Optimizing operational parameters for highly-concentrated sodium hydroxide production via electrodialysis with bipolar membranes from concentrated brines

Sodium hydroxide necessitates the implementation of cleaner production methods that deviate from the conventional practices in the chlor-alkali industry. New sustainable sources such as concentrated brines, which are typically regarded as waste, are currently being investigated for the production of sodium hydroxide using Electrodialysis with Bipolar Membranes (EDBM). This process has the advantages of not producing gas by-products, reducing operational risks, and providing value to waste brines after converting them into acids or alkali solutions. However, the production of sodium hydroxide via EDBM using brines is limited by the low concentration of the final base (e.g. typically below 2 M), which increases the cost of transport. This study aims to overcome this limitation by optimizing parameters such as salt-to-base volume ratio, initial salt concentration, and current density values. Notably, this research is one of the few to employ Response Surface Methodology with a Central Composite Design to maximize the final sodium hydroxide concentration; two models using second-order polynomial equations were proposed. Results showed the possibility to achieve 5.3 M NaOH under a volume ratio range of 9.8:1–10:1, a current density range of 490 A/m−2(−|-) to 500 A/m−2(−|-), and an initial salt concentration in the range of 6 M NaCl. Moreover, the energetic analysis showed values of specific energy consumption in a range of 2.5 kWh kgNaOH-1-3.5 kWh kgNaOH-1 and specific productivity of the process up to 3.08 tonNaOH year−1 m−2, which are moderate in comparison with values previously presented in literature. Finally, an economic analysis showed that energy was the most significant cost component, making up 89 % of the total process cost, which was estimated to be 0.69 € kgNaOH-1 (concentration 21.2 % w/w). Overall, these high concentration values open a real chance to shift towards sustainable production of NaOH by means of EDBM from brines, highlighting the novelty of this study