Sodium Bicarbonate Production via On-Site CO2 Capture
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Solution Overview
Problem
Current industrial processes for producing sodium bicarbonate are inefficient, introduce impurities, and rely on external carbon dioxide sources, leading to quality control issues and environmental concerns, particularly in food and medical applications.
Innovation Solution
A method that utilizes low-carbon dioxide product streams from carbonaceous feedstock treatment, capturing and reacting the CO2 with sodium carbonate to produce high-purity sodium bicarbonate, while also utilizing heat for energy efficiency and reducing waste, integrating carbon capture and bicarbonate synthesis in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If commercial sources of carbon dioxide are used, then high purity sodium bicarbonate can be produced, but logistical challenges and high costs arise for transport and storage
Solution Approach 1:
The patent uses an ammonia-soda process plant as an intermediary system to generate carbon dioxide on-site from calcium carbonate decomposition, eliminating the need for external CO2 transport and storage infrastructure while maintaining product purity through controlled reaction conditions
Solution Approach 2:
The system generates its own carbon dioxide feedstock by decomposing calcium carbonate in kilns, making the process self-sufficient regarding CO2 supply and eliminating dependence on external commercial sources or complex logistics chains
2Productivity
If kiln gas from ammonia-soda process is used, then sodium bicarbonate can be produced, but impurities are introduced affecting quality control
Solution Approach 1:
The patent extracts only the carbon dioxide component from the kiln gas stream by capturing it from the flue gas, separating it from other impurities such as nitrogen and sulfur compounds, thereby achieving high purity sodium bicarbonate production while maintaining efficient carbon utilization
Solution Approach 2:
The system controls the composition and purity of carbon dioxide by adjusting combustion parameters in the kilns and using solvent capture processes to selectively remove CO2 from the flue gas, ensuring consistent product quality despite variations in feedstock
3Quantity of substance
If low CO2 content product streams are used, then previously unused CO2 sources can be utilized, but the efficiency of sodium bicarbonate production is reduced
Solution Approach 1:
The patent implements continuous carbon dioxide capture from low-concentration flue gas streams using solvent absorption towers operating in continuous mode, maintaining steady production rates despite the low CO2 concentration in the feed gas by processing large volumes continuously
Solution Approach 2:
The system serves multiple functions simultaneously: generating heat for process requirements, producing carbon dioxide for sodium bicarbonate synthesis, and capturing CO2 from low-concentration streams that would otherwise be vented, thereby efficiently utilizing previously wasted resources
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of high-purity sodium bicarbonate from previously unused CO2 sources, reduces energy demand, and minimizes environmental impact by recycling heat and water, thus improving the overall efficiency and sustainability of the process.
Implementation Method 1
treating a carbonaceous feedstock to form a product stream comprising up to 10 v/v% carbon dioxide
Implementation Method 2
capturing at least a portion of the carbon dioxide from the product stream to form a carbon dioxide stream
Implementation Method 3
contacting at least a portion of the carbon dioxide stream with at least a portion of the aqueous sodium carbonate solution to form a slurry comprising solid sodium bicarbonate
Implementation Method 4
separating the solid component of the slurry from the liquid component of the slurry to provide solid sodium bicarbonate and an aqueous liquor
Data Source
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AI summary
The present invention relates to a method for the production of sodium bicarbonate, particularly for producing sodium bicarbonate on an industrial scale, the method comprising the steps of: a. treating a carbonaceous feedstock to form a product stream comprising up to 10 v/v% carbon dioxide; b. capturing at least a portion of the carbon dioxide from the product stream to form a carbon dioxide stream; c. feeding the carbon dioxide stream to a reaction vessel; d. feeding an aqueous sodium carbonate solution to the reaction vessel; e. contacting at least a portion of the carbon dioxide stream with at least a portion of the aqueous sodium carbonate solution to form a slurry comprising solid sodium bicarbonate; and f. separating the solid component of the slurry from the liquid component of the slurry to provide solid sodium bicarbonate and an aqueous liquor.