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Jan 1, 1966

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Jan 1, 1958

Jan 1, 1958

By A. A. Collins

OF widespread interest to all lead metal¬lurgists is a dross smelting process that will consistently give mattes and speiss of low lead and high copper contents. It is -a problem that has intrigued operators through the years. In the past few years, with increased amounts of copper and overcrowded metallurgical furnaces, it has been almost imperative to evolve some method. Experience at El Paso has shown that high copper-to-lead ratios can be consistently attained by use of the new soda process.* OLDER METHODS Three older methods; i.e., I. Dross plus siliceous ore and limestone, 2. Dross plus one fourth blast-furnace speiss and siliceous ore, 3. Dross plus sulphides and siliceous ore and scrap iron, do not give consistent results and the products are higher in lead and lower in copper than those produced with the soda process. Any radical changes in the blast-furnace drosses will throw any of these older methods into a tailspin. For almost ten years, El Paso used the third method, with varying results. It was noted that as the arsenic and antimony contents of the dross increased, the speiss and matte steadily increased in lead and decreased in copper. A dross containing four parts of copper to one part of arsenic was considered to be ideal. At times this balance of copper to arsenic was almost impossible to obtain, especially when handling copper Cottrell dusts, which vary so greatly in copper and arsenic. Custom smelters like El Paso, handling a great variety of dusts, concentrates and ores, are apt to have anywhere from 1 to 15 pct copper on charge, with a variable in arsenic of from 0.5 to 2 pct. With such conditions, and drosses varying from 12 to 40 pct copper, an operator using the older dross reverberatory practices would find it just about im¬possible to control the reverberatory operations and to produce a good product low in lead and high in copper. These conditions prevailed at El Paso from the year 1940 to the present. In May 1942 it, was decided to experiment with the soda process. THE SODA PROCESS After considerable work the soda method was finally evolved to the present state. It has never failed to produce a good product even under the most adverse conditions. It might be well to remember that many men of thought in the smelting industry have at one time or other suggested the removal of all copper, arsenic and antimony from the lead blast-furnace charge as an aid to better metallurgy.

Jan 1, 1947

By L. E. Mannion

Sodium carbonate or soda ash is one of the two principal alkalis of commerce, the other being sodium hydroxide. The use of sodium carbonate is recorded in ancient Egypt, where naturally occurring brines or solid salts were the source of impure soda for glass manufacture. In early modern times until the 19th century, soda ash, as well as potash, was recovered mainly by leaching the ashes of plants. In Europe, during the 18th century, a brown lye for laundering was produced by pouring hot water over burned seaweed. One of the better grades of this kind of material was a product from Spain termed "barilla," which analyzed 24 to 30% Na2CO3 (Hou, 1942). The birth of the modern chemical industry may be said to start with the LeBlanc process for making sodium carbonate from salt, sulfuric acid, and lime. Although invented in France in 1691, England made the most extensive use of it. In 1863 Ernst Solvay devised the ammonia-soda or Solvay process, and by 1874 the first of many Solvay plants was built. These were to supplant the LeBlanc method and dominate soda-ash production until the present time. Although of lesser importance, natural sodium carbonate deposits continued to support operations in various parts of the world. Shortages during World War II stimulated production of "natural" soda ash, particularly at Searles Lake, Calif., and at Lake Magadi, Kenya. Within the last ten years in the United States, a notable surge in production has occurred based on the vast trona deposits in Wyoming. Table 1 lists some principal producers of natural soda ash and the character of the source deposits. Uses and Specifications Sodium carbonate (Na2CO3) is a white, crystalline hygroscopic powder, an aqueous solution of which is strongly alkaline. Most commercial soda ash is a product that must meet high standards of purity and uniformity. Two forms are commonly sold: a fine, powdery material called light ash, and a more coarsely crystalline dense ash; these weigh 32 to 39 and 60 to 66 lb per cu ft, respectively. Dense ash may be produced by adding a little calcium chloride to the sodium carbonate solution to control crystal size and prevent agglomeration. Specifications and typical analyses of light and dense ash in the United States are shown in [Table 2]. Sizing generally achieves about 75% of light ash and 90% of dense ash between +30 and -100 U.S. screen mesh. World use of sodium carbonate now exceeds 24 million tpy, of which the United States produces more than 7 million tons. The market for soda ash is dominated by the glass industry, which uses almost half the supply. Inorganic chemicals, including phosphates and silicates, consume about 30%. Other principal uses include the manufacture of soaps and detergents, petroleum, caustic soda, organic chemicals, and paper; and nonferrous and ferrous metallurgy. [Fig. 1] shows the percent consumption by use of soda ash in Europe, Japan, and the United States. The price of soda ash in the United States remained relatively stable during the 1960s at about $33 per ton; in 1972 it reached $35 per ton. The price in 1975 was $42 per ton. Geology Mineralogy [Table 3] is a list of the more common sodium carbonate-bearing minerals. Anhydrous sodium carbonate is almost never found in nature; only natron, thermonatrite, and trona have been used directly as sources of sodium carbonate. At Searles Lake, burkeite and hanksite are important in the reconstitution of

