Detailed Project Report on Soda Ash Plant (From Solution Brine)

SODA ASH PLANT (FROM SOLUTION BRINE)

[EIRI/EDPR/1376] J.C.149

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.

Soda ash manufacture by Solvay technology is a very complex process. The natural sodium chloride solution (brine) is extracted and purified (removal of solid impurities by filtration and removal of calcium and magnesium ions by precipitation).

The discovery of the chemistry of the ammonia-soda process can be traced back to the early 1800s. A few British and French plants operated in 1840-1860, but without success.

The ammonia-soda process is usually called the Solvay process because in 1865 Ernest Solvay started the first really successful plant at couillet in Belgium.

 In 1874, the first successful ammonia-soda plant was erected in England. The ammonia-soda process is the dominant technology used throughout the world, hence this process is selected for production of soda ash.

Solvay process 

The Solvay process, also called ammonia soda process, uses salt (NaCl) and limestone (CaCO3) as raw materials. Ammonia, which is also used in the process, is almost totally regenerated and recycled. The main advantage of this process is the availability of the raw materials, which can be found almost everywhere in the world and therefore allows operating production units relatively close to the market. 

The Solvay process produces “light soda ash”, with a specific weight or pouring density of about 500 kg/m3. It is used in that form mainly for the detergent market and certain chemical intermediates. “Light soda ash” is transformed by recrystallization firstly to sodium carbonate monohydrate, and finally to “dense soda ash” after drying (dehydration). Dense soda ash has a pouring density of about 1000 kg/m3. It is used mainly in the glass industry. Dense soda ash can also be produced by compaction. 

Some producers have made several modifications to the original process. The main ones are: 

- The “dual process”, which allows production units to co-produce in nearly equal quantities ammonium chloride, which is used as a fertilizer in rice cultivation. There are several plants in the world which are working with that process. Most are situated in China 

- The “Akzo” or “dry lime” process, which uses dry lime instead of lime milk for ammonia recovery

COST ESTIMATION

Plant Capacity            1666.67 MT/Day

Land & Building (60 Acres)    US$ 1.66 Cr

Plant & Machinery                    US$ 57.63 Lac

Working Capital for 2 Months    US$ 5.58 Cr

Total Capital Investment          US$ 10.96 Cr

Rate of Return                          48%

Break Even Point                      32%

CONTENTS

INTRODUCTION

GRADES, SPECIFICATIONS & PROPERTIES

USES & APPLICATION

MARKET ANALYSIS/SURVEY

CHEMICAL REACTIONS

PROCESS:

BY-PRODUCTS

UTILITIES

GASEOUS, LIQUID & SOLID EFFLUENTS

SOLID EFFLUENTS

FLUIDIZED BED POWER PLANTS

MACHINERY SUPPLIERS ADDRESS

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)