Calcium Chloride Recovery in Soda Ash Production by Solvay's Process

Table of Contents

1. Introduction

1.2 Objectives

1.2.1 General Objective

1.2.2 Specific Objectives

2. Literature Review

2.1 Calcium Chloride

2.2 Properties of Calcium Chloride

2.3 Calcium Chloride Solutions

2.4 Production Methods of Calcium Chloride

2.5 Economic Aspects

2.6 Grades and Specifications

2.7 Environmental Concerns

2.8 Health and Safety Factors

2.9 Uses of Calcium Chloride

2.9.1 Deicing

2.9.2 Roadbed Stabilization/Dust Control

2.9.3 Oilfield Uses

2.9.4 Accelerator in Ready-Mix Concrete

2.9.5 Food

2.10 Central Salt and Chemical Research Institute

2.10.1 Solvay Process

2.10.2 Merferberg Process

2.11 Calcium Chloride Purification

2.11.1 Background of the Invention

3. Calcium Chloride Recovery Processes

3.1 Evaporative Crystallization Process

3.1.1 Byproduct Calcium Chloride

3.1.2 Chemical Reactions

3.2 Evaporation of Distiller Waste Setting Ponds

3.2.1 Raw Materials

3.2.2 Raw Waste Loads

3.2.3 Process Description

3.3 Ion Exchange Process for Purification of Calcium Chloride

3.3.1 Advantages

3.3.2 How Does the Separation Work

3.3.2 Technical Considerations

4. Process Selection and Detailed Description

4.1 Crystallize Evaporation Process in Detail

4.1.1 Crystallize Evaporation Process

4.1.2 Sedimentation process

4.1.2 Flotation

4.2 Multiple Effect Evaporators

4.2.1 Feeding of Multiple Effect Evaporators

4.2.2 Advantages of Multiple Effect Evaporators

4.2.3 Rising Film Tubular Evaporator

4.2.4 pH adjustment

4.3 Filtration and Drying of Calcium Chloride

4.3.1 Rotary Louvre Dryers

5. Major Engineering Problems

5.1 Choking in Dryer

5.2 pH adjustment

5.3 Conversion of Liquid Calcium Chloride to the flakes of calcium chloride

5.5 Product Cooling Systems

5.6 Storage and Handling of flake Calcium Chloride

5.7 Packaged Product Storage

6. Cost Estimation

6.1 Raw Materials

6.2 Utilities

6.3 Equipment Costs

6.4 Total Initial Investment Cost

6.5 Financial Evaluation

6.5.1 Profitability

6.5.2 Ratios

6.5.3 Break-even Analysis

6.5.4 Payback Period

6.5.5 Internal Rate of Return

7. Result Analysis

7.1 Evaporative Crystallization Process

7.2 Evaporation of Distiller Waste Setting Ponds

7.3 Ion Exchange Process for Purification of Calcium Chloride

8. Conclusion

Objectives and Core Topics

The primary research objective is to develop an efficient, cost-effective industrial method for the recovery of calcium chloride from the distiller waste generated by the Solvay process in soda ash production. This study evaluates various recovery techniques to minimize environmental waste and transform an industrial byproduct into a value-added, high-purity product for commercial use.

• Recovery of byproduct calcium chloride from Solvay process effluents
• Evaluation of evaporative crystallization versus ion exchange methods
• Economic analysis and financial viability of the recovery process
• Engineering solutions for product purification and drying (flake formation)
• Assessment of industrial applications for the recovered calcium chloride

Excerpt from the Book

Chapter Summary

1. Introduction: Outlines the industrial challenge of managing calcium chloride as a waste byproduct from the Solvay soda ash process and sets the research goals.

2. Literature Review: Provides technical background on the chemical properties, production methods, environmental impact, and industrial applications of calcium chloride.

3. Calcium Chloride Recovery Processes: Compares different recovery techniques, specifically detailing evaporative crystallization, waste pond evaporation, and ion exchange processes.

4. Process Selection and Detailed Description: Describes the selected industrial workflow for recovering, purifying, and drying calcium chloride using multiple-effect evaporators.

5. Major Engineering Problems: Addresses operational challenges such as dryer choking, pH regulation, and the specific conversion of liquid concentrate into flake form.

6. Cost Estimation: Analyzes the economic requirements for materials, utilities, machinery, and provides a financial evaluation including ROI and payback period.

7. Result Analysis: Concludes that the evaporative crystallization process is the most efficient method for achieving high-purity calcium chloride recovery.

8. Conclusion: Summarizes the study’s findings, confirming the economic and operational feasibility of implementing the proposed recovery system.

Keywords

Calcium chloride recovery, Solvay process, evaporative crystallization, flake calcium chloride, soda ash, distiller waste, industrial purification, chemical engineering, environmental sustainability, process economics, dehydration, pH adjustment, ion exchange, byproduct utilization, investment analysis.

Frequently Asked Questions

What is the core purpose of this research?

The research focuses on designing an industrial project to recover calcium chloride, a significant waste product of the Solvay soda ash process, to mitigate environmental waste and create a profitable product.

What are the primary fields of application for calcium chloride?

Calcium chloride is widely utilized for deicing, dust control on roads, as an accelerator in ready-mix concrete, in oil and gas drilling fluids, and for various food and pharmaceutical applications.

What is the main goal or research question?

The primary goal is to identify an efficient and economical process for calcium chloride recovery while minimizing operational costs and maximizing product purity.

Which scientific methods are analyzed for recovery?

The study evaluates three distinct methods: evaporative crystallization, evaporation of distiller waste setting ponds, and the ion exchange process.

What does the main part of the document cover?

The main section details the technical processes for recovery, including evaporation, sedimentation, filtration, and drying, alongside comprehensive cost estimations and financial evaluations.

Which keywords define this work?

Key terms include calcium chloride recovery, Solvay process, evaporative crystallization, process economics, and industrial waste management.

Why did the authors determine that the ion exchange process is unsuitable?

The study found that ion exchange is inefficient for this specific application because the calcium chloride salt tends to break into ions on the electrodes before successful separation can be achieved.

What are the main engineering hurdles identified in the production process?

Major challenges include preventing dryer choking caused by sodium chloride impurities, maintaining the correct pH levels using hydrochloric acid, and efficiently converting liquid solution into solid flakes.

What is the financial outlook for the proposed project?

The project is deemed financially viable, with an estimated Internal Rate of Return (IRR) of 16.23% and full cost recovery projected within five years.