What is a sodium chlorite project report?
A sodium chlorite project report is a detailed project report (DPR) for a plant that turns sodium chlorate into chlorine dioxide gas and absorbs it in caustic soda and hydrogen peroxide to make sodium chlorite liquor and 80% flakes. It sets out the process, machinery, raw materials, market, project cost, finance, projections, DSCR and break-even.
Promoters use it to size the plant and raise a term loan; banks and investors use it to judge whether the plant can repay and run safely.
Also known as: sodium chlorite business plan, project report on sodium chlorite, NaClO2 manufacturing plant report, sodium chlorite feasibility study.
Sodium chlorite manufacturing plant cost in India
Our sample report models a 4.7 MT per day plant, or 1,551 MT a year, running 330 days and moving from 60% to 80% of capacity over five years. Product is priced at ₹1,64,000 per MT ex-GST, which is ₹164 per kg of 80% flakes.
Plant and machinery is just over half of the project cost, because the gas side of the plant is built in titanium and corrosion-resistant plastics rather than mild steel. As an indicative guide, a liquid-only plant of 1.5–3 MT per day costs roughly ₹3.5–6 crore, and a liquid and flakes plant of 4–6 MT per day about ₹7–11 crore.
| Land and site development | 67.61 |
|---|---|
| Building and civil works | 161.90 |
| Plant and machinery | 441.88 |
| Other fixed assets | 56.91 |
| Contingencies | 30.19 |
| Preliminary and pre-operative | 18.96 |
| Working capital margin | 59.14 |
| Total | 836.59 |
| Promoter's contribution (25%) | 209.15 |
|---|---|
| Term loan from bank (75%) | 627.44 |
| Cash credit limit (separate) | 177.44 |
| Total project cost | 836.59 |
Sample figures are illustrative; term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. Other ranges are indicative and vary with route, product form and site.
Sodium chlorite manufacturing process
Sodium chlorite is made in two linked reactions. Sodium chlorate is first turned into chlorine dioxide gas. The gas is then reduced to chlorite in an alkaline peroxide solution (2ClO2 + H2O2 + 2NaOH gives 2NaClO2 + 2H2O + O2).
- Chlorate dissolving
Sodium chlorate crystals are dissolved in soft water and filtered, so no grit or organic matter reaches the generator.
- Chlorine dioxide generation
The chlorate solution meets sulphuric acid and hydrogen peroxide in a titanium generator kept under vacuum, with dilution air holding the gas well below its explosive strength.
- Absorption and reduction
The gas is drawn into a chilled absorption tower where caustic soda and hydrogen peroxide convert it to sodium chlorite and release oxygen.
- Liquor adjustment
The liquor is tested for chlorite, residual chlorate and free alkali, corrected, and sold as a 25–31% solution or sent on for drying.
- Concentration
A vacuum evaporator removes water at low temperature, because sodium chlorite breaks down if it is overheated.
- Flaking and drying
A steam-heated drum flaker dries the concentrate into flakes of about 80% sodium chlorite, the balance being mostly common salt.
- Testing and packing
Each lot is checked for assay and chlorate and packed in lined drums, stored dry and away from acids and organic material.
Which route and product form should a new plant choose?
The choice of chlorine dioxide route and whether to make flakes decides most of the capital cost, the by-products and the buyers you can serve.
| Chlorate with peroxide and sulphuric acid | The route in our sample. Oxygen is the main off-gas and sodium sulphate is the by-product, so there is no chlorine to separate. It suits a new stand-alone plant. |
|---|---|
| Chlorate with salt and sulphuric acid | An older route that releases chlorine along with chlorine dioxide. The chlorine must be split off and sold as hypochlorite, which adds towers and a second product to market. |
| Backward integration from salt | Electrolytic cells make sodium chlorate on site from common salt. It removes chlorate buying risk but needs far more power and capital; it is a second-stage option. |
| Liquid only (25–31%) | Skips the evaporator and flaker. Lower capital and faster start, but freight per kg of chlorite is higher, so buyers need to be close. |
| Liquid and 80% flakes | Flakes travel further and keep longer, opening textile and export buyers. In our sample the evaporator and drum flaker add ₹114.89 lakh of machinery. |
Raw materials for sodium chlorite
Raw materials are 55.3% of sales in our sample, and sodium chlorate alone is more than half of that. Chlorate is bought to IS 5301, and its impurities carry through to the product, so a poor lot can fail a buyer's test.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Sodium chlorate | 56% | 551.27 |
| Hydrogen peroxide (50%) | 22% | 216.57 |
| Caustic soda lye | 14% | 137.82 |
| Sulphuric acid | 8% | 78.75 |
| Total | 100% | 984.41 |
Hydrogen peroxide is used twice, in the generator and in the absorber, so its consumption per tonne is a key figure for the lender to check.
