The invention relates to a process for extracting high-purity
potassium chloride (KCl) from a
carnallite ore (KCl.MgCl2.6H2O) associated with
halite (NaCl). The process starts with selective
dissolution, prioritising KCl and MgCl2, due to the addition of water at
room temperature. Two basification steps follow, involving the addition of
potassium hydroxide (KOH) to the solution obtained after dissolving the ore. The first addition makes it possible to extract all of the Mg2+ ions in the form of
magnesium hydroxide (Mg(OH)2), an upgraded product. The second addition of KOH seeks to convert all the NaCl into
potassium chloride (KCl) and
sodium hydroxide (NaOH). This second addition of KOH is carried out in excess to promote the formation of the desired products during the following two crystallisation steps. After the chemical transformations of the mineral solution, a concentration step is undertaken to vaporise the water, thereby promoting the crystallisation of the potassium
chloride (KCl). A second concentration is followed by cooling in order to form the
solid sodium hydroxide (NaOH). The water vapours generated in the two concentration steps are liquefied by cooling to be recycled. The three
solid products resulting from the process are dried to remove
moisture, thereby complying with market requirements in terms of purity. The proposed process is characterised by zero-
waste management and low
water consumption, with more than 90% of the water being recycled initially, as well as recycling of the KOH at the end of the process. In addition, it has low energy requirements, since the
dissolution of KOH is exothermic. The KCl production of the process is high due to the regeneration of KCl during the chemical transformations, and the process is characterised by its flexibility with respect to different compositions of the starting ore.