Soda Ash (sodium carbonate)
WHAT IS SODA ASH?
FEATURES, PRODUCTION METHOD AND APPLICATIONS
Soda ash or soda ash Na2CO3, or sodium carbonate (also known as washing soda, soda ash and soda crystals) is a mineral compound that has different hydrated structures. All forms of this compound include white, odorless, water-soluble salts that produce moderately alkaline solutions in water. Historically, this substance was extracted from the ashes of plants grown in sodium-rich soils.
A LOOK AT THE HISTORY OF SODA ASH (SODIUM CARBONATE)
Humans have known and used soda ash for thousands of years. The ancient Egyptians extracted this compound from a mineral called natron, which was found at the bottom of dry lakes. Natron is a combination of baking soda and baking soda.
Egyptians used its soda in embalming corpses. This combination kept the bodies of the dead dry and prevented them from decaying. This technique was so effective that some mummified bodies with more than 3,000 years of age are still in the same condition as when they died. Over the centuries, sodium carbonate was also produced from the combustion of organic matter, especially seaweed. In this production method, this common compound is soda ash. Burning dead plants does not produce very large amounts of sodium carbonate, so chemists of the time looked for synthetic methods to produce this important compound. The first breakthrough in this quest came in 1791, when French chemist Nicolas LeBlanc (1806-1742) devised a method for producing sodium carbonate that became an industry standard for nearly a century. In 1900, almost all sodium carbonate produced in the world was made by the Solvay process. In the following, we explain these processes.
SODA ASH PRODUCTION
The total value of soda ash (sodium carbonate) produced in 2019 was estimated at $1.8 billion, and US production of 12 million tons was about the same as the previous year. The US soda ash manufacturing industry includes four companies in Wyoming with five plants and one in California with one plant. The five producing companies have a total annual capacity of 13.9 million tons.
SODA ASH PRODUCTION METHODS
1- Production of sodium carbonate from the mine
Trona, also known as trisodium hydrogen bicarbonate dihydrate, is mined in several regions of the United States and supplies nearly all of its soda ash consumption. Large natural deposits discovered in 1938, such as those near Green River, Wyoming, have made mining more economical than industrial production in North America.
There are significant reserves of trona in Türkiye. Two million tons of its soda is extracted from deposits near Ankara. Also, from some lakes such as Lake Magadi in Kenya, this compound is extracted by dredging operations. Hot springs produce lake salt continuously, provided the rate of dredging does not exceed the rate at which the spring draws water, a perfectly stable source of sodium carbonate.
2- Soda production from plants and algae (Barilla and kelp)
Several “halophyte” (salt tolerant) plant species and seaweed species can be processed to produce the crude form of sodium carbonate; These sources were mostly consumed in Europe and other places until the early 19th century. Plants or seaweed were dried and burned. Then the ashes were washed with water to form an alkaline solution.
This solution was boiled dry to produce the final product, which was called “soda ash”. “Barilla” is a trade term for the crude form of potash obtained from coastal plants, or kelp.
3- LeBlanc process to produce sodium carbonate
In 1792, French chemist Nicolas LeBlanc patented a process for producing sodium carbonate from salt, sulfuric acid, limestone, and coal. In the first step, sodium chloride is purified with sulfuric acid in the Mannheim process. This reaction leads to the production of sodium sulfate (salt cake) and hydrogen chloride:
2NaCl + H2SO4 → Na2SO4 + 2HCl
Salt cake and crushed limestone (calcium carbonate) are reduced under heating with coal. This conversion consists of two parts. The first is the carbothermic reaction in which coal, the carbon source, reduces sulfate to sulfide:
Na2SO4 + 2C → Na2S + 2CO2
The second stage of the reaction is the production of sodium carbonate and calcium sulfide:
Na2S + CaCO3 → Na2CO3 + CaS
This mixture is called black ash. Soda ash is extracted from black ash with water. From the evaporation of this extract, solid sodium carbonate is obtained.
Hydrochloric acid produced by the Leblanc process was a major source of air pollution, and the calcium sulfide byproduct also caused waste disposal problems. However, this main method of producing sodium carbonate remained in force until the late 1880s.
