{
  "authors": [],
  "basis": {
    "capacity": "1000 t/d light soda ash (ASSUMED normalisation basis)",
    "location": "generic (not chosen)",
    "operating_hours_per_year": 8000
  },
  "benchmarks": [],
  "chemistry": {
    "inputs": [
      {
        "chemical": "limestone",
        "grade": null,
        "note": "feed:LST: crushed and screened limestone, 1.08 kg/kg soda ash",
        "role": "feedstock"
      },
      {
        "chemical": "metallurgical-coke",
        "grade": null,
        "note": "feed:COKE: coke, kiln fuel",
        "role": "feedstock"
      },
      {
        "chemical": "sodium-chloride",
        "grade": null,
        "note": "feed:BRINE: purified saturated brine (26 wt-% NaCl) at battery limits, counted by mass of the brine",
        "role": "feedstock"
      },
      {
        "chemical": "ammonia",
        "grade": null,
        "note": "feed:NH3: liquid ammonia make-up",
        "role": "feedstock"
      },
      {
        "chemical": "water",
        "grade": null,
        "inventory_key": "feed:PW",
        "note": "Process water for slaking and cake washing (the brine water enters with feed:BRINE)",
        "role": "feedstock"
      },
      {
        "chemical": "air",
        "grade": null,
        "inventory_key": "feed:AIR",
        "note": "Kiln combustion air",
        "role": "feedstock"
      }
    ],
    "outputs": [
      {
        "chemical": "sodium-carbonate",
        "grade": null,
        "inventory_key": "product:SODA",
        "note": "Light soda ash to storage",
        "role": "main-product"
      },
      {
        "chemical": "wastewater",
        "grade": null,
        "inventory_key": "product:DSW",
        "note": "Distiller waste: CaCl2 and NaCl liquor with suspended CaCO3, Ca(OH)2 and insolubles, ~11 t/t soda ash",
        "role": "waste"
      },
      {
        "chemical": "carbon-dioxide",
        "grade": null,
        "inventory_key": "product:VENT",
        "note": "Unabsorbed kiln CO2 (calcination and coke) in the vent gas, ~0.31 t/t soda ash",
        "role": "emission"
      }
    ],
    "utilities": [
      {
        "chemical": "electricity",
        "grade": null,
        "inventory_key": "feed:POWER",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:LPS",
        "note": "LP steam 450 kPa(a), live steam to the distiller",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:HPS",
        "note": "HP steam 3000 kPa(a) to the calciner",
        "role": "utility"
      },
      {
        "chemical": "cooling-water",
        "grade": null,
        "inventory_key": "product:CW",
        "note": "25/35 C (ASSUMED)",
        "role": "utility"
      }
    ]
  },
  "description": "Limestone is burnt with coke in a mixed-feed shaft kiln; the kiln gas (about 37 mol% CO2) and\nthe CO2 recovered from the calciner are compressed to the carbonating towers. Purified brine\nis ammoniated with the gas of the ammonia distiller and carbonated; sodium bicarbonate\nprecipitates, is filtered, washed and calcined with HP steam to light soda ash. The mother\nliquor is distilled with milk of lime from the slaker and live steam; the ammonia returns to\nthe absorber, the CaCl2 liquor leaves as distiller waste. Overall CaCO3 + 2 NaCl -> Na2CO3 +\nCaCl2.\n\nAll values are concept estimates from an independent sequential balance with assumed\ndesign parameters (sodium utilisation, ammonia ratio, cake moisture, losses): no\nelectrolyte or solid-liquid equilibrium is calculated. The kiln heat use is the lime BREF\nvalue for the kiln type. See DESIGN.md for every assumption and gated step.\n",
  "design_basis": {
    "assumptions": [
      "ASSUMED sodium utilisation of the carbonating towers 0.73 (NaHCO3 precipitated / NaCl fed), inside the range the Solvay literature reports (D-006).",
      "ASSUMED NH3/NaCl 1.10 mol/mol in the ammoniated brine; CO2/free NH3 1.0 in the mother liquor (D-006).",
      "ASSUMED washed cake 15 wt% liquid; wash water 0.30 kg/kg dry cake; NH4Cl fully washed out (D-006).",
      "ASSUMED ammonia losses 2.0 kg/t soda ash: 0.5 to the vent, 1.5 with the distiller waste (D-006).",
      "ASSUMED lime 5 % over the NH4Cl stoichiometry; degree of calcination 0.95; milk of lime 20 wt% Ca(OH)2 (D-004, D-006).",
      "ASSUMED kiln heat use 4.0 GJ/t lime (mid-range of the lime BREF for mixed-feed shaft kilns), combustion air excess 1.10 (D-004).",
      "ASSUMED duties from a lumped enthalpy balance on formation enthalpies and constant heat capacities; compressor isentropic efficiency 0.75; auxiliary power 35 kWh/t (D-008).",
      "No electrolyte thermodynamics: liquors are carried as neutral molecules; no property package covers the streams (D-007)."
