News Karnalyte Resources : Patent Issued for Process for Synthesizing a Compacted Product
04/09/2014 | 07:28pm US/EasternRecommend:
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By a News Reporter-Staff News Editor at Journal of Engineering -- Karnalyte Resources Inc. (Okotoks, Alberta, CA) has been issued patent number 8685135, according to news reporting originating out of Alexandria, Virginia, by VerticalNews editors.
The patent's inventor is Phinney, Robin (Okotoks, CA).
This patent was filed on December 3, 2012 and was published online on April 1, 2014.
From the background information supplied by the inventors, news correspondents obtained the following quote: "As is generally known, potassium chloride occurs as sylvite. The compound is also known as muriate of potash and can be extracted from salt water. Further methodology to synthesize the compound is by crystallization from solution, electrostatic separation from suitable minerals or flotation.
"Other methods for forming potassium chloride include the preparation from solid ore. The ore is exposed to solution stripping and multi-element crystallization. Generally the stripping solution from the rejected liquid, salt and water generated in processing carnallite is selectively stripped the from the solid potassium salt ore to obtain halogen liquid. The liquid is rich in potassium chloride which is subsequently crystallized.
"There are innumerable other methods to achieve synthesis, however, these are typically limited in the same manner; expensive unit operations and the inability of the product to be stored without significant moisture absorption.
"Kali and Salz Aktiengesellschaft patented a method for manufacturing potassium chloride having a high potassium oxide content (55 wt. %). The precursor was the fine salt resulting from the degradation of carnallite In the process alkyl amine salts are used as conditioning agents and flotation media containing magnesium and potassium chloride are used to separate this fine decomposition salt in an initial flotation stage into a grain size fraction of less than 0.1 mm as a first concentrate and a residue having a grain size of more than 0.315 mm. Subsequent to auxiliary conditioning, the residue is again floated and the potassium chloride surfaces as a second concentrate. The potassium chloride is separated from the mixture without any further conditioning in another flotation stage, and collected.
"Ferguson et al., in United States Patent Publication 2005/0036929, published Feb. 17, 2005, disclose an apparatus and method for the production of a compacted potassium chloride granule Essentially, the method includes the use of sodium hexametaphosphate as a binder which is added to the potassium chloride feedstock. The binder is indicated to sequester moisture.
"In U.S. Pat. No. 5,503,641, issued Apr. 2, 1996, to Bakardjiev et. al., there is disclosed a process for synthesizing potassium chloride where a multitude of unit operations are required to effect the result. Many of the operations are involved and require high energy expenditures.
"Kleine-Kleffmann et al. in U.S. Pat. No. 6,379,414, teach a typical compactor circuit using a known cement of MgCl.sub.2 and MgO to harden the mixture. Although the initial flake and pellets are strong, storage is poor as the MgCl.sub.2 reacts with moisture in the air to form magnesium chloride hydration complexes and product quality degrades with storage in high humidity.
"Dancy et al., in U.S. Pat. No. 4,385,920, provides an agglomeration process that uses a feed stock of SOP or MOP with a size distribution of -80 to +325 mesh with H.sub.3PO.sub.4 mono or diammonium phosphate with MgO to complete the cement. This is not a compaction process.
"In U.S. Pat. No. 5,264,017, Van de Walle, provides an agglomeration process which uses a feed stock of -100 mesh to +325 mesh and MgO and PO.sub.4 binder system. This is not a compaction system.
"McGough et al., in U.S. Pat. No. 4,428,601, discloses a high grading process for removing NaCl from KCl by dissolving the NaCl in an under saturated brine of NaCl and saturated brine of KCl. This is practiced in all potash mines. The reference does not provide for compaction, agglomeration or granulation.
"Having regard to the fact that potassium chloride crystals are very high energy and high stress, dendrites can form between crystals when the same are stored in conditions having relative humidity of greater than approximately 70%. In this manner, the material must be purchased and immediately used in order to avoid particle accretion.
"It would be desirable to have a process where the unit operations were minimized with a low energy requirement with the resulting product being resistant to moisture absorption.
"The present invention satisfies these goals."
Supplementing the background information on this patent, VerticalNews reporters also obtained the inventor's summary information for this patent: "One object of one embodiment of the present invention is to provide an improved process for synthesizing potassium chloride.
"A further object of one embodiment of the present invention is to provide a method for synthesizing a compacted potassium chloride fertilizer product, comprising: providing a source of potassium chloride in a size distribution of between 30 mesh and 100 mesh; pulverizing a mixture of said source of potassium chloride in the presence of a binder, said binder being a grain type binder present in an amount between 0.5% to 2.5% by weight; said potassium chloride being present in a amount of not more than 8% by weight; mixing the pulverized mixture with potassium chloride in a size distribution of -14 mesh to +150 mesh; introducing at least one of sodium carbonate and sodium bicarbonate in an amount of between 0.01 to 0.5% by weight to said mixture to avoid formation of magnesium chloride hydration complexes; feeding the pulverized mixture to a counter rotating roller system and squeezing the mixture at a pressure of between 1000 and 2000 psi to homogenously distribute said binder and said potassium chloride into flakes in a roll or impact crusher; drying said flakes; and crushing said flakes to yield a product in a size distribution of between 4 mesh and 12 mesh in a yield of up to 70%.
"It has been found that the use of a grain type binder is particularly effective in inhibiting moisture absorption into the pellets or granules. The mechanism is not precisely known, however when the binder is commingled with the potassium chloride, the final results are favourable. Barley is an example that has been found useful.
"By making use of the sodium bicarbonate and/or sodium carbonate, magnesium chloride hydration complex formation is obviated. This contributes to longer term storage, while maintaining flowability. It may also be useful to substitute the sodium compounds for equivalent amounts of potassium carbonate and/or potassium bicarbonate.
"Another object of one embodiment of the present invention is to provide a potassium chloride granule synthesized in accordance with the methodology as set forth in claim 1.
"There are distinct advantages to the procedure set forth herein. The individual steps are important, namely providing the potassium chloride in the specified size distribution of between 30 mesh and 100 mesh as well as pulverizing a mixture of the potassium chloride in the size distribution noted in the presence of a binder. It is important to elucidate the compaction step with respect to the prior art and the instantly claimed invention. It has been found that the compaction effectively consolidates, in a homogenous manner for homogenous distribution, the binder and the potassium chloride into the flakes. This consolidation by the specified procedure results in uniform distribution of the potassium chloride which is an important factor for farmers employing the fertilizer.
"It has been found that by making use of a roll crusher a significant increase in the yield of the product can be achieved. The size and operating parameters will be appreciated by one skilled. As an alternative, the crusher may be an impact crusher.
"Having thus generally described the invention, reference will now be made to the accompanying drawings illustrating preferred embodiments."
For the URL and additional information on this patent, see: Phinney, Robin. Process for Synthesizing a Compacted Product. U.S. Patent Number 8685135, filed December 3, 2012, and published online on April 1, 2014. Patent URL: https://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&p=92&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=4559&f=G&l=50&co1=AND&d=PTXT&s1=20140401.PD.&OS=ISD/20140401&RS=ISD/20140401
Keywords for this news article include: Anions, Alkalies, Chemistry, Bicarbonates, Electrolytes, Light Metals, Carbonic Acid, Sodium Carbonate, Hydrochloric Acid, Magnesium Chloride, Potassium Chloride, Inorganic Chemicals, Magnesium Compounds, Potassium Compounds, Karnalyte Resources Inc..
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