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The CEO of FSTI, Inc., Stoney Barton founded the chemical manufacturing company and leads it in producing chlor-alkali and other chemicals for use in oil-field services and other industrial applications. Since 1998, Stoney Barton has guided the company’s expansion throughout six states. FSTI is now a member company of the University of Texas Hydraulic Fracturing and Sand Control joint industry project. A graduate of the University of Texas at Austin with a degree in chemistry, Mr. Barton has remained involved with his alma mater over the years. As an executive member of the College of Natural Sciences Advisory Board, he worked collaboratively on strategic direction and vision. He also spoke at the 2016 commencement ceremony for the College of Natural Sciences and at the 2019 College of Natural Sciences Chemistry graduation reception. Mr. Barton holds several patents and patents pending, including one for an apparatus for providing and blending fluids at oil and gas well locations. He also co-founded North Star 620, LLC, which focuses on innovative technology and research in the green energy sector.

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Common Chlorine Manufacturing Techniques

From bleach and disinfectants to crop protection chemicals and airbags to corn syrup and cosmetics, chlorine underlies the manufacture of an array of indispensable everyday products. Although a naturally-occurring chemical element thanks to its high reactivity, chlorine exists predominantly in compounds. Scientists have identified over 2,000 of them in various places and organisms, including human beings. To obtain chlorine in its pure form, people must separate the compounds. Sodium chloride (NaCl) or table salt is among the most common natural sources of chlorine found in ocean water and mineral deposits formed after the drying up of ancient oceans. The World Chlorine Council (WCC), an international representative organization for the chlorine and chlorinated products industries, reports that over 97 percent of the world chlorine is manufactured via the chlor-alkali process. It involves the electrolysis of NaCl or potassium chloride (KCl) solutions and dates back to 1888. During the chlor-alkali process, a direct electrical current is applied to salt and water solution, called brine, which leads to the rearrangement of the ions and the production of chlorine gas (Cl2) and alkali, sodium hydroxide (NaOH), or potassium hydroxide (KOH), and hydrogen gas (H2). The chlor-alkali industry uses several electrolytic production techniques: the membrane, diaphragm, and mercury cell techniques. In all of them, the electric current flows through electrodes submerged in the brine: positively charged anodes and negatively charged cathodes. According to the WCC, in 2021, the membrane technique and the diaphragm technique are the most widely used ways for chlorine manufacturing, with 83 percent and 12.5 percent, respectively. International agreements on the use of mercury, like the Minamata Convention, have led to discontinuing the mercury cell technique, and thus, it is the least common with 2.1 percent. The remaining 2.5 percent employ other techniques that use hydrochloric acid (HCl) to get chlorine and hydrogen or metal salts to produce chlorine and specific metal like magnesium or nickel. In the membrane cell technique, a perfluorinated polymer ion exchange membrane separates the anodes and the cathodes. High-purity brine flows through the anode compartment, where the oxidation of the chloride ions forms chlorine gas. The cation-selective membranes cause the sodium ions and water to migrate to the cathode compartment. After the reduction of water to hydrogen gas and hydroxide ions, the latter combine with the sodium ions to create NaOH. The produced via this technique sodium hydroxide is typically about 30 percent to 35 percent, which can be further concentrated to 50 percent with the help of evaporators. In the diaphragm cell technique, the separation between the cathode and the anode is via a diaphragm coated with a layer of asbestos fiber combined with an additive such as polytetrafluoroethylene, commonly known as Teflon, or other artificial asbestos-free fiber. A nearly saturated brine added to the anode compartment flows through the diaphragm to the cathode one. In the anolyte section, following oxidation, the chloride ions produce Cl2; in the cathode compartment, the H2 and the hydroxide ions are produced. Sodium ions pass from the anode section through the diaphragm to the cathode one to create cell liquor with 10 percent to 12 percent NaOH concentration. Some chloride ions also pass the diaphragm to form cell liquor with 16 percent sodium chloride. Again using evaporation, the NaOH cell liquor is further concentrated to 50 percent. The NaCl recovered during the evaporation is added back to the brine and reused. In the phasing out mercury cell technique, a stream of flowing mercury serves as the cathode. The anode is parallelly suspended just a few millimeters above it. Brine enters at one end of the cell box and flows between the electrodes driven by gravity. Chlorine gas production happens at the anode. The sodium ions, set down along the surface of the flowing mercury cathode, dissolve in the mercury forming a liquid amalgam. Pulled by gravity, the amalgam flows from the electrolyzer to a decomposer filled with carbon. There, deionized water is added, which removes the alkali metal from the mercury, resulting in hydrogen and 50 percent NaOH. A pump brings back the mercury to the cell inlet, and the whole process repeats.

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Founded in 1998, FSTI, Inc., has grown in volume or revenue every year since then. A leading manufacturer and distributor of chlor-alkali chemicals, FSTI operates in six states to offer a range of manufacturing, trucking, selling, and distribution services. The company produces several chemicals used in semiconductor manufacturing, among them hydrochloric acid, sodium hypochlorite, and sodium hydroxide, also known as caustic soda.

