Sodium carbonate, processes

Potassium Carbonate Process. The potassium carbonate process is similar to the sodium carbonate process. However, as potassium bicarbonate [298-14-6] is more soluble than the corresponding sodium salt, this process permits a more efficient absorption than the other. The equipment layout is the same and the operation technique is similar. 

Under hot BW conditions this reaction is reversible, leading to a serious risk of carbonate scale depositing on heat transfer surfaces. Consequently, many large water utilities and industries around the world continue to use the old established, but effective lime (calcium hydroxide) and soda ash (sodium carbonate) processes to soften water by precipitating out insoluble hardness salts. 

The introduction of the Alkali Act in 1863 to curb the adverse health effects produced from emissions of HCl from the Leblanc sodium carbonate process was discussed in Chapter 2. This act stated the particular steps companies had to take to reduce emissions. Whilst this approach, if used wisely, could ensure the adoption of the latest best practice it tends to stifle innovative solutions to problems. Also whilst helping to ensure an even playing field it may not be necessary or even appropriate to adopt the same technical solution to different processes in different locations. 

Soda-Ash (sodium carbonate) process introduced by du Pont Co. ... 

The industrial Solvay process (ammonia-sodium carbonate process) is based on the precipitation of the relatively poorly soluble sodium hydrogen carbonate from an aqueous sodium chloride solution according to ... 

Effective countercurrent contacting of two phases and good heat transfer are often difficult to combine. There are examples of gas/liquid absoiption columns with internal cooling (such as in nitric acid and sodium carbonate processes). In other cases one might opt for cross flow instead, and use a cascade of gasAiquid contactors. 

On standing, gelatinous aluminium hydroxide, which may initially have even more water occluded than indicated above, is converted into a form insoluble in both acids and alkalis, which is probably a hydrated form of the oxide AI2O3. Both forms, however, have strong adsorptive power and will adsorb dyes, a property long used by the textile trade to dye rayon. The cloth is first impregnated with an aluminium salt (for example sulphate or acetate) when addition of a little alkali, such as sodium carbonate, causes aluminium hydroxide to deposit in the pores of the material. The presence of this aluminium hydroxide in the cloth helps the dye to bite by ad sorbing it—hence the name mordant (Latin mordere = to bite) dye 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. 

Commercial diethyl carbonate may be purified by the following process. Wash 100 ml. of diethyl carbonate successively with 20 ml. of 10 per cent, sodium carbonate solution, 20 ml. of saturated calcium chloride solution, and 25 ml. of water. Allow to stand for one hour over anhydrous calcium chloride with occasional shaking, filter into a dry fiask containing 5 g. of the same desiccant, and allow to stand for a further hour. Distil and collect the fraction boiling at 125-126°. Diethyl carbonate combines with anhydrous calcium chloride slowly and prolonged contact should therefore be avoided. Anhydrous calcium sulphate may also be used. 

The following is a modification of the process described and gives quite satisfactory results. Wash the crude mixture of benzonitrile and dibromopentane with sodium carbonate solution until the latter remains alkaline, and then with water. Distil it under reduced pressure and collect the fraction boiling up to 120°/18 mm. Dissolve this in twice its volume of light petroleum, b.p. 40-60°, which has previously been shaken with small volumes of concentrated sulphuric acid until the acid remains colourless. Shake the solution with 6 per cent, of its volume of concentrated sulphuric acid, allow to settle, and run ofi the sulphuric acid layer repeat the extraction until the acid is colourless or almost colourless. Wash successively with water, sodium carbonate solution and water, dry over anhydrous calcium chloride or calcium sulphate, and distil off the solvent. Distil the residue under diminished pressure and collect the 1 6-dibromopentane at 98- 100°/13 mm. 

The soiution is aliowed to cool and the crystals of the P2P-bisulfite addition compound are then separated by vacuum filtration, washed with a little clean dH20 then washed with a couple hundred mLs of ether, DCM or benzene. The filter cake of MD-P2P-bisulfate is processed by scraping the crystals into a flask and then 300mL of either 20% sodium carbonate solution or 10% HCi soiution are added (HCI works best). The soiution is stirred for another 30 minutes during which time the MD-P2P-bisulfite complex will be busted up and the P2P will return to its happy oil form. The P2P is then taken up with ether, dried and removed of the solvent to give pure MD-P2P. Whaddya think of that ... 

