E R N A L . G R A M S E and L . H . D I A M O N D 1
and utilizing the basic chemicals: chlorine, sodium hydroxide or caustic soda,
potassium hydroxide or caustic potash, sodium carbonate or soda ash, potassium
carbonate, and sodium bicarbonate.
In the U . S . , approximately 40 companies operate over 80 chlor-alkali plants
for both captive and merchant production, according to the Department of
Commerce, Review of 1963—Outlook for 1964.
The chlor-alkalies find wide application i n the production of pulp and
paper, textiles, glass, solvents, soaps and detergents, plastics, petroleum prod
ucts, pesticides, rubber, metals and i n the treatment of water and wastes. In
fact, there is hardly a consumer product that has not required chlorine a n d / o r
alkali at some stage of its manufacture.
Because of the magnitude of the industry, its long history, and the diversity
of end uses, this survey covers only selected references on the production, prop
erties, and uses of the chlor-alkali chemicals.
a review of the industry for the period 1902-1952 (63). Since that date there
have been annual reports of the chlor-alkali committee (47, 48, 49, 29, 88, 56,
39, 31, 32, 33, 133). These reports give number of plants operating, processes
used, capacities, expansions, technical developments, markets and end-use pat-
terns, trends, and production and sales figures.
The chlor-alkali industry i n Germany prior to W o r l d W a r II was described
by Hunter (65) and i n the so-called " P B Reports" w h i c h were made available
by the U . S . Dept. of Commerce, Office of Technical Services, now the Clearing-
house for Federal Scientific and Technical Information at Springfield, V a . F o l -
lowing is a selected list of these reports:
feld
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Economics
Manufacturing Processes
(30).
Chlorine is also produced by the electrolysis of hydrochloric acid by a
process developed b y C . P . Roberts (112). Schroeder's process electrolyzes a
solution of nickel chloride to produce chlorine and nickel (117). D e Nora and
Farbwerke Hoechst are operating plants for the direct electrolysis of hydro-
chloric acid to produce chlorine (4, 41, 52, 77g, 108, 119d). T h e D e N o r a
process was used i n the U . S . by Monsanto C h e m i c a l C o . at Anniston, A l a .
(40, 77g, 131). T h e Hoechst process is being used b y Chemische Werke
Huls (62).
and their capacities, both synthetic and natural (129). The trend is to produce
soda ash from the less costly and practically unlimited supplies of trona (129).
Sodium bicarbonate is manufactured by carbonation of sodium carbonate
solution (77b, 77g).
The principal method for the production of potassium carbonate is the
carbonation of electrolytic potassium hydroxide (77e).
The physical and chemical properties of all the chlor-alkalies are given in
" K i r k - O t h m e r " (77 g), "International Critical Tables," and i n the "Condensed
Chemical Dictionary" edited by Rose. The properties of chlorine are described
by Laubusch (119g), in the "Chlorine M a n u a l " published by the Chlorine
Institute, and in the booklet by Kapoor and Martin entitled "Thermodynamic
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End Uses
consumption (77%).
A l l of the chlorinated methanes can be produced by thermal or photo-
chemical chlorination of methane (77i, 119%). Specific processes are used to
produce individual members of this series; for example, methyl chloride is man-
ufactured by the reaction of methanol with hydrochloric acid, and carbon tetra-
chloride is made by chlorination of carbon bisulfide (77i).
E t h y l chloride is produced by the chlorination of ethane or by hydro-
chlorination of ethylene (77i, 119]). 1,2-Dichloroethane (ethylene dichloride),
the largest volume chlorinated organic, is manufactured by chlorination of
ethylene (77i, 119j). Most of the 1,2-dichloroethane produced goes into the
manufacture of vinyl chloride, which is formed by dehydrochlorination of the
and formula, trade name, producers, properties, toxicity, and major end uses
as well as manufacture and market (74).
