Sustainable Process for the Extraction of Potassium from Feldspar Using Eggshell Powder

Clean Process to Utilize the Potassium-Containing Phosphorous Rock with Simultaneous HCl and KCl Production via the Steam-Mediated Reactions

In this paper, a clean process based on the steam-mediated reactions for simultaneous HCl and KCl production using the potassium (K)-containing phosphorous rock as a precursor is proposed. Through hydrochloric acid (HCl) leaching, not only the generation of H₃PO₄ and CaCl₂ (via further precipitation) were realized but also the acid-insoluble residue [phosphorous-rock slag (PS)] rich in elements, that is, K, Al, Si, and so on, in the form of microcline (KAlSi₃O₈) and quartz (SiO₂) was obtained and became readily available for further HCl and KCl generation. Over 95% of the elements, that is, K, Al, and Si, come into the final products, and the overall acid consumption (based on HCl) is significantly reduced (90%) due to recovery of acids. The impacts of the key operational parameters such as temperature, duration, and reagent impregnate ratio were rigorously analyzed via a supervised machine learning approach, and the optimal conditions were determined [reaction temperature, X₁, 850 °C; reaction duration, X₂, 40 min; and impregnate ratio (PS over CaCl₂), X₃, 2.5] with approximately ±10% uncertainties. Thermodynamic analysis indicates that the introduction of steam to PS + CaCl₂ not only enhances the chemical potential for the formation of HCl and KCl but also provides the transport advantage in continuously removing the generated products, that is, HCl and KCl, out of the system. Molecular simulation indicates that the presence of both steam and SiO₂ in the PS matrix plays critical roles in decomposing PS + CaCl₂ at high temperature. The shrinking core model shows that both the intrinsic kinetics and transport are influential with the activation energy being around 14.63 kJ/mol. The potential reaction pathway is postulated.

Life Cycle Based Climate Emissions of Charcoal Conditioning Routes for the Use in the Ferro-Alloy Production

Renewable reductants are intended to significantly reduce CO2 emissions from ferro-alloy production, e.g., by up to 80% in 2050 in Norway. However, charcoals provide inferior properties compared to fossil fuel-based reductants, which can hamper large replacement ratios. Therefore, conditioning routes from coal beneficiation was investigated to improve the inferior properties of charcoal, such as mechanical strength, volatile matter, CO2 reactivity and mineral matter content. To evaluate the global warming potential of renewable reductants, the CO2 emissions of upgraded charcoal were estimated by using a simplified life cycle assessment, focusing on the additional emissions by the energy demand, required chemicals and mass loss for each process stage. The combination of ash removal, briquetting and high-temperature treatment can provide a renewable coke with superior properties compared to charcoal, but concomitantly decrease the available biomass potential by up to 40%, increasing the CO2-based global warming potential of industrial produced charcoal to ≈500 kg CO2-eq. t−1 FC. Based on our assumptions, CO2 emissions from fossil fuel-based reductants can be reduced by up to 85%. A key to minimizing energy or material losses is to combine the pyrolysis and post-treatment processes of renewable reductants to upgrade industrial charcoal on-site at the metallurgical plant. Briquetting showed the largest additional global warming potential from the investigated process routes, whereas the high temperature treatment requires a renewable energy source to be sustainable.

Extraction of Potassium from Feldspar by Roasting with CaCl2 Obtained from the Acidic Leaching of Wollastonite-Calcite Ore

Potassium, which is included in certain contents in the structure of K-feldspar minerals, has a very important function in the growth of plants. Turkey hosts the largest feldspar reserves in the world and is by far the leader in feldspar mining. The production of potassium salts from local natural sources can provide great contributions both socially and economically in the agriculture industry along with glass production, cleaning materials, paint, bleaching powders, and general laboratory purposes. In this study, potassium extraction from K-feldspar ore with an 8.42% K2O content was studied using chloridizing (CaCl2) roasting followed by water leaching. Initially, to produce wollastonite and calcite concentrates, froth flotation tests were conducted on wollastonite-calcite ore after comminution. Thus, wollastonite and calcite concentrates with purities of 99.4% and 91.96% were successfully produced. Then, a calcite concentrate was combined with hydrochloric acid (HCl) under optimal conditions of a 1 mol/L HCl acid concentration, a 60 °C leaching temperature, and a 10 min leaching time to produce CaCl2. To bring out the importance of roasting before the dissolution process, different parameters such as roasting temperature, duration, and feldspar—CaCl2 ratios were tested. Under optimal conditions (a 900 °C roasting temperature, a 60 min duration, and a 1:1.5 feldspar—CaCl2 ratio), 98.6% of the potassium was successfully extracted by the water leaching process described in this article.