Presented By

M.Haris Ubaid
2K16-CHE-135

M.Saqlain 2K16-CHE-159

M.Adeel Khalid 2K16-CHE-107

Production of soda ash
Chapter no.1
introduction
Introduction
Soda ash is a white powder.
It’s chemical formula is (Na2CO3).
It’s an alkali and exists in hydrated forms.
sodium carbonate is domestically well known as a water softener.
Sodium carbonate is moderately soluble in cold water.
It is commonly known as the “Soda Ash”.
 Uses of Sodium Carbonate
Glass Making A mixture of Na2CO3. CaCO3, and SiO2 (silicon dioxide sand) is used for window
or bottle glass.

Water Softening Agent CO32- from dissolved Na2CO3 , can precipitate Mg2+ and Ca2+ ions from hard water as
the insoluble carbonates, preventing them from forming a precipitate with soap
.resulting in scum. For this reason, sodium carbonate is also known as washing soda

Paper Making Na2CO3, is used to produce the NaHSO3 necessary for the sulfite method of separating
lignin from cellulose.
Baking Soda Production Baking soda (or sodium hydrogen carbonate or sodium bicarbonate). NaHCO 3 is used
in food preparation and in fire extinguishers.

Sodium Hydroxide Na2CO3 is reacted with a Ca(OH)2, slaked lime, suspension.

Production
for Soaps and Detergents
Chemicals properties of Soda ash
Sodium carbonate is hygroscopic.
The aqueous solution of Na2CO3 is overall a strong base.
 It reacts violently with many acids.
Sodium carbonate is alkaline and its alkalinity is reduced. If it is
stored under moist conditions because it absorbs carbon dioxide and
moisture from the atmosphere.
At a temperature greater than 400℃, sodium carbonate reacts with
water vapors to form sodium hydroxide and carbon dioxide
Physical Properties of Soda ash

Chemical Formula Na2CO3

Molecular Weight 106.0 g/mol
Boiling Point 1600℃
Melting point 851℃
Density 2.54 g/cm3
color White
Soluble in Water
Local Survey

•Total production in Pakistan is 4,25,000 ton/year.

Industries Year Production

ICI Pak 2018-2019 800 ton/day

Limited(Khewra)
Olympia chemical 2018-2019 410 ton/day
LTD(Lahore)

• Soda ash consumption in Pakistan is 4,50,000 ton/year.

World Survey

Country Year Production

India 2017-2018 3.12 million
ton/year
China 2018-2019 25 million ton/year
U.S 2018-2019 12 million ton/year
Turkey 2018-2019 2.2 million
ton/year
Kenya 2018-2019 0.32 million
ton/year
Graphical Trend(Pakistan)
Year vs production
production(104 metric ton)

50

45

40

35

30

25

20

15

10

0
0 2 4 6 8 10 12

Years
Selection of Capacity
Total production in Pakistan is 4,25,000 ton/year. Soda ash consumption in
Pakistan is 4,50,000 ton/year. And we have declared a further increase by 75,000
tons to near our total capacity to half a million tons per year by next year. We
select the Capacity of 600 ton/day.
 Chapter no.2
PROCESS SELECTION
Types of Process
1-Leblanc Process
2-Solvay’s Process
3-Dual Process
4-Hou’s Process
.

 
Solvay Process Leblanc Process Dual Process Hou’s Process

It is a cheap process as raw Raw materials are easily The raw materials are It increases the rate of
materials are easily available. available. utilization of the raw
available . materials.

Carbon dioxide and The production of HCl as a
ammonia waste products.
are recovered and reused.
Process is pollution free. Its created lots of
Pollution.
Ammonia is not recovered.
It consume the more energy.
Hou’s process soda ash is
significantly more costly to
produce.
The Hou’s process is more
energy intensive.

Consumption of fuel is very In this Process byproducts In this process ammonium This process does not
less since no solution is to are unusable. chloride is obtained as co- produce calcium chloride
be evaporated. products. as a by-product.
 
