Technical feasibility and experimental validation of sodium carbonate production via Ion Exchange process

The increasing need to reduce carbon dioxide emissions has stimulated interest in carbon capture and utilization routes capable of converting captured CO2 into valuable products. Within this context, this thesis investigates the technical feasibility of producing sodium carbonate through a novel process. The work focuses specifically on an ion exchange unit, which represents a key step in the proposed process and has not previously been experimentally validated under the required operating conditions. The study combines laboratory scale experimentation and process simulation. Experimental work was carried out using a dedicated setup, including working phase, rinsing, regeneration, and a second rinse. The results confirmed that the resin was able to operate effectively under the investigated operating conditions and that the ion exchange cycle could be completed. Additional experiments were conducted to assess reproducibility and to evaluate the influence of operating parameters such as flow rate and regenerant concentration. A simulation model was developed to reproduce the experimental behaviour. Simulation results showed that axial dispersion was the dominant parameter affecting the shape of the breakthrough curve, while mass transfer resistance had only a minor effect. Although the model reproduced the general experimental trends, some deviations remained due to the non-ideal hydrodynamic behaviour of the real column. The validated model was then extended to an industrial scale plant in order to evaluate alternative operating scenarios and estimate column requirements. The industrial analysis highlighted the trade-off between reducing outlet product contamination and maintaining a practical column configuration. Overall, the work demonstrates the feasibility of the ion exchange step and provides a basis for further development of this alternative route for sodium carbonate production from captured CO2.