Department of Chemical Engineering

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

666, Upper Indira Nagar, Bibwewadi, Pune 411037

A Presentation on

CHEMICAL PROCESS TECHNOLOGY

Presented by ,

Prof. Amruta Mokashi

Lecture 8,9: 30th September and 1st oct 2021

 Chlorine-Caustic soda
• Properties of chlorine (Cl2)
 Molecular weight: 70.9 g/mol
 Melting Point: -101.6°C
 Boling Point: -34.6°C
 Critical temp.: 146°C
 Critical Pressure: 93.5atms
 Liquification Point: 5.7 atms and 15°C
 Toxic Gas: 0.35-2.0 ppm is max. conc.
 Grades: Technical (99.0%)
• Properties of caustic soda (NaOH)
 Molecular weight: 40.0 g/mol
 Melting Point: -318°C
 Boling Point: -1390°C
 Density: 2.13 g/mol
 Solubility: 1000 g/L (25°C) (water)
 Grades: 60% Na2O (77.4% NaOH)
76% Na2O (98% NaOH)
 History
• 1853 : Lime causticization
• 1883-1893 : Development of diaphragm and mercury cell
process
• 1893 : First diaphragm plant in the USA
• 1892 : First mercury cell
• 1960 : only electrolytic method used for chlorine and caustic
soda manufacturing
Uses
 Classification of processes
1. Electrolytic Process
a) Diaphragm electrolytic cell
b) Mercury electrolytic cell
c) Membrane electrolytic cell

2. Chlorine processes without co-product

a) HCl-air oxidation with Fe2O3 catalyst.
b) HCl-air-Cl2 oxychlorination processes.
c) HNO3-NaCl- air process

3. NaOH process with no Cl2 co-product

a) Na2CO3-Ca(OH)2
Mercury Process
Diaphragm Process
Membrane Process
 Electrolytic Process
Electrolysis Reactions :
Raw Materials :
● 10-15% NaCl or Solid Salt ● Na2CO3 and NaOH ● H2SO4

Quantitative requirements :
a) Basis : 1 ton of Cl2, 1.15 tons of NaOH (98%), 283Nm3 of H2 (26 kg)
Salt 1.3 tons
Soda Ash (58% Na2O) 26 kg
Sulfuric acid (98%) 5-6 kg
Sodium Hydroxide 10-15 kg
Graphite and mercury
Steam 11 tons (Diaphragm cell process)
Electricity 2900 KWH
b) Plant Capacities: 100-1000 tons/day of Cl2
• Major Engineering Problems
a) Choice of cell design
b) Corrosion

• Economics
a) Plant Location
b) Caustic-chlorine-hydrogen balance
c) Lime-soda process
d) Choice of electrolytic cell
e) Power costs
 Caustic soda capacity in India
• Aditya Birla Management Corp Pvt Ltd, Gujarat Alkalies and Chemicals Ltd, DCM
Shriram Ltd, Nirma Ltd and Reliance Industries Ltd together accounted for 57.6% of
the total Caustic Soda capacity in India in 2017.
• The main sectors that consume Caustic Soda in India are Textile, Organic Chemicals,
Alumina, Paper and Pulp, Soaps and Detergents, Inorganic Chemicals, and Water
Treatment. In 2017, these sectors accounted for almost 76.1% of the demand in the
country.
• The average price of Caustic Soda in India is expected to increase at a CAGR of
3.1% from $528.3/Ton in 2017 to $614.1/Ton in 2022.
• Between 2008 and 2017, India had been a net importer of Caustic Soda. According to
Global Data, India is expected to be a net exporter with exports being higher than
imports until 2022.
• Imports as percentage of demand in 2008 was 3.7%. Global Data forecasts imports
as percentage of demand to decrease from 7.5% in 2017 to 1.9% in 2022.
 Caustic soda manufacturers in India
• GACL-NALCO Alkalies and Chemicals Private Limited (GNAL) (Dahej, Gujarat)
• Grasim Industries Limited, (Gujarat)
• DCM Shriram Consolidated Limited, (Gujarat)
• Gujarat Alkalies and Chemicals Limited, (Gujarat)
• Reliance Industries Ltd, (Mumbai, Maharashtra)
• ChemPlast Sanmar, (Tamil Nadu)
• DCW Limited, (Mumbai, Maharashtra)
• Nirma Limited, (Gujarat)
• Meghmani Organics Limited, (Dahej, Gujarat)