CA1217026A - Process and composition for crystallizing potassium sulfate - Google Patents

Process and composition for crystallizing potassium sulfate

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Publication number
CA1217026A
CA1217026A CA000459124A CA459124A CA1217026A CA 1217026 A CA1217026 A CA 1217026A CA 000459124 A CA000459124 A CA 000459124A CA 459124 A CA459124 A CA 459124A CA 1217026 A CA1217026 A CA 1217026A
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CA
Canada
Prior art keywords
neutralized
acid
mono
potassium sulfate
langbeinite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000459124A
Other languages
French (fr)
Inventor
Hsi Meng
William B. Dancy
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International Minerals and Chemical Corp
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International Minerals and Chemical Corp
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Application filed by International Minerals and Chemical Corp filed Critical International Minerals and Chemical Corp
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Publication of CA1217026A publication Critical patent/CA1217026A/en
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Classifications

    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01DCOMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
    • C01D5/00Sulfates or sulfites of sodium, potassium or alkali metals in general
    • C01D5/06Preparation of sulfates by double decomposition
    • C01D5/10Preparation of sulfates by double decomposition with sulfates of magnesium, calcium, strontium, or barium

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)

Abstract

ABSTRACT
A process fox crystallizing potassium sulfate and, in particular, enhancing the crystal size of potassium sulfate crystals by conducting the reaction of potassium chloride with langbeinite thereby forming potassium sulfate crystals and magnesium chloride solution in the presence of a growth enhancer comprising monosulfated or monosul-fated surfactant and a neutralized disulfonated surfactant.

Description

7~26 This invention relates to a process for cry-stallizing potassium sulfa-te~ In a particular aspect, this invention relates to a process for enhancing the crystal size of potassium sulfate crystals.
Langbeinite, a naturally occurring double salt of potassiu~ and magnesium sulfate, is used as the raw material for commercial production of potassium sulfate for-the fertilizer industry. Comminuted langbeinite ~usually less than 200 meshi in the solid p~ase is reacted with a saturated aqueous solution of potassium chloride containing su~ficient solid phase potassium chloride to drive the reaction to completion. The magnesium sulfate from langbeinite is converted to the very soluble mag-nesium chloride and the potassium sulfate crystallizes.
It is then separated, dried and sent to storage. The reaction is conducted at a temperature of 45-55C which enables a reaction time of 6 hours or less, which is important for commercial operation.
The potassium sulfate obtained by this process is in the form of fine crystals, nearly all of which will pass a 65 mesh Tyler screen and are unsuitable for most markets because they tend to cake and cause fugitive dust emissions in violation of State and Federal regu-lations. The preferred crystal size is that retained on a 20 mesh screen and ideally this fraction will be e~ually distributed between 6 and 20 mesh.
The problem of cmall crystal size is one of long-standing importance to the industry and there have been many attempts to solve it. For example, A. F. Nylander, lZ~2~

U. S. Patent 3,271,1n6 diselosed that erystal size eould be enlarged by effeeting the erystallization in the pre-senee of speeifie neutralized sulfonie aeids or aeid sulfates, s~eh sulfonated fatty aeids and sul~ated alcohols. The aeids were neutralized with sodium, potassium, magnesium or triethanol-ammonium hydroxides.
This process worked well in the laboratory but when adapted to commercial size, it was found that a reaetion time of more than six hours was required and was, there-fore, impractical.
Aecordingly, there has been a long and pressing need for a crystal growth enhaneer for potassium sulfate.
The present inven-tion therefore provides an improved proeess for the production of potassium sulfate erystals by the reaction of saturated solution of potas-sium chloride with langbeinite in the solid phase at a temperature of from 45-55C, thereby forming potassium sulfate crystals and magnesium chloride solution comprising the step of eondueting the reaetion in the presenee of from 1.2 to 2.4 kg per ton of langbeinite of a erystal growth enhaneer eonsisting of from about 0.20 to 0.50 parts by weight of component (A) per part of eomponent (B) wherein (A~ is a mixture of neutralized alkylated diphenyloxide mono-sulfonic acid and a neutralized monosulfated fatty acid of 5 to 20 earbon atoms in a ratio of 1~66-20 parts of neutralized sulfated oleic acid per part of neutralized alkylated diphenyloxide monosulfonic acid and eomponent (B) 5 is a neutralized alkylated diphenyloxide disulfonic aeid, wherein the acids are neutralized with sodium or potassium cations and the alkylated moiety of the diphenyloxide mono-or disulfonic acid is of from 10 to 14 carbon atoms and may be branched chain or straight- chain or mixtures thereof.
It is the surprising discovery of this invention that a erystal growth enhancer comprising a combination of a neutralized mono-sulfonic aeid or sulfated fatty acid and a neutralized alkylated diphenyloxide disulfonic aeid enhanees erystal growth of K2SO4 to give a satis-factory yield of ~20 mesh crystals within an acceptable ?~ ~;

