Manufacturing Process of Chemicals

Epoxy Resins Epoxy resins are chemical resistant coatings that are used in many applications where a chemical surface protection is needed.

Polycarbonate Polycarbonates are transparent thermoplastic polymers which are mainly used as moulding compounds. The production of polycarbonate can be splitted in two stages: production of phosgene (COCl2) starting with chlorine (Cl2) and carbon monoxide (CO) according to the following reaction: CO + Cl2 COCl2. reaction between phosgene and bisphenol-A in a solution of methylene chloride: Cl-CO-Cl + HO-C6H4-C(CH3)2-C6H4-OH HO-C6H4-C(CH3)2-C6H4-O-CO-]80 till 100 + 2 HCl Large quantities of caustic soda lye are added during the second stage in order to form bisphenolate and to catalyse this reaction via neutralisation of the formed hydrochloric acid. The polycarbonate obtained in this way is precipitated as a solid substance after purification and centrifugation and subsequently dried until a powder remains.

Super Absorbent Polymer A crosslinked form of the Sodium salt of Polyacrylic Acid is used as a super absorbent material in Diapers and other personal hygiene products. SAP is manufactured by the polymerization of the Acrylic Monomer, the main raw material is Acrylic acid and Caustic Soda. From the Polymerization process, the gel granule is formed and passed to the drying process and surface coating to enhance the property before drying and packing.

Zeolites Caustic soda is used in the production of Zeolites. Zeolites are crystalline, hydrated aluminosilicates with a framework structure. They have a three-dimensional polyanionic network constructed of SiO2 and Al2O3 tetrahedra linked through oxygen atoms. The pores contain water and cations to balance the negative charge of the framework. These cations are mainly alkali metal or alkaline earth, and can be exchanged, giving to zeolites its main use : binding cations. A hydrothermal reaction of sodium aluminate, sodium silicate and caustic soda in an aqueous solution at elevated temperature and under high pressure is carried out for this production

process. A strong basicity is necessary to build the cristallized form between silica and aluminium ions with oxides. Caustic soda is used for this synthesis. Zeolites containing a high amount of silica are synthesised at high temperatures and pressures, while low-silica zeolites are usually crystallized at 70 100 C and with a pH in the range of 10 14, in a caustic soda solution. Different ratios between silica and aluminium contents give different types of zeolites. Due to its high of cation binding capacity, zeolites are used as a component of detergents; as adsorbents, for separating and purifying substances; as catalysts, in a great number of important processes in the chemical and petrochemical industries. And they are used also in a great number of uses where the cations binding capacity is needed.

Sodium Phosphates Caustic soda is used industrially to produce sodium phosphate salts. The different forms of these salts as monosodium phosphate, disodium phosphate and sodium tripolyphosphate are obtained by neutralization of phosphoric acid with soda ash or caustic soda. All salts can be produced with either caustic soda or soda ash except trisodium salt. Because the basicity of soda ash is insufficient, the trisodium phosphate form must be obtained with caustic soda.

Sodium Sulfite Sodium Sulfite and Sodium Metabisulfite is industrially produced by the neutralization of Sulfur dioxide solution with either Caustic Soda or Soda Ash. Sodium Sulfite salt is widely used in the Photographic Chemicals, Water Treatment, Pulp & Paper, Leather and Textile.

Sodium Aluminate Sodium aluminate is manufactured by the dissolution of aluminium hydroxides in a caustic soda solution. Aluminium trihydroxide (gibbsite) can be dissolved in 20-25 % aqueous NaOH solution at a temperature near the boiling point. The use of more concentrated NaOH solutions leads to a semi-solid product. The process must be carried out in steam-heated vessels of nickel or steel, and the aluminium hydroxide should be boiled with approximately 50 % aqueous caustic soda until a pulp forms. The final mixture has to be poured into a tank and cooled; a solid mass containing about 70 % NaAlO2 is then formed. After being crushed, this product is dehydrated in a rotary oven heated either directly or indirectly by burning hydrogen. The resulting product contains 90 % NaAlO2 and 1 % water, together with 1 % free NaOH. Sodium Aluminate is used for different purposes: for water treatment it is used as an adjunct to water softening systems, as a coagulant aid to improve flocculation, and for removing dissolved silica. In construction technology, sodium aluminate is employed to accelerate the solidification of concrete, mainly when working during frost. It is also used in the paper industry, for refractory bricks production, alumina production, etc.

Reference: http://www.vinythai.co.th/ourchemicalproducts/causticsoda/mkt1chemicalindustry/0,,2003-2-0,00.htm