Cabili, Inah

Cuadra, Jamil Francis

Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

THE COMPANY
Mabuhay Vinyl Corporation is the first and largest chlor-alkali
producer in the Philippines. It is the countrys leading manufacturer of
caustic soda and hydrochloric acid and the only company that
produces chlorine in commercial quantities. The products end up in
the manufacture of many useful consumer products that are important
in our daily lives. It is also internationally recognized standard of
world-class quality.
HISTORY HIGHLIGHTS
In 1935, Judge Guillermo B. Guevara founded the Mabuhay Rubber
Corporation, a shoe factory. However, the production facilities were
completely destroyed during the World
War II forcing the company to stop
operations.
Almost two decades after, Judge
Guevara, with his son Victor, reorganized the company to produce
two new products, caustic soda and polyvinyl chloride resin. At the
same time in 1965, a plant in
Iligan, Mindanao was set-up through the Japanese
Reparations Program. It engaged the technical services of
Shin-Etsu Chemical Industry Co. Ltd. Of Tokyo to assist its
initial operation.
In 1967, the name Mabuhay Rubber Corporation was changed to MABUHAY VINYL
CORPORATION (MVC) for a closer identification with its main product, polyvinyl chloride
resin.
In 1980, M/T Snoopy I, the first chemical marine tanker of MVC was
launched. This specialized ship was acquired to transport another new
product, hydrochloric acid.
In 1993, a consortium for the construction of a Luzon PVC resin plant
was formed. Also, in the same year when Mabuhay Premium Bleach
Plant (MPBP) in Laguna Technopark was completed.
It was in 1996 when MVC formed the Philippine Resins Industries, Inc.,
a fully integrated PVC project, together with BPI, Tosoh Corporation and
Mitsubishi Corporation.

Cabili, Inah
Cuadra, Jamil Francis
Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

In 2003, MVCs first Ion Exchange Membrane Plant in

was completed with an annual
capacity of 8000 MT of caustic soda
22000 MT of hydrochloric acid.

Iligan
and

In 2008, MVCs second IEM plant

came
on-stream. IEM2 uses the latest n-BiTAC electrolyzers from Chlorine
Engineers Corporation of Japan.
Today, MVC operates on a modern highly efficient and environment-friendly
manufacturing plant complex in Iligan City in Mindanao, supported by the
MVC Premium Bleach Plant at Laguna Technopark in Bian, Laguna. MVC has
remained the biggest domestic producer and importer of caustic soda and
enjoys a dominant position in the hydrochloric acid and chlorine markets.

Products

There are several products that this company makes. It includes

caustic soda which is commonly used in homes as an agent for unblocking
drains, either in the form of dry crystal or as a thick liquid gel. The process of
this product is specifically studied. There are actually three processes or
methods where caustic soda (also known as Sodium Hydroxide): Membrane
Cell Process, Mercury Cell Process and the Diaphragm Cell Process.

Membrane Cell Process

In the membrane cell, the anode and cathode are separated by an ion-permeable membrane.
Saturated brine is fed to the compartment with the anode (the anolyte). A DC current is passed
through the cell and the NaCl splits into its constituent components. The membrane passes Na +
ions to the cathode compartment (catholyte), where it forms sodium hydroxide in solution. The
membrane allows only positive ions to pass through to prevent the chlorine from mixing with the
sodium hydroxide. The chloride ions are oxidised to chlorine gas at the anode, which is
collected, purified and stored. Hydrogen gas and hydroxide ions are formed at the cathode.

Cabili, Inah
Cuadra, Jamil Francis
Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

Fig 1.1 Process flow of Membrane cell method

The membrane process is summarised in the diagram below. The cathode and anode
compartments are separated by a water-impermeable membrane. This means that ions can pass,
but water cannot. Concentrated sodium chloride solution (NaCl(aq)) flows though the anode
compartment and water flows though the cathode compartment. The sodium ions and hydroxide
ions combine in the cathode compartment to produce sodium hydroxide.

Cabili, Inah
Cuadra, Jamil Francis
Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

Fig 1.2 Membrane Cell Compartment.

Mercury Cell Process

Fig 1.3 Mercury Cell Flow Process

Cabili, Inah
Cuadra, Jamil Francis
Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

Fig 1.4 Mercury Cell System

The mercury cell process involves two "cells". In the primary electrolyser (or brine cell), purified
and saturated brine containing approximately 25% sodium chloride flows through an elongated
trough that is slightly inclined from the horizontal. In the bottom of this trough a shallow film of
mercury (Hg) flows along the brine cell co-currently with the brine. Closely spaced above the
cathode, an anode assembly is suspended.
Electric current flowing through the cell decomposes the brine passing through the narrow space
between the electrodes, liberating chlorine gas (Cl2) at the anode and metallic sodium (Na) at the
cathode. The chlorine gas is accumulated above the anode assembly and discharged to the
purification process.
As it is liberated at the surface of the mercury cathode, the sodium immediately forms an
amalgam. The liquid amalgam flows from the electrolytic cell to a separate reactor, called the
decomposer or denuder, where it reacts with water in the presence of a graphite catalyst to form
sodium hydroxide and hydrogen gas. The sodium-free mercury is fed back into the electrolyser
and reused.
Diaphragm Cell Process
In the diaphragm cell process, a permeable diaphragm, often made of asbestos fibers, separates
the anode and cathode compartments. Brine is introduced into the anode compartment and flows
into the cathode compartment. Similarly to the Membrane Cell, chloride ions are oxidized at the
anode to produce chlorine, and water is split into caustic soda and hydrogen at the cathode. The
diaphragm prevents the reaction of the caustic soda with the chlorine. Diluted caustic brine

Cabili, Inah
Cuadra, Jamil Francis
Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

leaves the cell. The caustic soda must usually be concentrated to 50% and the salt removed.
Evaporative process is achieved with about three tonnes of steam per tonne of caustic soda. The
salt separated from the caustic brine can be used to saturate diluted brine. The chlorine contains
oxygen and must often be purified by liquefaction and evaporation. When using asbestos
diaphragms, the diaphragm process inherently gives rise to environmental releases of asbestos.

Figure 1.5 Diaphragm Cell System

Cabili, Inah
Cuadra, Jamil Francis
Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

Figure 1.6 Process Flow of Diaphragm Cell

Diaphragm cells can operate with less pure brine than required by membrane cells and at a lower
voltage than mercury cells. Among the three manufacturing processes, diaphragm cell process is
the most suitable and generally accepted manufacturing processes of caustic soda
Waste
Caustic soda having a wide variety of applications has become an essential ingredient in many
industrial and commercial applications. However this product is specified as a deleterious
substance and is subject to regulation as to its marketing, storage, consumption, transportation,
etc. With this, safety precaution should be taken when processing and using such product so as to
prevent it from harming the environment. Sodium Hydroxide solutions are produced by three
different technologies. The mercury cell method produces chlorine-free sodium hydroxide, but
the use of several tones of mercury leads to serious environmental problems. The use of mercury
demands measures to prevent contamination. In a normal production cycle a few hundred pounds
of mercury per year are emitted, which accumulate in the environment. Additionally, the chlorine
and sodium hydroxide produced via the mercury-cell chloralkali process are themselves

Cabili, Inah
Cuadra, Jamil Francis
Guisadio, Johanna Whil
Hisona, Rezza
Velasco, Honey Fatima

contaminated with trace amounts of mercury. The membrane and diaphragm method use no
mercury, but the sodium hydroxide contains chlorine, which must be removed.