Caustic soda manufacture

AppHcations of mercury include use in batteries (qv), chlorine and caustic soda manufacture (see Alkali and chlorine products), pigments (see Pigments, inorganic), light switches, electric lighting, thermostats, dental repair (see Dental materials), and preservative formulations for paints (qv) (1—3). As of the end of the twentieth century, however, increased awareness of and concern for mercury toxicity has resulted in both voluntary and regulatory reduction of mercury usage (see also Mercury compounds). 

Asbestos-cement products, 3 311, 313 alternatives to, 3 315 Asbestos-containing insulation, 74 211 Asbestos diaphragms, in caustic soda manufacture, 22 839 Asbestosis, 3 316... 

Unit consumption factors enable the caustic soda manufacturer to determine how much caustic soda is going to be needed for a million or a billion pounds of soap of the quality and type for which the unit consumption factors are available. The composition of soaps vary greatly according to their use and market areas, and as these and the quality change, the unit consumption factors must change. This illustrates how a technical understanding is required for the evaluation of unit consumption factors. 

Identification of Some Hazards in Caustic Soda Manufacturing Plant... 

Table 17.3 Identifieation of some hazards in caustic soda manufacturing plant...

J. C. Iverstine, J.L. Kinard, and R.M. Cudd, Technological Response to Environmental Protection Regulations and Energy Price/Supply Structure A Case Study of Chlorine/Caustic Soda Manufacturing, Report PB83-114751 to National Science Foundation (1981). 

R. Powell Chlorine and Caustic Soda Manufacture, Noyes Data Corp., Park Ridge, N.J., 1971. 

Most of the ethylene dichloride produced is utilized for the manufacture of vinyl chloride, which may be obtained from it by pyrolysis or the action of caustic soda. Large quantities are also used in anti-knock additives for gasoline. As a solvent It has been displaced by trichloroethylene and tetrachloroelhyJene. U.S. production 1978 4-75 megatonnes. 

Three forms of caustic soda are produced to meet customer needs purified diaphragm caustic (50% Rayon grade), 73% caustic, and anhydrous caustic. Regular 50% caustic from the diaphragm cell process is suitable for most appHcations and accounts for about 85% of the NaOH consumed in the United States. However, it caimot be used in operations such as the manufacture of rayon, the synthesis of alkyl aryl sulfonates, or the production of anhydrous caustic because of the presence of salt, sodium chlorate, and heavy metals. Membrane and mercury cell caustic, on the other hand, is of superior quaUty and... 

Chemical Manufacturing. Chemical manufacturing accounts for over 50% of all U.S. caustic soda demand. It is used primarily for pH control, neutralization, off-gas scmbbing, and as a catalyst. About 50% of the total demand in this category, or approximately 25% of overall U.S. consumption, is used in the manufacture of organic intermediates, polymers, and end products. The majority of caustic soda required here is for the production of propylene oxide, polycarbonate resin, epoxies, synthetic fibers, and surface-active agents (6). 

Demand for Caustic Soda Types. Approximately 99% of the sodium hydroxide produced in 1987 was 50% caustic solution (5). Higher concentrations require additional evaporation and therefore increased prices relative to the sodium oxide values. To obtain maximum value, users have learned to adapt manufacturing processes to the 50% caustic soda. 

Handbooks pubHshed by Caustic Soda SuppHers, The Chlorine Institute, Washington, D.C., and The Manufacturing Chemists Assn., 1989. 

Other Organic Processes. Solvent extraction has found appHcation in the coal-tar industry for many years, as for example in the recovery of phenols from coal-tar distillates by washing with caustic soda solution. Solvent extraction of fatty and resimic acid from tall oil has been reported (250). Dissociation extraction is used to separate y -cresol fromT -cresol (251) and 2,4-x5lenol from 2,5-x5lenol (252). Solvent extraction can play a role in the direct manufacture of chemicals from coal (253) (see Eeedstocks, coal chemicals). 

Sodium fluoride is normally manufactured by the reaction of hydrofluoric acid and soda ash (sodium carbonate), or caustic soda (sodium hydroxide). Control of pH is essential and proper agitation necessary to obtain the desired crystal size. The crystals are centrifuged, dried, sized, and packaged. Reactors are usually constmcted of carbon brick and lead-lined steel, with process lines of stainless, plastic or plastic-lined steel diaphragm, plug cock, or butterfly valves are preferred. 

Alkalies. In the 1960s, 3.2-34 x 10 t /yr of lime was captively produced by the U.S. alkaH industry for manufacturing soda ash and sodium bicarbonate via the Solvay process. Electrolytic process caustic soda and natural soda ash (trona) from Wyoming have largely replaced the Solvay process. Three of the trona producers in Wyoming now purchase quicklime for producing caustic soda. 

