Process Flow of Sodium Percarbonate (SPC) Production Plants – High-Efficiency, Intelligent, and Green Manufacturing Solutions
Sodium percarbonate (Na₂CO₃·1.5H₂O₂) is a novel, environmentally friendly oxidant that combines the properties of both sodium carbonate and hydrogen peroxide. It possesses functions such as bleaching, sterilization, decontamination, and oxygen supply, and is widely used in washing, dyeing, papermaking, water treatment, and pharmaceutical industries, with market demand continuously increasing. Tianli has deep expertise in sodium percarbonate production equipment, creating complete standardized production facilities that integrate hydrogen peroxide preparation, sodium carbonate slurry preparation, reaction, crystallization, centrifugation, drying, and coating processes. Leveraging advanced technology and intelligent control, we provide customers with efficient, low-consumption, environmentally friendly, and intelligent integrated production solutions, helping enterprises achieve large-scale production and green development.
1.Material Properties
Sodium percarbonate is a white crystalline powder with the molecular formula Na₂CO₃·1.5H₂O₂, a relative molecular mass of 157.01, and a density of 1.77 g/cm³. It is readily soluble in water, releasing oxygen upon dissolution. It exhibits both oxidizing and alkaline properties, but its stability is poor; it decomposes easily when heated or exposed to moisture, requiring sealed storage. The sodium percarbonate produced by this device has a purity ≥99%, an active oxygen content ≥10.5%, uniform particle size, good flowability, and is not prone to agglomeration. It meets industrial-grade standards and is suitable for various applications. Strict temperature and humidity control is required during the production process to prevent decomposition and loss.
2.Process Introduction
1.Raw Material Introduction
The core raw materials for production are industrial-grade hydrogen peroxide, industrial-grade sodium carbonate, and auxiliary reagents: Hydrogen peroxide (H₂O₂) is a colorless and transparent liquid with a concentration of 27.5%-30%. It is easily decomposed and has oxidizing properties, making it the core raw material for providing active oxygen; Sodium carbonate (Na₂CO₃) is a white powder with a purity of ≥99%. It is easily soluble in water and alkaline, serving as the reaction substrate; Auxiliary reagents include stabilizers and dispersants, used to improve the stability of sodium percarbonate and prevent clumping. All raw materials meet industrial standards, offer excellent cost performance, and are easy to procure.
2.Process Introduction
Sodium percarbonate production follows closed-loop process: raw material preparation → reaction synthesis → crystallization → centrifugation → drying → coating → finished product packaging. Each stage is closely linked and the entire process is controllable. Seven core stages are detailed below:
1. Hydrogen peroxide preparation unit
Industrial-grade hydrogen peroxide is fed into the preparation tank, and pure water is added in proportion to dilute it to the specified concentration. At the same time, a small amount of stabilizer is added and stirred evenly to prevent premature decomposition of hydrogen peroxide. After preparation, it is sent to the raw material storage tank for later use.
2. Sodium carbonate slurry preparation unit
Industrial-grade sodium carbonate powder is fed into a dissolving tank, pure water is added, the temperature is controlled, and the mixture is stirred to dissolve, thus preparing a saturated sodium carbonate slurry. After filtration to remove impurities and ensure the purity of the sodium carbonate slurry, it is sent to the reaction section.
3. Reaction Section
The prepared hydrogen peroxide and sodium carbonate slurry are fed into the reactor simultaneously in a precise ratio. The reaction temperature and pH value are controlled, and the neutralization reaction is carried out under stirring to generate sodium percarbonate suspension. The reaction temperature is controllable, and a stabilizer is added to inhibit the decomposition of sodium percarbonate. The reaction conversion rate is ≥98%.
4. Crystallization Section
The sodium percarbonate suspension after the reaction is sent to the crystallizer, the temperature is controlled, and the mixture is slowly stirred to induce the growth of sodium percarbonate crystals, forming uniform crystalline particles with a crystallization rate of ≥97%, avoiding crystals that are too fine or agglomerated.
5. Centrifugation Section
The crystallized slurry is fed into a centrifuge for solid-liquid separation, separating wet sodium percarbonate crystals and mother liquor. The mother liquor is processed and returned to the raw material preparation unit for recycling. The moisture content of the wet crystals is controlled at 15%-20% to ensure subsequent drying efficiency.
6. Drying Section
The wet crystals are fed into the dryer, the temperature is controlled, and a hot air circulation drying mode is used to remove free moisture and ensure that the sodium percarbonate does not decompose. After drying, the moisture content is ≤0.5%. The dried crystals are then screened to remove impurities and obtain a pure semi-finished product.
7. Coating Section
The dried sodium percarbonate crystals are fed into a fluidized bed coating machine . The coating agent is atomized by a spray gun and comes into direct contact with the sodium percarbonate to form a coating layer . Then, it is dehydrated and cured under hot air drying to complete the coating process. The coating layer can effectively improve the stability of sodium percarbonate, prevent it from decomposing when heated or exposed to moisture, and extend its shelf life. After coating, the finished product is obtained.
III. Core Technological Advantages
1. Technological advantages: integrating seven core processes, the technology is mature and stable, suitable for large-scale production; the configuration of hydrogen peroxide and alkali is precise and controllable, the reaction and crystallization parameters are optimized, the coating technology is advanced, and the product stability is effectively improved; the modular design of the equipment makes operation and maintenance convenient, and the production capacity can be flexibly adjusted to adapt to different production needs, with production efficiency at an industry-leading level.
2. Energy consumption advantages: the energy consumption distribution of the entire process is optimized. The drying section adopts low-temperature hot air circulation technology to recover waste heat for raw material preheating. The mother liquor is recycled to reduce raw material loss and energy consumption. The overall energy consumption is reduced by more than 20% compared with traditional production equipment, which significantly reduces the company's production costs.
3. Environmental advantages: the entire production process is closed, with no leakage of harmful gases; the mother liquor and washing wastewater are recycled, achieving zero wastewater discharge; no harmful waste residue is generated during the production process, and the coating agent is environmentally friendly and non-toxic, which is in line with the concept of green and low-carbon development and fully meets environmental emission requirements.
4. Product advantages: the finished sodium percarbonate has a purity of ≥99%, an active oxygen content of ≥10.5%, uniform particle size, strong stability, and is not easily decomposed. The coating layer is uniform and dense, and the shelf life is long. It can be adapted to the needs of multiple fields such as washing and dyeing. The product quality is stable, meets industrial-grade standards, and has outstanding market competitiveness.
5. Control Advantages: equipped with a fully automatic DCS intelligent control system, it monitors key parameters such as temperature, pH value, concentration, and moisture in each process section in real time, achieving precise control throughout the entire process. It has automatic alarm and emergency shutdown functions, can be operated remotely, reduces manual intervention, lowers operational risks, ensures stable and safe operation of the equipment, and ensures uniform product quality.
Empowering green and intelligent manufacturing with technology, and forging high-quality products with professionalism. Tianli focuses on the core needs of sodium percarbonate production, creating efficient, environmentally friendly, and intelligent production facilities. Relying on mature processes and comprehensive advantages across all stages, we provide complete production solutions for various industries, helping enterprises reduce costs, increase efficiency, and achieve green development, thus promoting the high-quality upgrading of the sodium percarbonate industry.