Asia Chemical Engineering Co., Ltd. is one of the most reliable manufacturers and suppliers of full set caustic soda production equipment in China. Please rest assured to wholesale cost-efficient full set caustic soda production equipment from our factory. Good service and reasonable price are available.
Built for:
Greenfield investors building local NaOH capacity - replacing imported caustic soda with domestic production and capturing the margin on chlorine and hydrogen.
Alumina, pulp & paper, textile and PVC producers adding captive alkali supply and securing a stable chlorine feedstock for downstream units.
Chemical parks and industrial zones integrating chlorine, hydrogen and hydrochloric acid streams across multiple tenants.
Existing diaphragm or mercury cell operators converting to membrane technology to cut power consumption and meet current environmental requirements.
EPC contractors and equipment distributors sourcing a complete, interface-matched equipment package under a single vendor.
When we are probably not the right fit: if you need a single replacement electrolyzer or spare part, if you are trading liquid caustic rather than producing it, or if your site has no secure high-voltage power supply and no defined chlorine offtake route. In those cases we will tell you early - because a chlor-alkali project without a chlorine destination is not a viable project.
From Salt to Saleable Product
1. Salt dissolution - industrial salt or available brine is converted into saturated NaCl solution.
2. Two-stage purification - precipitation, filtration and chelating resin polishing remove hardness and heavy metals that would permanently damage the ion-exchange membrane.
3. Membrane electrolysis - purified brine enters the anode chamber, water the cathode chamber; DC power drives the reaction:
2NaCl + 2H₂O → 2NaOH + Cl₂↑ + H₂↑
Na⁺ migrates selectively across the membrane, so chloride contamination of the caustic product is kept extremely low.
4. Gas handling - wet chlorine is cooled, dried and compressed; hydrogen is separated, cooled and pressure-controlled. Both streams are routed to downstream use or safe treatment.
5. Concentration - 30–32% cell liquor is evaporated in multi-effect falling-film units to 48% or 50% commercial liquid caustic soda.
6. Solid forming (optional line) - further concentration and flaking produce ≥99% NaOH flakes or pearls, then automatic weighing and moisture-protected packaging.
7. Storage, loading and utilities - product tanks, loading arms / bagging, plus DCS supervision of the entire loop.
Main Equipment
A large-scale caustic soda plant is not a single machine. It is an integrated process system consisting of several major equipment groups.
| Process Section | Typical Equipment |
|---|---|
| Salt Handling | Salt Storage, Salt Dissolver, Salt Conveyor |
| Brine Preparation | Brine Saturator, Brine Tank, Pumps |
| Brine Purification | Reactors, Clarifiers, Filters, Ion Exchange Units |
| Brine Dechlorination | Dechlorination Tower, Pumps, Gas Separation Equipment |
| Electrolysis | Membrane Electrolyzers, Cell Stacks, Rectifiers |
| Electrical System | Transformer, Rectifier Transformer, DC Bus System |
| Chlorine Processing | Chlorine Cooler, Dryer, Compressor, Liquefier |
| Hydrogen Processing | Separator, Cooler, Compressor, Gas Treatment Equipment |
| Caustic Concentration | Evaporator, Heat Exchanger, Condenser |
| Storage | Caustic Soda Tanks, Chlorine Storage, Product Pumps |
| Utilities | Cooling Tower, DM Water System, Steam System, Air System |
| Control | DCS, PLC, Instrumentation, Safety Interlock System |
FAQ:
1. What equipment is included in a full set caustic soda production plant?
The complete line covers brine preparation and two-stage purification, membrane electrolyzers with rectifier power supply, chlorine and hydrogen treatment, caustic evaporation and optional flaking / packing, product storage, utilities, DCS automation and the engineering documentation package. The exact battery limit is listed in the technical proposal.
2. What is the smallest viable plant capacity?
Configurations start around 1,000–5,000 TPA for pilot or local-supply projects, but unit economics improve significantly above 10,000 TPA because power, brine refining and control systems do not scale linearly. We will model both CAPEX and cost per tonne for your capacity.
3. Why ion-exchange membrane instead of diaphragm cells?
Membrane cells deliver roughly 2,100–2,600 kWh/t NaOH versus 2,500–3,100 kWh/t for diaphragm cells, produce 30–32% caustic directly (far less evaporation), avoid asbestos and mercury, and give a much lower salt content in the product. They are the global standard for new capacity.
4. How much electricity does the plant consume per tonne of caustic soda?
Typical DC consumption at the cell is around 2,100–2,300 kWh per tonne of 100% NaOH equivalent. Some published figures refer to per-tonne-of-32%-liquor or to total AC plant load, so always compare on the same basis. Actual values depend on brine purity, current density, membrane condition, cooling water temperature and rectifier efficiency. We state the measurement basis explicitly in our guarantee.
5. Can one plant produce both liquid caustic soda and 99% flakes?
Yes. The electrolyzer produces 30–32% liquor; multi-effect evaporation raises it to 48/50% for liquid sales, and a downstream final concentrator plus flaking machine produces ≥99% flakes or pearls. The evaporation and solid-forming sections are sized to your chosen product split.
6. What happens to the chlorine and hydrogen?
Every tonne of NaOH generates approximately 0.89 t of chlorine and 0.025 t of hydrogen. Chlorine can feed PVC, HCl synthesis, sodium hypochlorite, water treatment chemicals or liquefaction for sale; hydrogen can feed HCl synthesis, hydrogenation or boiler fuel. Defining this route is the single most important feasibility step - we size the treatment section around your offtake plan, not the other way around.
7.Which consumables should we budget for?
Ion-exchange membranes, electrode / gasket sets, chelating resin, filter elements, sulphuric acid for chlorine drying, dosing chemicals and pump seals. A two-year recommended spares and consumables list is delivered with the handover package.
8.What do you need to issue a budgetary quote?
Target capacity, product slate, salt or brine analysis, power tariff, and your chlorine offtake plan. The full ten-point RFQ checklist above is available as a downloadable form.
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