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Abstract

This paper provides a comprehensive analysis of the fundamental principles of the classical Solvay process, a key component in the industrial production of soda ash. It is noted that despite its widespread use and technological maturity, the process has a number of significant technological, energy, and environmental limitations associated with high raw material and energy consumption, the generation of significant industrial waste, and CO₂ emissions. The need to modernize the traditional production process to improve efficiency, resource conservation, and environmental sustainability is substantiated. The review systematically summarizes current approaches to process improvement, including modified versions of the Solvay process, the introduction of membrane and sorption processes, the use of captured industrial CO₂, and the recycling of calcium-containing waste to close the material cycle. The potential for layered double hydroxides and composite materials as effective sorbents for CO₂ binding is discussed separately, as are biotechnological methods for carbon dioxide utilization and process integration into carbon neutral production concepts. Particular attention is paid to new physicochemical approaches aimed at optimizing carbonation and crystallization stages, reducing byproduct formation, and minimizing emissions. It is emphasized that the use of mathematical modeling, digital twins, and intelligent control systems opens up additional opportunities for improving the sustainability, cost-effectiveness, and environmental friendliness of ammonia-soda production.

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