Chapter 2

2.5

Best Available Techniques for the production of soda ash by the Solvay process

In understanding this section and its contents, the attention of the reader is drawn back to the preface of this document and in particular the fifth section of the preface: How to understand and use this document. The techniques and associated emission and/or consumption levels, or ranges of levels, presented in this section have been assessed through an iterative process involving the following steps: identification of the key environmental issues for the sector, including: o limited material efficiency of the Solvay process, due to intractable chemical equilibrium limitations, with the conversion of a Na+ cation at the level of ~ 70 % and CO32- anion at the level of ~ 80 %, this having a direct impact of the production of soda ash on the environment [85, EIPPCB, 2004-2005] o the influence of the quality and purity of the raw materials used (including the heavy metals content), in particular limestone, for the overall impact of the production of soda ash on the environment o the relatively high volume of the waste waters discharged from the process to the aquatic environment o the load of suspended solids in the waste waters, including heavy metals derived from the raw materials, and the limited possibilities to separate them from the waste waters in all soda ash producing sites. The best management option depends on local conditions, however, in several locations total dispersion is used without any separation of suspended solids examination of the techniques most relevant to address these key issues identification of the best environmental performance levels, on the basis of the available data in the European Union and worldwide examination of the conditions under which these performance levels were achieved; such as costs, cross-media effects, and the main driving forces involved in implementation of the techniques selection of the best available techniques (BAT) and the associated emission and/or consumption levels for this sector in a general sense, all according to Article 2(11) and Annex IV of the Directive.

Expert judgement by the European IPPC Bureau and the relevant Technical Working Group (TWG) has played a key role in each of these steps and in the way in which the information is presented here. On the basis of this assessment, techniques, and as far as possible consumption and emission levels associated with the use of BAT, are presented in this section that are considered to be appropriate to the sector as a whole and in many cases reflect the current performance of some installations within the sector. Where emission or consumption levels associated with best available techniques are presented, this is to be understood as meaning that those levels represent the environmental performance that could be anticipated as a result of the application, in this sector, of the techniques described, bearing in mind the balance of costs and advantages inherent within the definition of BAT. However, they are neither emission nor consumption limit values and should not be understood as such. In some cases it may be technically possible to achieve better emission or consumption levels but due to the costs involved or cross-media considerations, they are not considered to be appropriate as BAT for the sector as a whole. However, such levels may be considered to be justified in more specific cases where there are special driving forces. The consumption and emission levels associated with the use of BAT have to be seen together with any specified reference conditions (e.g. averaging periods).

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The concept of levels associated with BAT described above is to be distinguished from the term achievable level used elsewhere in this document. Where a level is described as achievable using a particular technique or combination of techniques, this should be understood to mean that the level may be expected to be achieved over a substantial period of time in a well maintained and operated installation or process using those techniques. Where available, data concerning costs have been given together with the description of the techniques presented in the previous section. These give a rough indication about the magnitude of the costs involved. However, the actual cost of applying a technique will depend strongly on the specific situation regarding, for example, taxes, fees, and the technical characteristics of the installation concerned. It is not possible to evaluate such site-specific factors fully in this document. In the absence of data concerning costs, conclusions on economic viability of techniques are drawn from observations on existing installations. It is intended that the general BAT in this section are a reference point against which to judge the current performance of an existing installation or to judge a proposal for a new installation. In this way they will assist in the determination of appropriate BAT-based conditions for the installation or in the establishment of general binding rules under Article 9(8). It is foreseen that new installations can be designed to perform at or even better than the general BAT levels presented here. It is also considered that existing installations could move towards the general BAT levels or do better, subject to the technical and economic applicability of the techniques in each case. While the BAT reference documents do not set legally binding standards, they are meant to give information for the guidance of industry, Member States and the public on achievable consumption and emission levels when using specified techniques. The appropriate limit values for any specific case will need to be determined taking into account the objectives of the IPPC Directive and the local considerations. All BAT figures hereafter relate to yearly average. They have been derived from information based on various measurements or estimation techniques [85, EIPPCB, 2004-2005]. For soda ash plants in the EU-25 based on the Solvay process, the following are BAT: 1. Total consumption of salt in the raw brine in the range of 1.5 1.7 tonne NaCl per tonne of soda ash, although the consumption of up to 1.8 tonne NaCl per tonne of soda ash produced may be justifiable in some circumstances, e.g. raw brine quality and local cooling water temperature see Sections 2.3, 2.3.1 and 2.4.1. 2. Total consumption of limestone at the plant inlet in the range of 1.1 1.5 tonne per tonne of soda ash, although the consumption of up to 1.8 tonne limestone per tonne of soda ash produced may be justifiable for plants where good quality limestone is not available (i.e. limestone with a lower carbonate content, poor burning characteristics and stone friability) see Sections 2.3, 2.3.1and 2.4.1. 3. Selection of appropriate quality limestone (see Sections 2.2.2.2, 2.2.4.1 and 2.4.7.1), including: high CaCO3 content, preferably in the range betweeen 95 99 % (low MgCO3, SiO2, SO3, and Al2O3+Fe2O3 content) appropriate physical limestone characteristics required in the process (particle size, hardness, porosity, burning properties), and limited content of heavy metals (As, Cd, Cr, Cu, Hg, Ni, Pb and Zn) in either the purchased limestone or limestone from the currently exploited own deposit.

