Chapter-2

PROCESSES' DISCUSSION

2.1: DESCRIPTION OF VARIOUS AVAILABLE PROCESSES:

Commonly three processes are available for the production

of Soda Ash on Commercial scale. These processes are briefly discussed

as follows:

2.1.1: The Leblanc Process:

This process is based on the series of reactions which are

given as follows:

2NaCl + H,SO, -

Na,so, +2HCI

Na,so, +40

---

Na S + 4CO

Na, S + Caco,

-------> Na,Co, + Cas

The common salt is shovelled into a furnace where the

necessary amount of sulphuric acid is run through a lead pipe. When ICT

gas evolution ceases, the pasty charge is pushed into the Mulle furnace.

Here the mass is broken up, stirred every half hour and finally withdrawn

after 2-3 hours. The entire unit is kept under slight suction to prevent

escape of gases. The heating is done by means of coal mine flue gases.

Reduction of Sodium Sulphate:

Salt cake, limestone and coal is put into the reverberatory

furnace with the hot combustion gases passing over the furnace charge with stirring. The black ash is
removed at the hotter end of the hearth.

Reduction occurs above 884°C which is the melting point of Na,so, The

gases that evolve are high in CO, contents but the mono oxide forms later

in the reduction. Reduction is rapid at 900-1000°C because the liquid phase

wets the coal particles.

Leaching of the Black Ash:

For rapid leaching the mass must be porous and contain some

lime which hydrates and swells, breaking up the mass and also producing

some NaOH in the solution. Leaching or "Lixiviation" is carried out in a

series of wooden tanks with false bottoms and connected so that solution

from one tank could enter any other. A discontinuous counter current

leaching system is used in which the solution leaving the system passed

through the richest black ash and the entering H,O leached the most

exhausted ash. The solution, known as “Green Liquor" because of its

colour, is then processed to obtain the Soda Ash

Processing of the Green Liquor to Produce Soda Ash:

Due to the lime in the black ash, the green liquor contains

considerable NaOH as well as carbonate, sulphide, some thiosulphate and

unreduced sulphate. This liquor is first carbonated with kiln or furnace

gas by allowing the liquor to trickle down within the tall iron towers.

2NaOH + Co,

Na,Co, +H,O

The solution is then filtered to remove Al

and then evaporated by

passing the hot black ash furnace gases over the surface of the solution.

When the solution becomes sufficiently concentrated, it is withdrawn and allowed to cool, upon which
the crystals of Na.co, decahydrate are

deposited. These can be recrystallised to give a better product, or calcined

to produce soda ash.

2.1.2: Ammonia Soda Process:

The Ammonia Soda process can be divided into following

steps:

a)
Preparation of Saturated Solution of Salt:

It is essential for the commercial success of the Ammonia

Soda process that an abundant supply of sodium chloride either as rock

salt or as fully saturated brine should be available. The desirable

concentration of sodium chloride in the brine is 300 gm/litre.

After the preparation of concentrated brine, it is led to the

purifying tank where it is mixed with soda ash and brine solution. The

impurities of calcium and Magnesium are precipitated and removed in the

settling tank

b)

Saturation of the Brine with Ammonia:

The gas from the Ammonia distiller is allowed to interact

with a stream of brine in a counter current fashion. The gases entering the

Ammonia Absorber consist of NH,, CO, and water vapours. The

ammoniation of brine generales 900,000 K. Cal/Metric ton of NH, distilled,

so cooling is necessary. Part of the fresh brine entering the process passes

through the scrubber to recover NH, from the outlet gases of Ammoniation

Tower. The liquor leaving the absorber is composed of 260 gm/litre Naci,

80 gm/litre NH, and 45 gm/litre Co,

Carbonation of the Ammoniated Brine:

The clear ammoniated brine is cooled to 86°F before carrying

out the process of carbonation in order to avoid vaporisation of NH, in a

Trombone cooler. The liquor is then pumped to the top where it falls over

the baffle plates and Co, is injected at the bottom to meet the liquor counter

currently. The heat evolved during carbonation is removed by means of

well known Cogwell coolers. The liquor leaving the tower contains 90

gn/litre co, and 20 gm/litre free NH,

The pre-carbonated liquor is now pumped to the top of the

Making Tower, where gases from the calciner are injected. The construction
of Making Tower is similar to that of the Carbonating Tower. The crystals

of NallCO, separate out and the crop is known as Magma of Nalico,

Filtration:

