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    Chapter 1: Introduction Chapter 2: Literature Survey

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    Zubair Khan
    The document discusses the production of sodium carbonate via the Solvay process. It provides detailed information on the process steps, equipment, materials, and environmental and safety aspects involved. The key steps include brine purification, limestone calcination, ammonia absorption, carbonation to produce sodium bicarbonate, separation and recovery steps.

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    Chapter 1: Introduction Chapter 2: Literature Survey

    Uploaded by

    Zubair Khan
    54 views5 pages
    The document discusses the production of sodium carbonate via the Solvay process. It provides detailed information on the process steps, equipment, materials, and environmental and safety aspects involved. The key steps include brine purification, limestone calcination, ammonia absorption, carbonation to produce sodium bicarbonate, separation and recovery steps.

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    CONTENTS

    Original Title

    CONTENTS

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    The document discusses the production of sodium carbonate via the Solvay process. It provides detailed information on the process steps, equipment, materials, and environmental and safety aspects involved. The key steps include brine purification, limestone calcination, ammonia absorption, carbonation to produce sodium bicarbonate, separation and recovery steps.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    54 views5 pages

    Chapter 1: Introduction Chapter 2: Literature Survey

    Uploaded by

    Zubair Khan
    The document discusses the production of sodium carbonate via the Solvay process. It provides detailed information on the process steps, equipment, materials, and environmental and safety aspects involved. The key steps include brine purification, limestone calcination, ammonia absorption, carbonation to produce sodium bicarbonate, separation and recovery steps.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 5

    CONTENTS

    CHAPTER 1: INTRODUCTION 1

    CHAPTER 2: LITERATURE SURVEY 3


    2.1. General Information 4
    2.1.1. Other Names for Sodium Carbonate 4
    2.1.2. Physical Properties of Sodium Carbonate 4
    2.1.3. Hydrates of Sodium Carbonate 4
    2.1.4. Chemical Properties of Sodium Carbonate 5
    2.1.5. Grades and Specification of the Soda Ash 5

    2.2. Uses of Na2CO3 in Industrial Sectors 6


    2.2.1. Glass Industry 6
    2.2.2. Detergent Industry 7
    2.2.3. Metals and Mining 7
    2.2.4. Steel Industry 7
    2.2.5. Paper and Pulp 8
    2.2.6. Textiles 8
    2.2.7. Non-ferrous metallurgy industry 8
    2.2.8. Chemical industry 8
    2.2.9. Other Applications 8
    2.3. Uses of NaHCO3 in Industrial Sectors 9
    2.4. History of the Production 9
    2.5. Overview about Type of Production 10
    2.5.1. Le Blanc process 11
    2.5.2. Solvay Process 13
    2.5.3. Hou's Process 13
    2.5.4. Dual process 13
    2.6. Sodium Carbonate Minerals 14
    2.6.1. Trona Based Process 15
    2.6.1.1. Trona Products 16
    2.6.1.2. Monohydrate Process 16
    2.6.1.3. Sesquicarbonate Process 17
    2.6.1.4. Alkali Extraction Process 19
    2.6.2. Nahcolite based process 20
    2.7. International Scenario 21

    CHAPTER 3: FEASIBILITY STUDY 22


    3.1. Preliminary Study 23
    3.2. Economical Feasibility 25
    3.3. Market Feasibility 27
    3.4. Technical Feasibility 28
    3.5. Social Feasibility 29

    CHAPTER 4: PROCESS SELECTION 32


    4.1. Introduction 33
    4.2. Comparison of Solvay process with Others Methods of Production 34
    4.3. Process Selection Conclusions 37

    CHAPTER 5: PROCESS DESCRIPTION 38


    5.1. Main Chemical Reactions in Solvay process 39
    5.2. Process Steps 40
    5.2.1. Brine purification 41
    5.2.2. Calcinations of limestone in kilns and the production of CO2 and milk of lime 49
    5.2.3. Absorption of ammonia into purified brine 50
    5.2.4. Carbonation of the ammoniated brine with CO2 to produce sodium bicarbonate 43
    5.2.5. Separation of Sodium Bicarbonate from Mother Liquid 44
    5.2.6. Recovery of the Ammonia using Milk of Lime 45
    5.2.7. Calcinations of Sodium Bicarbonate to form Sodium Carbonate (light ash) 46
    5.2.8. Densification of Sodium Carbonate to form Dense ash 46
    5.3. Product (Soda Ash) Storage and Handling 46
    5.4. Raw Materials 47
    5.4.1. Brine 47
    5.4.2. Limestone 48
    5.4.3. Carbon for the Lime Kiln 48
    5.4.4. Ammonia 48
    5.4.5. Various additives 49
    5.5. Utilities 49
    5.5.1. Steam 49
    5.5.2. Process water 49
    5.5.3. Cooling waters 50
    5.5.4. Electricity 50
    5.6. Energy saving in the process 56
    5.6.1. Heat recovery 51
    5.6.2. Energy Minimization 51
    5.7. Process Flow Diagram 54
    5.8. P & I Diagram 55