    ],
    "source": "process/design-basis.yaml"
  },
  "engineering": {
    "description": "",
    "name": "Soda ash (Solvay process)",
    "requires": "cheme-as-code>=0.8",
    "stage": "concept",
    "stages": [
      {
        "id": "concept",
        "title": "Concept and feasibility"
      },
      {
        "id": "basic",
        "title": "Basic engineering"
      },
      {
        "id": "detail",
        "title": "Detail engineering"
      }
    ],
    "tool": "plantcode"
  },
  "facets": {
    "feedstock_basis": [
      "mineral"
    ],
    "product_classes": [
      "chemicals"
    ],
    "region": "generic",
    "unit_operations": [
      "reaction",
      "absorption",
      "crystallization",
      "filtration",
      "calcination",
      "distillation",
      "compression"
    ]
  },
  "families": [
    "soda-ash"
  ],
  "gap_count": 0,
  "gates": null,
  "id": "soda-ash-1",
  "issues": {
    "closed_count": 0,
    "list_url": "https://github.com/ChemE-as-Code/process-library/issues?q=is%3Aissue%20label%3A%22process%3Asoda-ash-1%22",
    "new": {
      "action": "https://github.com/ChemE-as-Code/process-library/issues/new?template=1-action-item.yml&labels=process%3Asoda-ash-1&process=soda-ash-1",
      "change": "https://github.com/ChemE-as-Code/process-library/issues/new?template=4-design-change.yml&labels=process%3Asoda-ash-1&process=soda-ash-1",
      "hold": "https://github.com/ChemE-as-Code/process-library/issues/new?template=2-engineering-hold.yml&labels=process%3Asoda-ash-1&process=soda-ash-1",
      "process": "https://github.com/ChemE-as-Code/process-library/issues/new?template=6-process-development.yml&labels=process%3Asoda-ash-1&process=soda-ash-1",
      "tq": "https://github.com/ChemE-as-Code/process-library/issues/new?template=3-technical-query.yml&labels=process%3Asoda-ash-1&process=soda-ash-1",
      "tracker": "https://github.com/ChemE-as-Code/process-library/issues/new?template=7-process-tracker.yml&labels=process%3Asoda-ash-1&process=soda-ash-1"
    },
    "open": [],
    "open_by_gate": {},
    "open_count": 0,
    "private": false,
    "repository": "ChemE-as-Code/process-library"
  },
  "keywords": [
    "soda ash",
    "sodium carbonate",
    "Solvay process",
    "ammonia-soda",
    "lime kiln",
    "carbonation",
    "sodium bicarbonate",
    "calcination",
    "ammonia recovery",
    "calcium chloride",
    "distiller waste"
  ],
  "lca": {
    "allocation": "none",
    "backend": "factors",
    "boundary": "cradle-to-gate",
    "categories": [
      {
        "id": "climate-change",
        "method": "GWP100",
        "title": "Climate change",
        "unit": "kg CO2-eq"
      }
    ],
    "contributions": [
      {
        "basis": "ipcc2021-gwp100 (124-38-9, air, fossil)",
        "category": "climate-change",
        "impact": 0.306172,
        "key": "emission:CO2",
        "phase": "operation",
        "share": 1.0,
        "status": "PUBLISHED"
      }
    ],
    "data_sources": [],
    "factors_status": "published",
    "functional_unit": {
      "amount": 1,
      "chemical": "sodium-carbonate",
      "grade": null,
      "label": "1 kg sodium carbonate",
      "product": "SODA",
      "product_name": "Sodium carbonate",
      "product_title": "Light soda ash to storage",
      "unit": "kg"
    },
    "goal": "Preliminary foreground (gate-to-gate) life cycle inventory of light soda ash by the Solvay process at the concept stage: which raw materials, utilities, emissions and wastes the balanced flowsheet implies per kg of product, ready to be linked to background datasets later. Flows are concept estimates on assumed design parameters (DESIGN.md D-006, D-008).",
    "inventory": [
      {
        "direction": "input",
        "key": "feed:LST",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.08178,
        "title": "Limestone (crushed and screened)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:COKE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0875519,