- 2a -reaction time. According to the improved process, the reaction between ~olid phase langbeinite with saturated 7~

a~ueous potassium chloride solution is conducted at 45-55 C in the presence of from 1.2 to 2.4 kg of the crystal growth enhancer per ton of langbeinite. The mono-sulfonate or sulfate is present in a ratio of from about 0.14 to 0.60 parts by weight er part of the disulfonate, pre-ferably about 0.20 to 0.50.
The sulfonic acids useful in the practice of this invention are known in the art. The preferred disulfonates are the alkylated diphenyloxide sulfonates wherein the alkyl group is from 10 to 14 carbon atoms, and the com-pound wherein the alkyl is straight chain, e.y~ lauryl, is particularly preferred. The later compound is commer-cially available and the commercial product is suitable for the practice of this invention. The disulfonic acids may be neutralized by any suitable monovalent cation, e.g. sodium, potassiu, alkylamine or alkanolamine, but sodium is preferred as being most economical. A particu-larly preferred disulfon~ate is marketed by Conco Chemical Company as Conco 2Al. The alkyl group is straight chain and the product contains the monosulfonate in an amount of about 15% of total surfactants r i.e. a ratic of about 0.176. This ratio is not high enough to provide maximum crystal growth cb~u~ ~ess fortifying is necessary than with, e.g. Dowfax 2Al ma eted by Dow Chemical Company, which containes only 5% of the monosulfonate for a ratio of about 0.05. This latter product contains a branched alkyl group and it has been found that higher ratios of sulfated fatty acids are required when the alkyl group is branched chain than when it is straight chain. Since sulfated fatty acids slow the reaction rate of langbeinite, it is advantageous to minimize the sulfated acids consistent with the desired crystal size. For example, when the straight alkyl chain compound is used, excellent results are obtained with a volume ratic o,f~ll)part sulfated oleic acid to 4 parts of Conco 2A1 whéreas w~e3 the branched chain alkyl compount (Dowfax 2Al) is used, a ~2~

volume ratio of ~ is required for equi~alent results.
Since Conco 2All~usJtomarily contains about 7.0% mono-sulfonated diphenyl oxide and ~0% of the disulfonated diphenyl o~ide ~the remainder being largely water and inactive contaminants), a particular preferred crystal yrowth enhancer would have the following approximate com~osition.
Disodium diphenyl 31-33 oxide disulfonate Monosodium diphenyl5- 6 monosulfonate Sodium oleyl sulfate 19-21 Other 42-43 The commercial disulfonates sometimes contain a small proportion of monosulfonate as an impurity and this monosulfonate fraction should be taken into consideration when preparing the combination of this invention. The determination of the amount is well within the skill of the ordinary artisan.
The preferred monosulfonate of this invention is lauryl diphenyloxide sulfonate. Howe~er, other mono-sulfates or monosulfonates may be used, e.g. a monosul fate of a fatty acid of from 5 to 20 carbon atoms.
Sulfated oleic acid is a preferred compound. The mono-sulfonate or -sulfate is neutralized with a suitable cation which may be the same as that used for the disul-fonate or it can be different. Mixtures of monosulfonates or sulfates may also be used.
Sulfated fatty acid surfactants alone are not effective in enhancing crystal growth. ~hen sodium oleyl sulfate ~as employed, crystal growth response was poor at all concentrations tested and the reaction time was prohibiti~ely long.
The neutralized sulfonic acids may be mixed together before they are added to the reaction mixture or they may be added separately. They can be pre ~%~

