(A) The mercury cathode cell (Castner-Kellner cell): In this cell mercury flows along the bottom of the cell and is made cathode (as shown in figure (a)). The brine solution flows in the same direction and anode consists of a number of graphite blocks. The brine electrolyzes and since, hydrogen has a high overvoltage at mercury cathode, sodium is preferentially discharged forming amalgam with mercury.
The sodium amalgam flows out and is reacted with water to give NaOH
2NaHg+2H2O→2NaOH+2Hg+H2
The mercury is re-circulated to the cell. Hydrogen and chlorine are the two important by-products.
(B) Solvay ammonia soda process :
(a) 2NH3+CO2+H2O→(NH4)2CO3
CaCl2+(NH4)2CO2→CaCO3↓+2NH4Cl
MgCl2+(NH4)2CO3→MgCO3↓+2NH4Cl
(b) NH3+CO2+H2O→NH4HCO3;NH4HCO3+NaCl30oC−−−→NaHCO3+NH4Cl
(c) Calcination to get sodium carbonate :
2NaHCO3150oC−−−−→(steam)Na2CO3+CO2+H2O
(d) NH4HCO3Δ−−−−→(steam)NH3+CO2+H2O;2NH4Cl+Ca(OH)2Δ−−−−→(steam)2NH3+2H2O+CaCl2
(e) CaCO31375k−−−→CaO+CO2
CaO+H2O→Ca(OH)2 (slaked lime)
(C) Hargreaves process :
4NaCl(drylump)+2SO2(g)+2H2O(g)+O2(g)→2Na2SO4+4HCl.
(D) Le-Blanc process :
NaCl(orKCl)+conc.H2SO4→NaHSO4orKHSO4+HCl
NaHSO4+NaClΔ−→Na2SO4 (as intermediate product) + HCl
Na2SO4+CaCO3+4CΔ−→Na2CO3 or K2CO3+CaS+4CO