        "title": "Coke (kiln fuel)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:AIR",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.982679,
        "title": "Kiln combustion air",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:BRINE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 5.78139,
        "title": "Purified saturated brine at battery limits",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:NH3",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0019992,
        "title": "Ammonia make-up (liquid)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:PW",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 3.47992,
        "title": "Process water",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:LPS",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.88384,
        "title": "LP steam 450 kPa(a), live steam to the distiller",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:HPS",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.676279,
        "title": "HP steam 3000 kPa(a) to the calciner (condensate returned)",
        "unit": "kWh"
      },
      {
        "direction": "input",
        "key": "feed:POWER",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.111857,
        "title": "Electric power",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "product:SODA",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.0,
        "title": "Light soda ash to storage",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:DSW",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 11.1899,
        "title": "Distiller waste (CaCl2 liquor with suspended solids) to settling ponds",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:VENT",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.10922,
        "title": "Vent gas to atmosphere (unabsorbed kiln CO2 and air nitrogen)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:CW",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.46556,
        "title": "Cooling water return",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "emission:CO2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.306172,
        "title": "CO2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:H2O",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0274588,
        "title": "H2O to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:N2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.754333,
        "title": "N2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:NH3",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.00050026,
        "title": "NH3 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:O2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0207591,
        "title": "O2 to the environment",
        "unit": "kg"
      }
    ],
    "no_total": {},
    "not_computed": [],
    "pcf": [],
    "publishable": true,
    "result": {
      "classification": "partial",
      "gaps": 10,
      "label": "partial screening carbon footprint",
      "publication": "public"
    },
    "sources": [
      "lca/README.md",
      "lca/dataset.yaml",
      "lca/factors.yaml",
      "lca/gaps.csv",
      "lca/inventory.csv",
      "lca/lca.yaml",
      "lca/mappings.yaml",
      "lca/results.csv",
      "lca/results.md",
      "lca/uncertainty.csv"
    ],
    "totals": {
      "baseline": {
        "climate-change": 0.306172
      }
    },
    "withheld_reason": null
  },
  "lci_gaps": [],
  "maintainers": [
    {
      "name": "Artur Schweidtmann"
    }
  ],
  "maturity": "concept",
  "preliminary": false,
  "provenance": {
    "library_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "previews": {
      "sheets": [
        "BFD",
        "PFD"
      ],
      "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
      "tool": "cheme 1.6.0 (pyDEXPI 2.1.0)"
    },
    "previews_stale": false,
    "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0"
  },
  "publication": {
    "license": "CC-BY-4.0",
    "status": "public"
  },
  "references": [
    {
      "doi": "10.1002/14356007.a24_299",
