WO2021140075A1 - Integrated method for the commercial and industrial utilisation of calcium sulphate from the production of phosphoric acid - Google Patents

Abstract

The invention relates to a method for producing sulphuric acid and cement clinker using calcium sulphate, which is formed and separated as a solid by-product during the production of phosphoric acid in the reaction of raw phosphate with sulphuric acid to form phosphoric acid, wherein the method comprises the following steps: a) the calcium sulphate separated from the phosphoric acid is treated with an acid in order to obtain a suspension with purified calcium sulphate; b) the purified calcium sulphate is separated from the liquid phase of the obtained suspension as a solid material, wherein the obtained liquid phase can be introduced into the reaction unit of the phosphoric acid production as a feed material; c) the separated purified calcium sulphate is mixed with additives and reducing agents in order to obtain a raw meal mixture for cement clinker production; d) the raw meal mixture is burnt in order to obtain the cement clinker, wherein sulphur dioxide is formed as a waste gas; and e) the formed sulphur dioxide is supplied to a sulphuric acid production as a raw material in order to produce the sulphuric acid, wherein the produced sulphuric acid is used as a feed material in phosphoric acid production. The method is, in particular, an integrated method. The integrative approach as a total concept from phosphogypsum to cement clinker and sulphur dioxide takes into consideration the requirements in an existing phosphoric acid and sulphuric acid complex.

Description

Integrated process for the commercial and industrial utilization of calcium sulfate from phosphoric acid production

description

The invention relates to an integrated process for the production of sulfuric acid and cement clinker using calcium sulfate, which is formed during the production of phosphoric acid, and a system for carrying out the process.

Calcium sulphate is a waste product of the phosphoric acid producing industry and occurs as dihydrate and / or hemihydrate when phosphate ores are broken down with sulfuric acid. The calcium sulphate formed during the production of phosphoric acid is also known as phosphogypsum.

Due to impurities such as phosphorus, fluorine, radioactive components and heavy metals in calcium sulphate from phosphoric acid production, today's options for using calcium sulphate, e.g. as a cement additive, fertilizer, mortar or road construction material, are limited, so that worldwide only 15% of the annual production of calcium sulphate from the Phosphoric acid production can be used accordingly. The remaining 85% of the annual production of calcium sulphate are either stored on heaps or dumped in the sea.

Due to the current environmental situation, storage sites for the dumping of phosphogypsum or the dumping of phosphogypsum in the sea are either only permitted under stricter conditions or not at all.

The phosphogypsum quality obtained from the phosphoric acid process depends on factors such as the rock phosphate used and process conditions when the rock phosphate is broken down with sulfuric acid.

The processed rock phosphate can be used for phosphogypsum production using the following processing methods via the possible phosphoric acid processes: 1. Calcination, 2. Flotation, 3. Conversion into mono-calcium phosphate or di-calcium phosphate with the help of inorganic acids. The methods mentioned are known to the person skilled in the art and are described, for example, in Physical and thermal treatment of phosphate ores - An OverView; Int. J. Miner. Process. 85 (2008) 59-84; Abdel-Zaher M. Abouzeid; The Fertilizer Manual 3rd Edition; published by UNIDO & IFDC, 1998 edition; ISBN: 0792350324 9780792350323; and Pyroprocessing for the minerals industry, Thyssenkrupp Polysius; Identification: 1625 / D (1.0 12.11 Stu).

Depending on the production process, 4 to 5 tons of calcium sulfate are produced for each ton of phosphoric acid produced. Due to the naturally different qualities / compositions of the phosphate ores and the different process parameters for the production of phosphoric acid, different qualities of calcium sulphates are produced accordingly.

The increased requirements for handling the calcium sulfate or phosphogypsum produced pose complex challenges for the phosphoric acid producing industry. Estimates for lifetime storage of phosphorus gypsum are as high as $ 25 / tonne of gypsum for manufacturing companies.

As an example of the possible commercial and large-scale use of calcium sulfate / phosphogypsum, the conversion of phosphogypsum into cement clinker or cement and SO2 or sulfuric acid is often mentioned in the literature. Implementation of gypsum and phosphogypsum in cement and Sulfuric acid according to the Müller-Kühne process or according to the OSW-Krupp process have been known for a long time, see, for example, patent specification AT 292539 B; At least for the processing of phosphogypsum, this process is no longer widely used.

DE 3222721 C2 describes an improved process based on the Müller-Kühne process by means of an upstream partial dewatering of the gypsum by centrifugation with downstream two-stage drying, with the SC-containing exhaust gas emerging from the first drying stage being introduced directly into the gas scrubber of the sulfuric acid plant. The method described makes no reference to the quality of the phosphogypsum with regard to certain components and also no reference to the quality of the SO2 exhaust gas for the indicated, downstream sulfuric acid plant.

Kandil et al., Journal of Radiation Research and Applied Sciences; 10; 2017, describe a process for the production of ammonium sulfate from phosphogypsum, in which sulfuric acid is used in a first step to leach P2O5, F, lanthanides and other components. The process described is not related to the conversion of phosphogypsum into cement clinker and sulfuric acid.

EP 0041761 A1 relates exclusively to the recrystallization of calcium sulfate dihydrate to calcium sulfate anhydrite in connection with the conversion of phosphogypsum into cement clinker and SC gas. PzOs contents of less than 0.01% by weight and fluorine contents of less than 0.05% by weight can be achieved in calcium sulfate anhydrite. Calcium components and sulfur dioxide can be extracted from the anhydrite obtained in this way at high temperatures. The possibility of returning used sulfuric acid to the phosphoric acid process is mentioned, but influencing factors such as the grain size of the gypsum and the solid to liquid ratio (S / L), which have a direct influence on the water balance in the phosphoric acid complex, are not taken into account.

GB 120991 describes the production of cement by the Müller-Kuehne process on the basis of calcium sulphate hemihydrate, which is produced by recrystallization of calcium sulphate dihydrate during phosphoric acid production. Today this type of procedure is known as the so-called DHH (dihydrate hemihydrate) procedure. Furthermore, the production of sulfuric acid and Portland cement based on the hemihydrate is described. The treatment of the calcium sulfate with an acid after the separation from the phosphoric acid is not described.

US 3547581 relates to a method for processing filtered gypsum from phosphoric acid production, in which the gypsum is heated to temperatures of 200 ° C. to 400 ° C. after the addition of silica and sulfuric acid and calcined to hemihydrate or anhydrite. The product obtained is washed with water, which allows the phosphate and fluoride levels in the gypsum to be reduced. Due to the high temperatures required, it is an energy-intensive process that includes a large number of process steps. In addition, the method according to US 3547581 requires the heating and addition of silica in comparison to the process concept according to the invention presented here. The preparation of a suspension by adding acid to calcium sulfate is not described.

DE 1671215 relates to a process for the production of sulfuric acid and cement from waste calcium sulphate, such as phosphogypsum, which deals with the production of the raw meal.

DE 1912183 describes a process for the production of low-fluorine cement clinker from phosphogypsum, in which the fluorine in the phosphogypsum is selectively reduced by heating the waste gypsum in a finely ground state to temperatures between 500 and 900.degree.

US 4415543 describes a method in which the content of fluorides and phosphates in phosphogypsum is reduced by washing with water and subsequent heating.

In general, the literature only describes the individual processes such as preparation of the phosphogypsum, thermal decomposition of the phosphogypsum into cement clinker and sulfur dioxide. Possible connections with the necessary upstream and / or downstream processes are only mentioned sporadically.

The object of the present invention is to provide a method for the use of calcium sulfate (phosphogypsum) that is formed during the production of phosphoric acid for the production of products of value, which is specifically aimed at the use of phosphogypsum is oriented and can be used on an industrial scale in order to meet the environmental and economic requirements in order to be able to process the large amounts of phosphogypsum that is produced

The object is achieved according to the invention by a method according to claim 1. In particular, the object is achieved by a process for the production of sulfuric acid and cement clinker using calcium sulfate, which is formed and separated off as a solid by-product in a phosphoric acid production during the reaction of rock phosphate with sulfuric acid to form phosphoric acid, the process comprising the following steps: a ) the calcium sulfate separated from the phosphoric acid is treated with an acid to obtain a suspension with purified calcium sulfate, b) the purified calcium sulfate is separated as a solid from the liquid phase of the resulting suspension, c) the separated purified calcium sulfate is treated with additives and reducing agents mixed in order to obtain a raw meal mixture for cement clinker production, d) the raw meal mixture is burned in order to obtain the cement clinker, whereby sulfur dioxide is formed as exhaust gas, and e) the sulfur dioxide formed is used as raw material for sulfuric acid production In order to produce the sulfuric acid, the sulfuric acid produced can be used as feedstock in phosphoric acid production and / or can be fed to another use.

