CA2465461C - Compacted granular potassium chloride, and method and apparatus for production of same - Google Patents
Compacted granular potassium chloride, and method and apparatus for production of same Download PDFInfo
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- CA2465461C CA2465461C CA002465461A CA2465461A CA2465461C CA 2465461 C CA2465461 C CA 2465461C CA 002465461 A CA002465461 A CA 002465461A CA 2465461 A CA2465461 A CA 2465461A CA 2465461 C CA2465461 C CA 2465461C
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Abstract
Apparatus and method are disclosed for the production of compacted granular potassium chloride with improved handling qualities. A binding ingredient such as sodium hexametaphosphate is blended with the potassium chloride feed material in advance of compaction. The product of this apparatus and method has improved handling, storage, strength and other qualities over compacted granular potassium produced using prior art methods.
Description
Cf3MPACTED GRANITLAR Pt7TASSIUM CHL~DRIDE, AND MET~iOD ANIy AFPAXtrl,7C(,TS F4R P)EtODUCTl't~N QF SA1VIE
This invention is in the field of mineral extraction and production, and more particularly deals with a method arid apparatus for the production of corrcpacted granular potassium chloride.
BAGKGIt~CIUND
PotassiLUn chloride ('potash"~ has rna~ry industrial uses, but is most commonly known as a coznpoz~ent of a~icultural fertilizers, Potash is typically extracted from underground t sources either by convexttional mining techniques or by solution mining. Once extracted, potassium chloride can be processed into a number Qf different finished. forms or products suitable for specific industrial, chemical or agricultural applications as desired by individual customers.
Finished potassium. chloride is typically sold in a ,granular form, and the purity and graalule size may vary depending on the end me to which the product will be put. The grading of potash, and hence its market value are also dependent on bath the purity and granule size of the product. Typically the potassimn chloride i.~ screened to the de,;ired particle size for a particular need.
i A typical potassium chloride feed stock, has a granule size that is comparable to table salt, which is le:;s than the desired g~rartule size. In ordez to obtain larger granules, this feedstoclc is first compacted using a simple roll campacter ar floe like to produce a sheet-like product. 8ubscduent processing typically involves controlled breakage of the potassium chloride sheet into granules, which are then sorted to a desired size range by $creez~iug or other methods lcxzowa~ in the industry.
However, one of the limitations with compacted granular potassium chloride produced in 1~ this fashion has been that the product will physically break down when handled, stored or shilsped. Given that granule size is an important feature in the finished prroduct, breakage therefore diminishes the value of the finished product. These broken granules that arise front the handling of the finished product during processing are known as recycle ar reclaiz~a z~atexnial. Suclx broken granules are collected car reclaimed from vazaaus areas I S during processing and can be mixed back into tlxe feedstock and compacted again.
After the finished product leaves thG plant, breakage diminishes the value of the product.
Ezokez~ gmx~ules are smaller than the desired size and cause problems during th.e storage and handling of the finished product due to a tendency to generate dust arid form clumps, 2Q a property known as "bridging." Bridging impedes the flow of the product, and may result in significant storage problems. Excessive dust causes environmental concerns while uneven granule size can directly affect applicarion rates.
Shippiztg of potash, typically by rai.i, is not a gentle pmcess either iz~
tezxns of the handling involved in the loading of rail cars or mechanical agitation during the extended mQVement of the rail cars themselve$. Thus, storage, shipping and handlin,~
after the potash has left the mill can break up granules, with the result that over time undesirable characteristics occur in the product.
Therefore, it has been the desire of those in the field to find methods of producing art improved compacted granular potassium chloride product, with better shipping,, handling and storage characteristics as camparcd to compacted potash products rnanufa.ctured using prior art methods. Methods of production that improve the handling characteristics of compacted pota.~h products and which result in a mare durable finished product are of value as the result will be a more desirable and saleable commodity.
1 ~ SUMMARY O~F TAE INVENTION
Xt is the object of the pre~~nt invention to produce an improved compacted ~-anular potassium chloride product with improved haa~dlizag qualities.
2i? More specifically, it is the object of the present invention to provide a xrtetltod and apparatus for the production of an improved compacted granular potassium chloride product that is less likely to bxeak down during handling, transport or long-terra storage.
The invcntian accomplishes #iis objective by the addition of a bzndiz~~
ingredient to the potassium chloride feed material in advance of the corripaction step in a compaction feed process or production circuit. Addition of an effective amount of sodium hexametaphosphate {SHMF) as a binding ingredient to the potassium chloride feed material iz~ advaxzce of compaction yields a compacted granular potassium chloride with better handling or storage quahities.
SHMP is operative to sequester moisture, calcium and magnesium and glue the product together and thus it will be understood by persons skillod in the art chat binding ingredients otihex than SHNlP will accomplish then same objectives. Therefore, tha substitution or incozporation of such alternative binding ingredients into the process or product of the present invention is intended to be encompassed within the scope by the prcscntinvcntion.
x5 I~ES~CRIP')('iUN Ol~ T>FFE DRAWINGfi While the invention is claimed in the concluding portions h~ez~of, pre:Ferr,~d embodirxxents are provided in the accompanying detailed description which may be best understood in conjunction with the acoozx~panyiug diagrarrAS where like parts in each of the several diagrams are labeled with like numbers, and where:
. _.. _ . _ . a.. ~. ,q . ~;~~..~,~.~~,,~ ~"~~ ____ ____w_.~, r ..~___ .__ _ Page b Fig. 1 is a flew chart demonstrating one embodiment of the method of the present invention;
Fig. 2 is a schematic diagram of one embodiment of a cornpactian feed process circuit of the present invention, using only passive blending in. the potassium ehloridE
feed system;
Fig. 3 is a scherx~atic diagram of an alternative embodiment of compactian feed process circuit of the present invention, x~xcluding active blending equipnxent in the potassium i chloride feed in advance of the compactors;
IO
Fig. ~ shovVS the sfFect of SHMF concentration on a series of brcal~agc paranxctcrs in samples of a finished potassium chloride product;
Fig. 3~ S170W5 floe effect of SHMP concentration on prod~zction volatiles and the amount of dust present in samples of a finished potassium chloride product; az~.d Fig. 6 shows historical data of shipment weathered breakage analysis before and after adding SHIV1P to the feedstock.
as DETAILED DESCRIPTION OF TILL 1LLUSTRATEMIiODIMF~11TTS
The invention is a method and apparatus for the production of a compacted granular potassium chloride product with improved handling and storage capabilities, as well as the product of this method and apparatus. 1t is necessary to produce a compacted granular potassium chloride product comprising stronger finished particles that are less likely to break down during handling, transport or storage.
Addition of a Chemical Binding A ent In order to improve the strength or handling ability crf the finished potassium chloride granular product it is necessary to produce granules which are less likely to wear or break down during .handling or t~raz~spoz~t. 7Che presezxt xnvez~tion combines a chemical binding ~ ingredient or binding agent with the potassium chloride feed material in the compaction feed process circuit to yield this improved product.
A binding agent is a chemical that is added into the feed of a campactian circuit to I S improve the strength and duality of cornlracted particles. Such binding agents have been used on certain circamstxnc~ in the production of other granular ~nnaterials such as sodium chloride. 1-Iowever, chemical binding agents have not been used in the processing of a potassium chloride feed into a compacted granular product. Accoading to the method of the present invention, an effective arnaont of the bindiz~ agent sodium hexarnetaphvsphate (SHM.f') is added to the potassiurrx chloride feedstoek in advance of campactian, to yield a ~Fnished potassiiun chloride granular product witlx izxxproved handling and storage capabilities.
i . . . .,... .. ~ ..rt.~s ,~ .~~-.~,. ~ ~xo 7r ,k.~. ....~ ,~... . M , . _.. .
Chemically, SHMP is known to sequester moisture. 't~V'hen blended in a potassium chloride granular product StI.MP will prevent moisture from migrating out of the compacted particle. When moisture migrates out of a particle, it tends to become more fragile az~d breaks down with handling, ar during storage or transport.
Impurities in potash, such a,5 calcium and magneszuan, are krxown iz~ tt~e art to increase the fragility of a potassium chlox7ide product. The additional property of SHMP to ehelate calcium and magnesium, thus also produces the desired effect of kcepirlg the granule more stable. SHMP also has adhesive properties when blended in a potassium chloride product, and thus acts literally hold the particle together. This adhesive property zx~akes the particle stronger and allo~nrs the particle to stand up to storage, shipping and handling much better than does potassium chloride produced without SHIV.tP as an additive.
i Other binding ingredietxts which will accomplish the sarrxe result of sequestering moisture in the compacted potassium chloride particles andlar generally acting as an adhesive tc~
help those particles to maintain their shape and handling with minimized breakage during storage, handling or transport, are also contemplated wvithin the scope of the present invention. Same of the alternate bixxdiz~g agents contemplated within the scope of the present invention include tetra.-sodium pyrophosphate (TSPP), tetra potassium gyraphosphate (TICPP); sodium tri-polyphosphate (STPP); di-aooium phosphate (DAF), mono-ammonium phosphate {MA.P), granular mono-ammoniurzt phosphate (GMAP), potasvum silicate, sodium silicate, starch, dextran, .lignosulfonate, bentonite, montmarillonitc, kaolin and others.
