Trona mineralinden sodyum hidroksit üretimi (proses tasarımı ve ekonomik analiz)
Computer aided design and cost estimation model of commercial caustic soda production process from trona mineral
- Tez No: 19312
- Danışmanlar: DOÇ.DR. HASANCAN OKUTAN
- Tez Türü: Yüksek Lisans
- Konular: Kimya Mühendisliği, Chemical Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1991
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 129
Özet
ÜZET Sodyum hidroksit kimya sanayiinde önemli bir kullanım alanına sahiptir, üretimi tuzlu su ve sodyum karbonat kaynaklı metotlarla gerçekleştirilmektedir. Trona minerali de önemli bir sodyum karbonat kaynağı olduğu ve bu kaynaktan sodyum karbonat üretimi diğerli retim yöntemlerine göre daha ekonomik olduğundan dolayı trona mineraline ilgi gün geçtikçe artmaktadır. Türkiye trona rezervi açısından 210 milyon tonluk rezerv ile A.B.D.'den sonra dünyada ikinci sırayı almaktadır, ülkemizdeki bu kaynağın değerlendirilmesi durumunda kimya sektöründe önemli geliş meler meydana gelecek ve bu gelişmeler ülke ekonomisine büyük katkılar sağlayacaktır. Trona mineralinden ticari ölçekte sodyum karbonat üretimi klasik olarak iki yöntemle yapılmaktadır. Bunlar Monohidrat ve Sesqui- karbonat yöntemleridir. Bu yöntemlerin yanı sıra çözelti madenciliği ile de soda üretimi yapılmaktadır. Sodyum hidroksit üretimi kireç- soda ve elektroliz yöntemleriyle yapılmaktadır. Tronadan sodyum hidroksit üretimi için monohidrat yönteminin bir kısmı ile kireç-soda yöntemi birleştirilerek klasik bir metot, çözelti madenciliği yöntemi ile kireç-soda yöntemi bir arada kullanılarak ayrı bir metot geliştirilmeye çalışılmış ve bunlar kireç-soda ve çözelti madenciliği yöntemi olarak adlandırılmıştır. Yapılan bu çalışmada Beypazarı trona mineralinden sodyum hidroksit üretimi için kullanılması düşünülen kireç-soda ve çözelti- madenciliği yöntemlerinin uygulamaya konması durumunda proseslerin tasarımı ve gerekli olacak yatırım maliyetleri saptanmış, kar hesap lamaları, çeşitli ekonomik analizleri ve yöntemlerin karşılaştırılması yapılmıştır.
Özet (Çeviri)
COMPUTER AIDED DESIGN AND COST ESTIMATION MODEL OF COMMERCIAL CAUSTIC SODA PRODUCTION PROCESS FROM TRONA MINERAL SUMMARY Caustic soda is one of the basic chemical products produced in the largest quantity along with sulfuric acid, ammonia and ethylene. Moreover, because of its large production scale, caustic soda is generally classified as one of the heavy chemicals. This product is mainly used for the synthesis of various organic and inorganic chemical compounds, production of soap, pulp, paper and rayon as well as neutralization in a wide range of industries. Although caustic soda is produced and shipped in the anhydrous state in the form of a solid, flakes, or beads, \/ery little is actually consumed as such. It is used almost exclusively in water solutions of less than 50% concentration. Caustic soda is produced in over 44 countries, including our country, by the lime-soda process and by the electrolytic process. Until shortly before World War I, the amount of caustic soda reaching the markets as coproduct of chlorine was almost negligible compared to that made from soda ash by the lime reaction. The lime- process caustic exceeded electrolytic caustic in tonnage just before the beginning of World War I, but then the electrolytic product took a rapid spurt and, in 1966 substantially exceeded the lime product. The rapid increase in the tonnage of caustic soda reaching the market as coproduct of chlorine is a couse of concern to soda ash producers, who an that account have also become chlorine-caustic producers. Much effort has been put into the development of chlori ne processes that do not produce caustic, but apart from processes designed primarily for the production of metals, only one, which produces chlorine from salt and nitric acid, has met with any suc cess, and this as yet is a relatively small factor. The causticization of soda ash with lime and the electrolytic production from Gammon salt completely overshadow any other process for making sodyum hydroxide. The causticization of soda ash with strontium has been studied because of favorable solubility relationships, but has not come into use. Nowadays, caustic soda is produced by electrolysis and produ ce from soda ash is applied only in isolated areas throughout the world. World caustic soda production was 33 million metric tons in 1986. This value has been increased by the time. The U.S.A. is viproduce 35 