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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association
and Alkali Manufacturers Association of IndiaLocation: Gandhidham, Gujarat. May 16/17 2008.
Optimisation of Production and Quality of SolarSalt from New and Existing Solar Saltf ields using
Brine Mass Balance Computer Modelling.Roland Mottershead: CGV Pty. Ltd. Perth, Western
Australia.
Kevin Wellisch: K F Wellisch & Associates Pty. Ltd.
Perth, Western Australia.
In Association with: Salt Partners Ltd. Zurich,Switzerland.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Authors: Roly Mottershead
Kevin Wellisch
EXPERIENCE SINCE 1960sDESIGN, CONSTRUCTION, OPERATION
AND MARKETING OF SOLARSALTFIELDS
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Roly Mottershead assisting with Indian salt harvest
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Dampier Saltfield Western Australia Capacity > 3MTPA
1967 1972 Design, Construct, Operation, thru to First Ship
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Development of new computer-based
brine mass balance models. Optimise design , decreased capital and
operating costs for new solar saltfields Improved productivity and quality at
existing solar saltfields.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Association with Salt Partners Ltd.
One-stop option for clients. Optimises layouts
Reduces capital and operating costs Secures operational control through brine
chemistry and biology Optimises quality though effective washing
technology
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
SOLAR VERSUS ROCK SALT
Free solar energy versus expensive thermalenergy
No new significant areas available for largesolar saltfields, excluding India
China forced to use vacuum salt from rocksalt. Up to 10MTPA new vacuum saltvolume in China in 2007.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
CHLORALKALI PLANTS
DEMANDING HIGH QUALITY ANDCONSISTENT QUALITY SALT
AUSTRALIAN AND MEXICAN SOLARSALT QUALITY STANDARD IN J APAN,KOREA, TAIWAN AND INDONESIA
LOWER QUALITY CHINESE ANDINDIAN SALT NOT AN ECONOMICOPTION
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
TARGET SOLAR SALT QUALITY
Co m p o n e n t A v e r ag e
High Low
Sodium Chloride 97.794% 97.286% 97.540%
Moisture 2.526% 2.000% 2.284%
Calcium 0.026% 0.042% 0.034%Magnesium 0.042% 0.026% 0.018%
Sulphate 0.125% 0.083% 0.104%
Potassium 0.020% 0.010% 0.013%
Insolubles 0.009% 0.005% 0.007%
% w /w basis
Range
Pl an n e d Sp e c if i c at i o n o f P r o j e c t Pr o d u c t S PT
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 1 Site investigation
Evaluate area available and estimateproduction target.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 2 Estimate losses from harvesting
to shipment
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
NaCl passing through each activity accounting for losses.
Acti vi ty
Factor toaccount for
lossesNaCl passing
through
% tonnes
As shipped 975,400
As crystallized 1,091,812
After harvesting 1.0% 1,080,894
After wet salt haul 0.5% 1,075,490
After washing 7.0% 1,000,206
After stockpiling 1.0% 990,204
After recovery and barging 1.0% 980,302
After transfer to ship 0.5% 975,400
Product shipped 1,000,000 SPT
NaCl content 97.54%
Example of NaCl losses from harvest thrushipping for one million tonnes per annum
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 3 Estimate average long-term
monthly and annual freshwaterevaporation rates and rainfall.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Month Evaporation Rainfall
Net
Evaporation Evaporation Rainfall
Net
Evaporation
mm mm mm mm mm mm
J anuary 154.57 0.11 154.46 368.90 36.20 332.70February 150.80 0.00 150.80 301.00 56.10 244.90
March 185.40 0.00 185.40 299.15 55.25 243.90
A pril 190.54 0.00 190.54 232.50 13.10 219.40
May 225.17 0.00 225.17 172.05 51.55 120.50
J une 202.65 95.76 106.89 124.50 47.75 76.75
J uly 148.27 162.56 -14.29 137.95 21.30 116.65
A ugust 127.97 316.31 -188.34 173.60 12.50 161.10
September 155.69 141.24 14.45 237.00 1.80 235.20
October 164.76 0.00 164.76 310.00 1.40 308.60
November 161.48 0.00 161.48 337.50 2.30 335.20
December 156.99 0.00 156.99 370.45 4.15 366.30
Total 2,024.29 715.98 1,308.31 3,064.60 303.40 2,761.20
Typical Average Monthly Evaporation and Rainfall Rates in India and A ustralia
India A ustralia
Typical Evaporation and Rainfall for WesternAustralia and Gujarat Areas
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 4 Determine seawater density
Range of densities may occur duringannual cycle.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 5 Determine density of maiden
brine feed to crystalliser ponds. Usually around 1.216 SG (25.8 B)
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Typical
brinetransferweir
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models methodology
Step 6 Establish density of bitterns dischargedensity
Usually 1.25 SG (29 B)
Further recovery now practiced whilstmaintaining quality
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 7 Establish formulae for tracking
major ions as brine concentrates Calcium, chlorine, magnesium and
sulphate.