The method according to the invention is in particular an integrated method. The integrative approach as an overall concept from phosphogypsum to cement clinker and sulfur dioxide in the integrated process enables the coordination of the dependencies / influencing factors for the optimized process selection and the associated flexibility of the process management with the possibility of being integrated into existing phosphoric acid and sulfuric acid plant complexes. In this way, all process parameters and process stages of the overall complex can be coordinated to achieve specific product qualities based on a variable educt quality, such as the educt quality of the apatite used in the phosphoric acid production or the phosphogypsum of the current production or the stockpile. That was not considered until today. The combinations of features of the integrative method according to the invention cannot be derived from the prior art.

In the following, the terms complex and system are used interchangeably in this context. The separated liquid phase obtained in step b) can be introduced into the reaction unit for phosphoric acid production as a starting material.

The following points in particular can be mentioned as advantages of the method according to the invention, in particular the integrated method:

1. Use of the produced calcium sulphate / phosphogypsum as raw material for the production of valuable products

2. Conversion of calcium sulfate / phosphogypsum into cement clinker as a raw material for cement production and sulfur dioxide as a raw material for sulfuric acid production

3. Reduction to avoid environmentally harmful long-term consequences from landfilling / dumping of calcium sulphate / phosphogypsum

4. Recovery and circulation of the sulfur used in the phosphoric acid process and / or a further use, which only results in a need for additional sulfur to compensate for losses in the overall process. General embodiments are a recycling of sulfuric acid or the use of phosphogypsum from heaps. In the latter case, sulfuric acid has to be exported, since the supply of phosphogypsum from external sources, especially heaps, results in an excess of sulfur in the overall process. A balance of the sulfur balance is therefore particularly necessary in the context of the circulation of sulfuric acid

5. Increase in the yield of phosphorus from the rock phosphate, thus better utilization of the rock phosphate used for the purpose of phosphoric acid production

6. Reduction of the C02 footprint through the use of calcium sulfate / phosphogypsum as a raw material for the production of cement clinker

7. Integrative use of existing system components of the phosphoric and sulfuric acid complex, thus reducing additional investment The approach of the integrated process described here can be summarized in 5 categories of manufacturing processes:

Production of phosphogypsum of suitable quality for the cement clinker process according to steps a) and b) of the method according to the invention,

Production of the raw meal mixture, which is specific for the cement clinker process, according to step c) of the method according to the invention,

Production of the cement clinker according to step d) of the method according to the invention and, if necessary, further processing of the cement clinker to cement,

Production of sulfur dioxide gas with a quality that is suitable for the sulfuric acid process according to step d) of the method according to the invention, the sulfur dioxide gas optionally also having to be subjected to exhaust gas cleaning before it is fed to step e),

Production of the sulfuric acid according to step e) of the process according to the invention.

The method according to the invention for the production of sulfuric acid and cement clinker using calcium sulfate is preferably integrated into a phosphoric acid production. Phosphoric acid production is a common wet process in which rock phosphate is reacted or broken down with sulfuric acid in order to form phosphoric acid (digestion phosphoric acid).

Sedimentary and igneous phosphate rocks are used as rock phosphate, which are usually processed before use. The processing usually includes crushing and concentrating with regard to the phosphorus content. For processing, phosphate ore or phosphate rock, in particular ore containing apatite, for example, can be subjected to calcination, flotation and / or conversion into mono-calcium phosphate or di-calcium phosphate with the aid of inorganic acids. The preparation of phosphoric acid by the wet process is generally known to the person skilled in the art. General descriptions of the process can be found, for example, in Ullmann's Encyclopedia of industrial Chemistry, 5th Edition, 1991, Vol. A19, "Phosphoric Acid and Phosphate", pp. 465-505.

The phosphoric acid production plant preferably comprises a processing unit for phosphate rock, a reaction unit for converting rock phosphate with sulfuric acid and a filtration unit for separating calcium sulfate. As a rule, the phosphoric acid production plant also includes a sulfuric acid production plant, so that a phosphoric acid-sulfuric acid complex results.

For the production of cement clinker and sulfuric acid by the process according to the invention, calcium sulfate or phosphogypsum from the following existing processes known to those skilled in the art can be used for the production of phosphoric acid: 1. Dihydrate (DH) process, 2. Hemihydrate (HH) - Process, 3rd dihydrate hemihydrate (DHH) process, 4th hemihydrate dihydrate (HDH) process and 5th dihydrate attack hemihydrate filtration (DA-HF) process.

For the present invention, one of the above five processes is generally to be used, with processes 3 to 5 (DHH / HDH / DA-HF) recrystallizing the calcium sulfate, which is not required for the process according to the invention.

In the process according to the invention, in step a) the calcium sulfate, which was obtained, for example, by one of the five processes mentioned above, is treated with an acid after separation from the phosphoric acid production, which increases the PzOs yield.

The calcium sulfate separated from the phosphoric acid production is thus preferably not subjected to any recrystallization before being fed to step a).

In the process of phosphoric acid production, calcium sulfate is formed as a solid by-product during the reaction of rock phosphate with sulfuric acid to form phosphoric acid, which is separated from the phosphoric acid. The separation can take place, for example, by centrifugation, filtration, settling or evaporation, mechanical separation being preferred. The solid Calcium sulfate is preferably separated from phosphoric acid by filtration. The separation comprises or consists of the separation of the calcium sulfate formed from the phosphoric acid (product acid) (first separation), preferably by filtration. Depending on the process, the calcium sulfate solid (preferably filter cake) separated off by the first separation can optionally also be subjected to one or more washes with liquid, in particular water, with subsequent separation, preferably filtration, of the liquid.

For the calcium sulfate separated from the phosphoric acid, which is used in step a), the calcium sulfate obtained directly after the first separation from the phosphoric acid can be used, since further washing is not absolutely necessary. This enables a reduction in the filter area in the phosphoric acid process. However, it is also possible for the calcium sulfate separated from the phosphoric acid, which is used in step a), to use calcium sulfate which, after the first separation from the phosphoric acid, was subjected to one or more washes with a liquid, preferably water, before it Step a) is supplied.

Alternatively, calcium sulphate stored on flalden from phosphoric acid production can be used as the calcium sulphate which is used in step a). If necessary, the calcium sulphate of the flats must also be mechanically pretreated before use in step a).

The conversion of rock phosphate with sulfuric acid takes place in the phosphoric acid production complex in the reaction unit of the phosphoric acid plant. The reaction mixture obtained is then conveyed to the separation unit, preferably the filtration unit, of the phosphoric acid plant, where the phosphoric acid is separated or filtered off from the calcium sulfate formed in one or more separation stages. The calcium sulphate for use in stage a) is taken from the separation unit or filtration unit, preferably from the first separation stage, and / or calcium sulphate stored on flalden from phosphoric acid production is used as calcium sulphate for use in stage a).

The separated calcium sulfate, which is used in step a), is preferably calcium sulfate in the form of dihydrate, hemihydrate or a combination thereof. In step a) of the process according to the invention, the calcium sulfate separated off from the phosphoric acid production is treated with an acid. The acid is added to the calcium sulfate to carry out the treatment. In this way a suspension with purified calcium sulphate is obtained after the treatment. The suspension obtained can be, for example, a slurry or a slurry. As a result of the treatment, the impurities in the calcium sulphate, which have a negative impact on the downstream cement clinker process and the cement quality, can be reduced to the level required by the downstream cement clinker process.