percent of world caustic product. European countries fallow U.S.A. with 31 percent. Rest of the production is realized by other countries. In Turkey, caustic soda is produced by SEKA, PETKfM and Koruma Tarım in Kocaeli. Seka was established with 1700 metric ton annual ca- pasity in 1945, and has been developed more than 153.000 metric tons annual capasity. Koruma Tarım İlaçları was established in Kocaeli with 10.000 metric tons annual capacity in 1965. Petkim was established in 1975. These plants produce caustic soda by electroly sis method as coproduct of chlorine. Turkey's annual caustic soda capasity was 122 000 metric tons and is predicted to be 150 000 metric tons With 23 percent increase in 1994. The Mineral Research and Exploration Institute (M.T.A.) found the trona deposit near Beypazarı during coal exploration studies in 1979. Trona is a soda ash source which can be used in caustic soda produc tion by lime-soda process. Beypazarı Trona deposit is located approximately 15 km. northwest of Beypazarı in Central Anatolia. The total deposit surface area is about 8 km*. Field tests related with geology and hydorolgy was completed by M.T.A. and the resource was transferred to Eti bank which is state mining company in 1983. The studies showed that trona is present 150-400 m in deep, layers which are thicker and richer in quality compared to the ones in Wyoming (U.S.A.). Total reserve of the deposits is about 210 milli ons tons. The average grade of deposit is 85% trona. The whole trona deposit consists of thirteen different layers and the thick ness of the layers change between 0.7-6.0 m. Beypazarı trona mineral, due to its chemical content, can be processed more easily than Wyoming trona containing 8-10% NaCl, Na2S04 content. This resource will allow the natural production of chemicals such as sodyum hydroxide, soda and other sodium derivatives for about a hundred years. The possibilities of underground and solution mining methods has been considered by Etibank. If this project proceed, it could result in substantial changes in the European caustic soda market. By the time such a project reaches fruition Turkey could be a full member of Europian Economic Community. Sesquikarbonate and monohydrate processes are used in Wyoming to produce marketable product of soda ash. In monohydrate process, after crushing, the trona are is first calcined and all subsequent clarification and monohydrate crystallization takes place on a mono hydrate solution. In this study at first, mining calcination and clarification sections of monohydrate process and all of the time- soda process combined into one process called Conventional lime- soda Method. vi iIn lime-soda process NagCOo solution is reacted with slaked lime in, agitators after completed causticization reaction, the caustic soda liquior is clarified and evaporated till the desired concentration of caustic soda. Then, concentrated caustic liquior cooled to seperate soda ash from product. Both Monohydrate and Sesqui carbonate processes are applied as conventional mining technique in Wyoming by FMC Corporation. An alternative technique to recover trona deposit is solution mining technique. One of the first solution mining of trona patents was issued to Robert D. Pike in 1945. When a predecessor company to FMC conducted a single well solution mining trial in 1945, the results were so dissappointing that the approach was considered impractical and abandoned in favor of underground mining, in 1980, FMC Corporati on installed a pilot plant at westvaco. They began producing commer cial quantities of soda ash from the solution mining in October 1985. Company estimates that production costs for solution mining will be 25% lower than that required for conventional mining. This study, secondly, interested in production of caustic, soda by solution mining. Sodium carbonate solution, which is used in lime- soda process, is obtained from trona deposit by solution mining. Conventional Mining and Solution Mining methods can be conside red for Turkish trona. Processes should be designed separately so that a plant is established. One of them can be selected by comparing their capital cost estimations. The development of a complete plant design requires considera tion of many different subjects. The role of cost and the design of individual process of equipment is equally important. In additan, many other factors must be considered, such as plant location, plant layout, plant operation