Machinery for a sodium chlorite plant
The chlorine dioxide generator is the most expensive item. Wetted parts on the gas side are titanium, PVDF or FRP, since chlorine dioxide attacks ordinary stainless steel.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Chlorine dioxide generator | Titanium reactor under vacuum that makes the gas | 106.05 |
| Chilled absorption tower | Absorbs gas in caustic and peroxide | 61.86 |
| Vacuum evaporator | Concentrates liquor at low temperature | 61.86 |
| Drum flaker and dryer | Turns concentrate into 80% flakes | 53.03 |
| Chlorate dissolving and feed | Prepares and doses reagents | 35.35 |
| Chilling plant and cooling tower | Keeps the absorber cold | 35.35 |
| Instrumentation, DCS and QC lab | Controls dosing, interlocks and tests | 35.35 |
| Sulphate crystalliser and centrifuge | Recovers sodium sulphate from spent acid | 30.93 |
| Alkali vent scrubber | Captures stray gas before venting | 22.10 |
| Total plant and machinery | 441.88 | |
Costs are the sample report's estimates for a 4.7 MT per day plant. Get current quotations before you finalise.
Utilities and manpower for a sodium chlorite plant
The plant needs chilled water, steam and steady power at the same time. A power cut on the gas side must shut the generator down safely.
| Power and fuel | ₹90.01 lakh in Year 3 of the sample, 5.1% of sales, for vacuum pumps, chillers, blowers and the boiler |
|---|---|
| Steam | For the vacuum evaporator and the drum flaker; a small boiler is part of the plant |
| Chilled water | Keeps the absorber cold so chlorine dioxide is taken up fully and chlorite does not break down |
| Process water | Soft water for dissolving chlorate and making up liquor strength |
| Standby power | A DG set sized to run the vent fan, scrubber and interlocks during a grid failure |
| Manpower | 44 people in the sample, with wages of ₹99.84 lakh in Year 1, including shift chemists for every lot |
Approvals and safety rules for a sodium chlorite plant
Most of the approval work comes from the chemicals stored on site rather than from the product itself.
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board; state red lists include chlorates, peroxides and chlorine compounds |
|---|---|
| Hazardous chemical rules | Sodium chlorate, hydrogen peroxide, sodium hydroxide and sulphuric acid are listed in Schedule 1 of the Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 |
| Safety report and emergency plan | Where threshold quantities are exceeded, a safety report 90 days before start-up, an on-site emergency plan and mock drills every six months |
| Raw material standard | Sodium chlorate to IS 5301:1987 |
| Test method used by buyers | IS 7044:2026 sets the method for sodium chlorite content in textile materials |
| Factory, fire and registration | Factory licence, fire NOC, Udyam and GST registration; rules vary by state |
Who buys sodium chlorite?
Textile processors use sodium chlorite to bleach cotton and synthetic fibres with less fibre damage than hypochlorite. Water treatment users buy it to generate chlorine dioxide on site, and food, poultry and cooling water users buy it as a disinfectant and biocide.
Many users buy through chemical dealers rather than from a plant. A producer that supplies steady assay, low residual chlorate and reliable delivery can win those accounts directly.
- Textile processing and bleaching houses
- Water treatment formulators and chlorine dioxide system suppliers
- Municipal and industrial water and effluent plants
- Food processing and poultry units
- Leather tanneries
- Chemical traders and exporters
Plan for slow approvals: buyers test trial lots before they place regular orders, so the first year's sales build slowly. Our sample allows for this by starting at 60% capacity and 45 days of customer credit.
Mistakes that weaken a sodium chlorite project report
- Mixing assay bases
Capacity on a 100% basis and price per kg of 80% flakes or 31% liquor do not match; revenue can be off by a fifth or more.