Manufacture, Shipment, and Analysis. In the United States, sodium and potassium thiocyanates are made by adding caustic soda or potash to ammonium thiocyanate, followed by evaporation of the ammonia and water. The products are sold either as 50—55 wt % aqueous solutions, in the case of sodium thiocyanate, or as the crystalline soHds with one grade containing 5 wt % water and a higher assay grade containing a maximum of 2 wt % water. In Europe, the thiocyanates may be made by direct sulfurization of the corresponding cyanide. The acute LD q (rat, oral) of sodium thiocyanate is 764 mg/kg, accompanied by convulsions and respiratory failure LD q (mouse, oral) is 362 mg/kg. The lowest pubhshed toxic dose for potassium thiocyanate is 80—428 mg/kg, with hallucinations, convulsions, or muscular weakness. The acute LD q (rat, oral) for potassium thiocyanate is 854 mg/kg, with convulsions and respiratory failure. 

A newer technology for the manufacture of chromic acid uses ion-exchange (qv) membranes, similar to those used in the production of chlorine and caustic soda from brine (76) (see Alkali and cm ORiNE products Chemicals frombrine Mep rane technology). Sodium dichromate crystals obtained from the carbon dioxide option of Figure 2 are redissolved and sent to the anolyte compartment of the electrolytic ceU. Water is loaded into the catholyte compartment, and the ion-exchange membrane separates the catholyte from the anolyte (see Electrochemical processing). 

Of somewhat greater technical interest are the addition compounds and the cellulose esters and ethers. Of the apparent addition compounds the most important is alkali cellulose produced by steeping cellulose in caustic soda and considered to be of general form (CgHioOs), (NaOH) ) rather than a sodium alcoholate compound. Alkali cellulose is a particularly important starting point in the manufacture of cellulose ethers. The ability of aqueous cuprammonium hydroxide solutions to dissolve cellulose appears to be dependent on addition compound formation. 

Reaction of alkali cellulose with carbon disulphide to produce a cellulose xanthate which forms a lyophilic sol with caustic soda. This may be extruded into a coagulating bath containing sulphate ions which hydrolyses the xanthate back to cellulose. This process is known as the viscose process and is that used in the manufacture of rayon. 

Two classes of resol are generally distinguished, water-soluble resins prepared using caustic soda as catalyst, and spirit-soluble resins which are catalysed by addition of ammonia. The water-soluble resins are usually only partially dehydrated during manufacture to give an aqueous resin solution with a solids content of about 70%. The solution viscosity can critically affect the success in a given application. Water-soluble resols are used mainly for mechanical grade paper and cloth laminates and in decorative laminates. 

The paper and pulp industries consume taif/e quantities of Ca(OH)2 and precipitated (as distinct from naturally occurring) CaCOs. The largest application of lime in pulp manufacture is as a causlicizing agent in sulfate (kraft) plants (p. 89). Here the waste NajC solution is reacted with lime to regenerate the caustic soda used in the process ... 

The raw materials for the manufacture of soap, the alkali salts of saturated and unsaturated C10-C20 carboxylic acids, are natural fats and fatty oils, especially tallow oil and other animal fats (lard), coconut oil, palm kernel oil, peanut oil, and even olive oil. In addition, the tall oil fatty acids, which are obtained in the kraft pulping process, are used for soap production. A typical formulation of fats for the manufacture of soap contains 80-90% tallow oil and 10-20% coconut oil [2]. For the manufacture of soft soaps, the potassium salts of fatty acids are used, as are linseed oil, soybean oil, and cottonseed oil acids. High-quality soap can only be produced by high-quality fats, independent of the soap being produced by saponification of the natural fat with caustic soda solution or by neutralization of distilled fatty acids, obtained by hydrolysis of fats, with soda or caustic soda solutions. Fatty acids produced by paraffin wax oxidation are of inferior quality due to a high content of unwanted byproducts. Therefore in industrially developed countries these fatty acids are not used for the manufacture of soap. This now seems to be true as well for the developing countries. 

Further important auxiliary agents for the manufacture of soap are caustic soda solution, calcined soda, sodium chloride, and (for the manufacture of soft soap) caustic pottash solution, potassium carbonate, and potassium chloride. 

Improvement teams, Six-Sigma, 21 174 Impurities. See also Contaminants Metal ion impurities Purification caustic soda in removing, 22 832 in limestone, 15 33, 34t, 40 in magnesium, 15 342-343 in manganese ore, 15 542—545 in metal, 16 130 in MOCVD growth, 22 157 removal in vinyl chloride manufacture, 25 641, 642... 

Australia has a population of only 18 million people, spread geographically over an area similar to that of the mainland USA. The chlor-alkali industry in Australia is small by world standards and has a product mix unique in being aligned neither with chlorinated solvents nor the vinyl chain. The chlorine/caustic soda balance is heavily skewed towards caustic use in the alumina industry however, none of the locally produced caustic soda reaches this market. This has resulted in an industry limited by outlets for the chlorine half of the ECU and based on a relatively large number of small plants scattered across the country to serve localised chlorine market needs. Australia remains a large importer of caustic soda to fill the gap between local manufacture and demand, primarily for the alumina industry. 

Orica Australia Pty Ltd, formerly ICI Australia, is the largest manufacturer of chlorine and caustic soda in Australia. In December 1998, the Orica Board sanctioned a project to replace two mercury cell plants with new membrane plants. The plants are due to be commissioned sequentially at the end of 2000/mid-2001 at a total capital cost of US 100 million. 

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