Reference Document on Best Available Techniques for the

5,92
MB Manufacture of Large Volume Inorganic Chemicals - Solids and

711
stron Others industry

6061
ID JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS)

2007
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EXECUTIVE SUMMARYI

PREFACEXI

SCOPE XLI

1 GENERAL INFORMATION ON LARGE VOLUME INORGANIC CHEMICALS – SOLID AND

OTHERS (LVIC-S) INDUSTRY 1

1.1 Overview of the European LVIC-S industry 1

1.1.1 The European chemical industry sector . 1

1.1.1.1 Profile of the chemical industry . 1

1.1.1.2 International trade 4

1.1.1.3 Growth of the chemical industry 4

1.1.1.4 Costs and prices 6

1.1.1.5 Energy 6

1.1.1.6 Employment . 7

1.1.1.7 Investment and R&D 7

1.1.1.8 Sustainable development 8

1.1.2 Inorganic compounds. 10

1.1.3 Characteristics of the LVIC-S industry 10

1.1.4 Cornerstone and selected illustrative products in the scope of this document . 14

1.1.4.1 Main affiliations between compounds within the LVIC-S industry. 15

1.1.4.2 Main uses . 15

1.1.4.3 Economic aspects . 15

1.1.5 Production scale in the European LVIC-S industry . 16

1.1.5.1 Soda ash . 16

1.1.5.2 Titanium dioxide 16

1.1.5.3 Carbon black 17

1.1.5.4 Synthetic amorphous silica. 17

1.1.5.5 Inorganic phosphates 17

1.1.5.5.1 Detergent phosphates . 17

1.1.5.6 Production potential of the LVIC-S industry in the EU-25 17

1.1.5.7 Distribution of the LVIC-S plants in the EU-25 18

1.2 Key LVIC-S production processes. 20

1.2.1 Soda ash with refined sodium bicarbonate. 20

1.2.2 Titanium dioxide 20

1.2.2.1 The sulphate process 20

1.2.2.2 The chloride process 20

1.2.2.3 Wet treatment (coating) 20

1.2.3 Carbon black 20

1.2.3.1 Post-treatment 21

1.2.4 Synthetic amorphous silica 21

1.2.4.1 Synthetic amorphous pyrogenic silica 21

1.2.4.2 Synthetic amorphous precipitated silica. 21

1.2.4.3 Silica gel. 21

1.2.5 Inorganic detergent, food and feed phosphates 21

1.2.5.1 Detergent and food phosphates – sodium tripolyphosphate . 21

1.2.5.2 Feed phosphates – dicalcium phosphate 22

1.3 Overview of environmental issues in the LVIC-S industry 22

1.3.1 Main raw materials. 22

1.3.2 Secondary feedstock and energy 23

1.3.3 Use of water . 23

1.3.4 Emissions to air 23

1.3.5 Emissions to water . 24

1.3.6 By-products and solid wastes. 24

1.4 Unit processes and infrastructure in the LVIC-S industry . 25

1.4.1 Unit processes and unit operations in the LVIC-S industry . 25

1.4.2 Characteristics of a typical LVIC-S production plant 26

1.4.3 Infrastructure at a LVIC-S production site .26

1.4.3.1 Energy supply.26

1.4.3.2 Cooling .27

1.4.3.3 Refrigeration.28

1.4.3.4 Storage and handling 28

1.4.3.5 Vacuum.28

1.4.3.6 Utility fluids28

1.5 Best Available Techniques for the LVIC-S industry 29

2 SODA ASH 31

2.1 General information31

2.1.1 Introduction 31

2.1.2 Overview about the type of production 33

2.1.2.1 Solvay process 33

2.1.2.2 Trona and nahcolite based process .34

2.1.2.2.1 Trona.34

2.1.2.2.2 Nahcolite.34

2.1.2.3 Nepheline syenite process.35

2.1.2.4 Carbonation of caustic soda35

2.1.2.5 Soda ash as a by-product from the production of caprolactam.35

2.1.3 Uses in industrial sectors 35

2.1.4 Production capacity in the world and in Europe.36

2.1.4.1 Worldwide 36

2.1.4.2 European Union37

2.1.5 Socio-economic aspects39

2.1.5.1 Social integration – employment 39

2.1.5.2 Capital intensity in the EU soda ash industry .39

2.1.5.3 General economic standing.39

2.1.5.4 Environmental taxes and levies 39

2.1.5.5 Manufacturing and operating cost 40

2.2 Applied processes and techniques 41

2.2.1 The Solvay process.41

2.2.1.1 Main chemical reactions .41

2.2.1.2 Process steps .42

2.2.1.2.1 Brine purification43

2.2.1.2.2 Lime kilns and milk of lime production43

2.2.1.2.3 Absorption of ammonia 44

2.2.1.2.4 Precipitation of sodium bicarbonate .44

2.2.1.2.5 Separation of sodium bicarbonate from the mother liquor .44

2.2.1.2.6 Sodium bicarbonate calcination45

2.2.1.2.7 Ammonia recovery .45

2.2.1.3 Product storage and handling46

2.2.2 Raw materials .46

2.2.2.1 Brine .46

2.2.2.1.1 Typical brine composition 47

2.2.2.2 Limestone .47

2.2.2.2.1 Typical limestone composition .48

2.2.2.3 Carbon for limestone burning in the lime kiln49

2.2.2.3.1 Typical coke composition.49

2.2.2.4 Ammonia 49

2.2.2.4.1 Ammonia characteristics.49

2.2.2.4.2 Ammonia storage49

2.2.2.5 Miscellaneous additives50

2.2.3 Main output streams .50

2.2.4 Options for process optimisation and improvement .50

2.2.4.1 Purity of raw materials50

2.2.4.1.1 Heavy metals in raw materials used for the production of soda ash .51

2.2.4.2 Raw materials consumption52

2.2.4.3 Energy.52

2.3 Present consumption and emission levels.53

2.3.1 Raw materials .54

2.3.2 Utilities .54

2.3.2.1 Steam54

2.3.2.2 Process water 55

2.3.2.3 Cooling waters . 55

2.3.2.4 Electricity. 55

2.3.3 Emissions to air 56

2.3.3.1 Particulate dust . 56

2.3.3.2 Carbon dioxide and monoxide . 57

2.3.3.3 Nitrogen oxides 57

2.3.3.4 Sulphur oxides 57

2.3.3.5 Ammonia 58

2.3.3.6 Hydrogen sulphide . 58

2.3.4 Emissions to water . 59

2.3.4.1 Waste water from distillation . 59

2.3.4.1.1 Suspended solids and heavy metals discharged with waste waters 60

2.3.4.1.2 Waste water emissions from example plants 61

2.3.4.2 Waste water from brine purification 63

2.3.5 Solid wastes . 63

2.3.5.1 Fines of limestone 63

2.3.5.2 Non-recycled stone grits at the slaker 63

2.3.6 Co-products 64

2.3.6.1 Calcium chloride 64

2.3.6.2 Refined sodium bicarbonate. 64

2.3.6.2.1 Background information. 64

2.3.6.2.2 Process description. 65

2.3.6.2.3 Major environmental impact 66

2.3.7 Energy management in the production of soda ash 67

2.3.7.1 Energy conversion of primary fuels . 67

2.3.7.2 Energy saving in the process 68

2.3.7.2.1 Heat recovery . 68

2.3.7.2.2 Energy minimisation 68