- Costing the gas side in stainless steel
Chlorine dioxide service needs titanium and lined equipment. A cheaper quotation fails early and leaves the project over budget.
- No plan for residual chlorate
High chlorate fails buyer trials. The report should show peroxide dosing and testing that hold it down, and the cost of rework.
- Leaving out the sulphate by-product
Spent acid gives sodium sulphate to recover, sell or treat. Ignoring it understates both effluent cost and plant scope.
- Ignoring the safety timeline
Site notification and the safety report must reach the authority months before start-up, so the implementation schedule has to allow for them.
How NPCS helps you set up a sodium chlorite plant
- Route and product mixChoose between liquid only and liquid with flakes, and size the plant for your buyers.
- Material balance and costsChlorate, peroxide, caustic and acid use per tonne, by-products and utilities.
- Bank-ready project reportProjections, DSCR, break-even and working capital in your lender's format.
- Approvals and layoutPlant layout, hazardous chemical storage and the approvals list for your state.
NPCS, led by founder Ajay Kumar Gupta, has prepared project reports in specialty chemicals since 1994; its client list shows 269 assignments in the sector, including one for sodium chlorite.
What's inside the sodium chlorite sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
18 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
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Sodium Chlorite project report: frequently asked questions
What is the cost of a sodium chlorite manufacturing plant in India?
A liquid-only plant of 1.5–3 MT per day needs roughly ₹3.5–6 crore. A liquid and flakes plant of 4–6 MT per day needs about ₹7–11 crore, including land, building and working capital margin. Our sample report models a 4.7 MT per day plant at ₹836.59 lakh. These are indicative ranges; a project report prices your capacity, product form and site.
How is sodium chlorite manufactured?
Sodium chlorate is reacted with sulphuric acid and hydrogen peroxide to make chlorine dioxide gas. The gas is absorbed in chilled caustic soda with more hydrogen peroxide, which reduces it to sodium chlorite. The liquor is sold as a 25–31% solution or concentrated and dried on a drum flaker into flakes of about 80% strength.
What raw materials are needed for sodium chlorite?
Sodium chlorate, hydrogen peroxide, caustic soda and sulphuric acid. In our sample report sodium chlorate is 56% of raw material cost, hydrogen peroxide 22%, caustic soda lye 14% and sulphuric acid 8%. Chlorate price therefore moves profit more than any other input, and the report should test a rise in it.
What is the difference between sodium chlorite and sodium hypochlorite?
Sodium chlorite (NaClO2) is a stable solid or solution used mainly to generate chlorine dioxide and to bleach textiles. Sodium hypochlorite (NaOCl) is liquid bleach made by passing chlorine into caustic soda, sold at much lower strength and price. The two plants use different raw materials, equipment and safety systems, so each needs its own report.
Is a sodium chlorite plant profitable?
In our illustrative sample, a 4.7 MT per day plant earns a 24% return on investment in Year 3. It breaks even at 38% of capacity and pays back in about 3.4 years. Real results depend on chlorate buying price, product assay and residual chlorate, the liquor to flakes mix and how quickly buyers approve your material.
Which approvals does a sodium chlorite plant need?
Consent to establish and operate from the State Pollution Control Board, where chlorine compounds and chlorates sit in the red category, factory licence and fire NOC. Because sodium chlorate, hydrogen peroxide, caustic soda and sulphuric acid are listed hazardous chemicals, the Manufacture, Storage and Import of Hazardous Chemical Rules also apply. Confirm the list with your state authorities.
Is the sodium chlorite project report PDF free, and can I use it for a loan?
The sample is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report. Its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report for your own capacity, route, location and lender.
Sources and references
- Sodium Chlorite Supply Chain: Full Profile (EPA 817-F-22-045)United States Environmental Protection Agency, checked Oct 2026
- The Manufacture, Storage and Import of Hazardous Chemical Rules, 1989Punjab Pollution Control Board, checked Oct 2026
- List of red category industriesPunjab Pollution Control Board, checked Oct 2026
- IS 5301:1987 Sodium chlorateBureau of Indian Standards, checked Oct 2026
- IS 7044:2026 Determination of sodium chlorite content in textile materialsBureau of Indian Standards, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.