Selection of Process
we select the Solvay's process for the production of soda ash.
•The materials used in the Solvay process are easily available and
cheap.
•It is low cost method.
•Carbon oxide and ammonia are recovered and reused.
•Process is pollution free, if ammonia is control.
• Sodium carbonate of greatly high purity is obtained.
Raw Materials
1) Ammonia(NH3)
Ammonia gas is used to facilities absorption of carbon dioxide into brine.

2) Coke
coke is a solid fuel made by heating coal used to generate CO2 gas for the process.

3) Brine
 Brine is a sodium chloride solution. It provides sodium ions in the making of the sodium
carbonate.
4) Lime Stone(CaCO3)
Limestone is a carbonate sedimentary rock which burnt in the Kilns for the production of
Calcium oxide.
Description of Solvay's process
The following steps are concerned in method Solvay process industrial process and during this
process some quantity of ammonia recycled back as feedstock to begin new spherical of Solvay
process.

i) Brine purification

ii) Ammunition of brine

iii) Reactions in Solvay Tower

iv)Reactions in kiln / Separation of solid sodium hydro carbonate

v) Ammonia Recovery
Brine Purification
The solvay process will commences with brine purification which involves brine
solution is concentrated by evaporation to at least 30%.
Calcium, magnesium and iron are collected as precipitants in this reaction
Ca2+(aq) + CO32 CaCO3(s)
Mg2+ (aq) + 2OH-(aq) Mg(OH)2(s)
.
Ammoniation of brine
•In the Solvay process second step is the ammoniation of brine solution.
Ammonia gas is absorbed in concentrated brine to give a solution containing
both sodium chloride and ammonia.

NaCl.H2O + NH3 NaCl.NH4OH

Reactions in Solvay’s tower
•The Solvay Tower is tall and contains a set of mushroom-shaped baffles to
slow down and break up the liquid flow so that the carbon dioxide can be
efficiently absorbed by the solution. Carbon dioxide, on dissolving, reacts with
the dissolved ammonia to form ammonium hydrogen carbonate.
NH3(aq) + H2O(l) + CO2(g) NaHCO3(s)

NaCl(aq) + NH3(aq) +H2O(l) +CO2(g) NaHCO3(s) + NH4Cl (aq)

2NaHCO3(s) Na2CO3(s) + H2O (g) + CO2 (g)
Reactions in kiln / Separation of solid sodium hydro
carbonate
•A lime kiln is used to produce quicklime through the calcinations of
limestone. This reaction takes place at 1200°C.
•Kilns are fed with a limestone/coke mixture. The coke burns in a counter-
current of pre-heated air.
C(s) + O2(g) CO2(g)
The heat of combustion raises the temperature of the kiln and the limestone
decomposes
CaCO3(s) CaO(s) + CO2(g)
The gas, containing approximately 40 per cent carbon dioxide, is freed of lime
dust and sent to the carbonating (Solvay) towers.
Ammonia Recovery
•CaO is formed as a by-product of the thermal decomposition of limestone in
the lime kiln. This CaO enters a lime slaker to react with water to form calcium
hydroxide:

CaO(s) + H2O (l) Ca(OH)2 (aq)

•The calcium hydroxide produced here is reacted with the ammonium chloride
separated out of the carbonating tower by filtration:

•Ca (OH)2(aq) + 2NH4Cl(aq) CaCl2(aq) + 2H2O(l) + 2NH3(g)

Block Flow diagram of solvay’s process
NH3

CO2
Pure brine NH3+Little CO2 CaO+H20

Lime
Kiln AmmoniaR
Ammonia Carbonating
Absorber ecovery
Tower Cao Tower

NH4Cl
Calcination Rotray
Na2CO3 Tower Filter
Process Flow diagram of Solvay's process

550–1150°C

1200℃
98-99 ℃
Byproducts of Solvay's process
•Calcium Chloride(CaCl2) formed as a byproducts in this
process.
 Chapter no.3
Material & Energy Balance
 Material Balance
Mass of Input = Mass of output

For 1 Ton Production of soda Ash , Raw materials required

Brine = 1.44 ton

NH3 = 0.31 ton

CaCO3 = 1 ton

Coke = 0.096 ton

 Chapter no.4
Equipment Design
Brine Making Tank:
Diameter of tank=4v/ π
DT³=4v/ π
DT=(4v/ π) 1/3

V=

H=

Area=A=
Specification

Diameter = 9.6m
volume = 714.44 m3
Height = 9.87m
Area = 1157.5m2
Process design on Ammonia Absorber

Vm =KV
A=QS/Vm
D=
Shell Thickness = ts=PDi/(2fs-p)
SPECIFICATION
Vm = 6.787 ft.

