This Small Business Innovation Research (SBIR) Phase 2 project is in the general area of electrochemistry in the subfield of inorganic synthesis. Caustic soda is manufactured in the USA to the extent of about 36,500 tons/day at a market value of about $25 million/day, almost exclusively by the electrolysis of brine. Chlorine is produced simultaneously and has suffered a declining market with no economical routes for its destruction or dumping. Hence, there are real opportunities for alternative manufacturing processes not involving chlorine. The Phase I research project successfully demonstrated such a process based on the electrolysis of an alternative sodium salt. The Phase II research effort will identify state-of-the-art cell components and cell design and modify these accordingly to achieve minimum cell voltage, high caustic current efficiency, and high caustic concentration, of up to 50% by weight. Factors contributing to the stability and performance of the membranes and electrodes will be studied carefully, and the process will be evaluated under extended electrolysis conditions. Statistical design methodology will be followed. The results of these studies will form the basis of a preliminary engineering design for the overall process and an economic assessment of capital and operating costs. %%% This research has the potential for the development of a new way of making caustic soda without chlorine byproduct. This is an excellent example of an environmentally benign synthesis which could have a significant societal impact.
