SODA ASH (PRODUCTION CAPACITY – 550 TPD)
[EIRI/EDPR/4523] J.C.: 2740US$
INTRODUCTION
Soda Ash is the common name for sodium carbonate, which is a chemical compound with the formula Na2CO3. This compound is also known as washing soda and soda crystals. Soda ash can be categorized as an inorganic compound. It can be noted that all hydrates of sodium carbonate are referred to as soda ash. It can also be noted that all these forms of sodium carbonate are white solids under standard conditions. Soda ash is water-soluble and is known to form slightly alkaline solutions when dissolved in water. Traditional methods of obtaining soda ash involved the burning of plants that grow in sodium-rich soils and collecting their ashes (hence the name).
Sodium carbonate is known to be a diazonium salt of carbonic acid (a chemical compound with the formula H2CO3). When dissolved in water, soda ash is known to form carbonic acid and sodium hydroxide. In its pure form, soda ash exists as a white powder and is known to be odourless. It can also be noted that soda ash is a relatively strong base that can act as an antacid.
The preparation of soda ash is generally done using one of four processes – the Leblanc process, the Dual-process, the Solvay process, and the Electrolytic process. Soda ash is a weak acid that is slightly soluble in ethanol and insoluble in alcohol. One of the important applications of this compound is as a water softener.
Preparation of Soda Ash
Soda ash is typically prepared with the help of the Solvay process. In the Solvay process, ammonia and carbon dioxide are passed into a saturated solution of sodium chloride (kept at a relatively low temperature).
This triggers certain chemical reactions, resulting in the formation of sodium hydrogen carbonate. This compound is only very slightly soluble in the presence of sodium ions (as a consequence of the common-ion effect). Therefore, the sodium hydrogen carbonate is almost completely precipitated. It is then removed via the process of filtration and subsequently ignited in order to produce soda ash.
COST ESTIMATION
Plant Capacity 555.556 MT/Day
Land & Building (34,000 sq.mt.) US$ 41.82 Lac
Plant & Machinery US$ 1.88 Cr
Working Capital for 0.5 Months US$ 26.08 Lac
Total Capital Investment US$ 2.66 Cr
Rate of Return 30%
Break Even Point 73%
CONTENTS
INTRODUCTION
PREPARATION OF SODA ASH
STRUCTURE OF SODA ASH
USES/APPLICATIONS – SODA ASH
INDUSTRIAL APPLICATIONS
GLASS MANUFACTURE
DETERGENT MANUFACTURE
OTHER USES OF SODA ASH
USES/APPLICATIONS – AMMONIUM CHLORIDE
USES
APPLICATIONS
PROPERTIES & SPECIFICATIONS
SODA ASH
SAFETY DATA SHEET IS ENCLOSED AS ATTACHMENT
AMMONIUM CHLORIDE
HAZARD REVIEW
SODA ASH
AMMONIUM CHLORIDE
MARKET OVERVIEW
INDUSTRY DYNAMICS
GROWTH DRIVERS
INSIGHT BY DENSITY
INSIGHT BY TYPE
INSIGHT BY END-USE
GEOGRAPHIC OVERVIEW
COMPETITIVE INSIGHTS
SOME OF THE MAJOR PLAYERS OPERATING IN THE MARKET INCLUDE
PROCESS REACTIONS
THE CHEMICAL REACTIONS OF THE PROCESS ARE GIVEN BELOW:
OVERALL REACTION
FORMULATIONS
RAW MATERIALS
RAW MATERIAL SUPPLIERS
MANUFACTURING PROCESS STEPS
BRINE PURIFICATION
SODIUM HYDROGEN CARBONATE FORMATION
THE CARBON DIOXIDE DISSOLVES TO FORM A WEAK ACID:
THE AMMONIA IN THE BRINE REACTS WITH H+ TO FORM AMMONIUM IONS:
THE HCO3- THEN REACTS WITH THE NA+ TO FORM A SUSPENSION OF SODIUM HYDROGEN CARBONATE:
THE OVERALL MOLECULAR EQUATION FOR THE FORMATION OF SODIUM HYDROGEN CARBONATE IN THE CARBONATING TOWER IS:
THE NET IONIC EQUATION FOR THE FORMATION OF SODIUM HYDROGEN CARBONATE IN THE CARBONATING TOWER IS:
SODIUM CARBONATE FORMATION
PROCESS FLOW
UTILITIES
STEAM
THE STEAM PROCESS CONSUMPTIONS LIE IN THE RANGE OF:
PROCESS WATER
COOLING WATERS
ELECTRICITY
ENVIRONMENTAL ISSUES
AIR POLLUTION
THERMAL POLLUTION
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
WATER (ESTIMATED)
WASTE (ESTIMATED)
FLUE GAS (ESTIMATED)
PLANT & MACHINERY (BROADLY)
POTENTIAL TURNKEY/MAJOR PLANT/EQUIPMENT SUPPLIERS
CONDENSER
WASTE WATER TREATMENT PLANT
REACTORS/VESSEL/TANKS
DISTILLATION COLUMN/SCRUBBER/EXCHANGER/TANKS
HEATER
EOT CRANES
D.G. SETS
POWER TRANSFORMERS
COOLING TOWER
ETP PLANTS
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSOR
PLATEFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
SUBMERSIBLE WATER PUMP
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
UTILITIES REQUIREMENT (ESTIMATED - MONTH)
POTENTIAL RISKS
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)
SAFETY DATA SHEETS
ENVIRONMENTAL/SAFETY LIABILITY AND ENVIRONMENT CLEARANCE PROCESS - HAZARD
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
PRELIMINARY PLANT LAYOUT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
CONCLUSIONS
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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