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Abstract
The production of potassium sulfate from phosphogypsum and potassium chloride in the presence of ammonia and isopropanol has
been investigated. The solubility of phosphogypsum in aqueous solutions of KCl, HCl, and mixtures of both has been first measured at
various temperatures and concentrations. The factors affecting the conversion of potassium chloride to potassium sulfate, such as aqueous
ammonia to phosphogypsum ratio, weight percent of isopropanol in the solution, weight percent excess phosphogypsum, and reaction
temperature and pressure have also been investigated.
The optimum reaction conditions obtained at 25 C and atmospheric pressure have been 50% excess phosphogypsum, 4.32 ammonia
solution to phosphogypsum ratio, and aqueous solutions containing initial concentrations of 33 wt.% ammonia and 7 wt.% isopropanol.
The maximum conversion of KCl to K2 SO4 obtained under these conditions was 97.2%. 2000 Elsevier Science S.A. All rights reserved.
Keywords: K2 SO4 production; Double decomposition; Phosphogypsum process; Phosphogypsum solubility
1. Introduction
Potassium is one of the basic nutrients for plants. It retains
water in the plant cells by osmotic pressure that enables the
plants to resist weathering and frost, and also contributes
to the formation of cellulose, starch and sugar. Potassium
is found in soil in insufficient quantities to produce crops
of optimum quality, so it must be added to the soil as an
essential component in all fertilizers.
Potassium occurs rather frequently in nature. A shortage
of mineable potassium minerals is up to now not in sight. The
most important water-soluble potassium mineral is potassium chloride with up to 62% K2 O, potassium sulfate with
50% K2 O, and potassium nitrate with 44% K2 O [1]. Fertilizers with potassium chloride are necessarily connected with
bringing in chloride ions with large quantities into the soil.
But many plants are sensitive to chlorides, among these are
many useful crops such as potatoes, tomatoes, red pepper,
citrus trees and tobacco. These crops have a special great
need for potassium [2]. An additional disadvantage of chlorides is that they, as components of mixed or complex fertilizers, together with ammonium nitrate (the most important
fertilizer) form compounds that are of a great hazard to the
Corresponding author. Present address: Department of Chemical Engineering, University of Bahrain, P.O. Box 32038, Isa Town, Bahrain. Fax:
+973-684844.
environment. For these reasons, potassium chloride is converted to chloride-free potassium salts [3].
Potassium sulfate is recommended to be used as a fertilizer
instead of potassium chloride because it has the following
distinct advantages [4]:
1. It is a two-nutrient fertilizer (K+S), since it contains 50%
K2 O and 18% S.
2. It contains a very low amount of chloride.
3. It has a low salt index, so it is better suited for use on
saline-sensitive crops.
4. It possesses excellent physical properties and usually is
recommended for use in high quality crops.
For these reasons, many processes have been used to convert the potassium chloride, in the presence of a source of
sulfate, into potassium sulfate. These processes include the
Mannheim process by the reaction of potassium chloride
with sulfuric acid, the Glaserite process by the reaction of
potassium chloride with sodium sulfate, and the Phosphogypsum process by the reaction of potassium chloride with
phosphogypsum in the presence of ammonia and alcohol,
and others [5].
Since sulfate reserves are limited and the Phosphogypsum process uses an industrial waste (phosphogypsum) as a
source of sulfate, this will drastically reduce the cost of the
sulfate component. This process also avoids the production
of acid by-products (such as HCl as in the Mannheim process), thus no special materials of construction are needed.
1385-8947/00/$ see front matter 2000 Elsevier Science S.A. All rights reserved.
PII: S 1 3 8 5 - 8 9 4 7 ( 9 9 ) 0 0 1 5 8 - 8
198
K2 SO4
+CaCl2(aq) + 2H2 O
(3)
(5)
Potassium sulfate can be produced by the double decomposition reaction of potassium chloride and phosphogypsum
in aqueous ammonia solution at low temperatures.
