Means and method of chemical production

Abstract

Disclosed is a process for manufacturing bleach (or sodium hypochlorite) and caustic potash (or KOH) without the need for shipping or storing chlorine gas. Specifically, the present invention relates to the manufacture of potassium hydroxide and chlorine gas, through several process options, for the manufacture of sodium hypochlorite (or bleach), hydrochloric acid (HCl) and/or other chlorinated compounds. The disclosed process allows operating flexibility based on chlorine demand, reduces capital costs, and eliminates the need for the transportation and storage of chlorine gas.

1 . A method of manufacturing a sodium bleach and an alkali metal hydroxide solution comprising potassium hydroxide, said method comprising the steps of:
 providing an aqueous solution of a chloride salt comprising potassium chloride;   precipitating out impurities from said aqueous solution of said chloride salt by adding at least one of a barium or calcium chemical to form a precipitated aqueous solution;   secondary purification of said precipitated aqueous solution by purifying said precipitated aqueous solution through an ion exchange unit to form a secondary precipitated aqueous solution;   electrolyzing said secondary precipitated aqueous solution to collect chlorine gas at an anode and to collect hydrogen gas at a cathode, and to form an aqueous alkali metal hydroxide solution;   pumping the chlorine gas to a dechlorinator and cooling said chlorine gas to form cooled chlorine gas;   removing brine condensate from said cooled chlorine gas to form dried chlorine gas;   pumping said dried chlorine gas to a hypo system to be mixed with stored sodium hydroxide, wherein said hypo system comprises a plate exchanger with cooling water; and   combining said dried chlorine gas with said stored sodium hydroxide to form a sodium bleach.