Detailed Project Report on caustic soda (sodium hydroxide (naoh) by electrolytic process

CAUSTIC SODA (SODIUM HYDROXIDE (NaoH) BY ELECTROLYTIC PROCESS
 [CODE NO.3776]  


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.


COST ESTIMATION


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%            


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 – 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)