An acid is added to treat the calcium sulfate in step a). The acid is preferably a dilute acid. Dilute acids are acids that are diluted with water (aqueous acids). The acid, preferably the dilute acid, is preferably an inorganic acid, e.g. hydrochloric acid, nitric acid, sulphurous acid and / or sulfuric acid, with sulphurous acid and / or sulfuric acid being particularly preferred.

In step a) the acid is preferably added in such an amount that the ratio of solid to liquid (S / L ratio) in the suspension is in the range from 1/10 to 1/1, preferably 1/5 to 1/1 , more preferably 1/5 to 1 / 1.3 and especially 1/4 to 1/2. The ratio of solid to liquid (S / L ratio) relates to the mass of the solid in kilograms and the volume of the liquid in liters at a reference temperature of 20 ° C.

The concentration of the acid used is chosen so that the acid resulting from the treatment according to step a) is, for example, in the range from 1 to 12 molar, preferably in the range from 3 to 10 molar, more preferably in the range from 5 to 8 molar, which is an aqueous acid. 1 molar is understood to mean 1 mol of acid per 1 liter of solution at 20.degree. Since the calcium sulfate to be treated may contain water, the concentration of the acid added can be higher than the concentration of the acid resulting after the addition. In general, the molarity of the acid added is preferably in the ranges which are mentioned above and below for the resulting acid.

The acid resulting from the treatment after step a) is preferably a 1 to 12 molar, preferably 5 to 8 molar, sulfurous acid or a 1 to 12 molar acid molar, preferably 5 to 8 molar sulfuric acid. The acid added is therefore preferably a sulphurous acid or a sulfuric acid.

The treatment in step a) is carried out, for example, at a reaction temperature in the range between ambient temperature and the boiling point of the reaction mixture, for example at a temperature in the range from 15 ° C to 100 ° C, preferably 30 ° C to 80 ° C, more preferably 45 to 75 ° C .

The duration of the treatment in step a) or the reaction residence time for setting the content of impurities in the acid is, for example, in the range from 5 minutes to 120 minutes, preferably from 15 to 100 minutes, in particular from 15 to 90 minutes, particularly preferred 20 to 60 minutes.

During the treatment of step a), the suspension or the reaction mixture is preferably kept in motion in order to adjust the content of impurities, for example by circulating, stirring or blowing in gas.

For step a), the calcium sulfate generated in the phosphoric acid production is fed from the separation unit, preferably a filtration unit, to the phosphoric acid production of a calcium sulfate reaction unit, or the calcium sulfate is fed from a heap from the phosphoric acid production. There the calcium sulfate is treated with the added acid. The calcium sulphate reaction unit can be a simple stirring device, e.g. a stirred tank.

In step b) of the process according to the invention, the purified calcium sulfate is separated off as a solid from the liquid phase of the suspension obtained after the treatment. The suspension obtained can be a slurry. The separation of solid or purified calcium sulphate and liquid phase from the suspension is in particular a mechanical separation and can be carried out, for example, by centrifugation or filtration, with filtration being preferred.

The purified calcium sulfate obtained in step b), as obtained after the separation, can be dihydrate, flemihydrate, anhydrite or in the form of a mixture of at least two of said components, calcium sulfate in the form of anhydrite is preferred. The desired composition of the Calcium sulphate depends on the required degree of PzOs reduction, with a cement / clinker producer determining the required degree of PzOs reduction. Treatment with acid and subsequent separation from the liquid phase can, in particular, reduce the content of phosphorus and fluorine in the calcium sulfate, which are contained as impurities. The separated liquid phase is usually an acidic aqueous solution containing, inter alia, water and P2O5.

In a preferred embodiment, the separated, purified calcium sulfate obtained in step b) contains at least 5% by weight, preferably at least 30% by weight, more preferably at least 50% by weight anhydrite, based on dry calcium sulfate.

The D _v (50) value of the particle size distribution of the calcium sulfate, in particular calcium sulfate anhydrite, produced in step b) after purification is, for example, 0.5-100pm, particularly preferably 1-50pm, in particular 2-30pm. The D _v (50) value is defined as a measure at which 50% by volume of the particles have a larger diameter than the specified value.

In a preferred embodiment, in step b) the liquid phase, which is obtained after the solid has been separated off, is used as the starting material in phosphoric acid production. The liquid phase or the filtrate can be used in the existing phosphoric acid production, especially in the existing phosphoric acid-sulfuric acid complex, as so-called "Recycle Acid", which can be fed to the reaction unit of the phosphoric acid production for the reaction with the raw phosphate

For step b), the suspension / slurry contained in the calcium sulfate reaction unit is transferred to a calcium sulfate separation unit, in which the liquid and the resulting solid (purified calcium sulfate) can be separated from one another. The separation unit can be, for example, a filtration unit or a centrifuge unit, with a filtration unit being preferred.

The separated, purified calcium sulphate obtained in step b) can be used directly as the separated, purified and processed calcium sulphate. However, it is also possible that the purified calcium sulfate obtained in step b) is subjected to one or more further purification steps, in particular for the removal of rare earths and optionally for the removal of radioactive elements and / or heavy metals, such as, for example, Cd, Pb, Hg, before the purified calcium sulfate is fed to step c). The optional additional cleaning steps are explained below.

The purified calcium sulfate used in step c) preferably has a P2O5 content of less than 0.5% by weight, preferably less than 0.25% by weight, more preferably less than 0.05% by weight, and a fluoride content of less than 0.5% by weight, preferably less than 0.25% by weight, more preferably less than 0.15% by weight, and even more preferably less than 0.05% by weight. A purified calcium sulfate with the stated degree of purification with regard to P2O5 and fluorine is preferably obtained after step b). The cleaning step according to steps a) and b) and optionally the cleaning step for the removal of rare earths can optionally also completely or partially remove unwanted heavy metals and / or radioactive elements, in particular radioactive elements, contained in the calcium sulfate.

In step c) of the method according to the invention, the separated, cleaned and processed calcium sulfate is mixed with additives and reducing agents in order to obtain a raw meal mixture for cement clinker production. The calcium sulphate is mixed with the necessary additives for the required cement clinker quality in the correct ratio. As already mentioned, the Müller-Kühne process and the OSW-Krupp process for converting calcium sulfate with additives and reducing agents into cement clinker and SO2 or sulfuric acid have long been known. Further details on this can be found in the specialist literature, e.g. Ullmann's Encyclopedia of industrial Chemistry, 5th Edition, 1986, Vol. A5, "Cement and Concrete", p. 489-537, or the patent specification AT 292539 B. In general, cement clinker is produced from a raw material mixture called raw meal that contains calcium oxide, silicon dioxide and oxides of aluminum and iron, see, for example, Ullmann's Encyclopedia of industrial Chemistry, 5th Edition, 1986, Vol. A5, "Cement and Concrete", pp. 489-537.

Components for producing the raw meal in step c) can, in addition to purified phosphogypsum / calcium sulfate, be the additives for the clinker composition known to the person skilled in the art, which are added to the calcium sulfate, the calcium component being completely formed in the raw meal mixture from the separated, purified calcium sulfate. This does not completely rule out the fact that calcium may be contained in the additives in small amounts or as impurities. Complete here means that at least 95%, more preferably at least 99%, even more preferably at least 99.9% of the calcium contained in the cement clinker comes from the separated, purified calcium sulfate. This means that the additives used are free or largely free of calcium. Additives are in particular aluminum carriers such as bauxite, clays and mudstones, slate, etc., Fe carriers such as iron ores, laterites, etc. and Si carriers such as sands, sandstones, quartzites, clays and mudstones, slate , etc. and one or more reducing agents, such as a carbon and / or hydrocarbon carrier, for example coal, coke, petroleum coke or coal / coke produced from renewable raw materials (bio-coal / coke) and / or elemental sulfur.

It goes without saying that the type and amount of the additives are selected so that, together with the calcium sulfate, they result in a raw meal with a suitable chemical composition for a cement clinker.

In a preferred embodiment, the separated purified calcium sulfate from step b) used for step c) makes up more than 70% by weight, preferably more than 80% by weight, more preferably more than 90% by weight, of the total calcium sulfate in the raw meal mixture out. For the remainder of the calcium sulfate in the raw meal mixture obtained in step c), which is not the separated, purified calcium sulfate obtained in step b), calcium sulfate from other customary sources can be used.

