Environmental impact of Chlor-Alkali industry (Caustic Soda)

1. The caustic soda is widely produced by the electrolysis of brine solution in an electrolytic
cell. The electrolytic cells now days consist of membrane technology. In past the most
widely used technology was the diaphragm electrolytic cell and mercury electrolytic
cells. A brine solution (NaCl in water) having a concentration of about 290 g/lit is fed to
the electrolyzers where the electrolysis takes place.

2. The electrolytic cell consists of anode and cathode. The brine solution is fed to the
anodic part of cell where NaCl breaks into Na + and Cl- ions. The Na+ ion pass through the
membrane to the cathodic part of electrolytic cell where it reacts with OH - ion to form
caustic soda solution. The overall process is described in above picture. The chlorine gas
is released from the anodic chamber while the hydrogen is released from the cathodic
chamber. The equations involved are given below.

2Cl− → Cl2 + 2e−

H2O + 2e− → H2 + 2OH−
2NaCl + 2H2O → Cl2 + H2 + 2NaOH
3. After the production of caustic soda, the manufacturer will have to deal with two toxic
and flammable gasses i.e. hydrogen and chlorine.
Environmental Impact and Handling of Chlorine Gas

1. All caustic soda plants are coupled with the following plants to deal with the excess
chlorine which is produced as by-product during the production of caustic soda. These
plants include
a. Hydrochloric Acid Plant
b. Chlorine liquefaction Plant
c. PVC Plant
d. Sodium Hypochlorite Plant
2. All three major caustic producers of Pakistan i.e. Sitara Chemicals, Ittehad Chemicals and
Nimar Chemicals do not have PVC plant but they do have remaining three plants. In
internationally PVC plant is an integral part of the chlor-alkali industry.
3. The excess chlorine gas is fed to HCl furnace where hydrochloric acid is produced.
Remaining chlorine gas is sent to chlorine liquefaction plant where it is filled in cylinders
at high pressure for miscellaneous use. At last the remaining chlorine is sent to effluent
treatment plant i.e. sodium hypochlorite plant.
4. At sodium hypochlorite plant chlorine gas is absorbed in lime solution to produce the
sodium hypochlorite in a packed tower. Gas is fed to the tower from the bottom and at
the top of the tower lime solution is showered. Each and every PPM of chlorine gas is
either converted into valueable product or converted into sodium hypochlorite bleach.
But it is not released into the atmosphere.
5. Environmental Impact and Handling of Chlorine Gas
1. Hydrogen gas is another flammable and hazardeous gas which is released during the
production of caustic soda. It is very difficult to handle the hydrogen gas because it
forms flammable mixture with air under certiain conditions. To minimize and neutrize
the impact of hydrogen gas, the chlor-alkali plants are equipped with hydrochloric acid
plants and specially designed flare.
2. About all the hydrogen gas which is produced is converted into the hydro chloric acid
which rest is sent to specially designed flare. Here the purpose is the complete burning
of hydrogen gas took place and no gas is vented into the atmosphere.
3. Hydrogen gas is also kept in a specially designed water seal know as hydrogen gas
holder to ensure the maximum safety of plant and ultimately environment.
4. Hydrogen gas can also be used as fuel for different boilers and furnaces.