The invention concerns a process for extracting high-purity
potassium chloride (KCl) from
carnallite ore (KCl.MgCl2.6H2O) associated with
halite (NaCl). It begins with a selective
dissolution, prioritizing 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 the
dissolution of the ore. The first addition allows the extraction of all Mg2+ ions in the form of
magnesium hydroxide (Mg(OH)2), a valuable product. The second addition of KOH aims to convert all the NaCl into
potassium chloride (KCl) and
sodium hydroxide (NaOH). This second addition of KOH is excessive to promote the formation of the desired products during the two
crystallization steps that follow. After the chemical transformations of the mineral solution, a concentration step is undertaken to vaporize the water, thus promoting the
crystallization of potassium
chloride (KCl). A second concentration is followed by cooling to form
solid sodium hydroxide (NaOH). The water vapors generated during the two concentration steps are liquefied by cooling for recycling. The three
solid products resulting from the process undergo
drying to remove
moisture, thus meeting market requirements in terms of purity. The proposed process is distinguished by
zero waste management and low
water consumption, with more than 90% of water recycled initially, as well as KOH recycling at the end of the process. In addition, it requires little energy, as KOH
dissolution is exothermic. The KCl production of this process is high thanks to the regeneration of KCl during chemical transformations, and it is characterized by its flexibility in dealing with different compositions of the starting ore.