It will be understood that binding agents which accomplish the objective of sequestering moisture, sequestering calcium and magnesium or irnpmving adhesion in the finished compacted potassium chloride granular product are contemplated within the scope of the S present invention. Furthermore, one or mare binding agents might be used, and the effective amounts of each. used n~igt~t be varied, depending upon tha nahere of the pc~t<~ssium chloride feedstock material and the desired finished product.
Method of ~rodnction The method of the present invention, namely blending an effective amount of a binding agent such as SHM.P into the potasszuzx~t chloride feed ofr a cnmpaction circuit, comprises the addition of said effective amount of a binding agent to a feedstock of the coznpactzoz~
circuit in advance of compaction. Compacting this blended potassi~un chloride feed stoctc and then conventional further processing completes the modified method of production contezxaplated herein.
xt will be understood to those skilled in the art that many types of equipment or equipment modifcatioz~s could be used in different production environments to implement ar accomplish the method of the present invention. The basic requirement is to add an injector of some type to add a binding agez~.t such afi SHMF to the potassium ciazoride feedstnc:k in advance of cornp3ction.
i E
a .. _ .._ _ . ..~ ." ,,~ ,.z .~,. . . > . .~ , . . . ~ _ ~F.. ~ "~~ ~ ~4 ~~~:~.~ ~ ~~.,~ ~.",_ ... ". «.. . _._. . _._ _ ..~,~. ~ . .,. ~,~
.x..~,.,ri.,.." ."~... _.. _.... ~___ .
I
. A typical prior art production line ox praductioz~ circuit for compacted granular potassium chloride would consist of a material feed apparatus such as a belt conveyor, pneumatic conveyor or the like which input various particulate potassium chloride streams, S screenings, or recovered or discarded patassiusn chloride material to a comp~.ctor. The purpose of the compactor is to press the feed material into a compacted potassium . chloride intermediate sheet or cake, which can then be cnished, resized or otkrerwise refinished into a desired finished pota..5sium chloride product.
s 10 Fig. 1 is a flout Chart illustrating the steps involved in one contemplated embodiment of I
the method of production of the present invention. Specifically, Fig. 1 shows the injection of a binding agent into the potassium chloride (KCl) feed of a typical production circuit. The binding agent or agents could be added to the potassium chloride feed material by an injector. The injector may also include some type of meterixxg 15 equipment, such as tIZOSe discussed in further detail with respect to the proposed apparatus of the present invention below, to allow more precise control of the amounts of binding agent added per unit of potassium chloride feedstock.
' After addition of the binding agent to the potassium chloride feed material, the agent and 2p the potassium chloride feed material arc blended. 'The blending step can either take place passively, by basically allowing these materials to co;ne tol;ethex or blend during their joint carriage through the feed mechanism, ar alternatively thc.~re rna~r be specific blending equipment added to tlae potassiurx~; cktloride liroduction circuit between the Page '11 iunjector and the compactor to prnvide mare aggressive ~r active blending, of the binding went and potassium chloride feedstock prior to eompaction.
The blended pott~ssiuzxi chloride feed mate~ia.l, z~ow progerly mixed with the chemical binding agent or agents, is then compacted. The compaction process can be performed using conventional compaetion equipment such as a roll compactor or the like.
The i rolled. or compacted intermediate yielded can then be further processed into the cles~ired finished granular product using methods such as crushing, sieving or other coz~vex~tioz~al methods suitable to yield a finished product of the desired particle size or type. These steps are a,l so shown in. the flow diagram of Fi~_ 1 _ Tt rni~ht in certain circumstances be desirable to use more than one different birxdin~
agez~.t in combination, and this could either be accomplished by the injection of a pre-blended connitaizxatiozw of multiple binding agents or else by the separate placement or injection of the desired amounts oiFthe various binding agents into the potassium chloride foal. It will be understood that any attendant process or equipment zxxodifications to permit the addition of one or more binding agents, either concurrently or separately, to the potassxuxn chloride feedstock are contemplated within the scope of the present invention.
production Apparatus I T~age 12 Various types of'apparatus can be contemplated wh,iclr will accomplish the method of the i present inventioxx. A,n injector needs to bE provided to introduce the desired amount of the binding agent or meats into the potassium chloride feed o;F the production circuit in advance of coropaction. Zt xnay optionally be desired to provide a blending apparatus as well once the binding agent has been introdeeced to completely combine the potaasiurr~
chloride feed material with the binding agent in advance of coznpaction.
Various alterations or modifications could be made to this basic concept to extend its functionality or tailor its use to particular production cnviratttnants, sonic of which will be discussed herein and all of which aroc obvious to one skilled in the art and are eani:emplxted within I O the scope of the present invention.
Tn basic embodiments, we could rely upon passive blending of the potassium chloride feedvtock and the injected binding agez~,t(5) wittxin. the potassium chloride feed in advance of the compactor. rf there is sufficient length in the potassium chloride feed, and depending upon the type of feed equipment being used (for example in a pneumatic delivery system), tlxe potassium chloride feed material may be adequately blended with the added binding ingredienL(s) without the u3e of any particular additional ox specific bleeding equipment, However, depex~dang upon the type of conveyor or feed system i ! being used, as well as the typical pm~lc of the potassium chloride feed stock and the type of injection equipment used to add the SHMI~ or other binding agent to the potassiurrt chloride feedstack, it may also be desirable to provide a blending vessel or other blending equipment between the point of injection of tlae binding agent and tk~e point of Page I3 compactioz~. Both types of systems, with anti withr~ut a specific blending vessel, will be explained further herein.
Fig. 2 demonstrates one schematic of a compaction feed process circuit in accordance with the present invention. In this system a pneumatic feed systcrn is used bcturcen the injector and the compactor, which could provide for adequate passive agitation or blending of the SI'-iMP or other binding agexat and the potassium chlozade feed stock im advance of compactfan. Agitators might also be used i~zside of the pneumatic conduits to provide a mare aggressive blending behavior if required.
In aoy event, the potassium chloride feed 1 can be seen in Fig. 2. This would be the potassiunn chloride feed from the remainder of the processing plant, or from the storage i point where potassium chloride feedstock i~ aggregated for evente~al comp~cctian proccssin.,g. The delivery system might corrsprise a belt conveyor or pneumatic detivexy system, or other type of delivery apparatus that would accomplish the objective of a moving pot:assiurn chloride feedstock along the praduotion circuit. In this particular case it is coz~te3nplated that this might be a pneumatic system that would cause product feed blending without additioz~a.1 blending equipment or vessels.
i Shown next iz~. Fig. 2 is an injector 2. This injector 2 would be any type of apparatus capable of dispensing a desired amount of the bin,diuxg agent in question into the potassium chloride feed t . Tt is contemplated that the injector 2 would nod to inclm~e a metering function in order to adjust the rate of addition of binding agent, as the volume or other characteristics of potassium chloride feed matez~zal in the potassium chloride feed. I
were varied. Alternatively, if the feed rate of the potassium chloride feed 1 were constant, a silnplcr injector could be used for placement of the binding agent. ba a~ay event, any injector which can accomplish the objective of placement of the requisite amount of SHMP or other binding agent into the potassittrtt chloride feed l, and maintain the desired proportion of binding agent, is contezxaplated withizt ttze scope of the present invention.
The injector 2 will place the desired amount of the selected binding agent or ingredients in to the potassium chloride feed t of the compaction cirGUit. The potassium chloride feedstack and the placed binding agent wit) be blended within the potassium chloride I
'- feed 1 between the point of entry from the itnjector 2 and the point of termination of the potassium chloride feed 1 at the entry to the compactor 3. ,A,s xnentioxAed above, iz~ a pneumatic system the blending of the potassium chloride feed might be assisted by the provision of fluting or the like; inside of the pneumatic conduits. llrlore aressive blending might be accomplished by the addition of spccifxc blending equipment at this stage in the compaction aircuat if desired.
The blended potassium chloride feed material will be compacted in a compactor 3, and upon discharge from the compactor 3 tkAe cozx~pacted potassium chloride intermediate (in the form of a sheet or cake) twill be conventionally processed into the desired finished granular product.
loge 15 v Fig. 3 shows an alternative apparatus in accordance with aaxother embodiment of the ':
present invention. The difference between the apparatus of Fig. 2 and that of Fig. 3 is that in the apparatus of Fig. 3 a specific blending vessel 4 has laeezt added to specifically blend the potassium chloride feed material and the placed amount of the binding agent.
