Soda Ash (Production Capacity – 550 TPD)

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)