Documente Academic
Documente Profesional
Documente Cultură
13CF015140
CHE 414
MANUFACTURE OF SODA ASH
INTRODUCTION
Soda ash (Calcium carbonate Na2CO3) in arid state being colorless crystal
powder is produced using the ammonia soda process (Solvay process),
and also during integrated nepheline processing in Russia.
Soda ash is used in the glass, chemical, aluminum industries, iron and
non-ferrous metallurgy, soap, fats and oils industry, food, textile, paper, oil
and other industries, chemical treatment of water, production of
plastic and synthetic resins, processing gold bearing and uranium ores,
production of detergents and domestic use.
Soda ash is a white crystalline powder or granular material which is
readily soluble in water. Soda ash contains 99.3 % of Na2CO3 and is
graded according to its bulk density. The commercial standard that is
accepted is expressed in terms of the total equivalent sodium oxide
(Na2O) that it contains, meaning that commercial 58 % soda ash contains
an equivalent of 58 % Na2O. The equation to convert is % Na2O x 1.71 =
Na2CO3 %; 58 % of Na2O is equivalent to 99.2 % Na2CO3. In 1991 soda
ash was said to be the eleventh largest world commodity chemical.
MANUFACTURING METHODS
Leblanc process
The Leblanc or black ash process was discovered in the period around
between 1825 and 1890 by the French physician Nicolas Leblanc. This
synthetic process was named after its inventor. In this process, soda ash was
produced from common salt, sulfuric acid, coal and limestone.
Sodium chloride reacts with sulfuric acid to produce sodium sulfate and
hydrochloric acid. The sodium sulfate is then roasted with limestone and coal
and results into sodium carbonate and calcium sulfide mixture. The sodium
carbonate and calcium sulfide mixture is also known as black ash. Black ash
is then leached with water to extract the sodium carbonate. The Leblanc
process which is now of only historical interest, is based on the following
chemical reactions:
2NaCl + H2SO4 Na2SO4 + 2HCl (1)
Solvay process
The Solvay process is also known as the ammonia soda process. The Solvay
process was developed by the Belgian Ernest Solvay (1838 1932) in 1861.
This process reduced the operating cost and environmental impact. The
Solvay process is the most accepted technology for producing synthetic soda
ash because the investment and maintenance costs are low compared to
other processes. The Solvay process is still the dominant production route for
soda ash. The basic raw materials that are used in this process include salt,
limestone and coke or natural gas and also ammonia as a cyclic reagent.
In this process the ammonia reacts with carbon dioxide and water to form
ammonium bicarbonate. The ammonium bicarbonate is then reacted with salt
to form sodium bicarbonate, which is calcinated to form sodium carbonate.
Chloride is formed as a by-product and is neutralized with lime to produce
calcium chloride. Almost all the ammonia used in the reactions is recovered
and recycled. The Solvay process can be summarized by the following
theoretical global chemical reaction, which involves two main components
which are sodium chloride and calcium carbonate.
2NaCl + CaCO3 Na2CO3 + CaCl2
The Solvay process includes the following stages:
1. Production of a saturated salt solution
NaCl + H2O (5)
2. Burning of limestone and the CO2 recovered which is used in stage 4 while
CaO is used in stage 7.
CaCO3 CaO + CO2 (6)
3. Saturation of the salt solution with ammonia
NaCl + H2O + NH3 + CO2 (7)
4. Precipitation of bicarbonate by adding carbon dioxide (from stage 2 and 6)
NaCl + H2O + NH3 + CO2 NH4Cl + NaHCO3 (8)
5. Filtration and washing of sodium bicarbonate
6. Thermal decomposition of sodium bicarbonate to sodium carbonate (the
carbon dioxide that is given off is recycled to stage 4)
2NaHCO3 Na2CO3 + H2O + CO2 (9)
7. Production of milk of lime
CaO + H2O Ca(OH)2 (10)
8. Recovery of ammonia by distillation of the mother liquor from stage 4 with
milk of lime ( the ammonia that is released is recycled to stage 3)
2NH4Cl + Ca(OH)2 2NH3 + CaCl2 + 2H2O
At present, there are little or no Soda ash plants in Nigeria. The little Soda
ash produced is used mainly by plants in the country is used up
immediately by them to make glass or soap. This means that most of the
all Soda ash used in the country is imported. A Soda ash plant sited in the
country producing Soda ash made available to the Nigerian market will
not only reduce importation of the glass but also encourage soap
production, create job opportunities as well as develop the area in which it
is sited.
The production on Soda ash will lead to a provision of the chemical
used in the chemical process of many other important items in the
world today. Hence, high efficiency and quality in the production of
Soda ash must be ensured.
It will ensure high produce of glass, soap, pulp and paper.
The Scope of this project is to,
To design a plant that will deliver a large number of Soda ash per
annum.
To determine the technical and economic feasibility of the plant.
( )
Before calculation the flow rate it is advised that the process goes through
a continuous process because there are various factors involved.
MATERIAL BALANCE
Production of 750 Tons/day (31250 kg/hr) of Soda ash
Material balance around Lime Kiln
CaCO3 CaO+CO2
80% conversion
C+O2 CO2
90% conversion
Excess air is not used
Inputs:
Calcium carbonate = 36851.4125 kg/hr
Carbon = 2812.5 kg/hr
Oxygen = 7500 kg/hr
Nitrogen =24687.5 kg/hr
Total input =71851.4125 kg/hr
Outputs:
Carbon di oxide = 22252.9472 kg/hr
Calcium oxide = 16509.4328 kg/hr
Nitrogen gas = 24687.5 kg/hr
Carbon (unreacted) = 1031.25 kg/hr
Calcium carbonate (unreacted) =7370.282 kg/hr
Total output =71851.412 kg/hr
Material balance around Slaker
CaO + H2O Ca(OH)2
This is said to be the theoretical volume of the process tank i.e. the
volume gotten on a calculated basis without actually carrying out the
process.
OPERATION VOLUME
When carrying out reactions in real life basis, due to a never ideal case
scenario, some errors like variations of volumes due to expansion factors,
temperature gradients and others happen and cant be completely
eliminated. These are the conditions in which our systems operate
actually on a real life basis.
ESTIMATION OF LAND
Plant location refers to the choice of a region or the selection of a
particular site for settling up the business or a factory. However, the
choice is made only after considering alternative sites. It is a strategic
decision that cannot be changed once it is taken. Therefore, careful care
must be taken before a decision is made on the location of the plant site.
An ideal plant location is one where the cost of the production is minimal,
with a large market availability, least risk involved and maximum gain
obtainable. It is a place of maximum net advantage or with lowest unit
cost of production and distribution. For achieving this objective, small and
large scale entrepreneur can make use of local analysis.
RECOMMENDATION
PLANT SAFETY
Every organisation (company or industry) has the moral and legal
obligation to protect the health and welfare of its employees as well as
that of the general public. Therefore, good safety measures have to be put
in place to ensure the safety of lives and prevent damage to equipment.
The primary aim of these safety measures therefore is to prevent or
minimize workers exposure to the potential hazard, injury to workers, loss
of lives, and destruction of properties. They are also needed to ensure
safe as well as efficient operation.
These safety measures are employed in industry mainly to prevent or
control hazards.