SODA ASH PLANT (FROM SOLUTION BRINE)
[EIRI/EDPR/1376] J.C.149
INTRODUCTION
Sodium carbonate is a common inorganic industrial chemical, also known as soda ash (Na2CO3). It is widely used in the manufacture of glass, chemicals, such as sodium silicates and sodium phosphates, the pulp and paper industries, the manufacture of detergents and for the treatment of water.
Soda ash manufacture by Solvay technology is a very complex process. The natural sodium chloride solution (brine) is extracted and purified (removal of solid impurities by filtration and removal of calcium and magnesium ions by precipitation).
The discovery of the chemistry of the ammonia-soda process can be traced back to the early 1800s. A few British and French plants operated in 1840-1860, but without success.
The ammonia-soda process is usually called the Solvay process because in 1865 Ernest Solvay started the first really successful plant at couillet in Belgium.
In 1874, the first successful ammonia-soda plant was erected in England. The ammonia-soda process is the dominant technology used throughout the world, hence this process is selected for production of soda ash.
Solvay process
The Solvay process, also called ammonia soda process, uses salt (NaCl) and limestone (CaCO3) as raw materials. Ammonia, which is also used in the process, is almost totally regenerated and recycled. The main advantage of this process is the availability of the raw materials, which can be found almost everywhere in the world and therefore allows operating production units relatively close to the market.
The Solvay process produces “light soda ash”, with a specific weight or pouring density of about 500 kg/m3. It is used in that form mainly for the detergent market and certain chemical intermediates. “Light soda ash” is transformed by recrystallization firstly to sodium carbonate monohydrate, and finally to “dense soda ash” after drying (dehydration). Dense soda ash has a pouring density of about 1000 kg/m3. It is used mainly in the glass industry. Dense soda ash can also be produced by compaction.
Some producers have made several modifications to the original process. The main ones are:
- The “dual process”, which allows production units to co-produce in nearly equal quantities ammonium chloride, which is used as a fertilizer in rice cultivation. There are several plants in the world which are working with that process. Most are situated in China
- The “Akzo” or “dry lime” process, which uses dry lime instead of lime milk for ammonia recovery
COST ESTIMATION
Plant Capacity 1666.67 MT/Day
Land & Building (60 Acres) US$ 1.66 Cr
Plant & Machinery US$ 57.63 Lac
Working Capital for 2 Months US$ 5.58 Cr
Total Capital Investment US$ 10.96 Cr
Rate of Return 48%
Break Even Point 32%
CONTENTS
INTRODUCTION
GRADES, SPECIFICATIONS & PROPERTIES
USES & APPLICATION
MARKET ANALYSIS/SURVEY
CHEMICAL REACTIONS
PROCESS:
BY-PRODUCTS
UTILITIES
GASEOUS, LIQUID & SOLID EFFLUENTS
SOLID EFFLUENTS
FLUIDIZED BED POWER PLANTS
MACHINERY SUPPLIERS ADDRESS
PHOTOGRAPH
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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