Solid fuels, for example coal, coke, petroleum coke, solid secondary fuels, etc., and liquid fuels, for example oil, heavy oil, liquid secondary fuels, etc. or gaseous fuels, for example natural gas, biogas, hydrogen, and a combination of the above are suitable as fuel Fuels.

Additives and / or mineralizers to accelerate the decomposition of the purified calcium sulfate and / or to improve the formation of clinker minerals can also be added.

Raw meal for the production of cement clinker is the mixture of the substances calcium sulphate, all conventional cement additives and additives / mineralizers including reducing agents. For the preparation of raw meal in step c), the purified calcium sulfate is preferably dried to a desired residual moisture content, e.g. in a drum dryer and / or entrained flow dryer and / or fluidized bed, the water content of the dried calcium sulfate e.g. below 22% by weight, preferably 12-14% by weight %, more preferably below 5% by weight, even more preferably below 1% by weight. The water content here only refers to free water, any flydrat water that may be present is not taken into account.

The dried calcium sulfate and all other additives are fed to a conventional storage and / or mixing device. For example, a longitudinal mixing bed and / or circular mixing bed and / or tank storage and / or outdoor storage and / or conventional silos, such as tangential mixing silo, multi-cell silo, conical silo or multi-chamber silo, are used for this purpose. For example, such a mixed bed is described in DE 10252585 or those silo types that are described in more detail in DE10118142 or DE 10344040.

The raw materials (calcium sulfate and additives) are ground separately or together to the fineness required for the clinker process. This comminution can be carried out as grinding drying, in which waste heat from the process (e.g. preheated gases) and / or specially supplied heat (e.g. exhaust gases from a hot gas generator) are used.

For the comminution, comminution units such as at least one vertical roller mill and / or a roller press and / or an agitator ball mill and / or ball mill and / or vertical roller mill and / or rod mill and / or magnetic mill are used. Corresponding units are known, for example, from the property rights DE 102012111217, DE 102014108334 or DE 102017114831.

The ground raw materials are fed together or separately to one or more silos for intermediate storage and / or homogenization.

The chemical composition of the raw meal mixture is continuously checked before it is added to the clinker process and, in the event of deviations from specified target values, corrected by changing the dosage. The raw meal pre-treated in this way is metered into the clinker plant, if necessary together with reducing agent.

The reducing agent is used to support the splitting off of SO2 during the thermal decomposition of the purified calcium sulphate. The reducing agent is broken down and / or ground separately to the required fineness. This comminution can be carried out as grinding drying. The reducing agent prepared in this way is fed to the clinker plant and / or separately at one or more points of the clinker plant together with the pretreated raw meal.

Alternatively, if the liquid content of the mixture is 9% -22% by weight, preferably between 12% -14% by weight, the raw meal can be fed to a shaping device for producing agglomerates. These agglomerates can be dried and temporarily stored in a separate facility. The raw meal agglomerated in this way is then fed to the preheating device and the burning process. The agglomerates have a size of more than 250 μm, preferably more than 500 μm, down to the low mm range. A press and / or a plate and / or a drum and / or a mechanical fluidized bed reactor and / or a shaping agitator mixer, for example, can function as the shaping device.

In step d) of the method according to the invention, the raw meal that is produced in step c) is converted into cement clinker by a thermal process, in particular in a cement clinker process unit, with sulfur dioxide being formed as exhaust gas. The cement clinker produced in step d) can be used for cement production.

In step d), the raw meal is preferably preheated to a temperature of up to 800 ° C. with process gases from the burning or cooling process to reduce energy consumption, while adhering surface moisture is expelled and the additives are at least partially calcined.

With further preheating above 800 ° C, the main part of the calcium sulphate is decomposed under the action of the reducing agent with the formation of SO2. The preheating and decomposition of the raw meal can be carried out, for example, in a heat exchanger, preferably an entrained flow heat exchanger.

The process gas containing SO2 is preferably separated after the preheating device by a separation system and fed to a recycling process such as a sulfuric acid plant.

In a subsequent step, the raw meal is finally decomposed and the cement clinker is subsequently formed (clinker burn); the process gases of this step are fed to the heat exchanger. This burning of the raw meal takes place in an oven, preferably a rotary kiln. The firing temperature for cement clinker production can be, for example, in the range from 1200 ° C to 1600 ° C, preferably at a temperature of 1200 ° C to 1500 ° C. The burn time can be, for example, 5 minutes to 60 minutes.

In a preferred embodiment, the raw meal is burned with oxygen-enriched process air which contains more than 21% by volume, preferably more than 45% by volume, more preferably more than 60% by volume and up to 100% by volume, oxygen. Corresponding process air can easily be produced by adding oxygen. A particularly preferred embodiment here is the oxyfuel process. Details of the oxyfuel process are described, for example, in EP 2449328 A1, EP 1037005 B1, WO 2019-211196 A1, WO 2019-211202 A1 or JP 2007-126328 A, to which reference is made.

By using process air enriched with oxygen, the SO2 concentration in the process gas can be increased, which facilitates the extraction of sulfuric acid from gases containing SO2.

The process air mentioned above may have been used in advance to cool the fired material. It is also conceivable that this process air is fed directly to the furnace. It would also be conceivable that the process gas is at least partially drawn off in a bypass system and / or from the entrained flow reactor, then enriched with oxygen and fed back into the combustion process.

The clinker coming out of the kiln is preferably cooled to a temperature below 120 ° C, preferably below 100 ° C, using a suitable cooling system, cooled down. The cooler exhaust air can at least partially be fed to the burning process and / or the preheating process and / or the raw meal production and / or the calcium sulfate drying. The process air supplied to the cooling system can, at least partially, be enriched with oxygen.

It would also be conceivable that at least part of the cooler exhaust air is used to generate electricity. The material cooled by the cooling process is fed to a storage and / or packaging device after possible further process steps.

The cement clinker produced in this way can be further processed into cement. The cement clinker or cement produced by this method have a smaller CCV footprint than a conventional clinker or cement produced on the basis of carbonate-containing rocks.

The processes mentioned above, such as the use of phosphogypsum as a CO2-neutral raw material and the use of the oxyfuel process, reduce the C02 footprint of the cement plant. Furthermore, the use of at least partially renewable electricity to operate the plant components can further reduce the CO2 footprint.

In step e) of the process according to the invention, the sulfur dioxide formed in step d) is fed as a raw material to a sulfuric acid production facility in order to produce sulfuric acid, e.g. using the single-contact or double-contact process. The person skilled in the art is very familiar with the production of sulfuric acid based on SO2. Details on this can be found in the specialist literature, for example Flandbook of Sulphuric Acid Manufacturing, by Douglas K. Louie, 2nd edition, 2008, published by DKL Engineering, or Ullmann's Encyclopedia of industrial Chemistry, 5th edition, 1994, Vol. A25, " Sulfuric Acid and Sulfur Trioxide ", pp. 635-705.

The sulfuric acid produced in step e) can be used, for example, in phosphoric acid production as a starting material for the reaction with the raw phosphate. Alternatively, the sulfuric acid produced can be used for further or different purposes as required. The treated sulfur dioxide gas can optionally be fed to the existing phosphoric acid production facility or to a new sulfuric acid production facility. In a preferred embodiment, the sulfur dioxide, which is discharged from the cement clinker process unit as waste gas in step d), is fed to a sulfur dioxide waste gas treatment before it is fed to the sulfuric acid production according to step e). The exhaust gas treatment is preferably exhaust gas cleaning in order to remove solid particles and residual moisture from the SC gas.

With the optional exhaust gas cleaning, the sulfur dioxide to be cleaned leaves the clinker processing unit preferably at a temperature of 200 ° C to 450 ° C. If necessary, the sulfur dioxide to be cleaned is pre-cooled to this temperature in a cooling unit.

The purification of the sulfur dioxide before step e) can comprise a dry separation of particles (optional step 1)). In this step, particles with a size greater than 100 μm are preferably deposited.

The purification of the sulfur dioxide can further comprise the following optional steps 2), 3) and / or 4). Step 2) comprises wet separation, preferably in order to separate particles with a size of 20 to 100 μm.

