diaphragm Cell Mercury Cell process Membrane cell process

    Electrochemical methods of manufacture


    Diaphragm cell process:
    This process uses a steel cathode, and the anode area is separated from the anode area by a permeable diaphragm. A diluted caustic brine leaves the cell. The caustic soda must usually be concentrated to 50% and the salt removed. Mercury cell process: Sodium metal forms an amalgam at a mercury cathode. This sodium is then reacted with water to produce NaOH.

    Membrane cell process:


    This process is similar to the diaphragm cell process. Here a Naflon membrane is used to separate the cathode and the anode reactions. Only sodium ions and a little water pass through the membrane. It produces a high quality of NaOH. Of the three processes , it requires the lowest consumption of electric energy and the amount of steam needed for the concentration of the caustic soda is relatively small.

    Electrochemical methods of manufacture contd

    Diaphragm Cell type Process

    Electrochemical methods of manufacture contd

    Mercury Cell type Process

    10

    Electrochemical methods of manufacture contd

    Membrane Cell type Process

    Electrochemical methods of manufacture contd

    11

    Electrochemical methods of manufacture contd

    12

    Advantages and Disadvantages of Electrochemical methods of manufacture


    Process Advantages Disadvantages

    13

    Diaphragm Process

    Use of well brine Low electricity consumption

    Use of asbestos High steam consumption Low purity caustic Low chlorine quality

    Mercury Process

    50% caustic direct from cell High purity chlorine and hydrogen Simple brine purification

    Use of mercury Expensive cell operation Large floor space Costly environment protection

    Membrane Process

    Low energy consumption Cost of membrane Use of solid salt, high purity brine Low capital investment High oxygen content in chlorine High purity caustic Insensitivity to cell load variations and shutdowns

    14

    Comparison of cell technologies


    Mercury Diaphragm Membrane

    Operating current density(KA/m2) Cell voltage (V)

    8-13 3.9- 4.2

    0.9-2.6 2.9- 3.5

    3-5 3.0-6.0

    NaOH strength(wt%)

    50

    12

    33-35

    Energy Consumption(KWh/MT Cl2) Steam Consumption (KWh/MT Cl2) for concentration to 50% NaOH

    3360

    2720

    2650

    610

    180

    15

    Membrane cell process Flow sheet

    16

    17

    Dorr Continuous Causticization Process

    18

    19

    Other Chlor-Alkali Products

    20

    Liquid Chlorine
    Chemical Formula: Cl2 Appearance: Clear amber color Product Quality: Cl2 purity 99.5% Uses: Manufacture of various chemical compounds e.g., carbon tetrachloride, chlorinated lime, PVC, HCl, etc. Water purification, manufacture of metallic chlorides, chlorinated lime, chlorobenzene, etc. Shrink proofing wool, in flame-retardant compounds, manufacture of trichloroethylene, neoprene etc. Processing of meat, fish, vegetables and fruit, in special batteries (with lithium or zinc)

    21

    Hydrochloric acid
    Chemical Formula: HCl Product quality: 30-32% HCl Appearance: Colorless or slightly yellow fuming liquid Uses: Metal picking and cleaning, industrial acidizing, boiler scale removal Processing of bone in gelatin manufacturing industry, food processing (corn syrup, sodium glutamate). Manufacture of dyestuffs, casein, pharmaceuticals, synthetic rubber, laboratory reagent etc. Effluent treatment and the regeneration of ion-exchange resin in water treatment. Bangladesh demand: 150- 200 TPD

    22

    Sodium Hypochlorite
    Chemical Formula: NaOCl Product quality: Available Cl2 Appearance: Pale greenish liquid Uses: Disinfection, odor control, specification, bleaching. Chlorination of drinking and process water, oil refineries, petroleum refineries. Textile industry, pulp and paper industry, soap manufacturing, food processors, wood processing. Elimination of slime and algae in swimming pool and boiler water. Bangladesh demand: 40- 50 TPD

    23

    Stable Bleaching Powder


    Chemical Name: chlorinated lime Chemical Formula: Ca(OCl)Cl Product quality: 30-32% HCl Appearance: Dry free flowing dull white powder Product quality: Available chlorine conc. 35-37% min Uses: Sewage disposal, odor control, BOD reduction and removal of poisonous matter. Potable water purification, mosquito control, control of epidemic etc. Bleaching agent (paper & textile), algaecide, bactericidal and deodrant. Elimination of algae and slime in swimming pool, sanitation and general hygiene. Bangladesh demand: 100- 150 TPD

    24

    Na2CO3

    Shall be discussed on next class

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