Selective Crystallization for Salt Regeneration from Industrial Residues
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Solution Overview
Problem
Existing processes for regenerating soluble salts from industrial residues are complex and do not allow for the separate regeneration of high-purity crystals, particularly for potassium chloride, which is essential for various applications including electronics and fertilizers.
Innovation Solution
A process involving the use of a reactive aqueous solution to dissolve the salts, followed by separation and successive selective crystallization steps to obtain high-purity crystals of potassium chloride and sodium chloride, with adjustments in concentration and temperature to optimize crystallization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large number of dissolving and separating steps are used to recover soluble salts from industrial residues, then the regeneration of high-purity crystals is achieved, but the process complexity increases significantly
Solution Approach 1:
The patent applies parameter changes by systematically varying temperature, pH, and concentration parameters during selective crystallization to achieve separation of different salt components. By controlling supersaturation levels and crystallization conditions, high-purity potassium chloride and sodium chloride are obtained without requiring multiple sequential dissolution-separation cycles, thus reducing process complexity while maintaining manufacturing precision.
Solution Approach 2:
The patent utilizes phase transitions through selective crystallization from aqueous solution. By controlling the phase transition from dissolved state to solid crystal form under specific temperature and concentration conditions, different salt components are selectively precipitated in sequence. This approach replaces multiple mechanical separation steps with controlled phase transitions, simplifying the overall process while achieving high-purity product regeneration.
2Productivity
If conventional dissolution and separation processes are used to recover soluble salts, then salt regeneration is achieved, but separate regeneration of different salt types (e.g., potassium chloride and sodium chloride) is not possible
Solution Approach 1:
The patent applies local quality by creating different local conditions (temperature, concentration, pH) within the crystallization system to favor selective precipitation of specific salt types. By controlling local supersaturation zones and using seeded crystallization with specific crystal forms, potassium chloride and sodium chloride are separately regenerated with high selectivity. This allows different regions of the process to target different salt components, achieving separate regeneration while maintaining manufacturing precision.
3Ease of manufacture
If industrial residues containing soluble salts are disposed of without regeneration, then disposal costs are reduced, but contamination of subsoil through leaching occurs
Solution Approach 1:
The patent converts the harmful aspect of soluble salt-containing residues (contamination risk) into a beneficial resource (regenerated salt products). By implementing a regeneration process that recovers potassium chloride and sodium chloride from industrial residues, the system eliminates subsoil contamination risks while producing valuable chemical products. This transforms waste management from a cost center into a value-generating operation, addressing both environmental protection and economic considerations.
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 process effectively regenerates high-purity crystals of soluble salts, such as potassium chloride and sodium chloride, from industrial residues, reducing contamination risks and increasing the efficiency of salt recovery, suitable for diverse industrial applications.
Implementation Method 1
the amount of reactive aqueous solution needed to dissolve the salts which are desired to be regenerated is brought into contact with the residue
Implementation Method 2
the resulting aqueous suspension is subjected to a separation so as to obtain an aqueous production solution on the one hand and insoluble impurities on the other hand
Implementation Method 3
the aqueous production solution is successively subjected to at least two selective crystallization steps intended to crystallize, separately, the at least two soluble salts
Implementation Method 4
the concentration of at least one of the soluble salts to be regenerated in the aqueous production solution, at the moment when it is subjected to the step of crystallization of this salt, is adjusted so as to give rise to the selective crystallization of this salt
Data Source
Figure 1
AI summary
Process for the combined regeneration of at least two soluble salts contained in a residue of an industrial process comprising heavy metals, according to which: - an amount of reactive aqueous solution needed to completely dissolve the salts which are desired to be regenerated is added to the residue; - the resulting aqueous suspension is subjected to a separation so as to obtain an aqueous production solution on the one hand and insoluble impurities on the other hand, which are removed; - the aqueous production solution is successively subjected to at least two selective crystallization steps intended to crystallize, separately, the at least two soluble salts which are desired to be regenerated, which are washed, dried and regenerated separately; - the concentration of at least one of the soluble salts to be regenerated in the aqueous production solution, at the moment when it is subjected to the step of crystallization of this salt, is adjusted so as to give rise to the selective crystallization of this salt, by addition of a controlled amount of this salt to the aqueous production solution upstream of said crystallization step.