DESIGN AND SIMULATION OF SOLVAY PROCESS WITH EMPHASIS ON REDUCTION OF BICARBONATE MOISTURE AT WASH FILTERS

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.