Sodium carbonate manufacture

Also, sodium bicarbonate is obtained as a by-product of sodium carbonate manufacture using the Solvay process (see Sodium Carbonate). 

Calcium chloride (CaCl2) is produced as a by-product in the Solvay process for sodium carbonate manufacture. The overall process involved is ... 

In Western Europe about two thirds of the sodium chloride is utilized in the chemical industry (industrial salt), of which more than 90% is for electrolysis to chlorine and sodium hydroxide and for sodium carbonate manufacture. For the remainder (common salt) the most important use is for the salting of roads, which is very strongly weather dependent and is declining for ecological reasons. For taxation reasons sodium chloride utilized for the salting of roads is denatured . 

Development of industrial. sodium carbonate manufacturing processes such as the Leblanc (1790) and Solvay (1865) processes stimulated the development of the inorganic chemical industry... 

The world production of sodium carbonate has increased considerably from 12.7 10 t in 1960 to 20.6 10 t in 1970 to 31.5 10 t in 1993, which, except for production in the USA, was almost exclusively synthetic. The capacity in the Federal Republic of Germany is currently 1.9 10 t/a. USA production increased from ca. 7.7 10 t in 1981, of which 90% was from natural deposits, to 11 10 t/a in 1994, which was exclusively from natural deposits. In 1970, sodium carbonate from natural deposits accounted for 15% of the worldwide production. This proportion had increased to 35% by 1994. Further advances in the economics of sodium carbonate production from natural deposits are to be expected upon changing from mining to extraction as an aqueous solution, so-called solution mining . The high energy costs of sodium carbonate manufacture and stricter environment protection... 

Sodium carbonate manufacturing in the United States starts nearly entirely from naturally occurring trona mineral deposits. Trona (Na2C03-NaHC03-2H20), for example, Wyoming trona ore, is extracted and refined mainly by the monohydrate process. 

Carbon dioxide is used in the manufacture of sodium carbonate by the ammonia-soda process, urea, salicyclic acid (for aspirin), fire extinguishers and aerated water. Lesser amounts are used to transfer heat generated by an atomic reactor to water and so produce steam and electric power, whilst solid carbon dioxide is used as a refrigerant, a mixture of solid carbon dioxide and alcohol providing a good low-temperature bath (195 K) in which reactions can be carried out in the laboratory. 

Early demand for chlorine centered on textile bleaching, and chlorine generated through the electrolytic decomposition of salt (NaCl) sufficed. Sodium hydroxide was produced by the lime—soda reaction, using sodium carbonate readily available from the Solvay process. Increased demand for chlorine for PVC manufacture led to the production of chlorine and sodium hydroxide as coproducts. Solution mining of salt and the avadabiHty of asbestos resulted in the dominance of the diaphragm process in North America, whereas soHd salt and mercury avadabiHty led to the dominance of the mercury process in Europe. Japan imported its salt in soHd form and, until the development of the membrane process, also favored the mercury ceU for production. 

There are several processes available for the manufacture of cryoHte. The choice is mainly dictated by the cost and quaUty of the available sources of soda, alumina, and fluoriae. Starting materials iaclude sodium aluminate from Bayer s alumina process hydrogen fluoride from kiln gases or aqueous hydrofluoric acid sodium fluoride ammonium bifluoride, fluorosiUcic acid, fluoroboric acid, sodium fluosiUcate, and aluminum fluorosiUcate aluminum oxide, aluminum sulfate, aluminum chloride, alumina hydrate and sodium hydroxide, sodium carbonate, sodium chloride, and sodium aluminate. 

Significant amounts of cryoHte are also recovered from waste material ia the manufacture of aluminum. The carbon lining of the electrolysis ceUs, which may contain 10—30% by weight of cryoHte, is extracted with sodium hydroxide or sodium carbonate solution and the cryoHte precipitated with carbon dioxide (28). Gases from operating ceUs containing HF, CO2, and fluorine-containing dusts may be used for the carbonation (29). 

Sodium fluoride is normally manufactured by the reaction of hydrofluoric acid and soda ash (sodium carbonate), or caustic soda (sodium hydroxide). Control of pH is essential and proper agitation necessary to obtain the desired crystal size. The crystals are centrifuged, dried, sized, and packaged. Reactors are usually constmcted of carbon brick and lead-lined steel, with process lines of stainless, plastic or plastic-lined steel diaphragm, plug cock, or butterfly valves are preferred. 

In one manufacturing process, aluminum chloride is treated with a solution containing sodium carbonate and sodium bicarbonate. The product of this reaction is mixed with the precipitate obtained by reaction of a solution of aluminum chloride and ammonia. The mixed magma is dialyzed, the product mixed with glycerol (qv), sodium benzoate is added, and the mixture is then passed through a coUoid mill. 