The Magma of NaHCO, is introduced to the rotary drum

vacuum filter. The filter sucks the water and any separated gases. The

cake of NaHCO, would be deposited and ultimately knifed away.

e)

Distillation of Ammoniated Liguor:

The mother liquor is now treated with lime in a mixer where

it is continuously mixed for a certain time and fed to the distillation column.

Steam is fed from the bottom of column to strip off NH, in the liquor.

Calcination of Bicarbonate of Soda:

The NaHCO, cake obtained is conveyed to the steam tube calciner where NaHCO, is converted to Na,Co,
at high temperature. The

gases are cooled in the cooler and condensers and ultimately NH, and H.O

is separated from CO,. The Co, obtained then is fed to the Making Tower

The calcined product is sent to the bagging section.

2.1.3: Electrolytic Soda Ash:

Electrolytic Soda Ash is produced by passing a current

through a cell containing a saturated solution of salt in a manner similar to

the chlorine-caustic process. At the cathode, however, carbon dioxide is

bubbled into the solution and reacts with the sodium hydroxide formed.

Sodium bicarbonate is precipitated and filtered, dried, and calcined to

produce soda ash.

The most recently built soda ash plant is essentially an

electrolytic in which dilute caustic liquor from chlorine-caustic cells is

treated with flue gas, occasionally outside the cell, to produce sodium

bicarbonate solution from which soda ash is made.

This process, though much economical is impracticable in

our country due to following main reasons:

i.

The poisonous Cl, gas cannot be easily disposed off as useful

ii.

iii.

bye-product.

Non-availability of Technical know-how.

Cost of electricity is relatively higher.

2.2: SELECTION OF PROCESS:

Lablanc was the originator of one of the world's greatest industries, which have given us cheap soap and
glass and has poured

directly or indirectly untold wealth into numerous lands.

A supply of cheap H,SO, large quantities is one of the first

essentials of the Leblanc Process, and hence, the enormous H, SO, industry

of today owes its origin to this process. The production of excess of HCI.

as a waste product, in the salt cake furnaces called into existence the

chlorine industry and the manufacture of bleaching powder.

Solvay Process introduced in 1866, is more fruitful and

advantageous as;

No sulfuric acid is necessary in this process;

No hydrochloric acid is generated;

Moreover, this process allowed the production of sodium carbonate

at much lower cost than the Leblanc. The price of Na,Co, by this

process is 1/3rd to that produced by Leblanc process;

The enormous supplies of Na,co, formerly consumed by the glass

industry have been now largely replaced by the use of the cheaper

sodium sulphate. As a consequence of this first part of the Leblanc

process, namely, the formation of Na,so, (salt cake) by the action

of H,SO, or salt has actually increased of the late years. It is only

2nd part of the process - the calcining of this Na2SO4 with coal and

limestone - that has decreased subjected as it is to the competitive

action of Ammonia Soda Process;

V.

The Ammonia Soda Process is not threatened to any great extent by

the growth of the electrolytic processes for making caustic soda and chlorine, because the amount of
Na,Co, and alkali required for

industrial purposes is far greater than the amount of Cl, and bleaching

powder required, so that even in the event of electrolytic processes

completely covering the world's demand for Ci, and bleaching

powder, the yield of alkali then produced would only be a small

fraction of that which is necessary to commerce.

The manufacture of bleaching powder with the acid of electrolytic

CI,, has considerably affected the Leblanc industry and doubtless

this influence will be felt even more seriously in future;

vi.

The Ammonia Soda Process produces Na,Co, in a higher state of

purity and at a much lower cost than the Leblanc Process. Recently

competition and a desire to stimulate the demand for ammonia alkali

has resulted in a considerable reduction in price, with the

consequence that it is almost impossible for the makers of soda ash

by the Leblanc Process to compete.

