Industry Overview
Alkali chemicals represent one of the oldest segments of the chemical industry and serve as essential inputs for industries including aluminium, soap and detergents, glass, tyres and rubber, pulp and paper, pharmaceuticals, water treatment, textiles, leather and fibres. The principal chemicals associated with the chlor-alkali industry are caustic soda, chlorine, including liquid chlorine, and soda ash.
Caustic soda, chemically known as sodium hydroxide, and chlorine are produced together through the electrolysis of a common salt solution, or brine. They are generated in a ratio of 1:0.89. While global caustic soda production is significantly influenced by chlorine demand, the Indian chlor-alkali industry has developed primarily in response to the demand-supply balance of caustic soda.
Three principal technologies are used to manufacture caustic soda from brine: membrane cell, diaphragm cell and mercury cell technologies. Membrane cell technology generally involves lower power consumption than the other two processes and is considered more environmentally friendly because it does not use hazardous materials such as mercury or asbestos associated with mercury cell and diaphragm technologies, respectively.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 100 Ton/Day |
| Land & Building (10 Acres) | Rs. 24.09 Cr |
| Plant & Machinery | Rs. 89.80 Cr |
| Working Capital for 2 Month | Rs. 10.97 Cr |
| Total Capital Investment | Rs. 136.56 Cr |
| Rate of Return | 26% |
| Break Even Point | 60% |
Content Index
- INTRODUCTION
- USES
- USES OF CHORINE
- B.I.S. SPECIFICATION
- MARKET OVERVIEW OF CAUSTIC SODA CHLORINE
- INSTALLED CAPACITY & PRODUCTION IN LAST 10 YEARS
- IMPORTS
- EXPORTS
- SECTORWISE CAUSTIC SODA CONSUMPTION IN INDIA DURING 2017-18
- INSTALLED CAPACITY & PRODUCTION OF CAUSTIC SODA
- INSTALLED CAPACITY & PRODUCTION OF CHLORINE
- CONSUMPTION OF CAUSTIC SODA & LIQUID CHLORINE
- EXPORT OF CAUSTIC SODA
- EXPORT OF LIQUID CHLORINE
- IMPORT OF CAUSTIC SODA
- IMPORT OF LIQUID CHLORINE
- TOP FIVE EXPORT DESTINATION OF CAUSTIC SODA & LIQUID CHLORINE (2016-17)
- GLOBAL MARKET OVERVIEW OF CAUSTIC SODA
- PROCESS OVERVIEW
- DIAPHRAGM CELL
- MEMBRANE CELL
- PROCESS FLOW SHEET
- CHLORINE PRODUCTION FROM MEMBRANE CELLS
- PROCESS FLOW DIAGRAM FOR CAUSTIC SODA MANUACTURE
- PROCESS OF MANUFACTURE
- PROCESS DESCRIPTION
- ELECTROLYTIC PROCESS FOR CHLORINE AND CAUSTIC SODA
- OPERATIONAL OF MEMBRANE CELL PLANTS
- BACKGROUND OF THE FIRST MEMBRANE CELL PLANT IN INDIA
- SPECIAL FEATURES OF THE PLANT
- WATER SEAL CLARIFIER
- FILTERS
- SECONDARY BRINE UNIT
- CELL ROOM
- POWER CONSUMPTION
- PERFORMANCE
- PRIMARY BRINE
- FEED BRINE QUALITY
- DEPLETED BRINE
- QUALITY OF CAUSTIC SODA
- HYDROCHLORIC ACID
- LIQUID CHLORINE
- COMPRESSED HYDROGEN GAS
- CELL VOLTAGE AND POWER CONSUMPTION
- ADVANTAGE OF MEMBRANCE CELLS COMPARED TO MERCURY CELLS BRINE
- RESULTS IS, CASE OF A MEMBRANE CELL PLANT:
- CONSUMPTION FIGURES
- POWER CONSUMPTION
- CATHODE GAS
- CHLORIE LIQUEFACTION
- HYDROGEN TREATMENT
- CELL HOUSE OPERATION
- CELL MAINTENANCE
- MOVING EQUIREMENT IN CELL HOUSE
- ELECTROLYSIS OF BRINE
- THE NET RESULT OF THE REACTION CAN BE WRITTEN AS:
- PRINCIPAL AMONGST THESE ARE:
- CHLORINE AND CAUSTIC PRODUCTION
- THE DIAPHRAGM CELL PROCESS
- TYPES OF CHLORALKALI CELL PROCESSES
- THE MERCURY CELL PROCESS
- THE MEMBRANE CELL PROCESS
- DETAILS OF MEMBRANE CELL
- CHLOR-ALKALI ELECTROLYSIS PROCESS
- PROCESS DESCRIPTION
- DIAPHRAGM CELL -
- MERCURY CELL -
- SAFETY AND HEALTH HAZARDS
- 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
- RAW MATERIALS
- SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