Using Baseggio data.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
C h l o r i n e i n S e a w a t e r S o l a r S al t f ie l d B r i n e s
0
50
100
150
200
1.00 1.05 1.10 1.15 1.20 1.25
SG
C
h
lo
rin
e[
g
/1000g
b
rin
e
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
C a lc i u m i n S e aw a t e r S o l a r S al t f ie l d B r i n e s
0.00
0.20
0.40
0.60
0.80
1.0 0
1.2 0
1.4 0
1.6 0
1.8 0
1.00 1.05 1.10 1.15 1.20 1.25
S G
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
M a g n e s i u m i n S e a w a t e r S o l a r S a l t f ie l d B r i n e s
0.000
5.000
10.00 0
15.000
20.000
25.000
30.000
35.000
1.0 0 1.0 5 1.10 1.15 1.2 0 1.2 5
S G
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
S u l p h a t e i n S e a w a t e r S o l a r S a l t f i e l d B r i n e s
0.000
5.000
10.00 0
15.00 0
20.000
25.000
30.000
35.000
40.000
1.00 1.05 1.10 1.15 1.20 1.25
S G
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 8 Establish brine evaporation ratios
over brine density range. Know-how by authors gained from data at
operating saltfields
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
E v a p o r a t io n R a t io ( P o n d : P a n , B r in e a t S a lt in g P o i n t )
0.375
0.4
0.425
0.45
0.475
0.5
0.525
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
M o n t h
Evapo
rationR
atio(
Ponda
tsalting
point:freshw
ater
pan
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 9 Estimate any possible run-off into
concentration pond system during rainfallevents
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 10 Fix number of concentration
ponds Usually between 7 and 10. Economics and
topography may influence final number.
Chemical and biological controlmaintained
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 11 Establish pond layout option for
crystallisers Series preferred but topography may
favour batch system.
Usually now 2 ponds per series.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 12 Estimate vertical and horizontal
seepage losses. Avoid poor vertical seepage loss areas or
repair during construction
Avoid horizontal losses through disciplineduse of levee construction materials
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 13 Select brine density profile for
concentration and crystalliser ponds.This minimises area and maximisesproduction
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
C o n c e n t r at i o n P o n d s C o n v e x D e n s i t y P r o f il e f o r
a 7 -p o n d S ys t e m
1.00
1.05
1.10
1.15
1.20
1.25
0 1 2 3 4 5 6 7 8
Po n d Se q u e n c e N u m b e r
BrineDensityg
m
./m
l.@
20C
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 14 Estimate the annual volume of
seawater pumpingThis permits the model to be run toestablish approximate pond areas required
Use Baseggio data for volume.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 15 Run model and adjust seawater
volume to suit required production.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 16 Adjust pond areas to suit
topography, seepage areas, etc.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 17 Freeze pond areas and
recalculate annual mass balance.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Brine mass balance models
methodology Step 18 Expand the mass balance
model to provide monthly balances andbrine flows.
This requires estimate of monthly changes
in brine evaporation rates at varyingdensities. Internal know-how.
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Conclusion
Brine mass balance modelling asdescribed has the following advantages:
Optimal use of area Optimal design of pond system
Reduced capital costs
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SALT BUYERS AND SELLERS MEETOrganised by: Indian Salt Manufacturers Association and Alkali Manufacturers Association of India
Location: Gandhidham, Gujarat. May 16/17 2008.
Operational control efficiencies
High productivity Flexibility to adjust to changes in variables
Continuity of high quality Reduced operating costs
Options for further recovery of salt frombrine and losses during handling
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