FSTI produces caustic soda in concentrations of up to 32 percent by weight, and it can source the chemical in concentrations up to 50 percent by weight. A versatile alkali chemical, caustic soda has broad applications, primarily in the production of petroleum products, pulp and paper, aluminum, and soap and detergent.

A white, odorless solid, caustic soda appeared in soap-making recipes as early as the late 13th century. Early recipes called for passing water repeatedly through a mixture of alkali and calcium oxide to form a solution of sodium hydroxide. By the 20th century, electrolysis had become the common production method; in this process, chemical decomposition occurs when an electrical current passes through a solution of sodium chloride (table salt), yielding chlorine gas and sodium hydroxide. The Food and Drug Administration-approved chemical is generally classified as safe for household use when handled properly.

An effective ingredient in many drain cleaners, caustic soda can transmute hard fat and grease buildup into dissolvable soap. The chemical can also help eliminate certain nucleic acids and proteins, killing many viruses on contact. Additionally, it removes many microorganisms and gets rid of yeast and fungi. Because it is accessible, affordable, and easy to dispose of, caustic soda has become a critical element in sanitation across a variety of industries.

Caustic soda can cause burns when it comes into direct contact with the skin, and thus it should be handled with extreme care. In particular, eye protection can help prevent damage or irritation from fumes.

In addition to cleaning applications, caustic soda appears as an ingredient in medical supplies. For example, many pain relievers contain caustic soda, as do anticoagulants and various prescriptions that help patients maintain healthy cholesterol levels. Common brand names with sodium hydroxide include Aspir-Low, Nexium, Didanosine, and Sutent.

At smaller concentrations, caustic soda makes many household beauty products more effective. For example, because it has the ability to stabilize pH levels, it can aid hair products in reducing acidity on the scalp, hair, and skin. Additionally, it can help neutralize pH levels on the scalp when the oil from hands mixes with the hair product.

Finally, caustic soda comprises a key element in creating various types of bagels and pretzels. Before the pretzels or bagels are baked, they are dipped in an extremely diluted concentration of caustic soda. Unlike the caustic soda used in manufacturing and cleaning, food-grade caustic soda has been produced and packaged in a manner that makes it safe for consumption.

Bathing the bread in caustic soda (also known as lye) changes the heat-activated reaction between amino acids and sugar in the dough. Specifically, the caustic soda bath breaks down the proteins in the dough and thus changes the ratio of protein to sugar. This typically results in the pretzel’s deep-brown crust, chewy interior, and distinctive taste.

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The UTeach program at the University of Texas at Austin aims to serve underrepresented populations while inspiring students to explore opportunities in the areas of science, technology, engineering, and math (STEM). Part of the College of Natural Sciences, the program offers teaching opportunities to both undergraduate students and degree holders. From their very first semester, students work in pairs to develop lesson plans and deliver instruction in local classrooms.

A branch of UTeach, UTeach Outreach originated as a course that paired UT students with community teachers to assist with hands-on lessons. The course served a symbiotic purpose, providing real-world experience to aspiring teachers while providing much-needed classroom support for teachers in under-resourced schools.

The UTeach Outreach program has since expanded to work on various community-based projects, including after-school clubs and summer camps. Each year, approximately 200 UT students and volunteers visit Austin-area schools to teach inquiry-based science classes, as well as to serve as mentors for more than 30 after-school clubs.

UTeach Outreach participants practice the concept of service learning, an educational pedagogy that places equal emphasis on their own learning and service to the larger community. Students can complete their own coursework while achieving a positive impact in their communities, all while building connections with fellow UT students. Taken for class credit, UTeach Outreach courses provide a unique opportunity to earn academic credit while gaining fieldwork experience and engaging with the community.

In addition to learning in the classroom, UTeach Outreach participants mentor a variety of after-school STEM clubs. In this less formal setting, participants improve communication and leadership skills while inspiring students to explore their interests in STEM areas.

Finally, UTeach Outreach operates a number of summer programs designed to inspire students through hands-on STEM content. Ideally, students begin in sixth or seventh grade and take the five-week academic courses for four consecutive summers. Using engaging inquiry-based techniques, the courses prepare students for advanced high school coursework in STEM areas.

For degree holders and eligible upperclassmen, UTeach Accelerate qualifies individuals to teach secondary STEM courses in as little as a year. This pathway streamlines coursework and provides intensive coaching that helps candidates use project- and inquiry-based learning to engage students. After a year of rigorous coursework from master teachers and UT faculty, qualified candidates receive a recommendation for a full-time paid teaching position, or they may elect to complete one semester of student teaching before acquiring full certification.

During their year of preparatory coursework, UTeach Accelerate candidates receive personal mentorship to help them meet their educator preparation requirements. To enter the UTeach Accelerate program, students must have a cumulative GPA of 2.5 and sufficient STEM credit hours to meet UTeach content requirements.

Additional UTeach initiatives include UTeach Maker, a micro-credentialing program that invites UTeach participants to refine their teaching skills. Working one-on-one with Maker mentors, participants enhance their resumes and develop skills to infuse STEM learning with creativity and invention. Graduates of the selective UTeach Maker program will serve approximately 1,600 students in the classroom.

To learn more about how UTeach addresses educational needs in the Austin community, or to read about the program’s various initiatives, visit uteach.utexas.edu.