1 DESCRIPTION OF THE COMMODITY

1.1 Definition of Caustic Soda (Sodium Hydroxide), Hydrogen Chloride and

Sodium Hypochlorite
Caustic soda, also known as sodium hydroxide (NaOH), is a highly versatile and essential
industrial chemical. It is a white, solid crystalline base substance that is hygroscopic and highly
soluble in water, generating heat upon dissolution. It serves as a strong base in various chemical
reactions and used in the production of soaps, detergents, and textiles. This chemical is highly
corrosive and can cause severe burns on contact with skin or eyes. Hydrogen chloride (HCl) is a
colorless gas with a pungent odor that is highly soluble in water, forming hydrochloric acid. It is
widely used in various industrial applications. Various industries which manufacture chlorides,
fertilizers, and dyes used this chemical compound. The chemical also used for metal cleaning
and in food manufacturing industries. Sodium hypochlorite (NaOCl) is a pale yellow liquid
widely recognized as a powerful disinfectant and bleaching agent. It is commonly used in
household and industrial cleaning applications.

1.2 Uses of Caustic Soda (Sodium Hydroxide), Hydrogen Chloride and Sodium
Hypochlorite
Caustic soda, hydrogen chloride, and sodium hypochlorite are indispensable chemicals with a
wide range of applications across industries, including manufacturing, food processing, water
treatment, and pharmaceuticals.

1.2.1 Uses of Caustic Soda (Sodium Hydroxide)

Caustic soda is fundamental in the manufacturing of soaps and detergents. In the saponification
process, it reacts with fats and oils to produce glycerin and soap. This reaction is crucial for
creating both personal care products and household cleaners. Additionally, in the textile industry,
caustic soda is used in the bleaching and dyeing processes, enhancing fabric quality and color.
Sodium hydroxide serves as a key ingredient in producing various sodium compounds. It is vital
in the manufacture of sodium carbonate (soda ash), which has applications in glass production
and water softening. In the pharmaceutical industry, caustic soda is used in the synthesis of
numerous active ingredients, playing a critical role in drug formulation. In the food industry,

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caustic soda is used to regulate pH levels in various processes, such as curing olives. Caustic
soda is employed in water treatment facilities to adjust the pH of water. It neutralizes acidic
water, which helps to prevent corrosion in pipelines and improves the effectiveness of chlorine
disinfection processes.

1.2.2 Uses of Hydrogen Chloride

Hydrogen chloride is primarily known for its role in producing hydrochloric acid, one of the
most widely used industrial acids. Hydrochloric acid is crucial in various chemical reactions and
processes, including metal cleaning and ore processing. In metal processing, hydrogen chloride
is employed in pickling, a method used to clean metal surfaces. Hydrogen chloride acts as an
acidulant in food processing, helping to preserve food products and enhance flavors. It is used in
the production of gelatin and various other food additives. In laboratories, hydrogen chloride is a
vital reagent in analytical chemistry. It is often used to adjust pH levels, facilitate chemical
reactions, and prepare samples for analysis. Hydrogen chloride is also important in the
pharmaceutical industry, where it is used to synthesize active pharmaceutical ingredients

1.2.3 Uses of Sodium Hypochlorite

Sodium hypochlorite is best known for its powerful disinfectant properties. It is widely used in
water treatment facilities to disinfect drinking water and treat wastewater. In the textile industry,
sodium hypochlorite serves as a bleaching agent, effectively removing stains and enhancing the
whiteness of fabrics. It is also commonly found in household laundry products, helping to keep
clothes bright and clean. Sodium hypochlorite is effective in neutralizing odors, particularly in
waste management facilities. It is used to treat wastewater and mitigate unpleasant smells,
ensuring a more sanitary environment. In food processing, sodium hypochlorite is used for
sanitizing equipment and surfaces to prevent contamination. This compound is a key ingredient
in many household cleaners, disinfectants, and bleach products. Its versatility allows it to be used
for a variety of cleaning applications, from kitchens to bathrooms, making it a staple in many
households.

1.3 Quality standard of the commodity

The quality standard of the product is primary issue in production and marketing of the product.
The quality standards for of the above listed chemicals can vary depending on the specific
application, industry requirements, and regulatory frameworks. These standards typically cover
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various aspects, including material properties, manufacturing processes, and performance
criteria. Here’s a comprehensive overview of the key quality standards and considerations for
Caustic Soda (Sodium Hydroxide), Hydrogen Chloride and Sodium Hypochlorite:

 Manufacturing Standards: Production standards for Caustic Soda (Sodium Hydroxide),

Hydrogen Chloride and Sodium Hypochlorite ensure that the manufacturing processes
yield high-quality products that meet industry requirements and safety regulations.
Regular inspection and testing during production to ensure adherence to specifications.
 Performance Criteria: These criteria often encompass various physical, mechanical,
thermal, and chemical properties.
 Safety and Compliance: Safety and compliance for Caustic Soda (Sodium Hydroxide),
Hydrogen Chloride and Sodium Hypochlorite involve adhering to regulations and
standards designed to protect human health and the environment.
 Environmental Considerations: Environmental considerations for Caustic Soda
(Sodium Hydroxide), Hydrogen Chloride and Sodium Hypochlorite are crucial due to the
potential impact of its production, use, and disposal on the environment. Major issues to
be considered here are: material sourcing, production impact, recycling the product and
waste management. Certifications for environmentally friendly production processes are
also required.