      "title": "Thieme, C. (2000) Sodium Carbonates. Ullmann's Encyclopedia of Industrial Chemistry (route reference lead; production sections not audited in this run)"
    },
    {
      "doi": "10.2788/12850",
      "title": "European Commission JRC (2013) Best Available Techniques Reference Document for the Production of Cement, Lime and Magnesium Oxide, Schorcht et al., EUR 26129 EN, Table 2.23 (kiln heat use by type)"
    },
    {
      "title": "European Commission (2007) Reference Document on Best Available Techniques for the Manufacture of Large Volume Inorganic Chemicals - Solid and Others industry (soda ash chapter; consumption and emission ranges to audit, not read in this run)"
    },
    {
      "title": "EMEP/EEA air pollutant emission inventory guidebook, chapter 2.B.7 Soda ash (vented CO2 range per t soda ash; cross-check only)",
      "url": "https://www.eea.europa.eu/publications/emep-eea-guidebook-2019/part-b-sectoral-guidance-chapters/2-industrial-processes/2-b-chemical-industry/2-b-7-soda-ash"
    },
    {
      "title": "Wagman, D. D. et al. (1982) The NBS tables of chemical thermodynamic properties. J. Phys. Chem. Ref. Data 11, Suppl. 2 (formation enthalpies; values to be checked)"
    }
  ],
  "repository": {
    "access": "public",
    "path": "processes/soda-ash-1",
    "url": "https://github.com/ChemE-as-Code/process-library"
  },
  "representations": [
    {
      "bytes": 44985,
      "id": "BFD",
      "kind": "bfd",
      "preview": "artifacts/soda-ash-1/BFD.svg",
      "source": "process/BFD.xml",
      "status": "preview",
      "title": "Block flow diagram"
    },
    {
      "bytes": 181514,
      "id": "PFD",
      "kind": "pfd",
      "preview": "artifacts/soda-ash-1/PFD.svg",
      "source": "process/PFD.xml",
      "status": "preview",
      "title": "Process flow diagram"
    },
    {
      "id": "process-model",
      "kind": "process-model",
      "source": "process/flowsheet.yaml",
      "status": "viewer",
      "title": "Flowsheet and stream table"
    },
    {
      "id": "simulation",
      "kind": "simulation",
      "source": "process/simulation.yaml",
      "status": "viewer",
      "title": "Process simulation"
    },
    {
      "id": "equipment-list",
      "kind": "equipment-list",
      "source": "equipment/equipment-list.yaml",
      "status": "viewer",
      "title": "Equipment list"
    },
    {
      "id": "lca",
      "kind": "lca",
      "source": "lca/lca.yaml",
      "status": "viewer",
      "title": "Life cycle assessment"
    }
  ],
  "summary": "Synthetic soda ash from brine and limestone by the Solvay process: lime kiln, brine ammoniation, carbonation, filtration, steam calcination and ammonia recovery with milk of lime; CaCl2 distiller waste and kiln CO2 explicit. Concept stage, assumed basis.",
  "title": "Soda ash by the Solvay ammonia-soda process (1000 t/d light ash, concept)",
  "validation": {
    "notes": "Concept BFD/PFD with closed mass, component and element balances (cheme validate, cheme process streams: 6 blocks, 12 steps, reactive balances by extents). All flows and compositions are specified values of an independent balance (scripts/solvay_balance.py) on assumed design parameters; no electrolyte speciation or reciprocal-salt equilibrium is calculated, and no property package covers the liquors and solids, so energy closure is not evaluable in core: the duties are a lumped script estimate. The kiln uses the specific-energy fallback of cheme process furnace (Cantera not available in this installation). The gate-to-gate LCI is preliminary, with every background unmapped. Not reviewed.",
    "status": "unreviewed"
  },
  "viewer": {
    "commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "dirty": false,
    "sheets": [
      "process/BFD.xml",
      "process/PFD.xml"
    ],
    "skipped": [],
    "snapshot": "snapshots/soda-ash-1/",
    "stale": false,
    "tool": "cheme-as-code 1.6.0",
    "views": [
      "checks",
      "streams"
    ]
  }
}