The ammonia soda process has been brought to an exceedingly high

state of economic efficiency, and inspite of the various factors

mentioned, it is questionable whether the commanding position

which it holds in the alkali industry at present is seriously threatened.

2.3DESCRIPTION OF SELECTED PROCESS (THE AMMONIA

SODA PROCESS:
The salt employed in the standard soda process is exclusively

in the form of brine.

The raw materials for the Solvay process are, salt lime and

NH. The composition of the salt employed is:

NaCl

97.87%

00.72%

Caso,

MgSO

00.48%

Na,so

00.24%

MgCI,

00.12%

insolubles

00.38%

Undetermined

00.12%

Moisture

0.07%

Conversion of NaCl to Nalco, is 75% only.

Pretreatment of the brine before sending it to the system for soda

ash manufacture has been employed. The reagents used in this treatment

are the usual soda ash and lime. Soda Ash precipitates calcium chloride

and causticization of soda ash yields sodium hydroxide, which precipitates

MgCl, and MgSo, as Mg(OH),

(A) PURIFICATION OF BRINE:

Salt used in NH-soda process contains impurities like

Na280, Nal, NaBr, CaCl, and Caso,, MgCl, and MgSO,, KCl and K,so,
Fe, Mn, Clay and sand.

There are several methods of treating brine:

1.

Treatment with NH, and Co, gas.

2.

3.

Treatment with lime, NH, and Co, gas.

Treatment with lime and Na2 so,

(followed by NH, and CO2 gas)

4.

Treatment with Time and soda ash.

1. Treatment with NH, and CO, Gas:

It eliminates Ca and Mg by means of NH, and Co, in hot

solution. This treatment must be done in a closed system to avoid loss of

NH3. The method however, is uneconomical when there are large amounts

of impurities such as in sea salt. The treatment is carried out in the hot

conditions prevailing in the NU, - absorber, which has a good effect for

setting. The reactions are as follows:

Mg + + 2NH,OH

Ca" + (NH4)2CO

Mg(OH), + 2NH,

→ CaC0, + 2NH,

Note: It was found that in the presence of CO,, Mg is forced to come

down as a carbonate or basic carbonate instead of hydroxide and also as a

double salt (NH),CO,, MgCO, 41,0 or as a triple salt (NaCl - MgCO, -

Na,C0.). Thus resulting in a loss of NaCl. Therefore, this method is not

generally recommended.

2. Treatment with Lime NII, and CO, Gas:

This treatment is based on the fact that Mg is very readily

precipitated by Ca(OH), even in cold brine. It is possible to eliminate 97-

99% Mg by using this method.

Mg+ Ca(OH),

Mg(OH), + Cat

Since it is known that calcium can easily be precipitated as

CaCO3 and settles more or less readily, and since calcium carbonate mud

does not form the kind of sticky, hard scale as does Mg mud, it can be drawn from the settling vats.
Therefore, the principles underlying this

treatment is first to remove the trouble-some Mg and later to remove all

the Ca by the regular ammoniation process.

Ca" + (NH), CO, -

Caco,+ 2NH,

Although this does not form a double or triple salt in the

mud from the ammoniated brine, it has the same objection of leaving much

fixed ammonia in the resulting ammoniated brine. The treatment is

particularly good for the sea salt which contains high magnesium.

3. Treatment with Lime and Sodium Sulphale:

The underlying principle in this treatment is first to precipitate

Mg with lime and then to precipitate most of the Ca as Caso, by the addition

of sodium sulphate. This method is uneconomical since large quantity of

sodium sulphate is required.