Jan 1, 1975

By L. E. Mannion

Sodium carbonate (soda ash) is one of two principal commercial alkalis. Its principal competitor is sodium hydroxide. The use of sodium carbonate is recorded in ancient Egypt, where naturally occurring brines and solid salts provided impure soda for early glassmaking. Until the 19th century, soda ash (as well as potash) was recovered mainly by leaching wood or other plant ashes. In 18th-century Europe, for example, leaching seaweed ash with hot water produced a brown laundry lye. One of the better grades of this material was a Spanish product, barilla, which analyzed 24 to 30% Na2CO3 (Hou, 1942). The modern chemical industry was born in 1691 with the LeBlanc process for making sodium carbonate from salt, sulfuric acid, and lime. English industry used this process extensively in the 17th and 18th centuries. The next major advance was in 1863, when Ernst Solvay devised the ammonia-soda, or Solvay process. The first of many Solvay plants was built in 1874. These supplanted the LeBlanc method and dominated worldwide soda ash production until 1974, when mined sodium carbonate became predominant. Although considerably less important until recently, natural sodium carbonate deposits historically have supported small soda ash operations throughout the world. Shortages during World War II stimulated production of "natural" soda ash from such deposits, particularly at Searles Lake, CA and Lake Magadi, Kenya. More spectacularly, increased production from the vast trona deposits in Wyoming has virtually supplanted the Solvay process in the US. Principal producers of natural soda ash as well as the character of the source deposits are listed in Table 1. [ ]

Jan 1, 1983

By Julien F. Phillips, Donald E. Garrett

The production of soda ash from natural sources is one of the United States' oldest industries. The London Company, which financed the settlement of Jamestown, in the fall of 1608 exported in its first cargo from Virginia " . . . trials of pitch, tar, glass, frankincense, and soap-ashes."1 This last product, a crude mixture of sodium and potassium carbonates obtained by the burning of wood in iron pots, was the commercial soda ash of its day, used in the infant soap, glass, and bleaching industries. Besides having a good cash value, its production helped to clear the land, and it was a compact, easily shipped commodity. The extra high potassium content of these American "pot-ashes" gave them an added market as a fertilizer, a field that they dominated until the opening of the Strassfurt deposits in 1860. This form of natural soda ash disappeared forever from commercial importance with the introduction of the Le Blanc process (1791), and later the Solvay process for manufacturing soda ash. The Solvay process was rapidly accepted in the United States, and has accounted for most of the country's soda ash production since 1884. It was not until the western part of the country began to be developed that natural soda ash was again produced. A number of lakes, playas, and springs west of the Rocky Mountains were found to be rich in this mineral, and climatic conditions were ideal for its easy recovery by solar evaporation. The production of natural soda ash from these deposits has become a steadily growing industry in the United States. Production A summary of the production and value of natural sodium carbonates in the United States is presented in Table 1. Prior to 1927 the principal output came from several different companies at Owens Lake, California. Then production at Searles Lake, California, began to [ ] increase until it became the most important source. In 1948 the sale of crude trona from Green River, Wyoming, commenced and since that time production from these latter two areas has been about equal. Table 2 lists the four

Jan 1, 1960

Because common salt, sodium chloride, is necessary to all animal and much plant life, it is probably the most widely used of all mineral commodities, except for water. Nevertheless, of the total salt consumed, only 7% is used for food, including animal food. Two-thirds of the total is used as chemical raw material, principally for making such basic chemicals as chlorine, caustic soda, and soda ash. Other uses are for road thawing (16%) and water softening. Some 162.5 million tons of salt were used, worldwide, in 1972 (Table 15.4F.1). Production is from bedded salt deposits, salt domes, and evaporation of brines, including solar evaporation of seawater. Production is worldwide from at least 20 countries, of which the United States, China, USSR, the United Kingdom, and West Germany are the leaders. Consumption increases about 7 % annually. Reserves are plentiful: Other important sodium salts are soda ash (sodium carbonate) and salt cake (sodium sulfate). Soda ash comes mainly from the Solvay process (70% ) , which uses salt, limestone, and ammonia as raw materials. A large and growing portion of United States production is from mining large bedded deposits of trona, a natural hydrated sodium carbonate and bicarbonate found in Wyoming, and from brine evaporation in California. Soda ash is used for glassmaking, phenol, soap, detergents, and bleaches. Half of the United States salt cake used is a byproduct from rayon manufacturing. The other half comes from brines and playa lakes in California, Texas, and Wyoming. Salt cake is used mainly for papermaking. ACKNOWLEDGMENT Appreciation is expressed to William B. Dickson, president, Salt Institute. [ ]

Jan 1, 1976

By S. V. Krishnan, I. Iwasaki

In the upgrading of finely disseminated iron ores, selective desliming is the critical step that must be controlled to achieve efficient flotation. A prerequisite for selective desliming is a properly-dispersed pulp; sodium silicate is commonly used as a dispersant. The mechanism by which sodium silicate acts as a dispersant in the presence of calcium ions was examined by streaming potential measurements, settling tests, abstraction density determinations, selective flocculation tests, and scanning electron microscope observations. The study established that calcium silicate precipitates on the mineral surfaces dispersed the pulp. Although sodium silicate was a nonselective dispersant, the addition of corn starch aided flocculation of goethite over quartz at low silicate additions, but became ineffective at higher silicate levels. A model is presented to explain the dispersant mechanism of sodium silicate in the presence of calcium ion for selective flocculation of iron ores.

Jan 1, 1983