Soda Ash Plant (From Solution Brine)

SODA ASH PLANT (FROM SOLUTION BRINE)

[EIRI/EDPR/1385] J.C.161

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.

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            1666.67 MT/Day

Land & Building (55 Acres)    US$ 1.37 Cr

Plant & Machinery                    US$ 29.49 Lac

Working Capital for 1 Month    US$ 4.96 Cr

Total Capital Investment          US$ 6.77 Cr

Rate of Return                          49%

Break Even Point                      35%

CONTENTS

INTRODUCTION

GRADES, SPECIFICATIONS & PROPERTIES

USES & APPLICATION

MARKET ANALYSIS/SURVEY

PROCESS BLOCK DIAGRAM

SOLAR EVAPORATION PONDS

MANUFACTURING PROCESS

UTILITIES

STEAM

PROCESS WATER

COOLING WATERS

GASEOUS, LIQUID & SOLID EFFLUENTS

PARTICULATE DUST

MACHINERY SUPPLIERS ADDRESS

DISTILLATION COLUMN

DRYER

CONDENSER

WASTE WATER TREATMENT PLANT

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)