    CHAPTER 6: SITE SELECTION & PLANT LAYOUT 56


    6.1. Introduction 57
    6.2. Site Selection Considerations 57
    6.3. Plant layout 60

    CHAPTER 7: ENVIRONMENTAL IMPACT ASSESSMENT 61


    7.1. Gaseous Effluents 62
    7.1.1. Particulate Dust 62
    7.1.2. Carbon dioxide and monoxide 62
    7.1.3. Nitrogen oxides 63
    7.1.4. Sulfur oxides 63
    7.1.5. Ammonia 63

    7.1.6. Hydrogen sulfide 64


    7.2. Gaseous Effluents Management 69
    7.2.1. Calcinations of Limestone 64

    7.2.2. Precipitation of Crude Sodium Bicarbonate 65


    7.2.3. Filtration of the Bicarbonate 65
    7.2.4. Conveying and Storage of Soda Ash 65
    7.3. Liquid Effluents 65

    7.3.1. Wastewater from Distillation 66


    7.3.2. Wastewater from Brine Purification 67
    7.4. Liquid Effluent Management 68

    7.4.1. Liquid Effluent Treatments 68


    7.4.1.1. Total Dispersion 69
    7.4.1.2. Separation of the Suspended Solids and Liquid Dispersion 69
    7.4.2. Liquid Effluent Discharge Management 70

    7.5. Solid Effluents 70


    7.6. Solid Materials Management 71

    7.6.1. Limestone Fines 71


    7.6.2. Grits from slaker 71
    7.7. By-Products Recovery and Reuse 71
    7.7.1. Calcium Chloride 72

    CHAPTER 8: SAFETY MEASURES 73


    8.1. Plant Safety 74
    8.2. General Plant Safety 74

    8.3. Personal Safety 76


    8.4. Safety Aspects of Equipments 76
    8.4.1. Lime Kiln 76

    8.4.2. NH3 Absorbing Unit 77


    8.4.3. Carbonator Unit 78
    8.4.4. NH3 Recovery Unit 78
    8.4.5. Drier 78
    8.4.6. Storage Vessels 78
    8.4.6.1. Ammonia 78
    8.4.6.2. Soda ash 79
    8.4.6.3. Baking soda 79
    8.4.6.4. Calcium Carbonate and Calcium Oxide 79
    8.4.7. Pipelines 79
    8.5. Safety Aspects of Chemical 80

    8.5.1. Carbon Dioxide (CO2) 80

    8.5.2. Ammonia (NH3) 81

    8.5.3. Sodium Carbonate (Na2CO3) 83

    CHAPTER 9: MATERIAL BALANCE 86


    9.1. Product specification 87
    9.2. Components in Purified brine 87

    9.3. Calculations for NH3 Absorption Unit 88


    9.4. Air Mixture 90
    9.5. Gas Washing Tower with Purified Brine 91
    9.6. Carbonator Unit 92
    9.7. Filter 94
    9.7.1. Calculation for residue solid 95
    9.7.2. Calculation for permeate 95
    9.8. Lime Kiln 96
    9.9. Slaker of lime 98
    9.10. Ammonia Recovery Unit 99
    9.11. Gas Cooler 102
    9.12. Air Mixture (Before the Gas Cooler) 103
    9.13. Dryer 104
    9.14. Material Flow Sheet 106

    CHAPTER 10: ENERGY BALANCE 107


    10.1. Kiln Energy Balance 108
    10.2. Energy Balance for Air Preheated 110
    10.3. Calcinations of Crude Bicarbonate 111
    10.4. CaCO3 Preheated 114
    10.5. Air Mixer Energy Balance 115
    10.6. Heat Balance for Gas Cooler 117
    10.7. Slaking of Lime 118
    10.8. Recovery of Ammonia Column Energy Balance 121
    10.8.1. Find Outlet Temperature of the Cool Gas 122
    10.8.2. Fine Quantity of Steam Consumption 123
    10.9. Carbonation of Ammoniated Brine Column 125

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