A = 34.15m

D = 6.596ft

ts = 1.4mm
Heat Exchanger
Heat Balance
Qh=mhcp(T1-T2)

LMTD =

D1=3.9q f 0.45 ρ0.13
a= Di2
G=w/a
Re = DiG/u

Pr =
hi =jhk/Di(Cpu/k)1/3
 G/=W/2L
ho= 65(G/Do)1/3
Uc = 1/hio + 1/ho
1/UD = 1/Uc + Rd
Specification
LMTD=9.85
D1=1.4670 in
a=0.08836ft2
Re=22119.3
hio=433 Btu/hr.ft2.F
G/=150 Lb/hr.ft2
ho=469.5 Btu/hr.ft2.F
Uc=234 Btu/hr.ft2.F
1/UD = 128 Btu/hr.ft2.F
Equipment Design on Carbonating Tower

Vm = Kv 1/3

A= Q/Vm
D = (4A/π)1/2

Specification

Vm= 4.565ft/sec
A = 56.6 ft2
D = 8.49 ft
Bubble cap tray Calculation
Select Bubble cap of outside diameter
A’ = 6 inch
Total Area covered by the caps
Tower area – liquid distribution area – Down flow area - End wastage area
= 56.6 – 5.66 - 8.49 – 5.66 = 36.79 ft

Total num of bubble caps = 187.70

Head = 20 m
 Chapter no.5
Instrumentation and Process Control
Instrumentation & Process Control
•Instrumentation Is a fundamental requisite to process control whether that control be
affected automatically, Systematically manually.
•The quality of control obtainable also bear a relationship accuracy, reproducibility and
reliability of the instrumental techniques which are used in this project .
The Indictors
The following indicators and recording instruments are selected for the measurement of
temperature, pressure level and placed at the appropriate process lines:
 
1.Temperature Indicator
 
2.Pressure indicator.
 
3.Level indicator.
Hardware Elements
1.Process Control
It represent the Material equipment together with the physical or chemical operation that occur
there.
2.Measuring Instruments
To measure the disturbance, the controlled output variables , or secondary output variable
Thermocouples or resistance thermometer for measuring the temperature venturi meters for
measuring the flow rate.
3.Transducers
A transducer is a device that converts energy from one form to another. Usually a transducer
converts a signal in one form of energy to a signal in another.
4.Transmission Lines
There are used to carry the measurements signal from the measuring device to the controller .
5.Controller
A controller is an instrument used for controlling a process variable (measurement). Its
continuously monitors the error signal and gives a corrective output to the final control
element.
6.Final Control Element
A final control element is defined as a mechanical device that physically changes a
process in response to a change in the control system set point.
7.Recorder
The recording instrument is defined as the instrument which records the continuous
variation of the magnitude of an electrical quantity for a particular period. It is used in a
placed where the continuous reading of circuit conditions is required
 Chapter no.6
Cost Estimation
Cost Estimation
•An acceptable plant design must present a process that is capable of operating under
conditions which will yield a profit.
•Since net profit equals total income minus all expenses, it is essential that the
chemical engineer be aware of the many different types of costs involved in the
manufacturing processes.
•A capital investment is required for any industrial process and determination of the
necessary investment is an important of a plant design project.
•The total capital investment for any processes consist of fixed capital investment for
physical equipment and facilities in the plant plus working capital, which must be
available to pay salaries, keep raw materials and products on hand.
Types of Capital Cost Estimates:
1. Order of magnitude estimate (or Ratio estimate) based on similar previous cost data
probably accuracy estimate over ± 30 percent.
2. Study estimate (or factored estimate) based on knowledge of major items of
equipment; probable accuracy of estimate up to ± 30 percent.
3. Preliminary estimate (or budget authorization estimate, scope estimate) based on
sufficient data to permit the estimate to be budgeted probable accuracy of estimate
within ±20 percent.
4. Definitive estimate (or project control estimate) based on complete data but, before
completion of drawings and specifications, probable accuracy of estimate within ±10
percent.
5. Detailed estimate (or contractor's estimate) based on complete engineering drawings,
specifications and site surveys, probable accuracy of estimate within ±5 percent
Cost Indices:
•A cost index is merely an index value for a given point in time showing the cost at that
time relative to a certain base time.
•If the cost at sometime in the past is known the equivalent cost at the present time can be
determined.
Methods for Estimating Capital Investment:
1. Detailed item estimate
2. Unit cost estimate
3. Percentage of delivered equipment cost
4. "LANG” factors for approximation of capital investment.
5. Power factor applied to plant capacity ratio.
6. Investment cost per unit of capacity.
7. Turn over ratios.
Using a generate form of estimation the cost of each equipment as,
Cost of E= cost of

