HPD® Evaporation and Crystallization

Innovative Process Solutions

Design-Build Soda Ash Crystallization Plant

American Soda - Parachute, Colorado, USA

The Client's Needs

American Soda set high expectations for their new $300 million Parachute, 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.

Project Development

Veolia developed a unique and efficient process to produce the soda ash and sodium bicarbonate. To test and validate the new process and determine optimal operating conditions, a custom pilot-scale system was designed and built for the project.

Utilizing the pilot system, one ton of sodium carbonate monohydrate crystals and one ton of sodium bicarbonate were produced 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.

Technology Solutions

Sodium Carbonate Monohydrate Crystallizers

HPD® Sodium carbonate monohydrate crystallizers

HPD® Sodium carbonate monohydrate crystallizers

  • The two, 32-foot diameter HPD 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 the crystallization research center demonstrated that the product quality would meet or exceed the market's needs.

Sodium Bicarbonate Crystallizer

HPD® Sodium bicarbonate crystallizer

HPD® Sodium bicarbonate crystallizer

  • The innovative HPD 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 Recovery System

Sodium Carbonate Decahydrate crystallizer

Sodium Carbonate Decahydrate crystallizer in construction phase

  • American Soda requested suggestions for management of a monohydrate purge stream for an alternative to external disposal. Veolia recommended and installed an HPD sodium carbonate decahydrate crystallizer for additional product recovery.

  • The decahydrate system operates at a low temperature to provide alkali recovery from the purge with capacity up to 260,000 tons annually.

Sodium Bicarbonate Solids Handling Improvements

  • Ongoing evaluations helped identify another area of opportunity for American Soda. Veolia 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 supplied by Veolia Water Technologies was smoothly integrated into the facility and met the local environmental requirements.