HPD Sodium Carbonate Monohydrate Crystallizer
American Soda turnkey construction of soda ash production facility

American Soda Parachure, Colorado, USA

Through innovative process development and results-oriented pilot testing, HPD helped American Soda reach their goal to produce exceptional high-quality soda ash and high purity sodium bicarbonate from natural nacholite deposits. A sodium carbonate monohydrate crystallization system and a unique sodium bicarbonate crystallization system were the first of several commercial production systems that HPD would design and supply to the soda ash producer.

 

Project Objectives and Challenges

sodium bicarbonate crystallizer from HPD

American Soda set high expectations for their new $300 million Colorado facility. They wanted to be the world's most efficient and lowest cost producer of soda ash and sodium bicarbonate while producing these products in an environmentally responsible way.

To reach these objectives, American Soda needed efficient crystallization systems specifically designed to produce soda ash and sodium bicarbonate from a natural nacholite deposit unlike the conventional trona method.

Process Design and Technology Solutions

HPD developed a unique and efficient process to produce the soda ash and sodium bicarbonate. To test and validate the new process and to determine optimal operating conditions, HPD designed and built a pilot-scale ystem.

Utilizing the pilot system, HPD produced one ton of sodium carbonate monohydrate crystals and one ton of sodium bicarbonate, which American Soda used for market testing.

The successful pilot testing led to the design, fabrication and installation of the commercial sodium carbonate monohydrate crystallizer system.

"Instrumental in this project was HPD's pilot testing in their research facilities and the subsequent supply of the monohydrate and bicarbonate crystallizers that serve as the heart of the production process."

-- Charles Yates COO & VP, Operations - American Soda, L.L.P.

System Features

Sodium Carbonate Monohydrate Crystallizers

  • The two 32-foot diameter sodium monohydrate crystallizers are the heart of the plant's production.
  • Production capabilities exceed the required capacity of one million tons of dense soda ash (DSA) annually.
  • Pilot testing in HPD's research center demonstrated that the product quality would meet or exceed the market's needs.

Sodium Bicarbonate Crystallizer

  • The innovative cooling style crystallizer was pilot demonstrated to validate the new process.
  • The commercial system has shown exceptional performance with annual production capacity of 150,000 tons of sodium bicarbonate.
  • The unique design has greatly extended clean out frequencies from normal industry practice.

Sodium Carbonate Decahydrate System

  • To recover additional alkali from the monohydrate purge, American Soda requested suggestions for recovery alternatives. HPD recommended and installed the Sodium Carbonate Dehydrate Crystallizer.
  • The decahydrate system operates at a low temperature to provide alkali recovery from the purge.

Sodium Bicarbonate Solids Handling Improvements

  • Ongoing evaluations helped identify another area of opportunity for American Soda. HPD provided a bicarbonate curing system, which enhanced product quality and opened new markets for American Soda by providing additional grades of product.

The Results

American Soda has experienced reliable production of soda ash and sodium bicarbonate at exceptional product purity. Each system and equipment enhancement was smoothly integrated into the facility and met the local environmental requirements.

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