Carnallite Process for Chloride-Free Potassium Sulphate
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Solution Overview
Problem
Current fertilizers, particularly controlled-release fertilizers, face challenges in efficiently providing potassium to plants without chloride contamination, which can harm certain crops, and there is a need for a reliable method to produce potassium sulphate effectively.
Innovation Solution
A process involving the reaction between Carnallite and Sodium Sulphate bearing minerals to produce Potassium Sulphate (K2SO4) and Potassium Magnesium Sulphate, including steps like dissolving Carnallite in water, adding Sodium Sulphate, separating precipitants, filtering, and decomposing Leonite to yield high-purity K2SO4.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fertilizers are used to provide potassium, then plant growth is enhanced, but chloride contamination occurs which harms certain crops
Solution Approach 1:
The patent extracts potassium from carnallite while deliberately excluding chloride through selective chemical reactions. Sodium sulphate is used to precipitate potassium sulphate from the carnallite solution, separating it from chloride ions that remain in the brine phase, thus providing potassium without harmful chloride contamination
Solution Approach 2:
The patent changes the chemical parameters by controlling pH, temperature, and concentration ratios during the reaction between carnallite and sodium sulphate. By optimizing these parameters, the process achieves selective precipitation of potassium sulphate while preventing chloride incorporation into the product
2Manufacturing precision
If multiple separation steps are performed to achieve high purity K2SO4, then product purity is improved, but process complexity increases
Solution Approach 1:
The patent segments the purification process into distinct functional stages: initial precipitation of K2SO4 from carnallite-sodium sulphate reaction, flotation separation to remove NaCl impurities, filtration to separate solid K2SO4 from brine, and washing to achieve final purity. Each segment targets specific impurities, making the overall complex process manageable and efficient
Solution Approach 2:
The patent uses flotation as an intermediary separation mechanism between precipitation and filtration. The flotation process selectively removes NaCl particles from the K2SO4 precipitate using air bubbles and surfactants, acting as a mediator that simplifies the burden on subsequent filtration and washing steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively produces high-purity Potassium Sulphate with minimal chloride content, suitable for crops sensitive to chloride, ensuring optimal plant growth and soil nutrient availability.
Implementation Method 1
Dissolving Carnallite in water to obtain Sylvenite and high Magnesium Chloride brine
Implementation Method 2
Adding Sodium Sulphate in various proportion to Carnallite, e.g., weight ratio Carnalite to Sodium Sulphate 14:3, to produce mixture of Kainte\Leonite, KCl and NaCl precipitant and brine containing MgCl2, KCl, NaCl
Implementation Method 3
Separating the NaCl from the mixture, e.g., by flotation method
Implementation Method 4
Decompose the Leonite with the KCl to SOP in Crystallizer
Implementation Method 5
Separating the crude SOP, e.g., using by filtration and/or centrifugation
Implementation Method 6
Separating the crude SOP, e.g., using by filtration and/or centrifugation
Implementation Method 7
Washing the SOP with water to appropriate grade, e.g., 93-96% K2SO4
Data Source
AI summary
According to some embodiments there is provided a process for the recovery of SOP from Sulphate bearing mineral and Carnallite or Sylvenite, comprising: Dissolving Carnallite in water to obtain Sylvenite and high Magnesium Chloride brine; Adding Sodium Sulphate to said Carnallite to produce mixture of Kainte\Leonite, KCl and NaCl precipitant and brine containing Mg Cl2, KCl, NaCl; Separating the NaCl from the mixture; Obtaining a precipitant mixture of Leonite with KCl; Filtering said Leonite and washing with water to yield pure mixture of Leonite with KCl; Adding KCl to the Leonite with the KCl; and Decompose said Leonite with the KCl to SOP.