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. 

Historically, soda ash was produced by extracting the ashes of certain plants, such as Spanish barilla, and evaporating the resultant Hquor. The first large scale, commercial synthetic plant employed the LeBlanc (Nicolas LeBlanc (1742—1806)) process (5). In this process, salt (NaCl) reacts with sulfuric acid to produce sodium sulfate and hydrochloric acid. The sodium sulfate is then roasted with limestone and coal and the resulting sodium carbonate—calcium sulfide mixture (black ash) is leached with water to extract the sodium carbonate. The LeBlanc process was last used in 1916—1917 it was expensive and caused significant pollution. 

Another mining process involves the recovery of sodium carbonate decahydrate from alkaline ponds. EMC mines this material from its solar evaporation pond using a bucket wheel dredge. The decahydrate slurry is dewatered, melted, and processed to soda ash. 

Sodium carbonate monohydrate crystals from the crystallizers are concentrated in hydroclones and dewatered on centrifuges to between 2 and 6% free moisture. This centrifuge cake is sent to dryers where the product is calcined 150°C to anhydrous soda ash, screened, and readied for shipment. Soda ash from this process typically has a bulk density between 0.99—1.04 g/mL with an average particle size of about 250 p.m. 

Lime Soda. Process. Lime (CaO) reacts with a dilute (10—14%), hot (100°C) soda ash solution in a series of agitated tanks producing caustic and calcium carbonate. Although dilute alkaH solutions increase the conversion, the reaction does not go to completion and, in practice, only about 90% of the stoichiometric amount of lime is added. In this manner the lime is all converted to calcium carbonate and about 10% of the feed alkaH remains. The resulting slurry is sent to a clarifier where the calcium carbonate is removed, then washed to recover the residual alkaH. The clean calcium carbonate is then calcined to lime and recycled while the dilute caustic—soda ash solution is sent to evaporators and concentrated. The concentration process forces precipitation of the residual sodium carbonate from the caustic solution the ash is then removed by centrifugation and recycled. Caustic soda made by this process is comparable to the current electrolytic diaphragm ceU product. 

Pentaerythritol may be nitrated by a batch process at 15.25°C using concentrated nitric acid in a stainless steel vessel equipped with an agitator and cooling coils to keep the reaction temperature at 15—25°C. The PETN is precipitated in a jacketed diluter by adding sufficient water to the solution to reduce the acid concentration to about 30%. The crystals are vacuum filtered and washed with water followed by washes with water containing a small amount of sodium carbonate and then cold water. The water-wet PETN is dissolved in acetone containing a small amount of sodium carbonate at 50°C and reprecipitated with water the yield is about 95%. Impurities include pentaerythritol trinitrate, dipentaerythritol hexanitrate, and tripentaerythritol acetonitrate. Pentaerythritol tetranitrate is shipped wet in water—alcohol in packing similar to that used for primary explosives. 

The basis of this process was the injection of sodium carbonate solution into the viscose, although direct injection of carbon dioxide gas that reacts with the viscose soda to form sodium carbonate could also be used (44). The carbonate route yielded a family of inflated fibers culminating in the absorbent multilimbed super inflated (SI) fiber (Eig. 5c). 

Neste patented an industrial route to a cellulose carbamate pulp (90) which was stable enough to be shipped into rayon plants for dissolution as if it were xanthate. The carbamate solution could be spun into sulfuric acid or sodium carbonate solutions, to give fibers which when completely regenerated had similar properties to viscose rayon. When incompletely regenerated they were sufficientiy self-bonding for use in papermaking. The process was said to be cheaper than the viscose route and to have a lower environmental impact (91). It has not been commercialized, so no confirmation of its potential is yet available. 

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. 

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. 

Electrolysis. GalHum can be extracted by direct electrolysis of the aluminate solution at a strongly agitated mercury cathode. The recovery from a sodium gallate solution resulting from the carbonation process is another possibiHty. This process is probably no longer operative because of the environmental problems associated with the mercury. 

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. 

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