4. Treatment with Lime & Soda Ash:

The removal of Ca and Mg from brine by the NH, and Co,

treatment results in the formation of an equivalent amount of ammonium

salts in place of Ca and Mg salts in the resulting brine. It is therefore,

preferable to introduce soda ash in place of ammonia carbonate for the

elimination of Ca after the precipitation of Mg by lime,

Ca(OH), + Mg** ------

Ca** + Na CO,

---> Cat* + Mg(OH),

Caco, + 2Nat

Thus sodium salts are formed instead of ammonium salts in amounts equivalent to the calcium and Mg
salts originally present, and

these sodium salts will form sodium bicau bonate in the same way as sodium

chloride, giving better decomposition. However, this pretreatment must

necessarily be done in cold, as it has to be used to scrub NH, gas. Sludge

from the cold brine is difficult to settle, but if the conditions are controlled,

settler proper designed and sufficient lime is used, rate of settling is quite

rapid even in cold brine and Mg is removed upto 97-99%. A characteristic

settling curve is shown in figure

This method is advantageous because there is no NH, losses

involved and all Ca and Mg salts are converted to the corresponding sodium

salts.

B.

Ammoniation of Saturated Brine:

The fresh brine from storage tank is employed first to scrub

small quantities of NH, from filter-gas, from absorber outlet gas and from

carbonator.

The ammoniation of the brine serves a two-fold purpose.

First, it is a means of introducing the required amount of NH, into the

brine and secondly, it eliminates Ca and Mg impurities. The ammoniation

also serves the following purposes:

1. The Effect of the Decrease in Solubility of NaCl:

It is general rule that a substance which does not react with

the solute or from any complex ion with the solute, commonly decreases

the solubility of the solute when the substance is introduced into the same solution. The decrease in the
solubility of salt upon the introduction or
monin is one of the factors that reduced the quantity of Nallco, which

could be formed in the towers due to the decrease in the concentration of

NaCl in the resulting ammoniated brine.

2. The Increase in the Volume of Brine:

The NH, gas dissolved in the brine increases its volume just

as it increases the volume of 11,0. At a concentration of 80 gms of NH/

litre, the increase of volume is a little less than 12%. In the case of brine,

at the same concentration of NH,, the volume increase in the resulting

ammoniated brine is slightly greater (about 13%), as compared with plain

brine of the same NaCl concentration. Fortunately, the presence of Co, in

the NII, gases forming some (NIO), CO in the ammoniated brine tends to

off-set this increase in volume,

3. The Dilution of the Saturated Brine by Steam Condensate:

Theoratically it is impossible to get perfectly dry NH, gas

from the distillers. Production of water vapor can be minimized only by

operation at a low temperature, taking advantage of the fact that the ageous

tension of H.O is much less at a low than at a high temperature (at 50°C, it

is only 12% of what it would be at 100°C). We cannot cool below 55°C

because the NII, and Co, present in the distiller gases has the tendency to

form solid crystals. This results in choking of the pipe line.

4. The Generation of Heat by the Solution of NH,, Vapor in the

Brine and Partial Neutralization of Ammonia by CO,

The heat of solution of NH, gas is 8430 Cal/gm-mole – a very large quantity. Therefore, to make NII, gas
stay in the brine this

quantity of heat must be extracted, i.e., the brine must be cooled during

absorption. H,O in the brine absorbs NII, gas with great nvidity and there

would be no difficulty in preparing NII, solution. After the NH, absorption,

the impurities in the brine begin to separate in the form of Ca and Mg

carbonates, Fes, etc. On sticking the cooling tubes these precipitates

coagulate and settle on the tubes in the apparatus, and in the piping system.

This seriously reduces the cooling capacity.

The brine after ammoniation contains 80 gm/litre of NIJ, and

260 gm/litre of NaCl. Some CO, is also absorbed with the ammonia. The

clear ammoniated brine is now cooled to 86°F in Trombone type coolers.

If not ammoniated brine is led to the top of the columns, it would cause

excessive vaporization of ammonia by the Co, in carbonation.

It is quite important that ammoniated brine for the column

operation should be well settled and free from mud. This is why impure

brine is purified before ammoniation and carbonation, otherwise mud would

be carried to column and precipitated with the bicarbonate. This results in

poor quality of soda ash.

Carbonation of Ammoniated Brine:

In the past solutions of salt and ammonium bicarbonate were

used in the ammonia Soda Process. Later on Ammonia gas was employed.