4- Production of sodium carbonate in the Solvay process
In 1861, Belgian chemist Ernest Solvay devised a method to produce sodium carbonate by first reacting sodium chloride, ammonia, water, and carbon dioxide to produce sodium bicarbonate and ammonium chloride:
NaCl + NH3 + CO2 + H2O → NaHCO3 + NH4Cl
Then the resulting sodium bicarbonate was converted into sodium carbonate by heating and water and carbon dioxide were released:
2NaHCO3 → Na2CO3 + H2O + CO2
Ammonia was produced from the by-product of ammonium chloride and by treating it with lime (calcium oxide) remaining from the production of carbon dioxide:
2NH4Cl + CaO → 2NH3 + CaCl2 + H2O
The Solvay process recovers ammonia. Only salt water and limestone are used in this process and calcium chloride is the only waste product. This process is considerably more cost-effective than the Leblanc process, which produces two waste products, calcium sulfide and hydrogen chloride.
The Solvay process quickly dominated sodium carbonate production worldwide. By 1900, 90% of this material was produced by the Solvay process, and the last Leblanc process plant closed in the early 1920s.
5- Production of sodium carbonate in Hou's process
This process was developed by the Chinese chemist Hou Debang in the 1930s. Carbon dioxide, the primary byproduct, was pumped through a saturated solution of sodium chloride and ammonia to produce sodium bicarbonate by these reactions:
CH4 + 2H2O → CO2 + 4H2
3H2 + N2 → 2NH3
NH3 + CO2 + H2O → NH4HCO3
NH4HCO3 + NaCl → NH4Cl + NaHCO3
Because of its low solubility, baking soda is collected as a precipitate and then heated to about 80 °C (176 °F) or 95 °C (203 °F) to obtain pure sodium carbonate, similar to the last step of the Solvay process. .
More sodium chloride is added to the remaining ammonium and sodium chloride solution. Also, more ammonia is pumped into this solution at a temperature of 30-40 degrees Celsius. Next, the temperature of the solution drops below 10 degrees Celsius. The solubility of ammonium chloride is higher at 30°C than sodium chloride and lower at 10°C.
Due to this temperature-dependent solubility difference and common ion effect, ammonium chloride precipitates in sodium chloride solution. The Hawes process is more economical because it does not require more ammonia and, on the other hand, the ammonium chloride byproduct can be sold as fertilizer.
SODA ASH APPLICATIONS IN VARIOUS INDUSTRIES
Heavy soda ash is often used in making glass, while light soda ash is used to produce chemicals and detergents.
About 45% of soda ash produced in the world is used in the glass industry. The use of alkaline substances such as Na2CO3 in glass making reduces the temperature of glass formation from 1700 to 1500-1450 degrees Celsius, which leads to a decrease in energy consumption in this industry. Among other uses of its soda, the following can be mentioned:
- Oil industry: to precipitate calcium ions in blue mud and barium sulfate in mud with low pH
- Dyeing: as a bonding agent between dyes and fibers
- Food industry: Boric acid is another chemical used in the food industry as a pH regulator and preservative.
- Electrolysis: as an electrolyte to increase the rate of water decomposition
- Chemistry laboratories: as primary standards in titration reactions
ESTIMATED DISTRIBUTION OF SODA ASH BY END CONSUMER
Glass production industry 47%, chemicals 30%, soap and detergents 6%, miscellaneous uses 11%, desulfurization of flue gases 4%, pulp and paper 1% and water treatment 1%.
MAJOR PRODUCERS AND EXPORTERS OF SODA ASH IN THE WORLD
High demand has caused excess production and more exports. This includes China, which has the largest soda ash production capacity, but is also the largest soda ash consumer. China exports about 9% of the total global supply of soda ash, although it owns about 45% of global production capacity.
In addition, the top 5 countries account for approximately 86% of the total global export volume. The United States is the largest exporter of soda ash, supplying about 43% of the total world volume, followed by Turkey.
There are three leading producer groups in the world for soda ash: National Soda Ash Corporation of America, which has 5 major producers of soda ash in the United States, Chinese producers and the Belgian company Solvay.