Shawn main in Fig. 3 is a potassium chloride feed 1, which ixt this case might be a belt conveyor or solve other type of a feed that will produce sufficient blending of the potassium chloride and the binding agent in advance of compaction. The injector 2 again would be a device capable of dispensing the desired or appropriate amount ofthe selected 1 U binding agent ar agents ixtto the potassium chloride feed 1. In the case of a belt conveyor, the injector could place the binding agent on top of the potassium chloride died on the laclt and the binding agent would move down thmuglz the paxassitmt chloride as the two moved toward the compactor and thus blend with floe potassium chloride. It may be desired to further blend the two in advance of introduction of this combined material into t 5 the compactor 3. As such there is shown a blending vessel 4. into which the potassittrn chloride feed 1 is discharged, and from which the blended potassittrn chloride and binding agents are dispensed in turn to the compactor 3, in this case by another conduit or conveyor 5. It will be understood that various types of blending vessels or equipment 4 could be used but that any type of equipment that would accomplish the objective of 24 sufficiently amalgamating the potassitun chloride and binders in advamce of compactian are contemplated within the scope of the present invention.
__ _ __ _ _.___e_ _. .,nF~.,_ ~~,,,,~ ~.~ "..~,_ ~t~". ~~A...a... _~,~ w __._ ___~___W..,.~~._"._~,.kn, M~ w __._....._ri.., ~i plurality of potassium chloride feeds from different points in the plant might also .feed into the blending vessel 4 which would allow for the injection ofbinding agents into only one of the pOtaSSlllm. Ghloride feeds ~ .fox sizz~plicity ixz fumctioz~
without requiring the cor~sotidatic~n of the various potassium chloride feeds 1 at any point in advance of the blending vessel 4 or erther cc~n:~c~lidatian point in advance of cornpaction.
Fox the sake of demonstration of tlus concept, thexe are sbowaa two supplemental potassium chloride feeds 6, vahich feed into the blending equipment 4. The supplemental potassiusn chloride feeds G in this case do not include separate injectors. They simply feed additional potassium chloride feed material ft~m elsewhin the plant into the blending vessel 4.
The supplexxaex~tal potassium chloride feeds 6 might be equipped with sensors or rnoterinp;
equipment 7 whiclx can be connected to the injector 2 on the primary potassium chloride feed l, so that the aanouztt of the binding agent which is dispensed is adjusted accordingly to be the right amount for the aggregated potasszuz~n. chloride feed volume going into they blending vessel 4 from the various feeds 1, b.
In this case the sensor eduipment 7 is shown which could transmit quantity data from the various supplemental feeds ~ to the injector 2 can the primary Feed. 1 for the purpose c~f calculating the proper inclusion rate of the binding a~;ez~.ts by the xz~jeotor 2, lout again it will be understood that various methods of applying the proper amount of the binding agent or agents at flue injectoz~ 2 can be contcznplated, including a fixed va~Iume or rate limitation on the supplemental feeds 6 so that sensors were not required and these constant volumes could be calculated iu~to the application rates at the injector 2. Another i Page 1?
approach would be to put an injector 2 an each supplemental feed 6, which.
would ef=Fectively turn each potassium chloride feed into a primary potassium chloride feed 1.
The blending vessel 4 might be any kind of tank or hopper or more active blending equipment, which would accomplish the objective of mixing the potassium chloride feed material, and the injected binding agent or agents, in advance of compaction.
All such equipment and attendant systezxz znadifZCations are contemplated within the scope of the prcscntinvcntion.
1 d It will also be rmderstoad that it might be possible to create .an apparatus far the proper placement and blending of the binding agent in the potassium chloride feed right at the point of entry of the potassium chloride feed into the compactor itself, and that this type of an apparatus or approach would also be conternp.tated within the scope of the present invention.
Another approach rather than the use of specific blending ecluipmcnt, such as in the embodiment of Fig. 3, might be to place the injeatar 2 at a paint in the system Where even if the conveyor or potassium chloride feed system being used were rzot suf!"ZCiently aggressive in its blending or mixing ability, there would still be sufficient time or activity within that rx~avement to adequately and passively amalgarnafe the material in question.
For example if the potassium chloride feed were aggregating potassium chloride feed material fsozxi various points in the processing plant, placement of tile SHMP
or other binding agents in the potassium chloride feed at ar near the first or initial points of T ,~, ~ ~ "._ " ~.:~, . ...,,,. ,H ..,. . . . ,. ... ... w,. _~, ,,~a~._. .. ~
. _...
collection might result in sufficient blending activity once additional layers or amounts of potassiunZ chloride feed material were added to the conveyor at athc,~r collection points. Tt will be understood that this type of approach., ox an appxoach that avoids specific blending altogether and allows that to simply take place at the throat or entry of the cozxzpaat~rr(s} will also be contemplated within the scope of the present invention.
It will also be understood that where potassium chloride feeds from various points in the plant all converge in the compaction circuit at the compactor, that the placement of the binding agent or agents in one of the pt~tassium chloride feeds for blending at the poizxk of 1 U entry to the cann~pactor are also contemplated within the scope c~f the present irxvox~tJion.
Asscssing_thc compacted potassium chloride granular produced Tests were conducted using sodium hcxamctaphosphate (~I~MP) as the binding agent to ' be added to the potassium ahlaride feed to a concentration of about 100 parts SHIVA' pox million parts potassium chloride ~eed (ppm) to about 150Q ppm. The best results were obtained at SHMP concentrations near the high end, however satisfactory results were obtained at SHMIp cc~noentrations of around 5D0 ppm. It will be understood that other injection rates might be used either with the same binding agent to obtain a desired different result, or a new inclusion rate might also need to be calculated ar e~cpaz-im~ntally derived if a different binding agent or cozzxbizzation of binding agents were used. Such optimi~atioz~ tests would be obvious to those skilled in the art.
A number of samples of compacted potassium chloride ,product were taken from the production circuit prior to the addition of ShCM:I', to provide baseline saz~nples against wi~ose characteristics the cornpacCed granular product of the present inv4antion S incorporating the SMMP could be assessed A large batch of the r;rnnpacted granular product of the present invention, using SHNII' as a bindarag agent added in advance of compaction, vcras then produced and a nurnbcr of tests conducted to assess the product of the present invention against the prior art carnpaated granular product. The follov~ring Table t dsrnonstrates the overall test results conducted on a number of the samples containing S.~IMP at vaxious coxACer~trations as indicated:
i 'Fable ~: 1~u$ntita~iwe assessment of the produced Potassium chloride product I
i I where SHMP is included as a binding iogredyent rJ~ay._ ..-~mc~~",.,~,."".~.,~m~Total.._.._._.~As .._~~~ e~~ - dust SHMP
is ._.. -.~.
(of ~alatilcs fn n/o % (ppm) day) .._ 1 x8:00 ..-- x_054__.._.gØ_.._16.8_.._ -. a.1~13~.-.1 -- -~ . -..._ $.0 . i~3.S
~
t ___ __ _ _ ~ ~ - -. a$:~~...-. ~.083'.._.,..,..,."....".,...,~.4.."_,~..__ _._ --~.10$-..__._._'$2.5~~...._ s s ._ ..-14.9~.~......~.7 -.
i , ___ _ _ __ _ 1. - ' lq:p0.~.
~.0~g'.,~._.,_...._._...'..,~.5....,_....__...__,...__...g.1_~...._.__._ ~-.Ø120~-._ .._ ;~.b--.-.-. 116g~.p .._ 1 1 U; 0. X 03 __ ~.4 ...".~~~.n."$.7.~"..-.~... ~_-~",~.1457.p i 50 '_.-. _,_"~,.._ ~.8 0.123 _ - ".-.
4 ~- ~~ -... _ ._.......__ _.
... '..,......._ .__..._ _.
._...
i 11:40 0.079 G,8 g.4 '.~ ~ ~ 08.0 1 1 ~S
i _ __ ____ ....._ ..._._..~ - .
._ . -.
i 12.30 0.124 -. _._.-_.._...__-_._._._..-.-..~-..
j _ 511.5 S
.. . . . ~.~;~x,.~-:_~,~t~~~, ~2..,M. .. .q ....m , ~~.ro... ~..~,~~ . _......
_.
1 13:20 0.082 400.5 _. ,.", .._... ..._..._ _.._.._..._..._ _._..~.~
f _,. ~ .._ ._.. ~ .., _.._ ..._.. _.._._._~.._...7.4 0.116 466.5 ~: ~ .~,..,_- ~ .x.'125 .._ _x14.7 _ _'9.5__ ~_. i.__ 1~:~__ ..__.._._0.16~_.._.............._.._..."".,...._._....__.._._..._...__.._......
.,.,........,....,....."_....,.__.~_...__....__...m.,..___.__.__.....~~~.5.__.!
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...__.._.._..._,.,._..._..._.._.._.__..._..._..,......~.,___._.._..__..~_..,.~_ ___ i ~ 1.- 15:50 ~ ._...._. w.wl 0.149 ._ -,~~34.p'' _...._..____.__ _.._._._..__._._.._.._....__..._._...._..._..._.._._.._...__,...,..............
...~.._._._.._..._~._.___..".....___..,...,.,....~~.,.I
a 1 16:40 0.133 7.3 11.0 7.8 O.lp6 496.5 E s i ~_. ~ _._. ~7:3~._.
.__._~.127,~..._.....__...,__....._..__._..__........w......,......._.......~..
