Elimination of the calcium cycle: direct electrolytic causticizing of Kraft smelt. Final report

An electrochemical molten salt alternative to the classic Kraft causticizing process has been investigated and the feasibility of the process was successfully shown. The experiments include (A) the determination of background thermal decomposition gases, (B) the electrolysis of a sodium carbonate only smelt to show that sodium oxide can be electrochemically produced, and (C) electrolysis of a synthetic smelt containing 80 mole % Na{sub 2}CO{sub 3} and 20 mole % Na{sub 2}S. The experiments show, that sodium hydroxide (NaOH) was produced by the electrochemical reduction of sodium carbonate to sodium oxide in the molten state. In the experiment containing sodium sulfide, there was formation of less than 5 mole % of polysulfide. Energy savings on the order of 500,000 BTU per ton of kraft pulp produced are estimated, based on the energy used by the mill. Operating costs are estimated to be currently similar to conventional processing. However, price increases of fossil fuels and increased co-generation of electricity in the mill will give the electrolytical process significant cost advantages