Internationally high-quality caustic soda, hydrogen chloride, and sodium hypochlorite exhibit
several key characteristics that are essential for their effectiveness and safety in various
applications.

1.3.1 Caustic Soda (Sodium Hydroxide)

 High-quality caustic soda typically has a purity level of 98% or higher, ensuring minimal
impurities that could affect its performance in chemical reactions or manufacturing
processes.
 A highly alkaline solution (pH > 13) when dissolved in water, crucial for its role as a
strong base in chemical reactions.
 Consistent particle size and moisture content to ensure uniform performance in industrial
applications.

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1.3.2 Hydrogen Chloride
 High-quality hydrogen chloride gas or solution (hydrochloric acid) should have a purity
of 99% or higher, which is essential for industrial and laboratory applications.
 Available in various concentrations, typically up to 37% for hydrochloric acid, allowing
flexibility based on specific application needs. High reactivity with organic and inorganic
compounds, making it suitable for a wide range of chemical processes.

1.3.3 Sodium Hypochlorite

High-quality sodium hypochlorite solutions typically contain 10-15% available chlorine,
indicating effectiveness as a disinfectant and bleaching agent. Stable under proper storage
conditions, with minimal decomposition over time, provided it is kept away from light and heat
sources. A slightly alkaline pH (around 11-13) in solution, which is optimal for its disinfecting
properties.

2 THE PRODUCTION PROCESSES FOR CAUSTIC SODA, HYDROGEN

CHLORIDE, AND SODIUM HYPOCHLORITE AND TECHNOLOGY
SELECTION
The production processes for caustic soda, hydrogen chloride, and sodium hypochlorite are
interconnected, primarily centered on the electrolysis of sodium chloride (brine).

2.1 Production of Caustic Soda (Sodium Hydroxide)

Basic raw material utilized for the production of sodium hydroxide is a concentrated solution of
brine. Brine is prepared by dissolving sodium chloride in water. Electrolysis of brine is the
carried out to produce sodium hydroxide. The electrolysis process involves the following steps.
A concentrated solution of sodium chloride (NaCl) is prepared by dissolving salt in water. The
brine must be purified to remove impurities that can interfere with the electrolysis process. The
brine is fed into an electrolytic cell, which contains two electrodes: an anode and a cathode.
Electrolysis occurs when an electric current is passed through the brine.

Chemical Reactions: The electrolysis process will produce the following:

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  At the Anode: Chlorine gas (Cl₂) is produced.

2Cl−→Cl2 + 2e−2

 At the Cathode: Hydrogen gas (H₂) and hydroxide ions (OH⁻) are produced.

2H2O+2e−→H2 + 2OH−2

The hydroxide ions combine with sodium ions from the brine to form sodium hydroxide
(NaOH):

Na+ + OH− → NaOH

The products (sodium hydroxide, chlorine gas, and hydrogen gas) are separated. The sodium
hydroxide solution is then concentrated, typically by evaporation, to produce solid caustic soda
or a concentrated liquid solution.

2.2 Production of Hydrogen Chloride

During the electrolysis of brine to produce caustic soda, hydrogen chloride is formed as a
byproduct when chlorine gas is reacted with hydrogen produced at the cathode:

Cl2+H2→2HCl

The hydrogen chloride gas is typically absorbed in water to form hydrochloric acid. This process
must be done carefully to control concentration and avoid excessive heat release

2.3 Production of Sodium Hypochlorite

Chlorine gas (Cl₂) is generated, typically as a byproduct of the chlor-alkali process mentioned
earlier. Chlorine gas is bubbled through a diluted solution of sodium hydroxide. This reaction
produces sodium hypochlorite (NaOCl) along with sodium chloride (NaCl) and water:

Cl2 + 2NaOH→NaOCl + NaCl + H2O

The sodium hypochlorite solution is separated from the reaction mixture. Depending on the
intended use, it may be concentrated through evaporation or sold as a solution containing a
specific concentration of available chlorine.

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2.4 Equipment required in the Production of caustic soda, hydrogen chloride, and
sodium hypochlorite
The production of caustic soda (sodium hydroxide), hydrogen chloride, and sodium hypochlorite
involves specific equipment and processes. Here’s an overview of the equipment typically
required for each product: Limestone Processing Unit:

2.4.1 Caustic Soda (Sodium Hydroxide)

The chlor-alkali process is an industrial method for producing chlorine and sodium hydroxide
(caustic soda) from sodium chloride (salt) and water through the electrolysis of brine. Equipment
for the Production of caustic soda is the following:

 Electrolytic Cell: Used in the chlor-alkali process to produce caustic soda by

electrolysis of brine (sodium chloride solution).
 Brine Preparation Tank: For dissolving salt in water to create a brine solution.
 Electrolyte Supply System: For maintaining the brine concentration and
temperature.
 Separator: To separate chlorine gas, hydrogen gas, and caustic soda solution
 Caustic Soda Concentrator: To concentrate the caustic soda solution, often
using evaporators.
 Instrumentation and Control Systems: For monitoring and controlling
various parameters (temperature, pressure, flow rates).
 Storage Tanks: For storing caustic soda and by-products.

