Method for concentrating aqueous caustic alkali solution

Claim 2

In a continuous process for producing an aqueous alkali metal hydroxide solution by electrolysis of an aqueous alkali metal halide solution using a cation exchange membrane to divide the cell into cathode and anode compartments and concentrating, in an evaporator, the alkali metal hydroxide solution obtained as a catholyte the improvement which comprises utilizing the heat generated by electrolysis as a heat source for the heating side of the evaporator by the steps of: 1. circulating a first portion of the catholyte through a heat exchanger where it gives up heat values; 2. diverting a second portion of the catholyte to an evaporator;

Claim 3

adding sufficient water to the circulating catholyte to replace said second portion of catholyte; 4. evaporating and thereby cooling said second portion of the catholyte in said evaporator to a selected concentration and temperature; 5. collecting a first fraction of said second portion of the catholyte as a final product; 6. circulating a second fraction of said second portion of the catholyte through said heat exchanger where it is heated by the heat values of said first portion of the catholyte and thereby reheated; and 7. returning the reheated second fraction to said evaporator; the liquid flow in Steps 1 through 7 being maintained at a rate such that: a. the temperature of the catholyte in the cathode compartment is from 50° C to 120° C; b. the concentration of alkali metal hydroxide of the catholyte is from 15% to 35%; c. the volume of liquid to be concentrated in the evaporator is substantially constant.

Claim 4

adding sufficient water to the circulating catholyte to replace said second portion of catholyte; 4. evaporating and thereby cooling said second portion of the catholyte in said evaporator to a selected concentration and temperature; 5. collecting a first fraction of said second portion of the catholyte as a final product; 6. circulating a second fraction of said second portion of the catholyte through said heat exchanger where it is heated by the heat values of said first portion of the catholyte and thereby reheated; and 7. returning the reheated second fraction to said evaporator; the liquid flow in Steps 1 through 7 being maintained at a rate such that: a. the temperature of the catholyte in the cathode compartment is from 50° C to 120° C; b. the concentration of alkali metal hydroxide of the catholyte is from 15% to 35%; c. the volume of liquid to be concentrated in the evaporator is substantially constant.

Claim 5

A process as in claim 1 wherein gas generated in the cathode is passed through a heat exchanger prior to collection and gives up heat values to a portion of said second fraction of said second portion of the catholyte, and said portion is returned to said evaporator.

Claim 6

A process as in claim 1 wherein gas generated in the anode is passed through a heat exchanger prior to collection and gives up heat values to a portion of said second fraction of said second portion of the catholyte, and said portion is returned to said evaporator.

Claim 7

A process as in claim 1 wherein the amount of water added to said first portion of the catholyte is at least 18 grams per Faraday of current passage.

Claim 8

A process as in claim 1 wherein the alkali metal halide is sodium chloride.

Claim 9

A process as in claim 1 wherein the evaporator is a multi-stage flash evaporator.

Claim 10

A process as in claim 1 wherein the evaporator is a multi-effect evaporator.

Claim 11

A process as in claim 1 including the additional step of compressing the steam generated in the evaporator.