2KCl + CaSO4 2H2 O K2 SO4 + CaCl2 + 2H2 O
in 35 min at 30% excess gypsum, 0104 m gypsum particles size range, a weight ratio of ammonia solution to gypsum of 9.08, 36 wt.% initial ammonia concentration in the
solution, and 15 C.
Goerlich [3] studied the effect of adding methanol to the
mixture at ambient temperature. He found that the optimum
conversion lies at a methanol content of about 5 wt.%, and
at ammonia content near the saturation point. At longer reaction times syngenite is supposedly formed. This points to
the fact that ammonia and methanol do not influence the
equilibrium itself, but serve as catalysts for the rate of one
of the two competing reactions
(1)
199
Table 1
Physical properties of isopropanol and n-propanol
Physical property
Molecular weight
Normal boiling point ( C)
Freezing point ( C)
Density at 20 C (g/ml)
Vapor pressure at 20 C (kPa)
Isopropanol
n-Propanol
60.1
82.3
88.5
0.7849
4.4
60.1
97.2
126.2
0.8038
1.987
XA =
(6)
XA =
K+ equivalent to Ca2+
content of the sample V
Total K+ charged to the reactor
Volume of the sample
(7)
For each sample, the value of V was calculated from the initial liquid volume charged to the reactor (ammoniaalcohol
solution), with corrections being made for the following:
1. The water of hydration released from phosphogypsum
into the reaction mixture as reaction proceeds.
2. The solution volume is reduced by 5 ml at each sampling
time.
3. The presence of dissolved salts (initially KCl, with its
gradual replacement by CaCl2 ) contributes by a small
increase in the total liquid volume, V.
Two additional sets of small corrections must be made for
each value of the conversion:
1. The loss of dissolved CaCl2 from the reactor at each
sampling time has to be allowed for in the numerator of
Eq. (7) when subsequent samples are analyzed.
200
Before washing
(wt.%)
Total P2 O5
Acid insoluble residue
Loss on ignition (550 C)
Loss on ignition (950 C)
CaO
SO3
Cl
F
2.04
3.12
6.78
8.04
34.6
49.68
0.0686
0.83
1.98
2.78
5.3
6.07
38.0
50.34
0.0177
0.56
201
Fig. 2. Experimental setup used in this work for production of potassium sulfate by the Phosphogypsum process.
Ca2+
(mg/l)
K+
(mg/l)
Na+
(mg/l)
Mg2+
(mg/l)
Tap water
Water after 1st wash
Water after 2nd wash
Water after 3rd wash
229
593
484
410
2.98
15.36
7.70
5.33
41.5
491.5
209
108.5
25.8
37.15
30.1
28.65
202
ufactured in the Engineering Workshops at the Jordan University of Science and Technology (JUST). It is made of
a corrosive-resistant stainless steel 316, cylindrical in the
shape (0.2 m internal diameter0.3 m height), and has a
working volume of about 6.0 l.
The reactants can be added to the reactor through a 0.5 in.
diameter stainless steel tube, fitted with a funnel and an
isolating valve, at the top of the vessel. Agitation of the
reaction mixture is carried out with a pitched-blade turbine
having four blades at 45 pitches (each is 70 mm long and
25 mm wide) and driven by a variable speed DC motor.
The agitator shaft is fitted with a mechanical pressure seal
mounted on the top lid of the vessel. Samples of the slurry
can be drawn off the reactor via a 0.5 in. diameter stainless
steel tube fitted with a valve at the bottom of the vessel.
The reactor can be drained through a 0.5 in. stainless steel
tube fitted with an isolating valve, at the center of the vessel
base. The temperature of the reactor is controlled using a
constant-temperature water bath, while the pressure inside
the reactor is controlled using nitrogen gas as a purge. Details
of the experimental procedure followed in this work are
presented elsewhere [15].
5. Results and discussion
5.1. Solubility of phosphogypsum in KCl and HCl solutions
The solubility of the washed phosphogypsum in tap water
at 25 C has been determined experimentally to be 1.98 g/l.