...____~..,......._,..__..~.~14.5a.'~~'I
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_. ~ .__. ~ $ -2Q w ._.._. -, , ..,.,....,.~",~,.,.",.w......__.._.__S
84.
x.077"'.",."",~..,,., ~~ _ ~ .,~..~ S_ ", . "~,..."_.
I _ _ .. ~._..~.. ~ ~:1~._.,_.,..,.,.,."x.126 ~~ 7.3 -_._i4.3 ~y7 ~
0.104582.5 -_~ - -._~_ - ~~
i_... 1..._...~_,.,..~20:00_._ Q,157 ~.- -~..'.~ -"- 533.0 i J i _..._..~..".,....,.. - - .----.-, 0.125 1 zaao ~5.0 z I _ _._ _. ._ _.J
(~ 1 ~ 21:40 0.125 ~ 8.0 14.0 7:5 p.132 524.5 i _~ ..W....,..r.".."..~.."....,.w._~....,~...,."...,..._~_. ,~.~~..,~
J .~..w~....".~.._... __ 1 22:30 0.139 ~ _...
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~ a3:2o - '""~~~.~o:- -_._._._.._-~_ _.__.__...
f i 3~ ~ _ ~~.
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i _ __ ___ ___ "....."_,...._._ ~. ._._ 7.6 _.._ .-
This invention is in the field of mineral extraction and production, and more particularly deals with a method arid apparatus for the production of corrcpacted granular potassium chloride.
BAGKGIt~CIUND
PotassiLUn chloride ('potash"~ has rna~ry industrial uses, but is most commonly known as a coznpoz~ent of a~icultural fertilizers, Potash is typically extracted from underground t sources either by convexttional mining techniques or by solution mining. Once extracted, potassium chloride can be processed into a number Qf different finished. forms or products suitable for specific industrial, chemical or agricultural applications as desired by individual customers.
Finished potassium. chloride is typically sold in a ,granular form, and the purity and graalule size may vary depending on the end me to which the product will be put. The grading of potash, and hence its market value are also dependent on bath the purity and granule size of the product. Typically the potassimn chloride i.~ screened to the de,;ired particle size for a particular need.
i A typical potassium chloride feed stock, has a granule size that is comparable to table salt, which is le:;s than the desired g~rartule size. In ordez to obtain larger granules, this feedstoclc is first compacted using a simple roll campacter ar floe like to produce a sheet-like product. 8ubscduent processing typically involves controlled breakage of the potassium chloride sheet into granules, which are then sorted to a desired size range by $creez~iug or other methods lcxzowa~ in the industry.
However, one of the limitations with compacted granular potassium chloride produced in 1~ this fashion has been that the product will physically break down when handled, stored or shilsped. Given that granule size is an important feature in the finished prroduct, breakage therefore diminishes the value of the finished product. These broken granules that arise front the handling of the finished product during processing are known as recycle ar reclaiz~a z~atexnial. Suclx broken granules are collected car reclaimed from vazaaus areas I S during processing and can be mixed back into tlxe feedstock and compacted again.
After the finished product leaves thG plant, breakage diminishes the value of the product.
Ezokez~ gmx~ules are smaller than the desired size and cause problems during th.e storage and handling of the finished product due to a tendency to generate dust arid form clumps, 2Q a property known as "bridging." Bridging impedes the flow of the product, and may result in significant storage problems. Excessive dust causes environmental concerns while uneven granule size can directly affect applicarion rates.
Shippiztg of potash, typically by rai.i, is not a gentle pmcess either iz~
tezxns of the handling involved in the loading of rail cars or mechanical agitation during the extended mQVement of the rail cars themselve$. Thus, storage, shipping and handlin,~
after the potash has left the mill can break up granules, with the result that over time undesirable characteristics occur in the product.
Therefore, it has been the desire of those in the field to find methods of producing art improved compacted granular potassium chloride product, with better shipping,, handling and storage characteristics as camparcd to compacted potash products rnanufa.ctured using prior art methods. Methods of production that improve the handling characteristics of compacted pota.~h products and which result in a mare durable finished product are of value as the result will be a more desirable and saleable commodity.
1 ~ SUMMARY O~F TAE INVENTION
Xt is the object of the pre~~nt invention to produce an improved compacted ~-anular potassium chloride product with improved haa~dlizag qualities.
2i? More specifically, it is the object of the present invention to provide a xrtetltod and apparatus for the production of an improved compacted granular potassium chloride product that is less likely to bxeak down during handling, transport or long-terra storage.
The invcntian accomplishes #iis objective by the addition of a bzndiz~~
ingredient to the potassium chloride feed material in advance of the corripaction step in a compaction feed process or production circuit. Addition of an effective amount of sodium hexametaphosphate {SHMF) as a binding ingredient to the potassium chloride feed material iz~ advaxzce of compaction yields a compacted granular potassium chloride with better handling or storage quahities.
SHMP is operative to sequester moisture, calcium and magnesium and glue the product together and thus it will be understood by persons skillod in the art chat binding ingredients otihex than SHNlP will accomplish then same objectives. Therefore, tha substitution or incozporation of such alternative binding ingredients into the process or product of the present invention is intended to be encompassed within the scope by the prcscntinvcntion.
x5 I~ES~CRIP')('iUN Ol~ T>FFE DRAWINGfi While the invention is claimed in the concluding portions h~ez~of, pre:Ferr,~d embodirxxents are provided in the accompanying detailed description which may be best understood in conjunction with the acoozx~panyiug diagrarrAS where like parts in each of the several diagrams are labeled with like numbers, and where:
. _.. _ . _ . a.. ~. ,q . ~;~~..~,~.~~,,~ ~"~~ ____ ____w_.~, r ..~___ .__ _ Page b Fig. 1 is a flew chart demonstrating one embodiment of the method of the present invention;
Fig. 2 is a schematic diagram of one embodiment of a cornpactian feed process circuit of the present invention, using only passive blending in. the potassium ehloridE
feed system;
Fig. 3 is a scherx~atic diagram of an alternative embodiment of compactian feed process circuit of the present invention, x~xcluding active blending equipnxent in the potassium i chloride feed in advance of the compactors;
IO
Fig. ~ shovVS the sfFect of SHMF concentration on a series of brcal~agc paranxctcrs in samples of a finished potassium chloride product;
Fig. 3~ S170W5 floe effect of SHMP concentration on prod~zction volatiles and the amount of dust present in samples of a finished potassium chloride product; az~.d Fig. 6 shows historical data of shipment weathered breakage analysis before and after adding SHIV1P to the feedstock.
as DETAILED DESCRIPTION OF TILL 1LLUSTRATEMIiODIMF~11TTS
The invention is a method and apparatus for the production of a compacted granular potassium chloride product with improved handling and storage capabilities, as well as the product of this method and apparatus. 1t is necessary to produce a compacted granular potassium chloride product comprising stronger finished particles that are less likely to break down during handling, transport or storage.
Addition of a Chemical Binding A ent In order to improve the strength or handling ability crf the finished potassium chloride granular product it is necessary to produce granules which are less likely to wear or break down during .handling or t~raz~spoz~t. 7Che presezxt xnvez~tion combines a chemical binding ~ ingredient or binding agent with the potassium chloride feed material in the compaction feed process circuit to yield this improved product.
A binding agent is a chemical that is added into the feed of a campactian circuit to I S improve the strength and duality of cornlracted particles. Such binding agents have been used on certain circamstxnc~ in the production of other granular ~nnaterials such as sodium chloride. 1-Iowever, chemical binding agents have not been used in the processing of a potassium chloride feed into a compacted granular product. Accoading to the method of the present invention, an effective arnaont of the bindiz~ agent sodium hexarnetaphvsphate (SHM.f') is added to the potassiurrx chloride feedstoek in advance of campactian, to yield a ~Fnished potassiiun chloride granular product witlx izxxproved handling and storage capabilities.
i . . . .,... .. ~ ..rt.~s ,~ .~~-.~,. ~ ~xo 7r ,k.~. ....~ ,~... . M , . _.. .
Chemically, SHMP is known to sequester moisture. 't~V'hen blended in a potassium chloride granular product StI.MP will prevent moisture from migrating out of the compacted particle. When moisture migrates out of a particle, it tends to become more fragile az~d breaks down with handling, ar during storage or transport.
Impurities in potash, such a,5 calcium and magneszuan, are krxown iz~ tt~e art to increase the fragility of a potassium chlox7ide product. The additional property of SHMP to ehelate calcium and magnesium, thus also produces the desired effect of kcepirlg the granule more stable. SHMP also has adhesive properties when blended in a potassium chloride product, and thus acts literally hold the particle together. This adhesive property zx~akes the particle stronger and allo~nrs the particle to stand up to storage, shipping and handling much better than does potassium chloride produced without SHIV.tP as an additive.
i Other binding ingredietxts which will accomplish the sarrxe result of sequestering moisture in the compacted potassium chloride particles andlar generally acting as an adhesive tc~
help those particles to maintain their shape and handling with minimized breakage during storage, handling or transport, are also contemplated wvithin the scope of the present invention. Same of the alternate bixxdiz~g agents contemplated within the scope of the present invention include tetra.-sodium pyrophosphate (TSPP), tetra potassium gyraphosphate (TICPP); sodium tri-polyphosphate (STPP); di-aooium phosphate (DAF), mono-ammonium phosphate {MA.P), granular mono-ammoniurzt phosphate (GMAP), potasvum silicate, sodium silicate, starch, dextran, .lignosulfonate, bentonite, montmarillonitc, kaolin and others.
