The _raw soda_ thus obtained in the black ash furnace is subjected to
lixiviation by water in iron tanks in which the impurities or tank
waste (see below) are deposited. The crude soda liquor so obtained is
then further treated and converted into calcined soda, crystal soda, or
caustic soda. In the production of calcined soda the crude soda liquor is
first purified (‘oxidised’ and ‘carbonised’) by blowing through air and
carbonic acid gas, pressed through a filter press, and crystallised by
evaporation in pans and calcined, i.e. deprived of water by heat.
[Illustration: FIG. 5.—Revolving Black Ash Furnace—Elevation (_after
Lueger_)
A Firing hearth; B Furnace; C Dust box.]
_Crystal soda_ is obtained from well-purified tank liquor by
crystallising in cast-iron vessels.
Caustic soda is obtained by introducing lime suspended in iron cages into
the soda liquor in iron caustic pots, heating with steam, and agitating
by blowing in air.
The resulting clear solution is drawn off and evaporated in cast-iron
pans.
As already mentioned, the _tank waste_ in the Leblanc process, which
remains behind—in amount about equal to the soda produced after
lixiviation of the raw soda with water—constitutes a great nuisance.
It forms mountains round the factories, and as it consists principally
of calcium sulphide and calcium carbonate, it easily weathers under
the influence of air and rain, forming soluble sulphur compounds and
developing sulphuretted hydrogen gas—an intolerable source of annoyance
to the district.
At the same time all the sulphur introduced into the industry as
sulphuric acid is lost in the tank waste. This loss of valuable material
and the nuisance created led to attempts—partially successful—to recover
the sulphur.
The best results are obtained by the Chance-Claus method, in which the
firebrick ‘Claus-kiln’ containing ferric oxide (previously heated to
dull redness) is used. In this process calcium sulphide is acted on by
carbonic acid with evolution of gas so rich in sulphuretted hydrogen that
it can be burnt to sulphur dioxide and used in the lead chambers for
making sulphuric acid. Sulphur also as such is obtained by the method.
These sulphur-recovery processes which have hardly been tried on
the Continent—only the United Alkali Company in England employs the
Chance-Claus on a large scale—were, as has been said, not in a position
to prevent the downfall of the Leblanc soda industry. Before describing
briefly the Solvay method a word is needed as to other processes for
manufacture of sulphate and hydrochloric acid.
_Hargreaves’ process_ produces sodium sulphate (without previous
conversion of sulphur dioxide into sulphuric acid) directly by the
passage of gases from the pyrites burners, air and steam, through salt
blocks placed in vertical cast-iron retorts, a number of which are
connected in series. A fan draws the gases through the system and leads
the hydrochloric acid fumes to the condenser.
Public-domain text, read in full here on John Shaqi.
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