<Flemion>
A fluoropolymer ion-exchange membrane which protects global environment through outstanding technologies
Developing an Environmentally Friendly Caustic Soda Production Process
The AGC Group has been fully meeting the needs of the times concerning environmental friendliness and safety regarding its caustic soda (sodium hydroxide) production process. Caustic soda is an indispensable chemical for a variety of industries and is used in the production of diverse products, including chemical fibers, paper and pulp, and soaps. Caustic soda is manufactured by the electrolysis of brine, and the mercury process and the asbestos diaphragm process were traditionally used in its manufacture. However, due to the pollutive effects of mercury and asbestos emissions into the environment, early in the 1970s, the Japanese government required domestic manufacturers to develop a new manufacturing process for caustic soda.
In 1974, in response to the governmentfs request, the AGC Group embarked on the development of an ion-exchange membrane process, in which the electrolysis of brine is conducted using an ion-exchange membrane for selective filtering of ions to produce caustic soda and chlorine. Subsequently in 1975, Asahi Glass developed a fluoropolymer ion-exchange membrane (Flemion) to be used for caustic soda production. We also developed highly durable and energy-saving activated cathodes, and established the electrolysis technology to manufacture caustic soda by the use of Flemion and the activated cathodes.
The ion-exchange membrane process does not require the use of hazardous substances. Also, the process leads to substantial energy-saving. The AGC Group, by the use of this newly developed manufacturing process with these advantageous features, has achieved an approximately 40% reduction in energy consumption as compared to the mercury process and the diaphragm process.
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<Flemion> 
<Flemion>is highly appreciated by its users as an extremely low voltage, energy-saving membrane. |
Ion-exchange membrane process equipment 
Ion-exchange membrane process equipment newly installed at the Phrapradaeng Plant of AGC Chemicals (Thailand) Co., Ltd. |
Further Improvement to <Flemion> with a View to Environmental Contribution
The AGC Group has made various improvement of Flemion, in addition to improvement of the caustic soda manufacturing process. Recently, poorly refined brine containing impurities has been increasingly used in some areas, and in consideration of this fact, we developed Flemion F-8020, which is highly durable against impurities contained in brine. Furthermore, we are applying our ion-exchange membrane technology to the development of fuel cells.
Becoming the Worldfs First Manufacturer to Complete the Conversion to the Ion-Exchange Membrane Process
In 2006, AGC Chemicals (Thailand) Co., Ltd., an affiliate of the AGC Group in Thailand, converted its caustic soda manufacturing process from the mercury process to the ionexchange membrane process. This marked the completion of conversion to a manufacturing process using Flemion by all the AGC Group caustic soda manufacturing plants. In the world, however, the ion-exchange membrane method is applied by 50% or smaller percentage of caustic soda manufacturers, and even in Europe, which leads the world in the reduction of greenhouse gas emissions, the targeted deadline for the full discontinuance of the use of the mercury process has been set at 2020.
The AGC Group has thus converted its production process to a clean and more energy-saving process ahead of its competitors around the world. Also, we will expand the sales of highly energy-saving Flemion to help other manufacturers convert their production processes to more environmentally friendly ones, thereby contributing to reducing the global environmental impact caused by manufacturing activity.
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Recognition from Japan's Environment Ministry for Developing Activated Cathodes for the Caustic Soda Production Process
These four representatives of the AGC Research Center and the AGC Chemicals Company represented the AGC group at the award ceremony
In June 2006, at the 33rd Environment Prize awards, held jointly by the Hitachi Environment Foundation and Nikkan Kogyo Shimbun,Ltd. the AGC Research Center and the AGC Chemicals Company earned recognition from Japan's Ministry of the Environment for the ion-exchange membrane process they developed to produce caustic soda and chlorine. That process has eliminated reliance on mercury and asbestos. The ministry made special note of the AGC Group's success in developing and adopting ultra-durable cathodes in the process. The ion-exchange membrane process, which combines the high performance ion-exchange membrane Flemion and the newly developed ultra-durable activated electrodes, is widely used across relevant facilities in the world, and the process has greatly contributed to energy saving and the prevention of environmental pollution. Receiving high acclaim, we won an award for our achievement.
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