Optimization of Energy Efficiency in Boiler Operations for Sodium Bicarbonate Production

Abstract

Soda is a highly significant raw material used in various production processes, ranging from the food to the pharmaceutical industry, and it also serves as a fundamental raw material for the production of detergents and glass (both light and heavy soda). At the "Sisecam Soda Lukavac" plant, soda is produced using the Solvay process with the aid of an aqueous solution of sodium chloride (NaCl) and calcium carbonate (CaCO₃). Since global soda sources are quite limited, efforts are being made to increase production capacity. However, increasing production capacity requires greater quantities of industrial water, which ultimately results in higher consumption of fresh water from the natural Modrac reservoir. In order to reduce the consumption of this natural resource, as well as emissions into the atmosphere, efforts are being made to maximize the use of waste streams generated in the soda production process. The primary goal of this work is to demonstrate the possibility of reusing the waste condensate stream from the slaking drums for the aqueous solution of calcium hydroxide (lime milk) by installing a barometric condenser that operates on the principle of direct contact between the cooling medium and the steam. Reusing this waste condensate would achieve significant operational and ecological improvements, as well as economic savings, with a return on investment realized within five years.