It will be understood that binding agents which accomplish the objective of sequestering moisture, sequestering calcium and magnesium or irnpmving adhesion in the finished compacted potassium chloride granular product are contemplated within the scope of the S present invention. Furthermore, one or mare binding agents might be used, and the effective amounts of each. used n~igt~t be varied, depending upon tha nahere of the pc~t<~ssium chloride feedstock material and the desired finished product.
Method of ~rodnction The method of the present invention, namely blending an effective amount of a binding agent such as SHM.P into the potasszuzx~t chloride feed ofr a cnmpaction circuit, comprises the addition of said effective amount of a binding agent to a feedstock of the coznpactzoz~
circuit in advance of compaction. Compacting this blended potassi~un chloride feed stoctc and then conventional further processing completes the modified method of production contezxaplated herein.
xt will be understood to those skilled in the art that many types of equipment or equipment modifcatioz~s could be used in different production environments to implement ar accomplish the method of the present invention. The basic requirement is to add an injector of some type to add a binding agez~.t such afi SHMF to the potassium ciazoride feedstnc:k in advance of cornp3ction.
i E
a .. _ .._ _ . ..~ ." ,,~ ,.z .~,. . . > . .~ , . . . ~ _ ~F.. ~ "~~ ~ ~4 ~~~:~.~ ~ ~~.,~ ~.",_ ... ". «.. . _._. . _._ _ ..~,~. ~ . .,. ~,~
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I
. A typical prior art production line ox praductioz~ circuit for compacted granular potassium chloride would consist of a material feed apparatus such as a belt conveyor, pneumatic conveyor or the like which input various particulate potassium chloride streams, S screenings, or recovered or discarded patassiusn chloride material to a comp~.ctor. The purpose of the compactor is to press the feed material into a compacted potassium . chloride intermediate sheet or cake, which can then be cnished, resized or otkrerwise refinished into a desired finished pota..5sium chloride product.
s 10 Fig. 1 is a flout Chart illustrating the steps involved in one contemplated embodiment of I
the method of production of the present invention. Specifically, Fig. 1 shows the injection of a binding agent into the potassium chloride (KCl) feed of a typical production circuit. The binding agent or agents could be added to the potassium chloride feed material by an injector. The injector may also include some type of meterixxg 15 equipment, such as tIZOSe discussed in further detail with respect to the proposed apparatus of the present invention below, to allow more precise control of the amounts of binding agent added per unit of potassium chloride feedstock.
' After addition of the binding agent to the potassium chloride feed material, the agent and 2p the potassium chloride feed material arc blended. 'The blending step can either take place passively, by basically allowing these materials to co;ne tol;ethex or blend during their joint carriage through the feed mechanism, ar alternatively thc.~re rna~r be specific blending equipment added to tlae potassiurx~; cktloride liroduction circuit between the Page '11 iunjector and the compactor to prnvide mare aggressive ~r active blending, of the binding went and potassium chloride feedstock prior to eompaction.
The blended pott~ssiuzxi chloride feed mate~ia.l, z~ow progerly mixed with the chemical binding agent or agents, is then compacted. The compaction process can be performed using conventional compaetion equipment such as a roll compactor or the like.
The i rolled. or compacted intermediate yielded can then be further processed into the cles~ired finished granular product using methods such as crushing, sieving or other coz~vex~tioz~al methods suitable to yield a finished product of the desired particle size or type. These steps are a,l so shown in. the flow diagram of Fi~_ 1 _ Tt rni~ht in certain circumstances be desirable to use more than one different birxdin~
agez~.t in combination, and this could either be accomplished by the injection of a pre-blended connitaizxatiozw of multiple binding agents or else by the separate placement or injection of the desired amounts oiFthe various binding agents into the potassium chloride foal. It will be understood that any attendant process or equipment zxxodifications to permit the addition of one or more binding agents, either concurrently or separately, to the potassxuxn chloride feedstock are contemplated within the scope of the present invention.
production Apparatus I T~age 12 Various types of'apparatus can be contemplated wh,iclr will accomplish the method of the i present inventioxx. A,n injector needs to bE provided to introduce the desired amount of the binding agent or meats into the potassium chloride feed o;F the production circuit in advance of coropaction. Zt xnay optionally be desired to provide a blending apparatus as well once the binding agent has been introdeeced to completely combine the potaasiurr~
chloride feed material with the binding agent in advance of coznpaction.
Various alterations or modifications could be made to this basic concept to extend its functionality or tailor its use to particular production cnviratttnants, sonic of which will be discussed herein and all of which aroc obvious to one skilled in the art and are eani:emplxted within I O the scope of the present invention.
Tn basic embodiments, we could rely upon passive blending of the potassium chloride feedvtock and the injected binding agez~,t(5) wittxin. the potassium chloride feed in advance of the compactor. rf there is sufficient length in the potassium chloride feed, and depending upon the type of feed equipment being used (for example in a pneumatic delivery system), tlxe potassium chloride feed material may be adequately blended with the added binding ingredienL(s) without the u3e of any particular additional ox specific bleeding equipment, However, depex~dang upon the type of conveyor or feed system i ! being used, as well as the typical pm~lc of the potassium chloride feed stock and the type of injection equipment used to add the SHMI~ or other binding agent to the potassiurrt chloride feedstack, it may also be desirable to provide a blending vessel or other blending equipment between the point of injection of tlae binding agent and tk~e point of Page I3 compactioz~. Both types of systems, with anti withr~ut a specific blending vessel, will be explained further herein.
Fig. 2 demonstrates one schematic of a compaction feed process circuit in accordance with the present invention. In this system a pneumatic feed systcrn is used bcturcen the injector and the compactor, which could provide for adequate passive agitation or blending of the SI'-iMP or other binding agexat and the potassium chlozade feed stock im advance of compactfan. Agitators might also be used i~zside of the pneumatic conduits to provide a mare aggressive blending behavior if required.
In aoy event, the potassium chloride feed 1 can be seen in Fig. 2. This would be the potassiunn chloride feed from the remainder of the processing plant, or from the storage i point where potassium chloride feedstock i~ aggregated for evente~al comp~cctian proccssin.,g. The delivery system might corrsprise a belt conveyor or pneumatic detivexy system, or other type of delivery apparatus that would accomplish the objective of a moving pot:assiurn chloride feedstock along the praduotion circuit. In this particular case it is coz~te3nplated that this might be a pneumatic system that would cause product feed blending without additioz~a.1 blending equipment or vessels.
i Shown next iz~. Fig. 2 is an injector 2. This injector 2 would be any type of apparatus capable of dispensing a desired amount of the bin,diuxg agent in question into the potassium chloride feed t . Tt is contemplated that the injector 2 would nod to inclm~e a metering function in order to adjust the rate of addition of binding agent, as the volume or other characteristics of potassium chloride feed matez~zal in the potassium chloride feed. I
were varied. Alternatively, if the feed rate of the potassium chloride feed 1 were constant, a silnplcr injector could be used for placement of the binding agent. ba a~ay event, any injector which can accomplish the objective of placement of the requisite amount of SHMP or other binding agent into the potassittrtt chloride feed l, and maintain the desired proportion of binding agent, is contezxaplated withizt ttze scope of the present invention.
The injector 2 will place the desired amount of the selected binding agent or ingredients in to the potassium chloride feed t of the compaction cirGUit. The potassium chloride feedstack and the placed binding agent wit) be blended within the potassium chloride I
'- feed 1 between the point of entry from the itnjector 2 and the point of termination of the potassium chloride feed 1 at the entry to the compactor 3. ,A,s xnentioxAed above, iz~ a pneumatic system the blending of the potassium chloride feed might be assisted by the provision of fluting or the like; inside of the pneumatic conduits. llrlore aressive blending might be accomplished by the addition of spccifxc blending equipment at this stage in the compaction aircuat if desired.
The blended potassium chloride feed material will be compacted in a compactor 3, and upon discharge from the compactor 3 tkAe cozx~pacted potassium chloride intermediate (in the form of a sheet or cake) twill be conventionally processed into the desired finished granular product.
loge 15 v Fig. 3 shows an alternative apparatus in accordance with aaxother embodiment of the ':
present invention. The difference between the apparatus of Fig. 2 and that of Fig. 3 is that in the apparatus of Fig. 3 a specific blending vessel 4 has laeezt added to specifically blend the potassium chloride feed material and the placed amount of the binding agent.