- SUPPLIERS OF CAUSTIC SODA PLANT & EQUIPMENTS ON TURNKEY BASIS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF SALT
- SUPPLIERS OF SODIUM CARBONATE
- SUPPLIERS OF SULPHURIC ACID
- SUPPLIERS OF LIME
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF BOILERS
Appendix
- 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)
Frequently Asked Questions
The chlor-alkali industry produces important chemicals such as caustic soda and chlorine through the electrolysis of brine. These chemicals are widely used as industrial inputs in sectors including aluminium, soaps and detergents, glass, pulp and paper, pharmaceuticals, water treatment, textiles and rubber. The industry also encompasses related products and processes, including liquid chlorine and hydrogen generated during chlor-alkali electrolysis.
Caustic soda and chlorine are produced together by electrolysing sodium chloride solution, commonly called brine. The electrochemical reaction separates the brine into products that include chlorine and caustic soda, while hydrogen is also generated. The report identifies a production ratio of 1:0.89 for caustic soda and chlorine. Industrial plants use dedicated process equipment for brine preparation, electrolysis, product handling, gas treatment and associated operations.
Three principal technologies are used to manufacture caustic soda from brine: membrane cell, diaphragm cell and mercury cell processes. These technologies differ in cell construction, operating conditions, product handling and environmental considerations. The report specifically discusses membrane, diaphragm and mercury cell processes, together with their process descriptions, operating requirements, power consumption, maintenance and associated brine systems.
Membrane cell technology is used because it can provide lower power consumption than the other two major cell technologies and avoids the use of mercury and asbestos. The process employs a membrane to separate the relevant electrochemical compartments while allowing the required ionic transport. Proper brine quality, cell operation, voltage control, maintenance and downstream treatment are important factors in achieving reliable plant performance.
Caustic soda and chlorine are widely used across chemical and process industries. Caustic soda is an important input for applications involving chemical processing, pulp and paper, textiles, water treatment, soaps and detergents, and other industrial operations. Chlorine is used in chemical manufacturing, water treatment and the production of numerous downstream chemicals. Their broad industrial use makes chlor-alkali products important raw materials for several manufacturing sectors.
The primary raw material for chlor-alkali production is sodium chloride, or salt, which is prepared as brine for electrolysis. Depending on the process configuration, additional materials can be required for brine treatment, chemical adjustment and supporting operations. The report includes supplier categories for salt, sodium carbonate, sulphuric acid, lime and other raw materials, along with suppliers of plant and machinery and effluent treatment equipment.
Safety management is essential because chlor-alkali plants handle reactive chemicals and gases such as chlorine, hydrogen and caustic soda. Appropriate containment, ventilation, gas detection, process controls, personal protective equipment, emergency procedures and effluent management are important elements of plant safety. The report includes dedicated sections on safety and health hazards and the treatment of effluents released from chlor-alkali plants, highlighting the importance of controlled operation and environmental management.
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