Detailed Project Report (DPR) on Soda Ash Plant from Solvay Process

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)