It was first absorbed in brine and then carbon dioxide was injected in the

ammoniated brine. This is appreciated because it is very difficult to precipitate sodium bicarbonate in
the laboratory. Using hrine and

ammonium bicarbonate, even when they are super-saturated. Abi

advantage was made when method of introduction of ammonia and carbon

dioxide without lowering the strength of brine, was practised. The present

method of ammoniation with tolerably dry ammonia gas followed by carbon

dioxide is indeed the key to success of ammonia soda process

Furthermore, ammoniation is incidently an important process for

purification of crude hrine when the brine has not been pretreated.

Moreover, necessary carbonate and bicarbonate ions, heat of neutralization

of Co, and NHON is essential to the formation of good sodium

bicarbonate crystals in the columns

The ammoniated brine should be at 86 F before being sent to

the towers for carbonation, otherwise, because of the increased vapor

pressure of ammonia at an elevated temperature, an excessive amount of

NIT, otherwise available for reaction would be distilled off by the bubbling

Co, gases. So the load on the washing towers would be increased. This is

one reason why ammonia titer in the ammoniated brine should be slightly

higher than the chloride titer.

The composition of the ammoniated brine is as follows:

Free NII,

97-99 liter

Fixed NH,

3 - 5 Liter

Chlorine

89.90 Liter

Sulphide

0.02 Liter

CO,

450-500 cc liter N.L.P.

I lower

ration temperature remnan is very

im

The temperature andient in the lowers should be so uraded hy

out of the conter water that bicarbonate crystals will grow larger

la

towards the bottom as the liquor descends and is cooled.

The lowest temperature is of course to be found at the dras

ring at the bottom as cooling is arranged counter currently. The las

temperature is primarily limited by the cooling capacity and a temperature

or 22°C hias been found advantageous. The formation of good crystals in

the column depends upon;

a

lligh concentration of NII, and NaCl in cooled unmonated brine

Rich Co, gas properly cooled,

High reaction temperature at a point about 2/3rd of the height of

column above the base.

d.

Gradual cooling from this point down to the draw ring.

In the tower operation was are more concerned with the

reaction:

NaCl + NHLICO,

+ NaHCO, + NII,CI

At equilibrium at any given temperature:

(NaHCO,) (NIC)

(NaCl) (NHLICO)

For most effective decomposition. K should be as high as peschle. This means :

(i)

higli concentration of Nact in annoniated liquor

rii)

high molal cancentration of NII, in

(iii)

high molalconcentration of Co, in the tower

(iv)

low draw temperature in the tower.

These four factors are discussed further:-

High concentration of NaCI:

Decrease in the concentration of NaCl occurs due to ammonia

a absorption and by condensation of steam. The concentration of NaCl in

the resulting brine is 250-260 gn/litre. The strengthening by addition of

solid salt was abandened due to difficulties.

ii.

lligh concentration of NII:

With good cooling facilities it is not difficult to get an

amonia concentration higher than 80 g/litre. Theoretically, an equivalent

strength of ammonia with respect to sodium chloride is required. By inass

action puinciple, a higher concentration would of course be desirable, but

much higher concentration reduces the concentration of NaCl. The general

practice now is to employ not more than 12% excess NH, over the

equivalent amount of Naci

iii.

High Concentration of CO, Gas:

The amount of carbon dioxide dissolved is proportional to

The partial pressure of 0. gas in contact with solution. It means a high

concentration of co, in the gaseous phase. Theoretically the amount of kiln was and hence

should be equal but it is not so dute to

Turnate pas The ratio of kilit as to that of furnaces

Theilu

gas contains 42% CO, and CO, in the calciner gas is 90'

The pas is forced up in the carbonating tower under a pressure o

34

36 lbs. The partial pressure is thus inaterially increasod, giving high

absorption and better utilization of co

iv.

Low Draw Temperature:

it is unquestionably better to draw the liquor at 221 than

301. The decomposition is improved and loss of ammonia gas by exposure

is ininimized. The bicarbonate crystals will then give a good settling test
and can be filtered washed and calcined without difficulty.

The towers are clogged and fouled due to deposition of crystals on

the cooling coils. This is cleaned by fresh ammoniated brine. The fresh

ammoniated brine flows down one such fouled tower with its cooling coils

shut off, and this partly carbonated and warm brine is led to 4 making

towers by CO, liſts.