and control, utilities, structural design, storage, materials handling, waste disposal, health and safety, patent and legal restrictions. A plant design obviously must present a process that is cap-> able of operating under conditions which will yield a grafit. Since net grafit equals total income minus all expenses, it is essential that the many different types of cost involved in manu facturing processes should be awared. Money must be paid out for direct plant expenses, such as those for raw materials, labor and equipment. In addition, many other indirect expences are incurred, and these must be included if a complete analysis of the total cost is to be obtained. Same examples öf these indirect expenses are administrative salaries, product-distribution costs, and costs for interplant commoni cations. A capital investment is required for any industrial process, and determination of the necessary investment is a important part vmof a plant design project. The total investment far any pocess consis-ts of the fixed-capital investment for the physical equipment and facılities in the plant plus the working capital for money which must be avaible to pay saları'es,keep row materials and products on hand, and handle other special items requiring a direct cost out- laby. Thus, in an analysis of cost in industri-al processes, capital investment costs, manufacturing costs, and general expenses inci uding income taxes must be taken into consideration. Economical analysis and evaluation are often needed as a quide to planning new capacity and in studying how changes in plant size selling price and demand and alternative processes ör equipment might effect profi tabi l ity. in this study, computer aided design and cost estimation mo¬ del were developed for the conventional and solution Mining Methods, which are introduced, to produce caustic soda from the trona mineral. To achieve this scope, firstly flow sheets of these two processes were prepared, material and energy balances equations were derived. Secondly, the equipments in the flowsheets were listed and the size of equipments were determined for the different production of caus¬ tic soda capacities. Finally cost analysis were made and the capital costs, fixed capital, vıorking capital, total capital, manufacturing expenses, product cost, net annual profit and rate of return were determined for conventional mining and Solution Mining Methods. in addition, solution mining Method was carried out as the part of soda ash producing process which uses solution mining, and ali analysis were made for this process. As the main results of this study, the total capital investment cost of a caustic soda plant with 350.000 tons per year capacity from 98% trona öre by lime..- soda. Method was found 197 billion TL. Each 150.000 tons/year increase in this capacity, caused about 40-43 billion TL. increase in cost. The investment cost of solution mining method is lovver when compared with conventional mining method due to some extra equipment used in lime - soda method, which are crusher, vibratory sereen, calcination kiln, ete. When the solution mining method was carried out as the part of soda ash producing process, it has been observed that the results obtained from analysis, are nearly the same by the results rObtained from solution mining method. There is a little difference between solution mining method because of inlet liquior from soda ash producing process. The l ast processes values are a little bit bigger than solution mining method. it is also indicated in this study that the solution mining method is the most advantageous method in the lime - soda method, solution mining method ant its application as soda ash producing process by production method. The advantages of solution mining method can be listed as lower investment, production and unit costs and as a cansequent of these, with a higher P rofi t, v/hen compared with others. As a final conclusion of this study, it was proved by ali the calculations, that caustic soda production ixfrom trona ore is much cheaper than the synthetic caustic soda pro duction. Therefore, if Beyparan Trona deposits are recovered by solution mining method then it would be possible to produce caustic soda at low cost and this would be beneficial for Turkey.
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GÖZDE GÖZKE
Yüksek Lisans
Türkçe
2006
Kimyaİstanbul Teknik ÜniversitesiKimya Mühendisliği Ana Bilim Dalı
DOÇ. DR. ÖZGÜL ÖZCAN