IWUOHA CHIBUEZE CHIAGOZIEM

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)

Na2S + 2CO2 (2)

Na2S + CaCO3 Na2CO3 + CaS (3)
Na2SO4 + 2C

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

PROCESS FLOW DIAGRAM

JUSTIFICATION AND SCOPE

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.

THEORETICAL, MODEL, EXPERIMENTAL TECHNIQUES.

The theoretical, model and experimental techniques are usually applied
during the design stage. They are required to accurately estimate the
sizes of the process units and also estimate the amount of raw materials
required for the required quantity of products. They also help to determine
the efficiency of the process units.

CALCULATING FLOW RATE.

The flow rate of a liquid is a measure of the volume of the liquid that
moves in a certain amount of time. The flow rate depends on the area of
the pipe or channel that the liquid is moving through, and the velocity of
2
the liquid. If the liquid is flowing through a pipe, the area is A= r ,
where r is the radius of the pipe. For a rectangle, the area is A=wh
where w is the width, and h is the height. The flow rate can be measured
3
L
m
.
in meters cubed per second ( s ) , or in litres per second
s

( )

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

200% Excess water used

Inputs:
Calcium oxide = 16509.4328 kg/hr
Water = 10613.2068 kg/hr
Total input = 27122.6396 kg/hr
Outputs:
Calcium hydroxide = 21816.0362 kg/hr
Water = 5306.6034 kg/hr
Total output = 27122.6396 kg/hr
Material balance around ammonia absorber
Assuming 99% absorption of input ammonia
Inputs:
Sodium chloride = 45990.5625 kg/hr
Water = 136693.1508 kg/hr
Ammonia = 18376.95 kg/hr
Inerts = 18345.59 kg/hr
Total input = 219406.25 kg/hr
Outputs:
Sodium chloride = 45990.5625 kg/hr
Water = 117429.7832 kg/hr
Inerts = 18345.59 kg/hr
Ammonia(with inerts) = 183.7695 kg/hr
Ammonium hydroxide = 37456.548 kg/hr
Total output = 219406.22 kg/hr
Material balance around Carbonating Tower
NaCl + NH4OH +CO2 NH4Cl + NaHCO3
Conversion 75%
Inputs:
Sodium chloride = 45990.5628 kg/hr
Carbon di oxide = 34591.1896 kg/hr
Ammonium hydroxide = 37456.548 kg/h
Water = 117429.7832 kg/hr
Total input = 235468.0836 kg/hr
Outputs:
Ammonium chloride = 31544.8091 kg/hr
Sodium bi carbonate = 49528.3019 kg/hr
Sodium chloride (unreacted) = 11497.6397 kg/hr
Ammonia hydroxide (unreacted) = 16819.754 kg/hr
Carbon di oxide (unreacted) = 8647.7974 kg/hr
Water = 117429.7832 kg/hr
Total output = 235468.0853 kg/hr
Material balance around Ammonia distiller
2NH4Cl + Ca (OH)2 2NH3 + CaCl2 + 2H2O
NH4OH NH3 + H2O
Inputs:
Calcium hydroxide = 21816.0362 kg/hr

Ammonium chloride = 31544.8091 kg/hr

Ammonia hydroxide = 16819.754 kg/hr
Water = 122736.3866 kg/hr
Sodium chloride (unreacted) = 11497.6397 kg/hr
Total input = 204414.6251 kg/hr
Outputs:
Ammonia = 18193.179 kg/hr
Calcium chloride = 32724.0543 kg/hr
Water = 141999.7521 kg/hr
Sodium chloride (unreacted) = 11497.6397 kg/hr
Total output = 204414.6251 kg/hr
Material balance around calciner
2NaHCO3 Na2CO3 + CO2 + H2O
Complete decomposition
Inputs:
Sodium bi carbonate = 49528.3019 kg/hr
Outputs:
Sodium carbonate = 31250 kg/hr
Carbon di oxide = 12971.6972 kg/hr
Water = 5306.6034 kg/hr
Total output = 49528.3019 kg/hr
ENERGY BALANCE
The Energy balance gives the account of all the energy requirement
of the process which is based on the principle of conservation of energy.
The principle states that energy can either be create nor destroyed but
can be transformed from one form to another. Also energy can be
transferred from one body to another. If a plant uses more energy than its
competitor, its product could be priced out of the market. Accountability of
the energy utilization of a process plant is necessary in every design
project.
The conservation of energy however differs from the mass in that energy
can be generated (or consumed) in a chemical process. Material can
change form; new molecular specie can be formed in a process unit and
must be equal to the one out at steady state. The same is not true for
energy. The total enthalpy of the outlet stream will not be equal to that of
the inlet stream if energy is generated or consumed in the processes,
such as that due to heat of reaction. In plant operation, an energy balance
on the plant will show the patterns of energy usage and suggest area for
conservation and saving. As for materials balance, a general equation can
be written for energy balance;
Energy out Energy in + Generation Consumption =
Accumulation
DESIGN VOLUME

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

Due to the cost intensive nature of this project, a lower annual

production rate should be used.

The issue of safety and control should be enforced at all levels and
times to ensure the smooth running of the plant, to protect lives and

the environment as a whole.

The marketing department should market the product to raise the
profitability measure higher than as shown during the plant life.

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.

A hazard is a property which in particular circumstances could lead to

harm. Common safety hazards in the manufacturing industry include;
dangerous machinery, explosion to fires, faulty electrical connections and
falling materials due to poor housekeeping among others.