Sodium silicate is the common name for compounds with the formula (Na2SiO2)nO. A well-known member of this series is sodium metasilicate, Na2SiO3. Also known as waterglass or liquid glass, these materials are available in aqueous solution and in solid form. The pure compositions are colourless or white, but commercial samples are often greenish or blue owing to the presence of iron-containing impurities.
Sodium silicate is made by fusing sodium carbonate and silica sand in an open hearth furnace. In most common commercial silicates, the ratio of sodium carbonate to silica, in molar basis is about 1.2. Other compositions are obtained by mixing and more alkaline ratios by adding caustic soda.
The product after cooling forms clear light bluish green glass. In all case, co2 comes out as a by-product.
Sodium silicate could be sold as a solution where the product is ground and dissolved in water or by steam, under pressure where the ratio of silica to alkali is above two.
The basic process of production is stated below
Raw Material Storage: The raw materials Silica is dumped in the yard while the Soda ash is stored in the ware house.
Batch Preparation: The raw materials are batched in proportion depending on the final product grade and specification.
Mixing:The batched mixture is ball milled for proper mixing and blending, this is done to prevent setting out during firing.
Charging: The blended materials are charged into the furnace operating at preset temperature for melting, the melting process is carried out in the furnace.
Melting: The solid materials turn to molten form.
Discharging: The molten material flows out through a sprout links, to a concrete floor and solidifies to rocky mass.
Testing: This is done for Quality control
Packaging: The sodium silicate is now packaged in 50kg long (solid) or 200L drum (liquid)
The equipment and machines required for the production of sodium silicate can be locally sourced and includes
– Furnace
– Autoclave
– Crusher
– Grinder
– Boiler
– Weighing Hoppers
– Dissolving tanks and agitators
– Mild Steel barrels
Sodium Silicate is used in soaps detergents and in the manufacture of silica gel. It is used as a cement, binder, filler and adhesive. And also used as a wall coating, in concrete, fire proofing material and as a sealant. It is also used to preserve eggs and wood. Sodium Silicate also finds use in textile and pharmaceutical industries. Neutral sodium silicate in liquid form is suitable for use in pharmaceutical and toilet preparations.
Sodium silicates of certain ratios are used for application over concrete floors for hardening making dustless concrete floors and protecting pervious building materials against the effects of moisture. Sodium silicate is also used in foundries and welding electrode industries.
In ceramic industries, sodium silicate is used as a deflocculant in the preparation of casting slips for keeping solid particles in suspension without settling. Sodium silicate is used in refractories industries as an air-setting bond for manufacturing refractory cements and mortars. In vitreous enamel industries, it is used for cleaning the metal, known as pickling, prior to enamelling.
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