CHLOR ALKALI

PRODUCTION
By: Edward Didy S
 Chlor Alkali Flow Diagram

Hydrogen Hypo
System Hypo
Handling
Salt

Brine Chlorine Cl2 Gas to HCl Plant

Electrolyzer
Treatment Handling
Liquid Cl2 to storage
Water

Caustic
Handling Caustic
ELECTROLYZER
• Kind of electrolyzer
• Diaphragm cell. (1885)
• Mercury cell. (1942)
• Membrane cells. (early 19 century)
Diaphragm cell
Mercury Cells
Membrane Cells
Membrane Cells
Electrolyzer Component
Reaction
• Overall Reaction
• 2NaCl + 2H2O + e- → 2NaOH(s) + H2(g) + Cl2(g) ........(1)
The main Anode Reaction
• NaCl(s) ↔ Na+(aq) + Cl- (aq) ......(2)
• 2Cl- → Cl2 + 2e- .....(3)
The main Cathode Reaction
• H2O + e- →1/2H2 + OH- ....(4)
Intermediate Reaction
• OH- + Na+ ↔ NaOH ....(5)
• Cl2 (g)↔ Cl2 (aq) ....(6)
• Cl2 (aq) + 2H2O + e- ↔ HOCl + H+ + Cl-.....(7)
• HOCl ↔ H+ + Ocl- ....(8)
• 2HOCl + Ocl- ↔ ClO3- + 2H+ + 2Cl-........(9)
• H2 (g)↔ H2 (aq) ....(10)
Reaction
• Side Reaction
• The large majority of significant electrolytic side reaction occur at
the anode producing oxygen and chlorate
• Oxygen formation is due to oxidation of hydroxyl ion or of water
• 2OH-  O2 + 2H+ + 2e-....(11)
• 2H2O  O2 + 4H+ + 4e-....(12)
• Chlorate is formed by a series of electolytic and chemical reaction
steps involving the hypochlorite ion. The overall reaction is :
• Cl- + 3H2O  ClO3- + 6H+ +6e-....(13)
• Chlor alkali cells are designed to reduce the side reactions.
Usually the efficiency of chlor alkali cell 95%
Parameter
• Feed Brine
• NaCl : 300 – 310 gpl
• SO4 : max 10 gpl
• Hardness : max 30 ppb
• pH : 10 – 11
• NaClO3 : max 5 gpl.
• Feed Cautic :
• Cosentration : 28% – 30%
• Exit Brine :
• NaCl : 210 - 230 gpl
• SO4 : max 10 gpl
• NaOCl : max 3 gpl
• pH : max 5
• NaClO3 : max 5 gpl.
• Exit Cautic :
• Consentrasi : 31.5% – 32.5%
• H2 content on Cl2 gas max : 0.1%
• O2 content on Cl2 gas max : 5%
Caustic Production Calculate
 Chlorine and Weak Brine Handling
HCl NaOH SO2

pH 1.5 - 1.8

Cl2 Weak brine Dechlorinator Dechlorinated

electrolyzer tank tank
Saturator
Weak tank Weak
brine brine
87oC Cl2
Condensate
Chlorine Cooling water
Cooling water
Cooler
35-40oC Cl2
Condensate
Chiller water
Chlorine
Chiller water
chiller
15oC Cl2

Chlorine
Demin Water Condensate Pressure Seal Vaccum Seal
Candle Filter
Cl2
Cl2
Chlorine HCl Syntesis
Blower Plant
Caustic and Hydrogen Handling

Brine
electrolyzer H2

Catholyte
H2 Cooler H2 Chiller
Tank
NaoH 28-30%
o
87 C

NaoH 32% H2 Blower

Cautic Heat
Exchanger
Caustic HCl Synthentis
Cooler Plant

NaoH 32%

Intermeadiate Internal caustic

tank consumption

NaoH 32%

Caustic
Fiberline
storage tank
Hypo System
Hypo System
Hypo System - Component
Hypo System - Component
Hypo System - Component
Hypo System
Thank You
 • Weak brine tank reaction :
• Hypochlorous Acid + Hydrochloric Acid → Water + Chlorine
• HOCl + HCl → H 2O + Cl2

The chlorine pressure/vacuum seal pot protects the electrolyzers from high
and low pressure conditions. The top half provides pressure relief while the
bottom half provides vacuum relief.

The dechlorinated brine tank provides the residence time for the chemical reactions
which destroy traces of chlorine to complete.
Caustic + Sodium Sulphite + Chlorine → Sodium Sulphate + Salt + Water
NaOH + Na2SO3 + Cl2 → Na2SO4 + 2NaCl + H2O