The crude sodium bicarbonate formed in the making tower is drawn

off from the bottom as a suspension. At the top of the making tower, the

temperature should be 25*C, which is allowed to rise by the heat of reaction

to 55°C about half way down. This temperature is gradually reduced hy

use of cooling reactions to 22°C at the bottom, resulting in the growing

of the sodium bicarbonate crystals particularly in size this suspension is

filtered on a rotary open drum filter.

Di ULTRATION CRUDI SODIUM

CARBONATE

hered at from the other for Thar

en dat het

centrifugal filter are the

n formele Thrum

er

through the journal at one and where the

pled The

helps in dry in the bicarbonate on the filter and sucks the NI m

ardi

that NII, loss is reduced. Drum filter should live il peripheral speed

20-10 1/minThe vacuum for the drum literis 6-8 in all

Analysis of crude Bicarbonate from the filter is as follows:

Nallco
75.60%

6.94%

Na CO,

NH HC0,

NaCl

0.39

Сасо,

Nil

MgCO,

11,0 by difference

The gases from the filter are drawn through a small washer. The

NH, present in the gases is serubbed in this filter washer with fresh brine

The filter operation is important because a difference of a lew percent in

the moisture contents causes difficulty in drying operation

E) CALCINATION OF SODIUM BICARBONATE:

The washed sodium bicarbonate from the filters drop on to a belt

e r which feeds the furnaces in which bicarbonate is decompose by calcination. Sodium bicarbonate
decomposes into soda ash. CO,. und

H.O. This is the most difficult process in the whole plant because :

Sodium bicarbonate has a tendency to cake into lumps when

moisture content is high:

The wet sodium bicarbonate forms a hard scale on the surface of

the steel shell through which heat can not penetrate, and

consequently the localized heat is likely to burn out the metal':.

Plugging may also occur.

A steel rotary furnace is developed closed at both the ends so as to

able to collect the gases evolved. The kiln is of the horizontal type heated

through the shell and with firing furnace at the feed end, so that the healing
is not counter current. This prevents some of the caking. The inside of

the dryer has a heavy scrapper chain dragging on the shell to keep it free

from soda lumps. "To reduce the caking of the wet bicarbonate, some of

the lot soda ash takin from the calciner is fed back and mixed with the

fresh bicarbonate as dry feed. The power required to drive the rotary dryer

at 4 to 5 r.p.m. is 15 to 20 I1P

AL 160°C, the crude bicarbonate can be completely

decomposed but it requires a longer time than at high temperatures. A

160°C, the ash can be completely freed from bicarbonate provided that it

is allowed to remain in the furnace for longer time. At a high ratio of

operation, the time is greatly reduced. The best working temperature to

lie between 175-190°C.

The exit gases contain some NII, CO,.steam and a little sodas

dust. These are cooled, precipitating a small quantity of an aqueous

ammoniated solution, but permitting the large amount of rich CO, to be

freed. This is compressed and used in the making tower to form the sodium

bicarbonate. The hot soda ash from the calciner is passed through a rotary

cooler and is screened through a vibrating screen of 8-12 mesh. It is then

packed in bags for sale.

(F) RECOVERY OF THIE AMMONIA:

The recovery of ammonia from mother liquor is the most essential

part of the process. As the economy is totally dependent on the maximum

recovery of NII.. The composition of the mother liquor is as follows:

NH OH

0.2502 N

NaCl

1.3082 N

NH,CI

3.6062 N
0.0658

0.6153 N

(NII...SO

NH, TICO -(NII), CO3

Nallco, + Na,co,

H.CO, (r)

0.0820 N

0.0374

Total Co, (diss)

1.4245 N

Total free ammonia

0.8655 N

The distiller feed must have the ratio of free NII, to fixed

NH, as high as 3 to 7. At the same time the liquor on its way to the

distiller is diluted, as far as CI is concerned, by :

Wash water on the filters;

2.

Steam conde

Steam condensate from the furnace condenser of line:

Steam condensate from gases in the furnace so scrubber;

Water contained in the crude liquor, or in the (NH),SO, solution.

added to replace the NII, lost.

