Systems and methods for soda ash production

Abstract

Provided herein are methods and systems to produce sodium carbonate (soda ash). The methods and systems provided herein modify a Solvay process by integrating it with an electrochemical process to produce a less carbon dioxide intensive Solvay process and an environmentally friendly sodium carbonate product.

1 . A method to produce sodium carbonate, comprising:
 a) absorbing carbon dioxide in an ammonia solution to form sodium bicarbonate; and   b) subjecting the sodium bicarbonate to a first electrochemical process to produce sodium carbonate.   
     
     
         2 . A method to modify a Solvay process to produce a less carbon dioxide intensive Solvay process, comprising:
 a) absorbing carbon dioxide in an ammonia solution to form sodium bicarbonate; and   b) subjecting the sodium bicarbonate to a first electrochemical process to produce sodium carbonate, thereby resulting in a less carbon dioxide intensive Solvay process.   
     
     
         3 . The method of  claim 1  or  2 , further comprising regenerating the ammonia solution using calcium oxide obtained by lime calcination. 
     
     
         4 . The method of  claim 1  or  2 , further comprising regenerating the ammonia solution using sodium hydroxide obtained from the first or a second electrochemical process. 
     
     
         5 . The method of  claim 1  or  2 , wherein the method does not comprise bicarbonate calcination, lime calcination, or a combination thereof. 
     
     
         6 . The method of  claim 1  or  2 , wherein the method produces less than 80% carbon dioxide as compared to a conventional Solvay process. 
     
     
         7 . The method of  claim 1  or  2 , further comprising treating the sodium carbonate with calcium or magnesium ions to form calcium carbonate, magnesium carbonate, or combination thereof. 
     
     
         8 . The method of  claim 7 , wherein the calcium carbonate, magnesium carbonate, or combination thereof is a cementitious material. 
     
     
         9 . The method of  claim 8 , wherein the cementitious material comprises vaterite. 
     
     
         10 . The method of  claim 8 , wherein the cementitious material has a compressive strength of greater than 10 MPa. 
     
     
         11 . A system comprising a Solvay system integrated with an electrochemical system, comprising:
 a) a Solvay system comprising an absorber configured to absorb carbon dioxide in an ammonia solution to form sodium bicarbonate; and   b) a first electrochemical system operably connected to the Solvay system configured to convert the sodium bicarbonate to sodium carbonate.   
     
     
         12 . The system of  claim 11 , further comprising a regenerator operably connected to the Solvay system configured to regenerate the ammonia solution after absorption of the carbon dioxide in the ammonia solution. 
     
     
         13 . The system of  claim 12 , further comprising a lime calciner operably connected to the regenerator and configured to produce calcium oxide for regenerating the ammonia solution. 
     
     
         14 . The system of  claim 12 , further comprising a second electrochemical system operably connected to the regenerator and configured to produce sodium hydroxide for regenerating the ammonia solution. 
     
     
         15 . The system of  claim 11 , further comprising a precipitator operably connected to the first electrochemical system configured to produce calcium and/or magnesium carbonate by treating sodium carbonate with calcium and/or magnesium ions.