Shawn main in Fig. 3 is a potassium chloride feed 1, which ixt this case might be a belt conveyor or solve other type of a feed that will produce sufficient blending of the potassium chloride and the binding agent in advance of compaction. The injector 2 again would be a device capable of dispensing the desired or appropriate amount ofthe selected 1 U binding agent ar agents ixtto the potassium chloride feed 1. In the case of a belt conveyor, the injector could place the binding agent on top of the potassium chloride died on the laclt and the binding agent would move down thmuglz the paxassitmt chloride as the two moved toward the compactor and thus blend with floe potassium chloride. It may be desired to further blend the two in advance of introduction of this combined material into t 5 the compactor 3. As such there is shown a blending vessel 4. into which the potassittrn chloride feed 1 is discharged, and from which the blended potassittrn chloride and binding agents are dispensed in turn to the compactor 3, in this case by another conduit or conveyor 5. It will be understood that various types of blending vessels or equipment 4 could be used but that any type of equipment that would accomplish the objective of 24 sufficiently amalgamating the potassitun chloride and binders in advamce of compactian are contemplated within the scope of the present invention.
__ _ __ _ _.___e_ _. .,nF~.,_ ~~,,,,~ ~.~ "..~,_ ~t~". ~~A...a... _~,~ w __._ ___~___W..,.~~._"._~,.kn, M~ w __._....._ri.., ~i plurality of potassium chloride feeds from different points in the plant might also .feed into the blending vessel 4 which would allow for the injection ofbinding agents into only one of the pOtaSSlllm. Ghloride feeds ~ .fox sizz~plicity ixz fumctioz~
without requiring the cor~sotidatic~n of the various potassium chloride feeds 1 at any point in advance of the blending vessel 4 or erther cc~n:~c~lidatian point in advance of cornpaction.
Fox the sake of demonstration of tlus concept, thexe are sbowaa two supplemental potassium chloride feeds 6, vahich feed into the blending equipment 4. The supplemental potassiusn chloride feeds G in this case do not include separate injectors. They simply feed additional potassium chloride feed material ft~m elsewhin the plant into the blending vessel 4.
The supplexxaex~tal potassium chloride feeds 6 might be equipped with sensors or rnoterinp;
equipment 7 whiclx can be connected to the injector 2 on the primary potassium chloride feed l, so that the aanouztt of the binding agent which is dispensed is adjusted accordingly to be the right amount for the aggregated potasszuz~n. chloride feed volume going into they blending vessel 4 from the various feeds 1, b.
In this case the sensor eduipment 7 is shown which could transmit quantity data from the various supplemental feeds ~ to the injector 2 can the primary Feed. 1 for the purpose c~f calculating the proper inclusion rate of the binding a~;ez~.ts by the xz~jeotor 2, lout again it will be understood that various methods of applying the proper amount of the binding agent or agents at flue injectoz~ 2 can be contcznplated, including a fixed va~Iume or rate limitation on the supplemental feeds 6 so that sensors were not required and these constant volumes could be calculated iu~to the application rates at the injector 2. Another i Page 1?
approach would be to put an injector 2 an each supplemental feed 6, which.
would ef=Fectively turn each potassium chloride feed into a primary potassium chloride feed 1.
The blending vessel 4 might be any kind of tank or hopper or more active blending equipment, which would accomplish the objective of mixing the potassium chloride feed material, and the injected binding agent or agents, in advance of compaction.
All such equipment and attendant systezxz znadifZCations are contemplated within the scope of the prcscntinvcntion.
1 d It will also be rmderstoad that it might be possible to create .an apparatus far the proper placement and blending of the binding agent in the potassium chloride feed right at the point of entry of the potassium chloride feed into the compactor itself, and that this type of an apparatus or approach would also be conternp.tated within the scope of the present invention.
Another approach rather than the use of specific blending ecluipmcnt, such as in the embodiment of Fig. 3, might be to place the injeatar 2 at a paint in the system Where even if the conveyor or potassium chloride feed system being used were rzot suf!"ZCiently aggressive in its blending or mixing ability, there would still be sufficient time or activity within that rx~avement to adequately and passively amalgarnafe the material in question.
For example if the potassium chloride feed were aggregating potassium chloride feed material fsozxi various points in the processing plant, placement of tile SHMP
or other binding agents in the potassium chloride feed at ar near the first or initial points of T ,~, ~ ~ "._ " ~.:~, . ...,,,. ,H ..,. . . . ,. ... ... w,. _~, ,,~a~._. .. ~
. _...
collection might result in sufficient blending activity once additional layers or amounts of potassiunZ chloride feed material were added to the conveyor at athc,~r collection points. Tt will be understood that this type of approach., ox an appxoach that avoids specific blending altogether and allows that to simply take place at the throat or entry of the cozxzpaat~rr(s} will also be contemplated within the scope of the present invention.
It will also be understood that where potassium chloride feeds from various points in the plant all converge in the compaction circuit at the compactor, that the placement of the binding agent or agents in one of the pt~tassium chloride feeds for blending at the poizxk of 1 U entry to the cann~pactor are also contemplated within the scope c~f the present irxvox~tJion.
Asscssing_thc compacted potassium chloride granular produced Tests were conducted using sodium hcxamctaphosphate (~I~MP) as the binding agent to ' be added to the potassium ahlaride feed to a concentration of about 100 parts SHIVA' pox million parts potassium chloride ~eed (ppm) to about 150Q ppm. The best results were obtained at SHMP concentrations near the high end, however satisfactory results were obtained at SHMIp cc~noentrations of around 5D0 ppm. It will be understood that other injection rates might be used either with the same binding agent to obtain a desired different result, or a new inclusion rate might also need to be calculated ar e~cpaz-im~ntally derived if a different binding agent or cozzxbizzation of binding agents were used. Such optimi~atioz~ tests would be obvious to those skilled in the art.
A number of samples of compacted potassium chloride ,product were taken from the production circuit prior to the addition of ShCM:I', to provide baseline saz~nples against wi~ose characteristics the cornpacCed granular product of the present inv4antion S incorporating the SMMP could be assessed A large batch of the r;rnnpacted granular product of the present invention, using SHNII' as a bindarag agent added in advance of compaction, vcras then produced and a nurnbcr of tests conducted to assess the product of the present invention against the prior art carnpaated granular product. The follov~ring Table t dsrnonstrates the overall test results conducted on a number of the samples containing S.~IMP at vaxious coxACer~trations as indicated:
i 'Fable ~: 1~u$ntita~iwe assessment of the produced Potassium chloride product I
i I where SHMP is included as a binding iogredyent rJ~ay._ ..-~mc~~",.,~,."".~.,~m~Total.._.._._.~As .._~~~ e~~ - dust SHMP
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~..._2"..,. . ".,..~:00_...__Ø133w--.-.._ .~.~~_- ~ .-err . ~z~.s -. .-.
__._.._..._._..._.__....._.......__..__.__.._._._._._._.__.._._._.._._..,.-.__._._-_. '.._.__.._.__..
r ' 2 Of :50 0. I 15 662.0 2 07:40 ~.~ 0.145-.'.._..._.._..._.._.._.._.,....__..._-_...~..,._..__._..._..__._.__._.._..._.._..~8~.0 i .._._.0~:3~._.._..' ~.151w._._.__.._.'._._..._._.._~.-.___._..__~~.._"~~~.5 I ;
'_...2..._.~_~9:2Q-.-.-.Ø1~~ .._.-_.._..-._._-.~-.._.-.~-__._.._._._.._.._._..___6~.5 I
tw..,...n..-.-..._..-.....-..~.._..._..~._..._..-.,....~...~.~.-~.~._~
_._..~.~ ~._-._.~,_._ J
The data in Table I were fiurther acxalyzed as follows.
'Weathered Breakage Anaty~is Several analyses were conducted on the recovered :samples. The Dusterbeck Breakage System consisting of "As Is )Breakage", "Conditioned T3reakage (CBkg.~"' and.
"Weathered Breakage (WBkg)" values are 1f1v1C laboratory test measures used to evaluate thv relative hardness of potash product of the present inve~xtion. The "As Is"
test is performed on fuvshed product immediately after the sample is taken. The CBkg test is fed after the finished product has been subjected to a 2f>°,/a relative humidity (RH) I enviracunent far 24 hours. The WBkg test is performed after the f~nistzed product has been subjected to a 72% R.(1 enviroiunent for 24 hours. A, ~Bkg analysis was conducted an the produced granular product that included SHMP. The results of that analysis are shown in Fig. 4.
The results indicate that breakage was ,highest in the untreated baseline samples and 2U decreased whm SHNfP was added as a binding agent. Thc; lowest WBkg values (e~ta poxr~ts 3,4,5 from Table 1) were eoiracident with the highest concentrations of SH1WIP.
The data show that the inclusion of S'HMP as a binding ingredient, in accordance with the method of the present invention, improves the duralaility of the end product as evidenced by the reduction in WBlcg values.
i :, 11na1vsis of Production Valatiles and Dust i i The quantity of volatiles in various sampies was aiso assessed. The results of the volatile testing axe shown, in. Pig. 5. The results indicate tk~at S~vJI:P addition has na effect on total volatiles production, t~ikewise, the xesults also indicate that SIIMP
addition had no effect on the proportion of dust present in the samples.