The filter liquor is pumped upto the feed distiller through an orifice

regulation.

The composition of one sample of crude ammonia liquor is

given as:

Sp. Gr.at 23°c

1.025%

Total ammonia (as NH)

2014%

31.605%

(NH),CO,

Sulphide as (NH),S

NH, free

10.98%

3.46%

The rate of decomposition of the fixed ammonia lime is wholly

dependent upon the rate of hydration and solution of calcium oxide in the

lime still. While the ionic reaction is instantaneous, the solution of CaO is

slow; which, therefore, controls the speed of its reaction with fixed NH

Ca) solid - Ca0 diss k } Ca" - 2011

Ca" + 2OH- + 2NH, ---- Cat +2NH,ON.

The mother liquor is mixed with Ca(OT), in a turbine mixer. The

Ca(OH), is prepared in a rotary slaker. The two streams after adequate

mixing is delivered to distiller where the recovery of NH, is achieved.

The reaction occurring in the distiller is as follows:

2NH,CI + Ca(OH),

(NH,),S0, + Ca(OH),

CaCl, + 2NH, +211,0

CaS0 + 2NH, + 20,0

The distillation column consists of two parts. The top part above

ieralled the heater. Ther bottoni part below the lime inlet is called the

the line inlet is called the

liquor from the bicarbonate filter is ſed to the heater or upper part of

Time still. The liquor from the

where the fixed NIT, is driven out by the following reactions:

NII- still, where the li

NH, (soln) + leat

+ NH (2)

NI,HC0 + heat.

Nal/CO, +NH CI

NaCl + NII, + 11,0 + CO,

Na.co, + 2NH,CI --------- + 2NaCl + 2NII, + 11,0 + CO

Na S + 2N11.CI -

2NaCl + 2NII,+ 11,0

The liquor from the bottom of the lime still free from NII,

and contains about 50 gm/litre of residual and unreacted sodium chloride

as well as calcium chloride formed. Caco, is in suspension. A small part

o this residual liquor is settled, evaporated for the separation of salt.

Most of CaCl, is wasted into the streams of the country.

Summary of The Process

This design report deals

The manufacture of s.

ess has been practised for

rightforward but its applica

de problem is to get /

nestone/CaCO) to

Calcium Chloride).

ia recoverable 'cyclical

Process technology

clitses the stone to be decom

vide/0.). Both of

art deals with the production of 600 tons of Soda Ash per day

ature of Soda Ash by the Ammonia Soda Process or the Solvay

dised for over a century. The basic chemistry of the process is

is application into a large industrial unit is complex. Very brielly.

lo eet the two ions of Salt(NaCl) and the two ions of

to change places to give Na CO.(Sodium Carbonate) and

ride) This cannot be done directly and ammonia has to be used

cyclical carrying agent' to carry the carbon dioxide

technology includes burning of limestone with coke in kilns. This

lebe decomposed into two components, bunt lime(Cao) and carbon

.)Both of these components are used later in the process.

wells ammonia gas is absorbed in brine. This liberales a considerable

of heat which must be removed. Alter cooling, the ammoniated brine is

and into the top of a series of lowers called carbonation towers. Whereby carbon

wie tas is introduced which carbonates the armoniated brine. A magma is

moduced, which comprises sodium bicarbonate in crystal form and ammonium

chiloride in solution. There is liberation of a considerable amount of heat during

arbonation which is removed by water cooled tubes at the bottom of the towers.

The sodium bicarbonate, which is in the form of wet cake, is then fed into

large rotary driers or calciners where heat decomposes the sodium bicarbonate to give

the product, sodium carbonate, with the evolution of carbon dioxide gas and water.

carbon dioxide gas is cooled, washed and added to the gas from the kilns for

absorption in the carbonation towers.

cium oxide obtained from the kiln is slaked in water and the milk of lime

(MOL) is used to recover

sed to recover ammonia gas in the distillers, and for the purification of

at the brinc purification plant.

Discharge of the distill

and waste which is dispy

of the distillers, called distiller blow off, forms the major part of the plant waste which is disposed of in
an environmentally safe manner.