Step 3) comprises an optional separation, preferably dry separation, of particles, preferably with a size of less than 20 μm. Step 4) comprises an optional separation of nitrogen oxides from the sulfur dioxide gas.

The dry separation of particles from the sulfur dioxide in steps 1) and / or 3) can be carried out by means of a cyclone, rotary flow separator and / or dry electrostatic precipitator. The wet separation of particles from the sulfur dioxide in step 2) can be carried out, for example, by means of a venturi washer, quencher / column washer and / or wet electrostatic precipitator.

The residual moisture that may be present in the sulfur dioxide after wet separation can be separated off by condensation. The separation of nitrogen oxides from the sulfur dioxide in step 4) can take place by decomposing the nitrogen oxides to form N2 and H2O. Methods that can be used for this are known to the person skilled in the art and are described, for example, in Handbook of Sulfuric Acid Manufacturing, by Douglas K. Louie, 2nd edition, 2008, published by DKL Engineering. The nitrogen oxides are preferably decomposed by gas treatment processes such as selective catalytic reduction, selective non-catalytic reduction and / or by scrubber technologies, or by wet chemical conversion in the liquid phase in the sulfuric acid process.

The term selective catalytic reduction (SCR) describes a technique for reducing nitrogen oxides in exhaust gases. The chemical reaction on the SCR catalytic converter is selective, which means that the nitrogen oxides (NO, NO ₂ ) are preferably reduced, while undesirable side reactions are largely suppressed.

Ammonia is preferably added to the exhaust gas for the reaction. The products of the reaction are water (H ₂ O) and nitrogen (N ₂ ). The reaction is a comproportionation of nitrogen oxides with ammonia to nitrogen. Two types of catalysts can be used: the first preferably consists mainly of titanium dioxide, vanadium pentoxide and tungsten dioxide, the other preferably uses zeolites.

In an optional variant of the method according to the invention, the method comprises an additional cleaning step for the calcium sulfate obtained after step b), which is carried out before the calcium sulfate is mixed with the additives and reducing agents according to step c). In this additional cleaning step, rare earth metals, which may be contained as impurities, can be washed out of the calcium sulfate.

In the optional additional purification step for removing rare earths from the calcium sulfate before it is fed to step c), the purified calcium sulfate obtained in step b) is preferably mixed with a liquid, preferably water or with an aqueous solution containing salt and / or chelating ligand, treated (optional step bl). After the treatment, the calcium sulfate is separated from the liquid phase as a solid from the suspension obtained in this way (optional step b2). The calcium sulphate which has been further purified and separated is then fed to step c). The liquid phase contains one or more rare earths as dissolved ions and can be fed to further processing to extract the rare earths. For example, this processing includes the conversion of poorly soluble rare earth sulfates into soluble forms. In the optional step bl), for the solution of the rare earths from the calcium sulfate, an aqueous solution is preferably used as the liquid, which contains a salt and / or a chelating ligand in a concentration of 1 to 50% by weight, preferably 1 to 20% by weight .-%, particularly preferably from 5 to 10% by weight. It is also possible that the rare earths are dissolved from the calcium sulfate in step bl) by adding water as a liquid.

The salt used for the solution of the rare earths from the phosphogypsum in step bl) comprises or is preferably a chloride and / or a nitrate and / or contains a chelating ligand. In principle, the chelating ligand is not limited, but includes all chelating ligands that form a soluble complex with at least one of the rare earths. Preferred chelating ligands include ethylenediaminetetraacetic acid (EDTA), diethylenetriaminepentaacetic acid (DTPA) and / or citric acid and / or their corresponding salts.

Particularly suitable salts here are the sodium, ammonium, calcium, magnesium and potassium salts with the anions chloride, nitrate, acetate, bromide, bromate, perchlorate and iodide. It has also been shown that in certain cases the use of ammonium sulfate can be effective. The nitrate can also be introduced in step bl) in the form of, preferably dilute, nitric acid.

The residence time for the solution of the rare earths from the phosphogypsum in step bl) is preferably 20 min to 80 h, preferably 1h to 76h or 2h to 72h, particularly preferably 3h to 70h and very particularly preferably 4h to 68h, in particular 5h to 68h or 5h to 64h.

The reaction mixture in step bl) is preferably kept in motion during the reaction time. The reaction mixture in step bl) is preferably kept in motion during the reaction time by circulating, stirring or blowing in gas.

The reaction in step bl) is preferably carried out at a temperature from 10 to 100.degree. C., preferably from 15 to 80.degree. C. and very particularly preferably from 20 to 75.degree. C., in particular from 20 to 60.degree. The reaction in step bl) can preferably also be carried out at room temperature without additional heating or cooling. The weight ratio of solid to liquid (S / L ratio) for the solution of the rare earths from the phosphogypsum in step bl) can be 1: 1 to 1: 10 and is preferably in the range of 1: 2 to 1: 5.

The separation of the further purified phosphogypsum as a solid from the liquid phase containing one or more rare earths in the optional step b2) preferably comprises centrifugation, filtration, sedimentation and / or evaporation of the liquid phase.

The rare earths are preferably obtained from the solution containing one or more rare earths obtained in step b2) by means of solvent-solvent extraction, ion exchange processes, precipitation as flydroxides, oxalates, carbonates and / or phosphates. Particularly suitable ion exchange processes are cation exchange processes or a combination of cation exchanger and anion exchanger.

The phosphogypsum separated off in step b2) can, for example, have a moisture content of 0 to 60% by weight, preferably 5 to 50 and particularly preferably 10 to 40% by weight. With this moisture content, the phosphogypsum can then be fed to step c). However, procedures are also conceivable in which a slurry or a suspension of calcium sulfate is obtained and further processed in step b2).

The method according to the invention can also serve to remove radioactive elements and / or heavy metals. When the reaction conditions (S / L ratio, residence time, acid concentration and temperature) are suitably set, the purified calcium sulfate obtained after step b) shows a clear depletion of radioactive elements, such as thorium and uranium. In the further optional cleaning step for the extraction of rare earths, heavy metals (and further radioactive components) such as cadmium and lead can also be removed by a suitable choice of the processing step. Before being fed to step c), the purified calcium sulfate can therefore have a reduced content of phosphorus and fluorine and, if appropriate, of rare earths, radioactive elements and / or heavy metals. It goes without saying that the reduced content of the respective element relates to the comparison to the content of the respective element in the calcium sulfate which is fed to step a). The integrative approach or the integrative method of the invention is characterized in particular by the following features and advantages:

The process for the production of cement clinker or cement can be carried out flexibly with regard to the initial quality of the phosphorus gypsum and in combination with the phosphoric acid process,

The sulfuric acid produced from the SC exhaust gas can be introduced into the overall complex and consumed as well as generated and, for example, circulated

The following process engineering processes can, for example, be combined in their entirety or optionally for the production of cement clinker / cement and sulfuric acid from calcium sulfate: o Chemical and thermal modification of the phosphoric acid process for the targeted production of a phosphor gypsum quality suitable for the cement clinker process o Mechanical separation of the phosphor gypsum from the ongoing phosphoric acid process for example by centrifugation, filtration, evaporation or settling / sedimentation of the calcium sulphate / phosphogypsum sludge o Chemical-thermal and mechanical separation of phosphorus from the phosphogypsum, for example by chemical conversion,

Recrystallization, precipitation, flocculation, o Chemical-thermal and mechanical separation of fluorine from the phosphogypsum, for example by chemical conversion,

Recrystallization, precipitation, flocculation, o chemical-thermal and mechanical separation of radioactive components from the phosphogypsum, for example by chemical conversion with heating / cooling, recrystallization, precipitation, flocculation, o chemical-thermal and mechanical separation of heavy metals from the phosphogypsum, for Example by chemical conversion with heating / cooling, recrystallization, precipitation, flocculation, o Chemical-thermal and mechanical separation of rare earths from the phosphogypsum, for example by chemical conversion with heating / cooling, recrystallization, precipitation, flocculation, o Chemical and / or thermal and / or mechanical dewatering of the phosphogypsum, for example by heating / cooling, flocculation and precipitation, filtration o Mechanical treatment of the dry phosphogypsum, for example by crushing, sifting, o Mixing the phosphogypsum with additives to form a raw meal mixture Achievement of specific and commercially available cement clinker / cement qualities o Thermal and mechanical separation of the sulfur dioxide from the raw meal mixture as part of the burning process in cement clinker production o Thermal and chemical conversion of the raw meal mixture into cement clinker o Chemical and mechanical conversion of the cement clinker into commercially available cement quality o Dry and wet chemical Purification of the separated exhaust gas containing sulfur dioxide, for example by electrofiltration, absorption o Chemical and thermal modification of the sulfuric acid process to incorporate and use the generated sulfur dioxide in plants for production of sulfuric acid o Chemical conversion of the cleaned exhaust gas containing sulfur dioxide into sulfuric acid of commercial quality that can be reused in the phosphoric acid process, for example according to the single-contact or double-contact process.

