SODA ASH PLANT FROM SOLVAY PROCESS
[EIRI/EDPR/1635] J.C.439
INTRODUCTION
Soda ash is chemically known as sodium carbonate. Broadly there are two ways in which soda ash is produced; it is either manufactured synthetically from salt or is obtained from refining of naturally available mineral, trona, or naturally occurring sodium carbonate-bearing brines. Globally, approximately 75% of soda ash is produced from the synthetic process.
Processing costs of soda ash from naturally available sources is less than the manufacturing costs of producing soda ash synthetically, thereby making the naturally available soda ash less expensive.
There are three main processes to manufacture soda ash from salt.
1. Standard Solvay Process: The standard Solvay process is characterized with low salt utilization and requirement of good quality of limestone and coke. This process, compared to other two processes, generates larger amount of effluents and hence require good disposal facilities
2. Modified Solvay Process: The modified solvay process has better salt utilization and requirement of limestone is less. But the process requires very high quality of salt without any impurities and ammonia requirement is also high.
3. Dry Liming Process: The raw material consumption is low in the dry liming process and it has a perfect steam power balance.
All the three processes are used in India and have their own advantages and disadvantages.
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.
Minerals which are found in environments such as enclosed basins and saline lakes, where annual evaporation exceeds total inflow of water, are known as solar evaporites. These minerals are formed from brines by solar evaporation and crystallize into deposits which may be commercially exploited.
A variety of products such as gypsum (calcium sulphate), thernadite (sodium sulphate), potash, lithium, uranium and silicates are obtained from solar evaporates, but the most important products are halite (sodium chloride) and soda ash (sodium carbonate). The production of salt and soda ash are quite large in many countries throughout the world. The annual production of salt is about 200 million tons per annum and soda ash approximately 29 million tons per year.
Salt
Among the marine evaporiles, salt is by far the most valuable mineral resource. Salt was one of the first observed and studied of all chemical substances. Salt from salt lakes has been an article of trade for centuries. Salt from North Mrican sabkas, for example was mined by Arab caravans some 2000 years ago. Nevertheless, it is only relatively recently that the full economic values or potentialities of salt lakes have been realized. Borax, soda ash (sodium bicarbonate), sodium sulphate and halite (sodium chloride) have long been obtained from salt lake sediments.
Soda ash (sodium carbonate) is an important industrial chemical, because of its chemical properties, and its use in the manufacture of other compounds such as sodium bicarbonate, sodium hydroxide and sodium nitrate. A potential large-scale use of one of its derivatives, sodium bicarbonate (NaHC03), is as a cleanser of sulphur dioxide from stack gases of power plants.
The manufactured soda ash which is usually made by the Solvay process from salt, limestone and ammonia is used by most countries, with the exception of the United States and a few in Africa.
COST ESTIMATION
Plant Capacity 300 MT/Day
Land & Building (40,000 sq.mt.) Rs. 27.50 Cr
Plant & Machinery Rs. 30.50 Cr
Working Capital for 3 Months Rs. 46.28 Cr
Total Capital Investment Rs. 106.39 Cr
Rate of Return 16%
Break Even Point 75%
CONTENTS
INTRODUCTION
GRADES, SPECIFICATIONS & PROPERTIES
PHYSICAL PROPERTIES AND HYDRATES OF SODIUM CARBONATE
USES & APPLICATION
INDIAN SCENARIO OF SODA ASH
MARKET ANALYSIS/SURVEY
MANUFACTURERS/SUPPLIERS OF SODA ASH
PROCESS BLOCK DIAGRAM
SOLAR EVAPORATION PONDS
MANUFACTURE OF SODIUM CARBONATE
PARTICULATE DUST
WASTEWATER FROM BRINE PURIFICATION
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERIES
WASTE WATER TREATMENT PLANT
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)