dissolved or slurried in a minimum amount of water and added either to the KCl solution or to the reaction mix-ture; or the sulfonates can be added as solids. Pre-ferably, they are dissolved in a minimum amount of water and added to the KCl solution before adding the lang-beinite.
Advantageously - and unexpectedly - the improved process provides considerable savings in energy re~uire-ments. ~hen produced by the previous process, the moisture content of a 1" thick filter cake (7.9 lb of solids per square foot of filter cloth) was reduces to about 10%
by weight at an air flow of 8 SCFM~ft2 and required about 31.6 sec. drying time. By comparison, using the improved process, the moisture content was reduced to 6.5% (35~
reduction~ in only 12 seconds (37% of the previous drying time).
The invention will be better understood with reference to the follo~ing examples. It is understood that these examples are intended only to illustrate -the invention and it is not intended t~at the invention be limited thereby.

A sample of langbeinite was ground and screened to pass 200 Tyler mesh and was used in this and the following examples. The potassium chloride used was technical grade in order to eliminate any possible inter-fering components which might be present in cruder material. Similarly, distilled water was selected for all tests.
Potassium chloride, 350 g, was dissolved in dis-tilled water, 1 kg, at 45C. As a crystal growth enhancer, there was added to the potassium chloride solution 2.32 g of a commercial grade sodium salt of alkylated diphenyloxLde disulfonic acid (Dowfax 2Al,~
product of Dow Chemical Company) containing 47% of total surfactant This product contained, as an impurity, ~2~

the monosulfonate in an appro~imate weight ratio of 0.053 to the disulfonate. Diesel oil, 1 cc, was added as an anti~oam agent. Langbeinite, 350 g, ground to less than 2Q0 T~ler mesh, was added. The mixture was heated to 55C and agitated -throughout the reaction period. The progress of the reaction was followed by monitoring the magnesium concentration in the liquid phase. The resulting K2SO~ crystals were separated by contrifugation, washed with organic solvents, dried and screened. The total yield of crystals was approximately 290 g. This experiment was designated as the control.
The results are given in the table.
The foregoing experiment was repeated exc~pt that there was su~stituted for the surfactant 0.62 g of the same growth enhancer fortified with the monosul-fonate to p~ovide a weight ratio of 0.18. The results obtained are given in the table.

The experiment of Example 1 was repeated in all essential details except that the ratic of monosulfonate to disulfonate was varied, as was the total amount used.
The results are given in the table.
Surfactant Crystals Retained, %, On Example Ratio ~ 20 Mesh 14 10 8 Control 0.053 1.09 0.5 - - -1 0.18 0.62 51 21
2 ~.26 0.66 50 43 24
3 0.32 Q.70 56 45 33 2
4 0.~6 0.78 55 49 36 3 0.59 0.85 21 - - -6 0.18 0.55 59 46 6 7 0,35 0.53 48 3 - -8 0.51 0.51 58 58 9 ~.4~ 0.53 60 60 24 7 _ EXA,~PLE 6 The experiment of Exa~ple 1 was repeated in all essential details except~that 0.55 g of a commer-c~al product ~Conco 2Al~ -havlng a mono to disulfona-te ratio of Q.18 was substituted as the growth enhancer.
_ ~MPLE_7 The experiment of Example 1 was repeated in all essential details except that a commercial grade of the sodium salt of sulfated oleic acid was used to fortify the monosul~onated component.
The mix-ture of mono- and disulfonate (,in this and the following examples, the term "mono" is intended to include monosulfonate and monosulfate~ was mixed into the KCl solution first and the sulfated oleic acid was-added. A total of 0.5264 of surfactant (100% acti~e basis) was used as the growth enhancer. It had the following composition:
Disulfonate 0.388473.79%
Monosulfonate , 0.02043.87%
Sulfated Oleic Acid 0.1176 22.34%
The ratio of mono to disulfonate was 0.36.