2.4.2 Hydrogen Chloride

 Reactor or Absorption Column: For the production of hydrogen chloride from the
reaction of hydrochloric acid or the chlor-alkali process
 Cooling System: To manage the heat produced during the reaction
 Gas Scrubber: To remove impurities from hydrogen chloride gas
 Compression System: For compressing hydrogen chloride gas for storage or
transport
 Instrumentation and Control Systems: For monitoring and controlling
various parameters (temperature, pressure, flow rates).
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  Storage Tanks: For storing hydrogen chloride gas or as an aqueous solution
(hydrochloric acid).
 Instrumentation and Control Systems: For monitoring and controlling
various parameters (temperature, pressure, flow rates).

2.4.3 Sodium Hypochlorite

 Chlorination Unit: Where chlorine gas is reacted with caustic soda to produce sodium
hypochlorite.
 Mixing Tanks: For combining chlorine and caustic soda in controlled conditions
 Reactor: A specialized reactor to facilitate the reaction under specific temperature and
pressure conditions.
 Instrumentation and Control Systems: For monitoring and controlling
various parameters (temperature, pressure, flow rates).
 PH Control System: To monitor and adjust the pH of the reaction mixture, ensuring
optimal production conditions.
 Storage Tanks: For storing the sodium hypochlorite solution.
 Dilution System: For adjusting the concentration of sodium hypochlorite before storage
or use

2.4.4 Process Flow Diagram

This process highlights the conversion of brine into valuable chemical products.

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 e
Brine
Caustic Soda Caustic soda
Preparation Electrolyti
Concentrator

electrolytic reaction
Cooling section for
Tank c Cell

Chlorine gas
collecting
Supply of
tank Reactor
Electrolysis
water
of water

Cooling section for the

HCl, hydrochloric
reactor
acid

NaOCl, sodium
hypochlorite

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2.5 Summary of Machinery and Equipment Requirement

Unit Process or
S/n Major Machinery required Purpose(Application)
operation

 Brine processing section

Chlor-alkali Used to produce chlorine and
01  Filters and
Processor sodium hydroxide (caustic soda)
 Electrolytic cells

Additive Mixing,
Used to mix various ingredients
Compounding and
02  Mixers and reactors and react the to produce HCL
reacting
and NaOCl
equipment

03 Instrumentation  Electric control system For monitoring and controlling

and Control various parameters

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 Systems

Auxiliary machines

For instrumentation of
1 Compressed air Compressors
machineries

Supply electric power during

2 Standby power Generator
main grid power outage

Table …... list of machinery and equipment

2.6 Building Units and Requirements for PVC production

Processing areas should be so designed and equipped as to allow adequate working space and so
staffed as to allow free movement of workers and to facilitate the free movement and cleaning of
movable equipment. Adequate staffing is essential to ensure unrestricted movement of workers
and facilitate the cleaning and movement of equipment. Production and Assembly hall and
Stores (Raw material or finished product or Work shop) are among the major buildings that are
important for the production factory. Construction requirements and cares to be taken to the
product in this processing area are as follows:

2.6.1 Factory Building

Foundation

Sound and stiff foundation to bear load of machineries should be provided.

Floor

Concrete slab is more suitable for floor or other suitable material which is finished smooth,
impervious and non- slip. Flooring material used should be easy to clean and laid to an even
surface that is free from cracks, crevices and open joints.

Sub surface drainage

Reinforced concrete structure provided with a suitable slope

Openings

The openings should be metal, open for adequate light and ventilation system.

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Finished product store (optional)

The block should be reserved for the purpose and is separated from production area and other
storage areas. Should be free from dampness, sufficient openings must be provided so that it is
well ventilated

2.6.2 Auxiliary Facilities

These buildings may be included in to the facilities of the canned soups manufacturing project as
per the need and size of the project:

 Office and Administration block

 Staff canteen
 Spare part store/Garage
 Generator House
 Shower, toilet and changing room (separate for each sex)
 Guard house

2.6.3 General Site Work

 The Compound of the plant should be graded to ensure proper drainage and also be
maintained in a clean and hygienic state.
 Sufficient Septic tanks with two chambers including a percolation ditch should be
provided.
 Site sanitary and Site Electrical installation works shall be provided following the
standard and working drawings.
 Walkways, driving ways and parking areas shall be constructed at least with semi dressed
stone bedded with selected material and pointed with cement mortar.
 To foster the raw materials supply and finished products dispatching processes, access
roads to the project shall be well graded and compacted with selected material to the
proper thickness so that heavy trucks can pass easily.
 Fence shall be barbed wire with concrete post and Metal gate.

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