USES OF SODA ASH (SODIUM CARBONATE)
1- Glass manufacturing industry
Sodium carbonate acts as a flux for the silica (2SiO, with a melting point of 1713°C) and raises the melting point of the mixture to a level that can be achieved without the need for special materials. This “soda mixture” dissolves slowly in water.
Therefore, some calcium carbonate is added to the molten mixture to make the glass insoluble. Bottle and window glasses are made by melting such mixtures of sodium carbonate, calcium carbonate and silica sand and silicon dioxide.
2- As a water softener
Hard water contains dissolved compounds, usually calcium or magnesium compounds. Sodium carbonate is used to remove temporary and permanent hardness of water. Since this material is soluble in water and magnesium carbonate and calcium carbonate are insoluble. It is used to soften water by removing 2+ Mg and 2+ Ca.
These ions form insoluble solid deposits after treatment with carbonate ions. Water becomes soft because it does not contain dissolved calcium ions and magnesium ions.
3- Food and cooking additive
Sodium carbonate has a variety of uses in cooking, mainly because it is a stronger base than baking soda but a weaker alkali than metal hydroxide (which may refer to either sodium hydroxide or potassium hydroxide). Alkalinity affects gluten production in kneaded doughs. A solution of alkaline salts of this compound is used to flavor Japanese noodles.
Bakers similarly use baking soda as a substitute for fresh water to give their cakes texture and improve browning.
This substance is used in the production of syrup powder. A cold, tingling sensation in the mouth is caused by an endothermic reaction between sodium carbonate and a weak acid, usually citric acid, which releases carbon dioxide gas, and occurs when the syrup is moistened by saliva.
This substance is also used in the food industry as a food additive (code E500) as an acidity regulator, anticoagulant, bulking and stabilizing agent.
4- Other uses of soda ash
- This substance is used as a relatively strong base in various industries. As a common alkali, it is preferred in many chemical processes because it is cheaper than sodium hydroxide and much safer to transport. Especially the mild alkalinity of this compound recommends its use in home use.
- Sodium carbonate is used as a pH adjuster to maintain stable alkaline conditions for photographic film production.
- Baking soda is a common additive in swimming pool and aquarium water to maintain optimal pH and carbonate hardness (KH).
- Sodium carbonate is used in dyeing with special fiber dyes to ensure proper chemical bonding of the dye with cellulose (vegetable) fibers and usually before dyeing.
- In addition to CaO and other mild alkaline compounds, sodium carbonate is used as a float softener in the foam flotation process to maintain the optimal pH.
IS SODIUM CARBONATE IS THE SAME AS BAKING SODA?
Sodium carbonate and baking soda are two different chemical compounds and differ from each other chemically and functionally. Sodium Carbonate has the chemical formula Na2CO3 and is known as a salt. This compound is used as an alkaline material and is used in various industries including glass industry, water treatment, detergent production, and copper and steel industries as a material with wide applications. Baking soda (Sweet Alkali or Sodium Acid Pyrophosphate) is a different chemical compound and has the chemical formula C6H11O7Na. This substance belongs to the family of carbohydrates and organic salts and is used as a pH regulator and modifier in food. Therefore, sodium carbonate and baking soda are two different substances and should not be confused with each other. Each of these materials have their own applications in different industries and are used for specific purposes.
THE SAFETY OF SODA ASH (SODIUM CARBONATE)
- This material is non-flammable.
- The autoignition temperature of the compound is not available.
- The flash points of sodium carbonate are not available.
- Flammable limits are not available.
- When sodium carbonate is heated to decompose, it emits Na2O fumes.
- Fire hazards are not available in the presence of various materials.
- Explosion hazards are not available in the presence of different substances.
- Sodium carbonate in contact with fluoride can ignite and burn severely.
- Its soda decomposes due to radiation in contact with fluorine at normal temperature.
- Its soda reacts explosively with hot aluminum metal.
- This combination is stable.
- Instability temperature, not available.
- Its unstable conditions are in the presence of incompatible substances such as acids and moisture.