Phosgene, which is carbonyl chloride, is produced b y the reaction of
carbon monoxide with chlorine (77k, 131) and is used as an intermediate for
isocyanates and carbamates (102). Isocyanates are used to produce the poly-
urethane plastics (77q). Carbamates are widely used i n the production of
pesticides (74).
Inorganic Chemicals. Hydrochloric acid is the most important inorganic
chemical made from chlorine. It is made by the reaction of chlorine w i t h
hydrogen or sodium chloride w i t h sulfuric acid (77h, 131). However, these
production methods are decreasing i n volume as the availability of by-product
hydrochloric acid from chlorination processes is increasing (131). 1963 pro-
duction figures for hydrochloric acid are listed (141). Uses of hydrochloric
acid are legion; some i n the production of organic chemicals have already been
mentioned. Other industries using hydrochloric acid include petroleum, metal,
food, and leather (77h), and the pickling of steel (67, 68, 105). A recent
paper discusses the substitution of hydrochloric acid for chlorine i n processes
such as oxychlorination and hydrochlorination of ores (60).
Titanium dioxide, used i n paints, paper, inks, rubber, etc., is made by a
process using chlorine (8, 131, 138).
Chlorine is used i n the production of a number of metal chlorides useful
as catalysts. U n t i l recently, aluminum chloride was the only one of significant
use, e.g., i n the Friedel-Crafts synthesis. Others, such as the chlorides of
titanium, silicon, boron, zirconium, antimony, and vanadium, are becoming
important i n this area. In addition, silicon tetrachloride is an intermediate for
producing silicones (119u).
Bromine, made by treating bromide-containing brines with chlorine, is
used i n the manufacture of gasoline additives (131).
Phosphorus trichloride, made by chlorinating phosphorus, is used to make
phosphorus oxychloride w h i c h is used i n plasticizers, gasoline additives, func-
tional fluids, etc. (131).
Hydrazine, a major rocket fuel, is manufactured by the Raschig process
from ammonia, chlorine and sodium hydroxide (131).
P u l p and Paper. The pulp and paper industry is one of the biggest users
of the chlor-alkalies (19). Chlorine and its derivatives, caustic soda and soda
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ash are used for bleaching purposes ( J 9 , 77j, 119w, 131), and i n pulping
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(19, 77j). The various pulping processes are described (64, 77j, 109, 114,
115). A literature survey on the cold soda pulping process, covering the period
1950-August 1959 and containing 119 references, was published i n Tappi i n
1960 (10). Tables showing the quantities of soda ash and caustic soda used
in wood pulp processes; chlorine, soda ash, and caustic soda used for bleaching
by paper and pulp mills; and chlorine, soda ash, and caustic soda used for
paper and board manufacture appear i n a January 1960 issue of Paper Trade
Journal (110).
A recently announced process, developed by W . H . Rapson, claims to
eliminate the need for chlorine and caustic soda i n the Kraft pulping and
bleaching system (35, 97, 99,111).
Textiles. The textile industry uses chlorine and its derivatives and caustic
soda for bleaching, mercerization, and other purposes (77u, 103, 132). A very
detailed review of the use of alkalies in textile processing, w i t h a table showing
the consumption of these chemicals for the year 1958, was presented by Currier
(34).
One of the largest uses of caustic soda is i n the manufacture of rayon
(77d) and cellophane (72) from cellulose by the viscose process.
treated with chlorine to effect purification and slime control (2, 131). Treat-
ment of waste water a n d sewage also consumes large quantities of chlorine
(81, 83, 119z, 131, 134). P u b l i c swimming pools continue to use elemental
chlorine for disinfecting purposes (131), and recommendations are discussed
by Laubusch (80).
Soda ash is used to condition water for both municipal and industrial use
to remove hardness (2).