~'roduct Reclaim Anahvsis A number of rail cars were landed with the newly compacted product, and reclaim samples obtained during the loading of these cars. The term reclaim sample here refers to product that haw been transferred from warehouse stt~rage to the refinery and xe-screened 2U prior to oil treatment. Typical reclaim breakage values for aged product produced without SHMP are as high as 25-30°,~0. To determine if the addition of SHMI'reduces the amount of reclaim product breakage, samples produced with SHMP were analyzed as fallawfi:
f _____ _. ._.., w.~~. ~Ax..~~., .~..,.~.~~a ~."..~~~.........e. ,.__.a. ."
n".",~.r~,.rv,______...
Fage 23 Ts~ble 2: Reclaim Analyses The results indicate that sl~xp~xzent weathered brealrage averaged 14°lo for C'rtanular reclaim product. C'xranular patassium chloride rcclasin product, displayiri,g breakage values below 20%, is aonsidcrid to be goad cLuality product.
Shipmcr~t~rsis Five test cars were loaded with the ~HMP tcst product, to determine whether ~~
pz~evented damage during loading and shippi~~;. Th.e results fxom shipment analyses arc shorn in Table 3 as follows:
Page 2~
x'able 3: S~txpnn~c~t.rl,nalyses Ticket 397090 397091 397092 397t)93397094 Loading AnaiysBs Total Volatiles 0.19 D.18 D.19 0_17 O.i7 (9'0) Weathered Breakage13.01 14.05 13.95 13.42 92.95 (wt lo) Conditioned Breakage3.32 2.97 3.27 3.23 3.49 (wt h) _ dust (~io) 0.01 0.01 0.01 a.o2 o.D2 Oil (Iblton) 2.5 2.18 2.27 2.11 1.97 SHMP (pprn) 649 522 493 595 $1$
Tyler Mesh Sieve 6 94.5 28.3 24.52 21.7 28.4 $ 60.9 73 74_U4 87.2 74.$
1 Q 92.2 9$.fi 95.59 94.4 96.7 12 8T.7 99.5 98.49 98.7 99.5 14 98.6 99.7 99.13 99.3 99.$
20 99.3 99.9 99.48 98.7 99.9 35 99.$ 98.9 99.78 99.9 99.9 Analyses After
_.__ s ~i' i - 0.14$ .._._.-._.~~.._.._._._............._.._..__._.._.._._.._._...__..__..._...__~S~aO..
1 -.- 1 '~.Z 01.50 1 _ -._ _ .' _. ._..._ _. . .. . _ . ._.
L_,.~._._..__.._ 0.123 17.5 -14.2 - 0.120 630.0 1 2 02:40 ..~.3 __ ~._ ..__ ._.._.._.._..~~._..__._....._....._.__.__,_.._..._.._._._.._._ . _J
~r_ 7 ~
p3:30 0.13 609.0 a }_..__..___.-.._ __ _._._.~.,._.~_.__._.._..._._._..__.._..._._._.._._.._._ _ ~31.~ i$02 z0 ~ 0 0 2 p4 : . .
;........
..~--.. ~5: I0 . _- 0.118. _ g.3'.-'_. 13.9~._...__..$ ~. .~ 591.0 ,~ t .-- 2~
.
~..._2"..,. . ".,..~:00_...__Ø133w--.-.._ .~.~~_- ~ .-err . ~z~.s -. .-.
__._.._..._._..._.__....._.......__..__.__.._._._._._._.__.._._._.._._..,.-.__._._-_. '.._.__.._.__..
r ' 2 Of :50 0. I 15 662.0 2 07:40 ~.~ 0.145-.'.._..._.._..._.._.._.._.,....__..._-_...~..,._..__._..._..__._.__._.._..._.._..~8~.0 i .._._.0~:3~._.._..' ~.151w._._.__.._.'._._..._._.._~.-.___._..__~~.._"~~~.5 I ;
'_...2..._.~_~9:2Q-.-.-.Ø1~~ .._.-_.._..-._._-.~-.._.-.~-__._.._._._.._.._._..___6~.5 I
tw..,...n..-.-..._..-.....-..~.._..._..~._..._..-.,....~...~.~.-~.~._~
_._..~.~ ~._-._.~,_._ J
The data in Table I were fiurther acxalyzed as follows.
'Weathered Breakage Anaty~is Several analyses were conducted on the recovered :samples. The Dusterbeck Breakage System consisting of "As Is )Breakage", "Conditioned T3reakage (CBkg.~"' and.
"Weathered Breakage (WBkg)" values are 1f1v1C laboratory test measures used to evaluate thv relative hardness of potash product of the present inve~xtion. The "As Is"
test is performed on fuvshed product immediately after the sample is taken. The CBkg test is fed after the finished product has been subjected to a 2f>°,/a relative humidity (RH) I enviracunent far 24 hours. The WBkg test is performed after the f~nistzed product has been subjected to a 72% R.(1 enviroiunent for 24 hours. A, ~Bkg analysis was conducted an the produced granular product that included SHMP. The results of that analysis are shown in Fig. 4.
The results indicate that breakage was ,highest in the untreated baseline samples and 2U decreased whm SHNfP was added as a binding agent. Thc; lowest WBkg values (e~ta poxr~ts 3,4,5 from Table 1) were eoiracident with the highest concentrations of SH1WIP.
The data show that the inclusion of S'HMP as a binding ingredient, in accordance with the method of the present invention, improves the duralaility of the end product as evidenced by the reduction in WBlcg values.
i :, 11na1vsis of Production Valatiles and Dust i i The quantity of volatiles in various sampies was aiso assessed. The results of the volatile testing axe shown, in. Pig. 5. The results indicate tk~at S~vJI:P addition has na effect on total volatiles production, t~ikewise, the xesults also indicate that SIIMP
addition had no effect on the proportion of dust present in the samples.
~'roduct Reclaim Anahvsis A number of rail cars were landed with the newly compacted product, and reclaim samples obtained during the loading of these cars. The term reclaim sample here refers to product that haw been transferred from warehouse stt~rage to the refinery and xe-screened 2U prior to oil treatment. Typical reclaim breakage values for aged product produced without SHMP are as high as 25-30°,~0. To determine if the addition of SHMI'reduces the amount of reclaim product breakage, samples produced with SHMP were analyzed as fallawfi:
f _____ _. ._.., w.~~. ~Ax..~~., .~..,.~.~~a ~."..~~~.........e. ,.__.a. ."
n".",~.r~,.rv,______...
Fage 23 Ts~ble 2: Reclaim Analyses The results indicate that sl~xp~xzent weathered brealrage averaged 14°lo for C'rtanular reclaim product. C'xranular patassium chloride rcclasin product, displayiri,g breakage values below 20%, is aonsidcrid to be goad cLuality product.
Shipmcr~t~rsis Five test cars were loaded with the ~HMP tcst product, to determine whether ~~
pz~evented damage during loading and shippi~~;. Th.e results fxom shipment analyses arc shorn in Table 3 as follows:
Page 2~
x'able 3: S~txpnn~c~t.rl,nalyses Ticket 397090 397091 397092 397t)93397094 Loading AnaiysBs Total Volatiles 0.19 D.18 D.19 0_17 O.i7 (9'0) Weathered Breakage13.01 14.05 13.95 13.42 92.95 (wt lo) Conditioned Breakage3.32 2.97 3.27 3.23 3.49 (wt h) _ dust (~io) 0.01 0.01 0.01 a.o2 o.D2 Oil (Iblton) 2.5 2.18 2.27 2.11 1.97 SHMP (pprn) 649 522 493 595 $1$
Tyler Mesh Sieve 6 94.5 28.3 24.52 21.7 28.4 $ 60.9 73 74_U4 87.2 74.$
1 Q 92.2 9$.fi 95.59 94.4 96.7 12 8T.7 99.5 98.49 98.7 99.5 14 98.6 99.7 99.13 99.3 99.$
20 99.3 99.9 99.48 98.7 99.9 35 99.$ 98.9 99.78 99.9 99.9 Analyses After
3 We~aks Weathered Br~akage 14.1 13.4 (wt ~o) The results indicate that shipment weathered breakagcs were 13 - 14°!o far product S treated with SHMP at about SUO ppm to about SttO ppm, and even after three weeks of storage, hreakages remained at 13 -14°l0. As breakage values below 20%
are considexed to indicate a good quality product, SHMP was efFective in maintaining the quality of a finished cozxapacted gcanuiar patassium chlaride pxoduct produced by the method of the present invention. Conditioned breakage and dust results gave typical canvcntional 11J values when compared to historical shipment data..
Campansons of shipment weathered breakage rncasurements were made far compacted granular product produced before and after SH1V1P was utiti~ed in the production of compacted granular potassium chloride. The results are shown in Fig. 6. The results 15 indicate that reduced levels of Ship»~ent Weathered )3reakage have been acltieved as a result of including SHNIP as a binding agent in the production circuit. Prior to the xz~clusion of S.HLvtP in the compactioz~ pxocess, granular pxoduct was produced that showed breakage levels in a range from 15.0 - 3t7.8%, with an average of 22.4 +/- 4.8°fa In contrast, since the inclu~sian of SHMP in the production circuit, breakage levels have been in a range frozxz 9.fi - 20.d %, with an average of 14.3 -i-I-5.3°/a. This 1S a significant improvement in granular product quality brought about by the addition of a binding went prior to cornpaction.