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In cases where a limestone deposit of lower grade, with a content of 85 to 95 % CaCO3, is used, and where other limestone of better quality are not readily available, low MgCO3, SiO2, SO3, and Al2O3+Fe2O3 content is not achievable. 4. Total energy consumption in the production of soda ash in the range of 9.7 13.6 GJ per tonne of dense soda ash produced (or 8.8 12.8 GJ per tonne of light soda ash produced) of which 2.2 2.8 GJ/t is in the lime kiln unit see Sections 2.3, 2.3.7, 2.4.1 and 2.4.2. 5. Optimised operation of the soda ash plant, to maintain the emissions of CO2 from the process in the range of 0.2 0.4 tonne of 100 % CO2 per tonne of soda ash produced (integrated production of soda ash with refined sodium bicarbonate at the site can lead to much lower emission levels) see Sections 2.3, 2.3.3.2, 2.4.1 and, in particular, to Section 2.4.3. 6. High concentration of the CO2 gas in the range of 36 42 % at the outlet of the vertical shaft lime kiln, thus allowing high process efficiency and low impact of the production of soda ash on the environment. For modern lime kilns and new soda ash plants, the concentration is expected to be at the higher end of the range see Sections 2.3.8.1, 2.3.8.1.2 and, in particular, Section 2.4.4. 7. High recovery of ammonia in the process, with the total losses of ammonia in waste waters from the distillation unit of less than 0.9 kg N-NH3 per tonne of soda ash produced. It should be noted, however, that older equipment may not be able to achieve such levels, as significant additional quantities of steam which has both the cross-media effects of emissions associated with the steam generated, as well as a significant increase in cost, are required. see Sections 2.3, 2.3.3.5, 2.4.1 and, in particular, to Section 2.4.6. 8. The quantity of waste waters, discharged from the distillation unit to a local watercourse, in the range of 8.5 10.7 m3 per tonne of soda ash produced see Sections 2.3.1, 2.3.4.1, 2.3.4.1.2 and 2.4.7. 9. The quantity of suspended solids in the waste waters discharged from the distillation unit, within the range of 0.09 0.24 tonne solids per tonne of soda ash produced see Sections 2.3, 2.3.1, 2.3.4.1, 2.3.4.1.1, 2.3.9.2 and 2.4.7.1. In cases where a limestone deposit of lower grade, with the content of 85 to 95 % CaCO3, is used, and where other limestones of better quality are not readily available, these levels will not be achievable. This is a process related BAT, whilst, e.g. BAT 10 in this section, addresses downstream waste water treatment options outside of the process plant itself. 10. With regard to the impact of waste waters (containing suspended solids and associated heavy metals) discharged from the production of soda ash to the aquatic environment: A. Where the final discharge is made to the marine environment (to the sea or into an estuary of a river under tidal influence, depending on local considerations), to ensure dispersion of the solids avoiding localised build-up of deposited solids and in any case to minimise the discharge of heavy metals using feedstock selection see Sections 2.3.10.1.1, 2.4.7.2, 2.4.7.1 and 2.4.7.3.

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B. Where the final discharge is made to a fresh water body, to: minimise the emission of heavy metals by the application of at least one of the following techniques: o o o o selection of appropriate feedstocks (see Section 2.4.7.1) removal of coarse solids from waste waters (see Section 2.4.7.3) deposition/dispersion settling ponds (see Section 2.4.7.4) deposition/dispersion underground disposal (see Section 2.4.7.5)

minimise the emission of suspended solids by the application of at least one of the following techniques, depending on the characteristics of the receiving water body: o o o o selection of appropriate feedstocks (see Section 2.4.7.1) removal of coarse solids from waste waters (see Section 2.4.7.3) deposition/dispersion settling ponds (see Section 2.4.7.4) deposition/dispersion underground disposal (see Section 2.4.7.5).

11. Where no use exists for the waste solids originating from the purification of salt brine (carbonates, sulphates, Ca, Mg and heavy metal ions), dispose of them either in the brine cavities or, if this is not possible, in a similar manner as with the liquid effluent from the distillation unit see Sections 2.3.4.2, 2.3.10.4.3, 2.4.7 and 2.4.7.5. 12. Discharge of fines of limestone and non-recycled grits from the slaker in the range of 50 - 350 kg per tonne of soda ash produced see Sections 2.3, 2.3.5 and 2.4.7. 13. Reduce dust emissions by using a combination of modern dust abatement techniques and optimum handling of raw materials and products (e.g. encapsulation of storage and transport facilities) see Section 2.3.3.1. A. For dry gas streams, apply bag filters to achieve a total dust emission level to air of <5 20 mg/Nm3. B. For wet gas streams, apply wet scrubbers to achieve a total dust emission level to air of <25 50 mg/Nm3. Recent experience shows that these levels can be difficult to achieve, e.g. in gas streams with pressure drop limitations.

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