Seaweeds. The eadiest successful manufacture of iodine started in 1817 using certain varieties of seaweeds. The seaweed was dried, burned, and the ash lixiviated to obtain iodine and potassium and sodium salts. The first process used was known as the kelp, or native, process. The name kelp, initially apphed to the ash of the seaweed, has been extended to include the seaweed itself. About 20 t of fresh seaweed was used to produce 5 t of air-dried product containing a mean of 0.38 wt % iodine in the form of iodides of alkah metals. The ash obtained after burning the dried seaweed contains about 1.5 wt % iodine. Chemical separation of the iodine was performed by lixiviation of the burned kelp, followed by soHd-Hquid separation and water evaporation. After separating sodium and potassium chloride, and sodium carbonate, the mother Hquor containing iodine as iodide was treated with sulfuric acid and manganese dioxide to oxidize the iodide to free iodine, which was sublimed and condensed in earthenware pipes (57). 

The principal material cost for the Chilean iodine producers is sulfur used for the manufacture of sulfur dioxide, the reducing agent for the iodates contained in the leach solutions. Also, the use of sodium carbonate for the neutralization of the depleted solutions is an important cost factor. 

Tetrasodium hexakiscyanoferrate decahydrate [14434-22-1], Na4[Fe(CN)g] IOH2O, or yellow pmssiate of soda, forms yellow monoclinic crystals that are soluble in water but insoluble in alcohol. It is slightly efflorescent at room temperature, but the anhydrous material, tetrasodium hexakiscyanoferrate [13601 -19-9], Na4[Fe(CN)J, is obtained at 100°C. The decahydrate is produced from calcium cyanide, iron(II) sulfate, and sodium carbonate in a process similar to that for the production of K4[Fe(CN)g] 3H2O. It is used in the manufacture of trisodium hexakiscyanoferrate, black and blue dyes, as a metal surface coating, and in photographic processing. 

A.mmonia-Soda Process. Ammonium chloride is made as a by-product of the classic Solvay process, used to manufacture sodium carbonate (12,13) (see Alkali and chlorine products, sodium carbonate). The method iuvolves reaction of ammonia, carbon dioxide, and sodium chloride ia water... 

Sodium bicarbonate precipitates from solution and is recovered by filtration. Ammonium chloride is then crystallised from the filtrate, separated, washed, and dried. The exact proportion of ammonium chloride recovered depends on the relative demands for sodium carbonate and ammonium chloride. If economic conditions requite, part of the ammonia can be recovered and returned to the hrine-ammoniation step by distillation of the ammonium chloride solution ia the presence of lime. The spent calcium chloride Hquor, a final product ia manufacture of sodium carbonate by the ammonia—soda process, can also be used to obtain ammonium chloride. This Hquor is treated with ammonia and carbon dioxide... 

Manufacture. Aqueous sodium hydroxide, sodium bicarbonate, sodium carbonate, or sodium sulfite solution are treated with sulfur dioxide to produce sodium metabisulfite solution. In one operation, the mother Hquor from the previous batch is reinforced with additional sodium carbonate, which need not be totally in solution, and then is treated with sulfur dioxide (341,342). In some plants, the reaction is conducted in a series of two or more stainless steel vessels or columns in which the sulfur dioxide is passed countercurrent to the alkaH. The solution is cooled and the sodium metabisulfite is removed by centrifuging or filtration. Rapid drying, eg, in a stream-heated shelf dryer or a flash dryer, avoids excessive decomposition or oxidation to which moist sodium metabisulfite is susceptible. 

Manufacture. Today benzyl alcohol is almost universally manufactured from toluene which is first chlorinated to give benzyl chloride [100-44-7]. This is then hydrolyzed to benzyl alcohol by treatment with aqueous sodium carbonate. 

Sodium Phosphate Manufacturing. Some pure carbon dioxide gas is available as a by-product ia plants manufacturiag sodium phosphate from sodium carbonate [497-19-8] and phosphoric acid [7664-38-2]. Two carbon dioxide plants were iastalled prior to 1962 to utilize this by-product gas. 

The manufacture of a related compound is first described. 28.1 parts of p-chloro-benzhy-dryl bromide are heated to boiling, under reflux and with stirring, with 50 parts of ethylene chlorohydrin and 5.3 parts of calcined sodium carbonate. The reaction product is extracted with ether and the ethereal solution washed with water and dilute hydrochloric acid. The residue from the solution in ether boils at 134° to 137°C under 0.2 mm pressure and is p-chloro-benzhydryl-(/3-chloroethyl) ether. 

---