- This material contains phosphorus pentoxide, lithium, fluorine, fluoride, ammonia + silver nitrate, 6,4,2-trinitrotoluene, ammonia, acids, sodium sulfide + water, hydrogen peroxide, molten red metal aluminum, sodium sulfide, zinc, calcium hydroxide. It is inconsistent.
- Sodium carbonate decomposes in the presence of acids by boiling.
- Hot concentrated solutions of sodium carbonate are mildly corrosive to steel.
- Polymerization does not occur in this material.
DANGERS OF SODIUM CARBONATE
Sodium carbonate is a chemical compound that is useful in many applications, but should be used with care. This combination can have risks:
Skin and eye contact: Direct contact can cause skin and eye irritation. Therefore, you must use special protection to avoid direct contact with skin and eyes.
Inhalation: Inhalation of tails containing sodium carbonate can lead to breathing problems. This problem may occur in environments where there is a high concentration of sodium carbonate.
Ingestion: Ingestion can cause stomach and digestive tract complications. Therefore, you should avoid sodium carbonate tanks and storage places.
Interference with other substances: It may interact with other chemicals and cause unwanted reactions. Therefore, it should be used with care and awareness of possible interactions.
Damage to the environment: the discharge of sodium carbonate into the environment without caution can lead to water pollution and damage to the environment.
STORAGE CONDITIONS OF SODA ASH
When working with this compound, do not breathe its dust. Wear appropriate protective clothing. Wear appropriate breathing equipment, masks, goggles, and gloves. Avoid contact with skin and eyes.
Sodium carbonate packages should be stored away from incompatible materials such as acids. Keep the ingredients in a closed container. Store containers and bags in a cool and well-ventilated place. This composition should not be stored at high temperatures; The best temperature is 24 degrees Celsius.
SODIUM CARBONATE PACKAGING
The packaging of light sodium carbonate and heavy sodium carbonate is available in the market in strong and strong bags with a weight of 50 kg. For bulk orders, side bags are also available, which are offered to the customer in a weight of 1000 kg.
TEHCNICAL DATA SHEET OF SODA ASH LIGHT
| CHEMICAL COMPOSITION | UNIT | Min | Max |
|---|---|---|---|
| Sodium Carbonate(Na2Co3) | %wt | 99.2 | 99.6 |
| Sodium Chliride(NaCl) | %wt | 0.5 | 0.7 |
| Sodium Bicarbonate(NaHCo3) | %wt | - | 0.1 |
| Sodium Solfate(Na2So4) | %wt | - | 0.05 |
| Iron(Fe) | ppm | - | 50 |
| Loss on heating | %wt | - | 0.2 |
| Moistore | %wt | - | 0.2 |
| Ni | ppm | - | 30 |
| Cr | ppm | 10 | |
| Mn | ppm | - | 10 |
| Cu | ppm | - | 30 |
| Characteristics | |||
| Total Alkalinity | %wt | 58.12 | 58.42 |
| Pouring Density | g/cm3 | 0.45 | 0.6 |
TEHCNICAL DATA SHEET OF SODA ASH DENCE
| CHEMICAL COMPOSITION | UNIT | Min | Max |
|---|---|---|---|
| Sodium Carbonate(Na2Co3) | %wt | 99.2 | 99.6 |
| Sodium Chliride(NaCl) | %wt | 0.5 | 0.7 |
| Sodium Bicarbonate(NaHCo3) | %wt | - | 0.1 |
| Sodium Solfate(Na2So4) | %wt | - | 0.05 |
| Iron(Fe) | ppm | - | 50 |
| Loss on heating | %wt | - | 0.2 |
| Moistore | %wt | - | 0.2 |
| Ni | ppm | - | 30 |
| Cr | ppm | 10 | |
| Mn | ppm | - | 10 |
| Cu | ppm | - | 30 |
| Characteristics | |||
| Total Alkalinity | %wt | 58.12 | 58.42 |
| Pouring Density | g/cm3 | 0.45 | 0.6 |
| Mesh <40 | %wt | 40 | |
| Mesh 40-140 | %wt | 59 | |
| Mesh >140 | %wt | 1 |
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