Depending on the quality of the calcium sulphate used, the production methods must be flexibly selected in terms of the process engineering processes and parameters and must be coordinated with one another. The quality of the calcium sulphate obtained from the phosphoric acid process depends on factors such as the rock phosphate used and process conditions during the digestion of the rock phosphate with sulfuric acid.

The scope of the cleaning, in particular with regard to the reduction of the content of phosphorus and / or fluorine, of the calcium sulfate in step a) can take into account the impurities in the additives used are included, and the standard values for phosphorus and fluorine to be observed for the cement clinker are set. The guide values for phosphorus are preferably a maximum of 1.0% by weight, more preferably a maximum of 0.5% by weight, even more preferably a maximum of 0.1% by weight P2O5 and / or the guide values for fluorine are preferably a maximum of 0.5% by weight %, more preferably a maximum of 0.25% by weight, even more preferably a maximum of 0.1% by weight of F. This is possible due to the integrative approach, since all process steps are considered together, taking their respective requirements into account. The scope of cleaning can be set by adjusting the parameters in step a), such as S / L ratio, acid concentration, treatment temperature and duration.

The fluid balance, in particular the water balance, of the phosphoric acid production is not or only insignificantly changed by the integrated process, in particular since the use of liquid, in particular water, for cleaning the calcium sulfate in the process according to step a) can be linked to the liquid balance, in particular the water balance, of phosphoric acid production . The liquid or water balance of phosphoric acid production includes the liquid or water that is fed to production and the liquid or water that is discharged from production. Changes in the fluid balance, especially the water balance, have a significant influence on the efficiency of the process steps in phosphoric acid production.

The invention also relates to a plant for the production of sulfuric acid and cement clinker using calcium sulfate, which is formed and separated off as a solid by-product in a phosphoric acid production during the reaction of rock phosphate with sulfuric acid to form phosphoric acid, the plant comprising the following devices: a) a Calcium sulphate reaction unit which is suitable for treating the calcium sulphate separated from the phosphoric acid with an acid in order to obtain a suspension with purified calcium sulphate, b) a calcium sulphate separation unit which is suitable for separating the purified calcium sulphate as a solid from the separating the liquid phase of the suspension obtained, c) a raw meal mixing unit which is suitable for adding the separated, purified calcium sulfate with additives and reducing agents mix in order to obtain a raw meal mixture for cement clinker production, d) a cement clinker production unit, for example a combination of a preheating unit, a burning unit and at least one cooling unit which is suitable for preheating, burning and cooling the raw meal mixture in order to obtain the cement clinker , whereby sulfur dioxide is formed as waste gas, and e) a sulfuric acid production plant, to which the sulfur dioxide waste gas formed in the cement clinker production unit and optionally purified is fed as raw material in order to produce sulfuric acid, the sulfuric acid production plant being part of the phosphoric acid production plant or an external sulfuric acid production facility and / or other use.

The plant can be used for the method according to the invention described above. For information on the individual facilities or units, please refer to the information provided above. The above information for the procedure applies accordingly to the system.

It is preferred that in the system according to the invention the calcium sulfate separation unit is fluidically connected, for example via a pipeline, to the phosphoric acid production system so that the liquid phase obtained in the calcium sulfate separation unit can be introduced into the phosphoric acid production as feedstock.

It is preferred that in the system according to the invention the calcium sulfate separated off for step a) can be fed from a separation unit of the phosphoric acid production, which separates the phosphoric acid from the calcium sulphate, or from a heap of calcium sulphate from the phosphoric acid production.

The invention is described below on the basis of exemplary embodiments, which are explained in more detail with the aid of the figures. The exemplary embodiments are not intended to limit the scope of the claimed invention in any way.

1 shows a schematic flow diagram for the utilization of calcium sulfate from phosphoric acid production with the aid of an integrated complex for the production of cement clinker and sulfuric acid. FIG. 2 shows a schematic flow diagram for the utilization of calcium sulfate from phosphoric acid production with the aid of an integrated complex for the production of cement clinker and sulfuric acid as in FIG. 1, with additional or additional process steps being shown.

Fig. 1 shows a flow diagram of phosphoric acid production (existing complex) and an integrated process for the production of cement clinker and sulfuric acid from calcium sulfate derived from phosphoric acid production (integrated complex). The phosphate rock is processed in a processing unit 1 in order to obtain the raw phosphate. The raw phosphate is reacted in the reaction unit of the phosphoric acid plant 2 with sulfuric acid originating from the sulfuric acid production plant in order to form phosphoric acid and solid calcium sulfate as a by-product. The calcium sulphate generated in the phosphoric acid production is separated from the phosphoric acid in the filtration unit 3 of the phosphoric acid plant and fed to the calcium sulphate reaction unit 5. There the calcium sulfate is treated with acid, so that after the treatment, for example, a 1-12 molar acid, in particular a 1-12 molar sulfuric acid, is obtained. For example, a 1-12 molar sulfuric acid can be added for the treatment. After the acid has been added, the treatment can be carried out, for example, at a temperature of 15-100 ° C. for 5 to 120 minutes, the suspension obtained preferably being agitated, for example by stirring. The impurities in the calcium sulphate, which have a negative impact on the downstream cement clinker process and the cement quality, are reduced to the level required by the cement clinker process. In a calcium sulfate separation unit 6, which is preferably a filtration unit, the liquid and the resulting solid are separated from one another. The liquid, in particular the filtrate, can be used in the existing phosphoric acid-sulfuric acid complex. The treated calcium sulfate is fed to the raw meal preparation unit 7 connected upstream for the cement clinker process. There, the calcium sulphate is mixed with the necessary additives for the required cement clinker quality in the correct ratio. The cement clinker process unit 8 is charged with the prepared cement clinker raw meal, the raw meal preferably being preheated in a heat exchanger (not shown) before it is fed to the process unit 8. In the cement clinker process unit 8, sulfur dioxide is separated from the calcium sulfate and fed as exhaust gas from the cement clinker process unit to the sulfur dioxide exhaust gas treatment 9. The treated sulfur dioxide gas can optionally the existing sulfuric acid production plant 4 are fed. Alternatively, the treated sulfur dioxide gas can optionally be fed to a new sulfuric acid production plant (cf. 13 in FIG. 2). The calcium remaining in the cement clinker process unit reacts with the additives to form cement clinker. The burning temperature for cement clinker production can be, for example, at a temperature in the range from 1200 ° C. to 1600 ° C. and a burning time from 5 minutes to 60 minutes. The cement clinker produced in this way is cooled and can be further processed into cement.

FIG. 2 shows a schematic flow diagram for the utilization of calcium sulfate from phosphoric acid production with the aid of an integrated complex for the production of cement clinker and sulfuric acid according to FIG. 1, with additional or additional process steps being shown. The alternative or additional process steps are discussed below, otherwise reference is made to the explanations relating to FIG. 1. Fig. 2 shows an alternative source for the calcium sulfate used in step a). Instead of the calcium sulfate from the filtration unit of the phosphoric acid plant 3, a calcium sulfate from a dump 10 can be used for the calcium sulfate used in step a), which is deposited calcium sulfate from phosphoric acid production. Furthermore, FIG. 2 shows the optional processing step for removing rare earths, which comprises a reaction unit for extracting rare earth metals from the calcium sulphate 11 and the calcium sulphate separation unit 12 for separating the liquid phase from the purified calcium sulphate. Furthermore, it is shown in FIG. 2 that the sulfur dioxide obtained from the SC treatment 9 can be used for the production of sulfuric acid in the existing sulfuric acid production plant 4 and / or a new sulfuric acid production plant 13.