Soaps and Detergents. Sodium hydroxide and potassium hydroxide are
used i n soap manufacture (77c, 79). Caustic soda is required i n manufacturing
alkylbenzene sulfonates used i n synthetic detergents (77n). Detergent formu-
lations also require builders w h i c h usually are alkali phosphates or silicates
(77r). Soda ash, caustic soda, and caustic potash are used i n the production of
these builders (142). T h e principal alkali phosphates used as detergent b u i l d -
ers are sodium tripolyphosphate, tetrasodium pyrophosphate and tetrapotassium
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Publication Date: January 1, 1968 | doi: 10.1021/ba-1968-0078.ch001
pyrophosphate (142).
Statistics
Oil, Paint and Drug Reporter regularly publishes " C h e m i c a l Profiles" on
various chemicals showing, briefly, producers and capacity, price, uses, and
outlook. T h e most recent references for the chlor-alkalies are: chlorine (24),
caustic soda (16), caustic potash (13), soda ash (125), potassium carbonate
(106), and sodium bicarbonate (127).
Oil, Paint and Drug Reporter also periodically publishes " D e p t h Reports"
w h i c h give more detail than the " C h e m i c a l Profiles." Some of these refer-
ences are: chlorine (140), caustic soda (20), caustic potash (14), soda ash
(122), and sodium bicarbonate ( 7 ) .
Producers and capacities are further listed: for chlorine (30, 130, 131
and the Chlorine Institute Pamphlet # 1 2 ) ; caustic soda (18); soda ash (123,
124,126); caustic potash and potassium carbonate (11,12, 14, 15). Production
figures for chlorine, caustic soda, soda ash and caustic potash are published
annually i n the C h l o r - A l k a l i Report (133), and in the Standard and Poors
Industry Survey. There are reports on world capacities for chlorine and caustic
soda (71); w o r l d production of caustic soda and soda ash (146), and of chlorine
(147). Canadian consumption of the chlor-alkalies, by specific industries, is
reported (145). The U . S . Tariff Commission annually publishes production
and sales figures for the chlorine-containing organic chemicals i n Synthetic
Organic Chemicals, U.S. Production and Sales. A recent three-part article on
chlorine gives production and distribution in Europe, U . S . A . and Canada, and
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Publication Date: January 1, 1968 | doi: 10.1021/ba-1968-0078.ch001
Directories
Lists of producers with plant location and products manufactured at each
can be found i n Fortune's Plant and Product Directory. SRI's Directory of
Chemical Producers contains listings by company, product, region, and new
plants and expansions. The Bureau of the Census Directory of Manufacturers of
Selected Inorganic Chemicals and Gases lists producers of the chemicals. The
B D S A Chemical Statistics Directory No. 3 is a guide to U . S . Government
end use.
1912 4. Electrochemistry
18. Acids, Alkalies, Salts & Sundries
1961 4. Electrochemistry
18. Inorganic Industrial Chemicals
1962 15. Industrial Inorganic Chemicals
22. Electrochemistry
1963 15. Electrochemistry
17. Industrial Inorganic Chemicals
1967 49. Industrial Inorganic Chemicals
77. Electrochemistry
Applied Science and Technology Index indexes from current periodicals,
mainly from the applied point of view. Engineering Index contains abstracts
from the world literature, mainly from the engineering point of view.
Services emphasizing the marketing and economic point of view include:
Chemical Market Abstracts, which indexes news items from English language
publications by company, chemical, and industry; Chemical Horizons, w h i c h
summarizes i n two 4-page reports: N o r t h American and Overseas, and i n the
Intelligence F i l e available on cards, information from selected periodicals by
product, industry or chemical, and country; Predicasts, w h i c h indexes market
data forecasts by S I C code number; Search, w h i c h abstracts market research
information w i t h cumulative monthly subject index; and Funk and Scott Index
of Corporations and Industries, w h i c h indexes by S I C code number and com-
pany name.
U . S . chemical patents are indexed by unit terms i n Uniterm Index of U.S.
Chemical Patents. Abstracts of foreign patents, i.e. British, German, French,
South African, Indian, Belgian, Japanese, Russian, and D u t c h , are published by
subject classification by Derwent Information Service.
