Question 02

Sri Lanka is an Island surrounded by the Indian Ocean. Explain how sea water could be
used for the socio economic benefit of Sri Lanka.
(a)Briefly explain the salt manufacturing process carried out in Sri Lanka and in the
Middle East.
Salt can be obtained from two sources: rock salt and brine. Rock salt is simply crystallized salt,
also known as halite which is the result of the evaporation of ancient oceans millions of years
ago. Sometimes pressure from deep inside the Earth forces up large masses of rock salt to form
salt domes. In the United States, salt domes are found along the Gulf Coast of Texas and
Louisiana.
Brine is water containing a high concentration of salt. The most obvious source of brine is the
ocean, but it can also be obtained from salty lakes such as the Dead Sea and from underground
pools of salt water. Since Sri Lanka is an island surround by the Indian Ocean and having
temperate climate throughout the year it is possible to produce salt at a very low cost because
this is one rare occasion having both the raw material (salt water) and the energy source totally
free.
Therefore the salt manufacturing processes carried out in Sri Lanka and Middle East are different
as according to their natural occurrence.
Processing Rock Salt (Middle East)
1. Excavating the salt mines via prospectors. Diamond tipped hollow drill can be used to take
several regularly spaced core samples to check.
2. Undercutting-: shaft are sunk in to the center of the salt deposit and create holes using electric
drill containing tungsten carbide bit. Placing explosives dynamite or ammonium nitrate rock can
be blast. Cutting and blasting are repeated in a pattern that leaves pillars of salt standing to
support the roof of the mining area
3. Underground crushing area-: particles above 9 inch size are crushed
4. Outside secondary crushing area-: Reduces the particle size to 3.2inches. At this stage picking
happens. (Removing of foreign matter from salt) Metal by magnets and rocky material by
Bradford beaker is removed
5. Tertiary Crushing area-: reduces the particle size smaller than 1inch.
6. Further Processing-: by dissolving salt in water, salt can be further purified
7. Packaging and transportation
Processing of Brine (Sri Lanka)

1. Evaporation-: Solar evaporation can be identified as the simplest method of evaporating brine.
The brine is collected into shallow ponds and allowed to evaporate in the sun.
A.Insoluble impurities such as sand and clay and slightly soluble impurities such as calcium
carbonate settle to the bottom as evaporation begins.
B. The brine is pumped or moved by gravity flow to another pond where calcium sulfate settles
out as evaporation continues.
C. The remaining brine is moved to yet another pond where the salt settles out as evaporation
proceeds
D. The brine is moved one more time before evaporation is complete to prevent highly soluble
impurities such as magnesium chloride, magnesium sulfate, potassium chloride, and magnesium
bromide from settling out with the salt. These substances may be collected separately for
commercial use.
2. Purification-: layer of salt then can be washed with highly concentrated salt water. This water
contains so much salt that it cannot hold any more, so the salt is washed free of any trace
impurities without dissolving. The washed salt is removed from the salt water, rinsed with a
small amount of fresh water, and piled into huge stacks to drain for two or three months.
3. Additives and Packaging-: salt used for most purposes is ready to be packaged in bags or
boxes and shipped to consumers. To make iodized table salt, however, potassium iodide is added,
then magnesium carbonate, calcium silicate, calcium phosphate, magnesium silicate, or calcium
carbonate is added to make it free-flowing. The salt is then packaged and shipped to restaurants
and grocery stores.
(b)Give 10 products that could be obtained by using sea water and salt as raw materials
and briefly explain their manufacturing processes with appropriate process flow diagrams.
Caustic Soda NaOH,Cholorine (Cl2) & Hydrogen (H2)
Caustic Soda could be obtained via three main processes
1. Mercury cell
2. Diaphragm cell
3. Membrane cell
Mercury cell
The reactions involved in Mercury cell can be listed as follows,
+ 2 Hg 2 NaHg+C l 2(g )
++2C l
2 N a

The reaction in the electrolyser

+ H 2( g )+ 2 Hg

++ 2O H
2 NaHg+2 H 2 O 2 N a

The reaction in decomposer

Electrolysis cell
The reactions involved can be expressed as follows;
Cathodic half reaction
1
++e H
2 2(g )

H
Anodic half reaction
1
C l 2(g )+ e
2
C l
Overall reaction
1
1
NaCl+ H 2 O NaOH + H 2 + Cl2
2
2

Na2CO3 (Solvay Process) & NaHCO3

The overall reaction can be write as follows,
2 NaCl+CaC O3 N a 2 C O3 +CaC l 2

Ca(OCl)2
bleaching agent, disinfectant, and bactericide
Lime, Caustic,Chlorine are mxed together in a reactor yield paste
Ca(OH )2+ 2 NaOH +2 Cl 2 Ca(OCl)2 +2 NaCl+ H 2 O

After the Paste is formed, it is then passed through a filter to collect the Filter Cake (i.e. solid
particles), which is then put through a drying process to further reduce the moisture to its final
content.
CaCl2
This chemical can be produced by no of ways. Below processes are most common cases
1. Solvay Process
2 NaCl+CaC O3 N a 2 C O3 +CaC l 2
2. Reaction of limestone and HCl
3. Natural occurring brine
NaOCl
Sodium Hypochlorite is prepared by reacting dilute caustic soda solution with liquid or gaseous
chlorine, accompanied by cooling.

Molten Na Metal
Hence to overcome such difficulties, the Downs cell was brought in the use. NaCl was mixed
with CaCl2 in the ratio of 2:3 by mass which reduces the working temperature to 600C. This
cell consists of graphite anode & iron cathode. The cell consists of one inlet through which the
electrolyte is poured into the cell. Then the electricity is passed into the electrodes which initiate
the electrolysis. The chlorine gas collected at anode escapes through the hood as byproduct and
the sodium metal is extracted in the cathode. Sodium, having low density than its salt, floats and
can be easily collected over kerosene.