As India’s chemical and manufacturing sectors scale rapidly, the chlor alkali process remains a cornerstone of industrial production—enabling large-scale caustic soda manufacturing, along with chlorine and hydrogen. These outputs are critical across water treatment, textiles, pharmaceuticals, PVC, and specialty chemicals.

In this evolving landscape, Indian Peroxide Limited (IPL) is strengthening its presence with a 400 TPD chlor alkali plant, built on advanced membrane cell electrolysis technology. The plant is engineered to deliver high-purity output, operational reliability, and energy-efficient performance—aligned with the needs of modern, continuous-process industries.

Membrane Cell Electrolysis & Ion Exchange Technology

At the heart of IPL’s facility lies next-generation membrane cell electrolysis, the most advanced and environmentally responsible method for chlor alkali production. In this process, purified brine undergoes electrolysis in a membrane-separated cell, ensuring controlled and efficient chemical conversion.

2NaCl+2H2O→2NaOH+Cl2+H2

The process produces:

• Caustic soda (NaOH)
• Chlorine gas (Cl₂)
• Hydrogen (H₂)

A key technological advantage lies in the ion exchange function of the membrane, which selectively allows sodium ions (Na⁺) to pass while restricting chloride ions and impurities. This controlled ion migration ensures:

• High-purity caustic soda manufacturing
• Dry, high-quality chlorine output
• Stable electrochemical performance
• Prevention of cross-contamination

By eliminating mercury-based systems and optimising ion transport, IPL achieves improved energy efficiency, enhanced safety, and long-term process stability—critical for modern chlor alkali plants.

Advanced Brine Purification for Electrolysis Efficiency

The efficiency of the chlor alkali process is highly dependent on brine quality. IPL incorporates a multi-stage brine purification system to remove calcium, magnesium, and trace contaminants that can degrade membrane performance.

This results in:

• Extended membrane life
• Stable current efficiency
• Reduced downtime
• Consistent production cycles

Such precision in feedstock preparation ensures reliable and optimised electrolysis operations.

Chlorine Processing, Liquefaction & Safety Systems

Chlorine handling is a critical component of chlor alkali operations. IPL integrates advanced systems including vacuum-based chlorine collection, drying, compression, and liquefaction under controlled conditions.

Safety is reinforced through:

• Continuous leak detection systems
• Automated scrubbing and neutralisation units
• Closed-loop handling mechanisms

These systems ensure safe chlorine management while supporting uninterrupted supply to downstream industries.

Caustic Soda Manufacturing & Industrial Applications

Caustic soda produced at IPL is concentrated from ~32% to 48% using energy-efficient evaporation systems, ensuring high purity and consistency.

Its applications span:

• Alumina refining
• Textile processing
• Pulp and paper manufacturing
• Water treatment
• Chemical and pharmaceutical industries

Reliable caustic soda manufacturing is essential for these sectors, where process continuity and quality consistency are non-negotiable.

Hydrogen Recovery & Bipolar Process Advancements

Hydrogen generated during electrolysis is captured, purified, and utilised by IPL as a value-added stream for industrial applications such as fuel use and chemical synthesis.

In parallel, modern chlor alkali systems are increasingly aligned with bipolar electrochemical configurations, where multiple cells are electrically connected in series to optimise voltage distribution and reduce energy consumption per unit output.

This approach enables:

• Improved energy efficiency
• Higher production intensity
• Compact and scalable plant design

While membrane electrolysis remains the core technology, such bipolar concepts support future optimisation and scalability of IPL’s chlor alkali operations.

IPL Driving Technology-Led Chlor Alkali Growth

With its 400 TPD chlor alkali plant, Indian Peroxide Limited (IPL) integrates advanced membrane electrolysis, ion exchange separation, and energy-efficient process design to deliver high-purity chemical outputs at scale.

As demand for caustic soda, chlorine, and hydrogen continues to grow, IPL’s technology-driven approach positions it as a reliable and forward-looking player in India’s chlor alkali sector—supporting both industrial expansion and next-generation chemical manufacturing.

© This article was first published by Indian Peroxide Limited in New Delhi, 05 May, 2026.