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(2) Allied Chemical Corp., "Alkalies and Chlorine in the Treatment of Municipal
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(3) "Are Your Chemicals Being Used?," Chem. Eng. 96 (Dec. 14, 1959).
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(42) Engel, W . F., Waale, M . J., Muller, S., "Recent Developments in the Oxidative
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Section I, Chemical.
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Derwent Information Service, Rochdale House, 128 Theobalds Road, London,
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Engineering Index, Engineering Index, Inc., 345 East 47th Street, New York, N. Y.
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Funk and Scott Index of Corporations and Industries, Predicasts, Inc., Colonnade
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Predicasts, Predicasts, Inc., 1960, quarterly.
Science Citation Index, Institute for Scientific Information, 325 Chestnut St., Phila-
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Search, Compendium Publishers International Corp., 2175 Lemoine Ave., Fort Lee,
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Uniterm Index of U. S. Chemical Patents, IFI/Plenum Data Corp., 1000 Connecticut
Ave., N.W., Washington, D. C. 20006, 1950, bimonthly.
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Canadian Chemical Processing, Southam Business Publications, Ltd., 1450 Don Mills
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Ceramic Industry, Cahners Publishing Co., Inc., 5 South Wabash Avenue, Chicago,
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Chemical Age, Bouverie House, 154 Fleet Street, London EC4, England, weekly.
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Department of Commerce, Bureau of the Census, Annual Survey of Manufactures,
annual except years of the Census of Manufactures, Washington, D.C.,GPO.
Department of Commerce, Bureau of the Census, Statistical Abstracts, annual. Wash-
ington, D. C., GPO.
Department of Commerce, Bureau of the Census, Foreign Trade Division: 1) FT 135
—U. S. Imports for Consumption and General Imports, Schedule A, Commodity
by Country, monthly; 2) FT 410—U. S. Exports, Schedule B, Commodity by Coun-
try, monthly; 3) FT 210—U. S. Imports for Consumption and General Imports,
SIC-Based Product Classification by Area, annual; 4) FT 246—U. S. Imports for
Consumption and General Imports, TSUSA Commodity by Country, annual; 5)
FT 610—U. S. Exports of Domestic Merchandise, SIC-Based Products and Area,
annual. Washington, D.C,.GPO.
Department of the Interior, Bureau of Mines, Mineral Facts and Problems, Bulletin
#630, 1965. Washington, D. C., GPO.
Department of the Interior, Bureau of Mines, Magnesium and Magnesium Compounds
—A Materials Survey, Information Circular 8201, by H. B. Comstock, 1963. Wash-
ington, D. C., GPO.
Department of the Interior, Bureau of Mines, Methods for Producing Alumina from
Clay, Report of Investigation 5997, by F. A. Peters, P. W. Johnson, and R. C.
Kirby, 1962. Pittsburgh, Pa. 15213.
Department of the Interior, National Petroleum Council, Office of Oil and Gas, Main-
tenance and Chemical Requirements for U. S. Petroleum Refineries and Natural
Gasoline Plants, 1961, Washington, D. C.
Senate, 85th Congress, 1st session, Report of the Subcommittee on Antitrust and
Monopoly to the Committee of the Judiciary, Concentration in American Industry,
1957. Washington, D. C., GPO.
Tariff Commission, Synthetic Organic Chemicals, U. S. Production and Sales, annual.
Washington, D. C., GPO.
U. S. Patents
The Patent Office Manual of Classification groups patents relating to the chlor-
alkalies in the following classes and subclasses:
Class 23: Chemistry
61 Carbonates
63 alkali metal
64 bicarbonates
65 ammonia soda process
183 Bases
184 alkali metal oxides or hydroxides
185 causticizing
Class 204: Chemistry, Electrical and Wave Energy
1 Electrolysis
59 synthesis
60 from fused bath