The solubility of the washed phosphogypsum in aqueous solutions of KCl, HCl, and mixtures of both, is shown in Figs.
35. The solubility of phosphogypsum in these solutions is
determined as the difference in phosphogypsum weight before and after dissolution divided by the total volume of the
solution mixture.
5.1.1. Solubility of phosphogypsum in KCl solution
As shown in Fig. 3, the solubility of the washed phosphogypsum is slightly increased with the increase of the con-
203
Fig. 6. Production of potassium sulfate from KCl and phosphogypsum (no ammonia, no alcohol for Runs No. 1 and 2), and (33% ammonia, no alcohol,
and 4.32:1 ammonia solution to phosphogypsum ratio for Runs No. 3 and 4), at 25 C, 1 atm, and mixer speed=230 rpm.
Fig. 7. Effect of ammonia solution to phosphogypsum ratio on the production of potassium sulfate at 25 C, 1 atm, 33% ammonia, 7% n-propanol, and
mixer speed=230 rpm.
204
Table 4
Operating conditions for the experiments carried out in this worka
Temperature ( C)
Alcohol (wt.%)
1
2
25
25
1:1
1:1.5
0% ammonia
0% ammonia
0% alcohol
0% alcohol
3
4
25
25
1:1
1:1.5
4.32:1
4.32:1
0% alcohol
0% alcohol
6
5
7
25
25
25
1:1
1:1
1:1
3.00:1
4.32:1
5.00:1
7% n-propanol
7% n-propanol
7% n-propanol
5
8
9
25
25
25
1:1
1:0.8
1:0.67
4.32:1
4.32:1
4.32:1
7% n-propanol
7% n-propanol
7% n-propanol
13
17
18
15
15
15
1:1
1:1.25
1:1.5
4.32:1
4.32:1
4.32:1
7% isopropanol
7% isopropanol
7% isopropanol
12
16
11
25
25
25
1:1
1:1.25
1:1.5
4.32:1
4.32:1
4.32:1
7% isopropanol
7% isopropanol
7% isopropanol
14
15
19
35
35
35
1:1
1:1.25
1:1.5
4.32:1
4.32:1
4.32:1
7% isopropanol
7% isopropanol
7% isopropanol
21
12
20
25
25
25
1:1
1:1
1:1
4:32:1
4.32:1
4.32:1
5% isopropanol
7% isopropanol
10% isopropanol
12
22
23
25 (0.0 bar)
25 (0.5 bar)
25 (1.0 bar)
1:1
1:1
1:1
4.32:1
4.32:1
4.32:1
7% isopropanol
7% isopropanol
7% isopropanol
Run No.
a
b
All experiments are carried at 0.0 bar gauge and 33% ammonia by weight in ammonia solution unless otherwise specified.
PG=phosphogypsum.
205
206
Table 5
Effect of temperature and excess phosphogypsum on the maximum KCl conversion and the time needed to reach that maximum
Excess phosphogypsum (wt.%)
0
25
50
25 C
35 C
97.4 (8)
97.6 (6)
98.0 (6)
96.1 (8)
96.3 (6)
97.2 (6)
90.0 (6)
92.4 (4)
92.5 (4)
7. Nomenclature
V
XA
References
[1] S.L. Tisdak, Soil Fertility and Fertilizers, Macmillian Co., New York,
1984.
[2] D.A. Bell, J.B. Sardisco, N.E. Anderson, J.S. Caldwell, Potassium
sulfate and potassium sulfate fertilizers manufactured from potassium
chloride, Potash Technol. (1983) 583.
[3] P. Goerlich, A New Process from Voest-Alpine AG for the
Manufacture of Potassium Sulfate from Potassium Chloride and
Gypsum, A Short Communication, Univ. of Lenz, Austria, 1984, 9pp.
[4] D.P. Patel, V. Safya, Potassium sulfate from phosphogypsum,
Fertilizer News 35 (1992) 214.
[5] S.I.
Abu-Eishah, Production of K2 SO4 Fertilizer from Phosphogypsum
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207