Examples

Below are some examples of how to clean various phosphor gypsums. The phosphor gypsums were each dried before and after the treatment by the method described for at least 24 h at 50 ° C. in order to remove free water. The chemical composition of the plasters was determined before and after treatment by means of X-ray fluorescence analysis (XRF) on an Axios Advanced spectrometer from PANalytical with the SuperQ 5.3B software package. For this purpose, the plaster of paris was made using lithium tetraborate open minded. The loss on ignition of the plasters was determined at 1050 ° C. The fluoride content was determined after digestion of the gypsum using sodium peroxide and hydrochloric acid using an ion-selective electrode. All the values of the results from the XRF given below relate to the gypsum samples free from ignition loss. Some plasters were also checked for their mineralogical composition before and after treatment by means of powder diffractometry on a D4 Endeavor diffractometer from Bruker. The software package Topas 4.2 from Bruker was used for evaluation by means of the Rietveld method. The Dv (50) value of the particle size distribution was determined on a Mastersizer 3000 from Malvern with ethanol as the dispersing medium. The Fraunhofer model was used as the scattering model.

Example 1:

50 g of a phosphorus gypsum designated as “PG A” with P ₂ 05 contents of 1.29% by weight and F contents of 1.25% by weight was combined with 200 ml (S / L = 0.25) 8 molar sulfuric acid for 30 minutes using a KPG stirrer at 60 ° C. After the time had elapsed, the suspension was quickly filtered and washed twice with 57.5 ml of water at room temperature , 02 or 0.01% by weight (corresponds to a leaching efficiency of 98% or 99%). The mineralogical composition before treatment was made with 2.8% by weight quartz, 91.5% by weight dihydrate (CaSO * 2Fi ₂ 0), 3.7% by weight of flemihydrate (CaSO * 0.5 Fi ₂ 0) and 2.9% by weight of anhydrite (CaSO) .After treatment, the following composition was determined: 3.3% by weight. -% quartz, 1.2% by weight dihydrate (CaSO * 2H ₂ 0), 0.1% by weight flemihydrate (CaSO * 0.5 Fl ₂ 0) and 95.5% by weight anhydrite (CaSC) .

Example 2:

75 g of the same gypsum PG A as in Example 1 was stirred in a further experiment with 150 ml (S / L = 0.5) 6 molar sulfuric acid for 30 minutes at 60 ° C. using a KPG stirrer. After the time had elapsed, the suspension was quickly filtered and washed twice with 86.3 ml of water at room temperature. After treatment, the P ₂ Os and F contents are still 0.29 and 0.03% by weight (corresponds to a leaching efficiency of 78% and 98%). To Treatment, the following mineralogical composition was determined: 3.2% by weight quartz, 73.2% by weight dihydrate (CaSO * 2H ₂ 0), 2.4% by weight hemihydrate (CaSO * 0.5 H ₂ 0) and 21.2% by weight anhydrite (CaSO). The D _v (50) value after treatment is 59.1 gm.

Example 3:

75 g of another gypsum (designated as PG B) with P ₂ Os content of 1.70% by weight and F content of 2.13% by weight was used in a further experiment with 150 ml (S / L = 0.5) 6 molar sulfuric acid for 30 minutes at 75 ° C using a KPG stirrer. After the time had elapsed, the suspension was quickly filtered and washed twice with 86.3 ml of water at room temperature. After treatment, the P ₂ Os and F contents are still 0.07 and 0.12% by weight (corresponds to a leaching efficiency of 96% and 94%, respectively). The mineralogical composition before treatment was determined to be 3% by weight quartz and 97% by weight dihydrate (CaSO * 2FI ₂ 0). After treatment, the following composition was determined: 2.5% by weight quartz, 0.4% by weight dihydrate (CaS0 ₄ * 2H ₂ 0) and 97.2% by weight anhydrite (CaSO). The D _v (50) value after treatment is 9.77 pm.

Example 4:

75 g of the same gypsum (PG B) was stirred in a further experiment with 150 ml (S / L = 0.5) 6 molar sulfuric acid for 45 minutes at 75 ° C. using a KPG stirrer. After the time had elapsed, the suspension was quickly filtered and washed twice with 86.3 ml of hot water at 75.degree. After treatment, the P ₂ Ü5 and F contents are still 0.03 and 0.11% by weight (corresponds to a leaching efficiency of 98% and 95%). After treatment, the following mineralogical composition was determined: 2.9% by weight quartz, 0.2% by weight dihydrate (CaSO * 2FI ₂ 0) and 97.0% by weight anhydrite (CaSO). The D _v (50) value after treatment is 9.34 pm.

Example 5

75 g of the same gypsum (PG B) was stirred in a further experiment with 150 ml (S / L = 0.5) 7 molar sulfuric acid for 30 minutes at 75 ° C. using a KPG stirrer. After the time had elapsed, the suspension was quickly filtered and washed twice with 86.3 ml of water at room temperature. After treatment the P2O5 and F contents are still 0.03 and 0.06% by weight (corresponds to a leaching efficiency of 98% and 97%). The D _v (50) value after treatment is 6.99 gm.

Example 6:

75 g of the same gypsum (PG B) was stirred in a further experiment with 150 ml (S / L = 0.5) 4 molar sulfuric acid for 20 minutes at 30 ° C. using a KPG stirrer. After the time had elapsed, the suspension was quickly filtered and washed twice with 86.3 ml of water at room temperature. After treatment, the P2O5 and F contents are still 0.43 and 0.17% by weight (corresponds to a leaching efficiency of 75% and 92%). After treatment, the following mineralogical composition was determined: 1.7% by weight quartz, 96.3% by weight dihydrate (CaSO * 2Fi ₂ 0), 2.0% by weight flemihydrate (CaSO * 0.5 Fi ₂ 0 ) and 0% by weight anhydrite (CaSO). The D _v (50) value after treatment is 16.1 pm.

Example 7:

To assess whether the process described can also be used with only separated and thus unwashed phosphorus gypsum from the phosphoric acid plant, 75 g of the same gypsum PG B as in Example 3 were _{mixed with 25 g of 25% P 2} Os solution (in the form of phosphoric acid ) and stirred with 150 ml (S / L = 0.5; 25 g P ₂ Os solution not taken into account) 7 molar sulfuric acid for 30 minutes at 75 ° C using a KPG stirrer. After the time had elapsed, the suspension was quickly filtered and washed twice with 86.3 ml of water at room temperature. After treatment, the P2O5 and F contents are still 0.07 and 0.08% by weight (corresponds to a leaching efficiency of 96% and 96%). After treatment, the following mineralogical composition was determined: 2.5% by weight quartz, 0.2% by weight dihydrate (CaSO * 2FI2O) and 97.3% by weight anhydrite (CaSO). The D _v (50) value after treatment is 6.62 pm.

Example 8:

To evaluate the filterability of the suspensions as a function of the influencing variables such as, for example, temperature, residence time and concentration of the acid, the filtration times of the suspensions from Examples 3, 4 and 5 were used a suction filter with a filter area of 56 cm ^{2 is determined} at a vacuum of 500 mbar. In all cases the filter cake height was between 13 and 14.5 mm. The suspension from Example 5 had a filtration time of 30 s and 52 s and 39 s in the 1st and 2nd wash. The suspension from Example 3 had a filtration time of 11 s and 22 s and 19 s in the 1st and 2nd wash. The suspension from Example 4 had a filtration time of 11 s and 20 s and 11 s in the 1st and 2nd wash. It turns out that the filterability can be optimized while maintaining the cleaning quality by adapting the influencing variables.