The experiment of Example 7 was repeated in all essential details except that all of the growth enhancers were added to the KCl at the same time. A
total of 0.5149 g of enhancer (100% active ~asis~ was added. It had the following composition:
Disulfonate 0.3415 g 66.32%
~onosulfonate 0.0180 3.50~
~Sulfated Olèic Acid 0.1554 30.18%
The ratio of mono to disulfonate was 0.51.

EXA~PLE g The experiment of Example 8 was repeated in all essential details e~cept that 0.5293 g of the growth enhancer ~as used. It had the following composition:
Disulfonate 0.3789 71.59%
. . .
Monosulfonate 0.0563 10.63%
Sulfated Oleic Acid 0.0941 17.78%
The ratio of mono to disulfonate was 0.40.

Claims (6)

The embodiments of the invention in which an exclusive property of privilege is claimed are defined as follows:
1. An improved process for the production of potassium sulfate crystals by the reaction of saturated solution of potassium chloride with langbeinite in the solid phase at a temperature of from 45-55°C, thereby forming potassium sulfate crystals and magnesium chloride solution comprising the step of conducting the reaction in the presence of from 1.2 to 2.4 kg per ton of langbeinite of a crystal growth enhancer consisting of from about n . 20 to 0.50 parts by weight of component (A) per part of component (B) wherein (A) is a mixture of neutralized alkylated diphenyloxide mono-sulfonic acid and a neutralized monosulfated fatty acid of 5 to 20 carbon atoms in a ratio of 1.66-20 parts of neutralized sulfated oleic acid per part of neutralized alkylated diphenyloxide monosulfonic acid and component (B) is a neutralized alkylated diphenyloxide disulfonic acid, wherein the acids are neutralized with sodium or potas-sium cations and the alkylated moiety of the di-phenyloxide mono- or disulfonic acid is of from 10 to 14 carbon atoms and may be branched chain or straight chain or mixtures thereof.
2. The process of claim 1 wherein the mono-sulfonated surfactant is neutralized alkyl diphenyloxide sulfonate and the disulfonated surfactant is aklyl dipheynloxide disulfonate.
3. The process of claim 2 wherein the alkyl group is straight chain.
4. The process of claim 2 wherein the alkyl group is branched chain.
5. The process of claim 2 wherein the alkyl group is lauryl.
6. The process of claim 2 wherein the sur-factant is sulfated oleic acid.
CA000459124A 1983-08-02 1984-07-18 Process and composition for crystallizing potassium sulfate Expired CA1217026A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US51944583A 1983-08-02 1983-08-02
US519,445 1983-08-02

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CA1217026A true CA1217026A (en) 1987-01-27

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5085670A (en) * 1990-09-17 1992-02-04 The Dow Chemical Company Production of potassium chloride crystals

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3271106A (en) * 1963-10-09 1966-09-06 Int Minerals & Chem Corp Production of potassium sulfate and potassium chloride
US3770390A (en) * 1971-02-26 1973-11-06 Dow Chemical Co Crystal habit modification of inorganic salts using polymeric sulfonates or sulfates
US3843772A (en) * 1972-09-14 1974-10-22 Int Minerals & Chem Corp Production of white potassium sulfate crystals
US3853490A (en) * 1973-01-22 1974-12-10 Int Minerals & Chem Corp Granulation of potassium sulfate

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DE3426855A1 (en) 1985-02-14
DE3426855C2 (en) 1993-10-07

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