Tlxe foregoizzg Xs coxxsidered as illustrative ozzly of the principles of the invention.
Furthermore, since numerous changes and modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operatson shown and described. Accordingly, all Such Suitable Chan~cs ar modifications in the structure or operation that may be resorted to in order to accomplish the objective r of yielding a compacted granular potassium chloride product including a binduag ingredient to improve the strength arid handling quality thcreo~f are intended to fall within the scope of the claimed iuzverztaoza.
are considexed to indicate a good quality product, SHMP was efFective in maintaining the quality of a finished cozxapacted gcanuiar patassium chlaride pxoduct produced by the method of the present invention. Conditioned breakage and dust results gave typical canvcntional 11J values when compared to historical shipment data..
Campansons of shipment weathered breakage rncasurements were made far compacted granular product produced before and after SH1V1P was utiti~ed in the production of compacted granular potassium chloride. The results are shown in Fig. 6. The results 15 indicate that reduced levels of Ship»~ent Weathered )3reakage have been acltieved as a result of including SHNIP as a binding agent in the production circuit. Prior to the xz~clusion of S.HLvtP in the compactioz~ pxocess, granular pxoduct was produced that showed breakage levels in a range from 15.0 - 3t7.8%, with an average of 22.4 +/- 4.8°fa In contrast, since the inclu~sian of SHMP in the production circuit, breakage levels have been in a range frozxz 9.fi - 20.d %, with an average of 14.3 -i-I-5.3°/a. This 1S a significant improvement in granular product quality brought about by the addition of a binding went prior to cornpaction.
Tlxe foregoizzg Xs coxxsidered as illustrative ozzly of the principles of the invention.
Furthermore, since numerous changes and modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operatson shown and described. Accordingly, all Such Suitable Chan~cs ar modifications in the structure or operation that may be resorted to in order to accomplish the objective r of yielding a compacted granular potassium chloride product including a binduag ingredient to improve the strength arid handling quality thcreo~f are intended to fall within the scope of the claimed iuzverztaoza.
Claims (30)
We claim:
1. A method for the production of compacted granular potassium chloride with improved handling, transport and storage capabilities comprising the steps of;
adding an effective amount of sodium hexametaphosphate (SIIMP) to a potassium chloride feedstock;
mixing the SHMP and the potassium chloride feedstock to produce a blended mixture;
compacting the blended mixture in a compaction process to produce a compacted potassium chloride product; and processing the compacted chloride product to produce a granular potassium chloride product.
adding an effective amount of sodium hexametaphosphate (SIIMP) to a potassium chloride feedstock;
mixing the SHMP and the potassium chloride feedstock to produce a blended mixture;
compacting the blended mixture in a compaction process to produce a compacted potassium chloride product; and processing the compacted chloride product to produce a granular potassium chloride product.
2. The method of Claim 1 wherein an effective amount of SHMP is greater than 1.0 ppm.
3. The method of Claim 2, wherein an effective amount of SHMP is in the range from 1.0 - 10,000 ppm.
4. The method of Claim 3, wherein an effective amount of SHMP is in the range of 300 - 1000 ppm.
5. The method of any one of Claims 1 to 4, wherein the SHMP is continuously added to a potassium chloride feedstock in a compaction feed process.
6. The method of any one of Claims 1 to 5, wherein the SHMP and potassium chloride feedstock are mixed in a blending vessel prior to the compaction feed process.
7. The method of any one of Claims 1 to 6, wherein a plurality of potassium chloride feedstocks are simultaneously blended with the SHMP in a single mixture.
8. A granular blended potassium chloride product comprising granules of potassium chloride blended with SHMP, wherein SHMP is present in an amount effective to improve the durability of the granules.
9. The product of Claim 8 wherein the effective amount of SHMP is an amount greater than 1.0 ppm.
10. The product of Claim 9 wherein the effective amount of SHMP is an amount in the range of 1.0 - 10,000 ppm.
11. The product of Claim 10 wherein the effective amount of SHMP is an amount in the range of 300 - 1000 ppm.
12. The product of any of Claims 8 to 11, wherein the granular potassium chloride product undergoes an average shipment weathered breakage of less than 20%.
13. The product of Claim 12 wherein the granular potassium chloride product undergoes an average shipment weathered breakage of less than 15%.
14. A method for the production of compacted granular potassium chloride with improved handling, transport and storage capabilities comprising the steps of;
adding an amount of a binding agent effective to sequester moisture in a potassium chloride feedstock;
adding an amount of a binding agent effective to sequester calcium and magnesium in a potassium chloride feedstock;
mixing the binding agent and the potassium chloride feedstock to produce a blended mixture;
compacting the blended mixture in a compaction process to produce a compacted potassium chloride product; and processing the compacted chloride product to produce a granular potassium chloride product;
wherein the binding agent is added in an amount effective to produce a granular blended potassium chloride product that undergoes an average shipment weathered breakage of less than 20%.
adding an amount of a binding agent effective to sequester moisture in a potassium chloride feedstock;
adding an amount of a binding agent effective to sequester calcium and magnesium in a potassium chloride feedstock;
mixing the binding agent and the potassium chloride feedstock to produce a blended mixture;
compacting the blended mixture in a compaction process to produce a compacted potassium chloride product; and processing the compacted chloride product to produce a granular potassium chloride product;
wherein the binding agent is added in an amount effective to produce a granular blended potassium chloride product that undergoes an average shipment weathered breakage of less than 20%.
15. The method of Claim 14 wherein the binding agent is a phosphate.
16. The method of Claim 15 wherein the phosphate compound comprises at least one of sodium hexametaphosphate, tetra-sodium pyrophosphate, tetra-potassium pyrophosphate, tri-sodium phosphate, di-ammionium phosphate or mono-ammonium phosphate.
17. The method of Claim 14 wherein the binding agent is a silicate.
18. The method of Claim 17 wherein the silicate is one of potassium silicate and sodium silicate.
19. The method of Claim 14 wherein the binding agent is a general compound, comprising at least one of starch, sugars, clays, ligonosulfonates and langbeinite.
20. The method of any one of Claims 14 to 19 wherein the binding agent is a blend of an effective amount of at least one of a phosphate, a silicate and a general compound.
21. The method of any one of Claims 14 to 20, wherein the binding agent is continuously added to a potassium chloride feedstock in a compaction feed process.
22. The method of any one of Claims 14 to 21 wherein the binding agent and potassium chloride feedstock are mixed in a blending vessel prior to the compaction process.
23. The method of any one of Claims 14 to 22 wherein a plurality of potassium chloride feedstocks are simultaneously blended with the binding agent in a single mixture.
24. A granular blended potassium chloride product produced by the method of any one of Claims 14 to 23.
25. The product of Claim 24 wherein the granular blended potassium chloride product undergoes an average shipment weathered breakage of less than 15%.
26. The method of Claim 14 wherein the binding agent is added in an amount effective to produce a granular blended potassium chloride product that undergoes an average shipment weathered breakage of less than 15%.
27. The method of Claim 14 wherein the binding agent is sodium hexametaphosphate (SHMP).
28. The method of Claim 27 wherein the effective amount of SHMP is an amount greater than 1.0 ppm.
29. The method of Claim 28 wherein the effective amount of SHMP is an amount in the range of 1.0 - 10,000 ppm.
30. The method of Claim 29 wherein the effective amount of SHMP is an amount in the range of 300 - 1000 ppm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002465461A CA2465461C (en) | 2003-08-11 | 2004-04-28 | Compacted granular potassium chloride, and method and apparatus for production of same |
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US49414203P | 2003-08-11 | 2003-08-11 | |
| US60/494,142 | 2003-08-11 | ||
| CA002444099A CA2444099A1 (en) | 2003-08-11 | 2003-08-22 | Compacted granular potassium chloride, and method and apparatus for production of same |
| CA2,444,099 | 2003-08-22 | ||
| CA002465461A CA2465461C (en) | 2003-08-11 | 2004-04-28 | Compacted granular potassium chloride, and method and apparatus for production of same |
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| Publication Number | Publication Date |
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| CA2465461A1 CA2465461A1 (en) | 2005-02-11 |
| CA2465461C true CA2465461C (en) | 2009-09-29 |
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| DE102016010586A1 (en) | 2016-09-02 | 2018-03-08 | K+S Aktiengesellschaft | Process for the preparation of potassium chloride granules |
| DE102016010584A1 (en) | 2016-09-02 | 2018-03-08 | K+S Aktiengesellschaft | Process for the preparation of potassium chlorite granules |
| DE102016010585A1 (en) | 2016-09-02 | 2018-03-08 | K+S Aktiengesellschaft | Process for the preparation of potassium chlorite granules |
| DE102024101862A1 (en) | 2024-01-23 | 2025-07-24 | K+S Aktiengesellschaft | Fertilizer granules containing sodium sulfate and potassium chloride |
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