Abstract:
The Solvay process is the common industrial process is the common industrial
process used for production of Sodium carbonate (Na2CO3), also known as soda ash
From Sodium Chloride (NaCl) and Calcium Carbonate (CaCO3) as a raw material. The
main objective of this project is the designing of Solvay Process and addressing the
challenges of reducing bicarbonate moisture at wash filter. By using simulation and
analysis, innovative strategies will be expected to increase the washing efficiency.
The approach that we entailed was a thorough examination of the existing process
flow to pinpoint the crucial areas where moisture reduction can be applied most
successfully. Aspen Plus, a top process simulation program, was used to run a number
of simulations in order to model various situations and improve the parameters for
moisture reduction. To find the best answers, the simulations used a variety of drying
approaches, including the use of sophisticated filter designs and a rotary drum drier.
The outcomes showed a notable decrease in moisture content at the wash filters,
resulting in the best possible balance between energy consumption and process
efficiency. The improved method lowers the overall cost of manufacturing by
improving the quality of the sodium bicarbonate generated and requiring less energy
for later drying steps. We also recycled the excess CO2 to reduce the overall cost and
to reduce the caron footprint by adding a 2-phase separator.
Overall, we designed the Solvay process with focus on moisture reduction at the wash
filters which presented a viable pathway to enhancing the sustainability and
economic competitiveness of sodium carbonate production. Using process
simulations, optimum conditions and cutting-edge drying technologies which helped
to increase the efficiency up to 90 % guarantees a more economical use of resources,
which is in line with the objectives of industrial sustainability and gives businesses a
competitive advantage. The environmental impact of the Solvay process was also
brought into consideration with most of the CO2 recovered and recycled back to the
system.