List of reference symbols

1 processing unit for phosphate rock or phosphate ore

2 reaction unit of the phosphoric acid plant

3 Filtration unit of the phosphoric acid plant

4 sulfuric acid production plant (existing)

5 Calcium Sulphate Reaction Unit

6 Calcium sulphate separation unit

7 Raw meal preparation unit

8 cement clinker processing unit

9 Sulfur dioxide waste gas treatment

10 calcium sulfate from Halde (from phosphoric acid production)

11 Extraction of rare earths from calcium sulphate

12 Calcium sulphate separation unit

13 sulfuric acid production plant (new)

Claims

Expectations

1. A process for the production of sulfuric acid and cement clinker using calcium sulfate, which is formed and separated off as a solid by-product in a phosphoric acid production during the reaction of raw phosphate with sulfuric acid to form phosphoric acid, the process comprising the following steps: a) from the phosphoric acid separated calcium sulfate is treated with an acid to obtain a suspension with purified calcium sulfate, b) the purified calcium sulfate is separated as a solid from the liquid phase of the resulting suspension, c) the separated purified calcium sulfate is mixed with additives and reducing agents to form a raw meal mixture for cement clinker production, d) the raw meal mixture is burned in order to obtain the cement clinker, whereby sulfur dioxide is formed as exhaust gas, and e) the sulfur dioxide formed is fed as raw material to sulfuric acid production in order to produce the sulfuric acid, w whether the sulfuric acid produced can be used as a feedstock in phosphoric acid production and / or can be put to another use.

2. The method according to claim 1, characterized in that the method is an integrated method.

3. The method according to claim 1 or 2, characterized in that the phosphoric acid production is carried out according to a process which is selected from a dihydrate (DH) process, hemihydrate (HH) process, dihydrate-hemihydrate (DHH) - Process, hemihydrate dihydrate (HDH) process and dihydrate attack hemihydrate filtration (DA-HF) process, preferably from a dihydrate (DH) process and a hemihydrate (HH) process.

4. The method according to any one of the preceding claims, characterized in that the calcium sulfate separated from the phosphoric acid production is not subjected to any recrystallization before being fed to step a).

5. The method according to any one of the preceding claims, characterized in that the calcium sulfate obtained from a separation unit of the phosphoric acid production is used as the calcium sulfate which is used in step a), wherein preferably the calcium sulfate solid obtained after the first separation from the phosphoric acid, preferably calcium sulfate filter cake, from which phosphoric acid production is used directly or after one or more washes with liquid, preferably water, and / or calcium sulfate stored on flalden from phosphoric acid production is used.

6. The method according to any one of the preceding claims, characterized in that the calcium sulfate separated from the phosphoric acid and used in step a) is calcium sulfate in the form of dihydrate, flemihydrate or a combination thereof.

7. The method according to any one of the preceding claims, characterized in that in step a) the acid is added in such an amount that the weight ratio of solid to liquid (S / L ratio) in the suspension is in the range from 1/10 to 1/1, preferably 1/5 to 1/1, and / or the acid resulting from the treatment according to step a) is a 1 to 12 molar, preferably 3 to 10 molar, more preferably 5 to 8 molar acid, and / or where the acid is selected from hydrochloric acid, nitric acid, sulphurous acid and / or sulfuric acid, and / or where the treatment in step a) is at a temperature in the range from 15 to 100 ° C, preferably 30 to 80 ° C, more preferably 45 to 75 ° C, and / or wherein the duration of the treatment in step a) is in the range from 5 to 120 minutes, preferably 15 to 90 minutes, more preferably 20 to 60 minutes.

8. The method according to any one of the preceding claims, characterized in that the D _v (50) value of the particle size distribution of the calcium sulfate obtained in step b), in particular calcium sulfate anhydrite, is in the range of 0.5-100pm, preferably 1-50pm, especially 2-30pm.

9. The method according to any one of the preceding claims, characterized in that the separated purified calcium sulfate obtained in step b) at least 5 wt .-%, preferably at least 30 wt .-%, more preferably at least 50 wt .-% anhydrite, based on dry calcium sulfate , contains.

10. The method according to any one of the preceding claims, characterized in that the liquid phase obtained in step b) is used as a starting material in phosphoric acid production, in particular as a portion of the sulfuric acid required to digest the rock phosphate.

11. The method according to any one of the preceding claims, characterized in that the additives for producing the raw meal mixture in step c) are raw materials or compounds which comprise one or more oxides selected from oxides of Si, Al, Fe and optionally Ca or precursors thereof, and / or carbon and / or hydrocarbons and / or elemental sulfur is added to the calcium sulfate as a reducing agent, and / or the cement clinker produced in step d) is used for cement production.

12. The method according to any one of the preceding claims, characterized in that the sulfur dioxide formed as exhaust gas in step d) is subjected to exhaust gas cleaning before being fed to step e) in order _{to remove solid particles and residual moisture from the S0 2} exhaust gas.

13. The method according to any one of the preceding claims, characterized in that the purified calcium sulfate obtained in step b) is subjected to an additional cleaning step for removing rare earths before being fed to step c), in which the purified calcium sulfate obtained in step b) is also subjected a liquid, preferably with water or with an aqueous solution containing salt and / or chelate ligand, and the further purified calcium sulfate is separated from the liquid phase as a solid from the suspension thus obtained, the further purified calcium sulfate being fed to step c) and one or more rare earths are contained in the liquid phase.

14. The method according to any one of the preceding claims, characterized in that the purified calcium sulfate has a reduced content of phosphorus and fluorine and optionally rare earths, radioactive elements and / or heavy metals before being fed to step c).

15. The method according to any one of the preceding claims, characterized in that the scope of the cleaning of the calcium sulfate in step a) taking into account the impurities contained in the additives used for the raw meal and the guide values for the cement clinker for phosphorus and fluorine , which is preferably a maximum of 1.0% by weight, more preferably a maximum of 0.5% by weight, even more preferably a maximum of 0.1% by weight P2O5 and / or preferably a maximum of 0.5% by weight, more preferably a maximum of 0, 25% by weight, more preferably a maximum of 0.1% by weight F, is set, and / or the fluid balance, preferably the water balance, of the phosphoric acid production is not or only insignificantly changed by the integrated process, in particular since the use of fluids, preferably the use of water to purify the calcium sulfate in the integrated process to the fluid balance, preferably the water balance, which is coupled to phosphoric acid production.

16. The method according to any one of the preceding claims, characterized in that the separated, purified calcium sulfate used for step c) from step b) is more than 70% by weight, preferably more than 80% by weight, more preferably more than 90% by weight. %, of the total calcium sulfate in the raw meal mix.

17. Plant for the production of sulfuric acid and cement clinker using calcium sulphate, which is formed and separated off as a solid by-product in a phosphoric acid production during the conversion of raw phosphate with sulfuric acid to form phosphoric acid, the plant comprising the following equipment: a) a calcium sulphate reaction unit which is suitable for adding the calcium sulfate separated from the phosphoric acid with an acid treat to obtain a suspension with purified calcium sulphate, b) a calcium sulphate separation unit which is suitable to separate the purified calcium sulphate as a solid from the liquid phase of the suspension obtained, c) a raw meal mixing unit which is suitable to be incorporated therein to mix the separated, purified calcium sulphate with additives and reducing agents in order to obtain a raw meal mixture for cement clinker production, d) a cement clinker production unit, in particular a combination of a preheater, at least one combustion device and a cooler, which are suitable for preheating the raw meal mixture burn and cool in order to obtain the cement clinker, whereby sulfur dioxide is formed as exhaust gas, and / or e) a sulfuric acid production plant, to which the sulfur dioxide exhaust gas formed in the cement clinker production unit and optionally purified is fed as raw material to sulfuric acid manufacture, taking the sulfur acid production plant can be part of the phosphoric acid production plant or an external sulfuric acid production plant.

18. Plant according to claim 17, characterized in that the calcium sulphate separation unit is connected to the phosphoric acid production plant and / or another production plant via a pipeline so that the liquid phase obtained in the calcium sulphate separation unit enters the phosphoric acid production reaction unit and / or the other Production plant can be introduced as an input material.

19. Plant according to claim 17 or 18, characterized in that the separated calcium sulphate for step a) can be supplied from a separation unit of the phosphoric acid production, which separates the phosphoric acid from the calcium sulphate, or from a heap of calcium sulphate from the phosphoric acid production.