E = New cost of equipment

E0 = Old cost of equipment
Table 6.1 (Purchased cost of Equipments)
The following table shows the purchased cost of equipments.
Total Purchased cost = $906,964.63
Sr. Equipment No. of Purchased Cost
No. Equipments used $

1. Heat Exchanger 1 90815.45

2. Storage tank 1 66047.60

3. Compressor 2 3302.38

4. Absorber 2 231,166.62

5. Carbonating Tower 2 264,258.06

6. Pumps 2 3632.6

7. Ammonia recovery tower 1 107,354.83

8. Lime Kiln 1 82580.64

9. Calciner 1 57806.45
Total Direct Cost: $2,394,386.615
Total Indirect Cost : $226,741.153
Fixed Capital Investment =$3,660,509.2
Total capital Investment = $4,209,585.59
Total product cost in $/day = $249358.848

Annual Revenue $/ year = cost * market value * total production *330 *24hr *1day
Annual Revenue $/ year = $ 0.4155 * 1year *600ton* 330*24hr*1day
= $1,974,546
Payback period = 1.2 year
Annual Profit = total product Cost/payback *1year
=$221,652
 Chapter no.7
HAZOP STUDY
HAZOP STUDY
A HAZOP survey is one of the most on the judgment of engineering and safety experts in the
areas with which they are most common and widely accepted methods of systematic
qualitative hazard analysis.
The objectives of a HAZOP study can be summarized as follows:
•To identify (areas of the design that may possess a significant hazard potential.
•To identify and study features of the design that influence the probability of a hazardous
incident occurring.
•To familiarize the study team with the design information available.
•To ensure that a systematic study is made of the areas of significant hazard potential.
•To identify pertinent design information not currently available to the team.
Table 7.1: Code Words of HAZOP Study
•The following table shows the codes words of HAZOP
study.

Guide word Meaning

No Negation of design intent

Less Quantitative decrease

More Quantitative increase

Part of Qualitative decrease

As well as Qualitative increase

Reverse Logical opposite of the intent

Other than Complete substitution

Personnel Protection
Although relatively harmless, there are a number of precautions that should be taken by
personnel working with soda ash:
•Eye googles and respiratory masks
Although classified as non-toxic the dust can be moderately irritating to the mucous
membranes of the eyes, throat and nose.
•Skin protection (Long sleeved shirts, pants and gloves)
Soda ash is mildly alkaline and will dissolve in human perspiration. This could lead to mild
skin irritation in individuals with sensitive skin, particularly in hot and humid conditions.
•Safety belts and lifelines
Soda ash piles can cake to give the appearance of a hard crust. This can yield and engulf a
worker. Personnel entering bins or silos containing soda ash must wear safety belts properly
roped to rescue facilities and be physically observed by someone not on the soda ash piles.
Soda Ash Plant Location Selections:
The geographical location of the final plant can have strong influence on the success of the
industrial venture. Considerable care must be exercised in selecting the plant site, and many
different factors must be considered. Primarily the plant must be located where the minimum
cost of production and distribution can be obtained.
The following
factors should be considered in selecting a plant site.
Raw materials availability
Markets
Energy availability
Climate
Transportation
Water supply
Waste disposal
•Labor supply
Taxation and legal restrictions
Flood and fire protection