* * * * *
A NEW ALKALI PROCESS.
In several former notes and articles in these pages, we have spoken of the severe crisis through which the old established, or “Leblanc,” process has now for some years been passing. It is, in fact, pushed well nigh out of the running by the newer process, known as the “ammonia-soda” process, and would have had to give up the battle before now were it not for the fact that one of its by-products, bleaching powder, cannot, so far, be produced at all by the ammonia-soda works. The bleaching powder trade has thus remained in the hands of the workers of the Leblanc process, and its sale has enabled them to cover much of the loss which they are suffering on the manufacture of soda ash and caustic soda.
In brief outline, the old Leblanc process consists in the following operations: Salt is decomposed and boiled down with sulphuric acid. Sulphate of sodium is formed, and a large amount of hydrochloric acid is given off. This is condensed, and is utilized in the manufacture of the bleaching powder mentioned above. The sulphate of sodium, known as “salt cake,” is mixed with certain proportions of small coal and limestone, and subjected to a further treatment in a furnace, by which a set of reactions take place, causing the conversion of the sulphate of sodium of the “salt cake” into carbonate of sodium, a quantity of sulphide of calcium being produced at the same time. The mass resulting from this process is known as “black ash.” It is extracted with water, which dissolves out the carbonate of sodium, which is sold as such or worked into “caustic” soda, as may be required. The insoluble residue is the “alkali waste,” which forms the vast piles, so hideous to look at and so dreadful to smell, which surround our large alkali works.
The sulphuric acid required for the conversion of the salt into “salt cake” is made by the alkali manufacturer himself, this manufacture necessitating a large plant of “lead chambers” and accessories, and keeping up an immense trade in pyrites from Spain and Portugal. The development of the alkali trade in this country has been something colossal, and the interests involved in it and connected with it are so great that anything affecting it may safely be said to be of truly national importance, quite apart from what technical interest it may possess.