PROCESS FOR THE MANUFACTURING OF CRUDE POTASSIUM CHLORIDE/ CALCIUM SULPHATE / MAGNESIUM CHLORIDE. FROM BITTERN.

RAW MATERIAL:- BITTERN OF sp gr. 1.25 to 1.26 i.e of 29-30 Be source bittern after removal of salt.

process for the manufacturing

sea water which is concentrated to remove salt is crystallized and salt is seperatedthe liquid which comes out after salt removal has the sp.gr of 1.25 to 1.26 i.e of 29-30 Bethis liquid is further evapourated to a density of sp.gr of 1.28 to 1.284 i.e of 32 to 33 Beat this point the excess salt crystallizes out which is removed the liquid which comes out after excess salt removal is further evapourated to a density of sp.gr of 1.318 to 1.324 i.e 35 to 35.5 Beat this point carnallite salt i.e KCl. MgCl2. 6H2O Crystallizes out. Along with some sodium chloirde.

the carnallite salt is further decomposed with water to get a liquid and a solid layer.the solid contains 80% potassium chloirde with sodium chloride which is further purified by hot crystillization and filtration. puity of 98% of KCLthe potassium chloirde/ sodium chloride mixture from the purification step is recycled back to the brines

bittern obtained after removal of carnallite at sp.gr of 1.324 and 35.5 Be is a concentrated solution of magnesium chloride and is called end bittern and contains around 400 to 430 g/litre of mgcl2

in going through the process the volume is reduced by a factor of 3

the end bittern is calcined at 500 to 600 degree c to get magnesium oxide and hydrochloric acid as the end product.

molecular weight of the componentsMol.wt

magnesium chloride 95.305sodium chloride 58.48potassium chloride 74.602calcium chloride 110.99magnesium sulphate 120.45potassium sulphate 174.26sodium sulphate 142.04calcium sulphate 136.14

MATERIAL BALANCE:-STEP- 1

note:- for ease of calculation the two ions are considered not presentINPUT brine of 29 Be having the folowing analysis ( desulphated )

atomic mol wt wt % of g/liter number

Mg2+ 46 24.255 Mgcl2 95.305 Mg2+ 25.50% Mgcl2Na+ 44 22.9898 NaCl 58.48 Na+ 39.31% NaClK+ 13.6 39.102 KCl 74.602 K+ 52.41% KClCa2+ 2 40.08 CaCl2 110.99 Ca2+ 36.10% CaCl2Cl- 197.9 35.5So42- _Br- _

STEP -2this brine is evapurated to sp.gr of 1.28 to 1.284 i.e 32 to 33 Be.

solidINPUT g/litre % OUTPUT gramsMgcl2 180.39 55.7 Mgcl2

NaCl 111.93 34.56 NaCl 104.76KCl 25.95 8.01 KClCaCl2 5.54 1.71 CaCl2

323.812

STEP-3the liquid brine from step -2 is further evapourted to sp.gr of 1.318 to 1.324 i.e 35 TO 35.5Be

5.5 kgsliquidINPUT grams % outputMgcl2 180.39 82.35 Mgcl2NaCl 7.16352 3.2703 NaClKCl 25.95 11.846 KClCaCl2 5.54 2.5292 CaCl2

219.0435 water

44.5 kgs

outputMgcl2NaClKClCaCl2water

step- 4

5.5 kgs of carnallite seperated from 50kgs of initial bitternsolid liquid

input % kgs output outputMgcl2 28.22 1.5521 1.5521NaCl 6.2 0.341 0.1 0.241KCl 15 0.825 0.6677 0.1573CaCl2 0.82 0.0451 0.0451water 49.76 2.7368 4.9368plus 5.5water 2.2

KCL out put 0.7677KGS

IMPURE 87%

step-5

KCL INPUT OF 87% OUTPUT0.7677KGS 0.6600KGS

97%

THERE FOR OUT OF 50 KGS BITTERN OF 29 Be GRAVITY WILL GIVEdesulphated bittern

kgssodium chloride 4.19potassium chloride 0.66magnesium chloride 5.5

10.35

entiresolid balanceinput 12.9524output 10.35recycled 2.6024

there for for the next cyclesthe make up bittern will be40 kgs

DESULPHATION OF BITTERN OF 28.5 Be

contains 37.0197 gms / litre of sulphate

for a desulphation process we need 0.21 lts/ min of bittern440g/litre of calcium chloride at calcium chloride required will be 0.013litres/min 286 gms

0.286 kgscalcium sulphate produce7.2796 gms/litre of bittern

0.3639kgs for 50 kgs of bittern

output products will be nowkgs

sodium chloride 4.19potassium chloride 0.66magnesium chloride 5.5

10.35calcium sulphate 0.3639total 10.7139

PROCESS FOR THE MANUFACTURING OF CRUDE POTASSIUM CHLORIDE/ CALCIUM SULPHATE / MAGNESIUM CHLORIDE.

source bittern after removal of salt.

the liquid which comes out after salt removal has the sp.gr of 1.25 to 1.26 i.e of 29-30 Bethis liquid is further evapourated to a density of sp.gr of 1.28 to 1.284 i.e of 32 to 33 Be

the liquid which comes out after excess salt removal is further evapourated to a density of sp.gr of 1.318 to 1.324 i.e 35 to 35.5 Beat this point carnallite salt i.e KCl. MgCl2. 6H2O Crystallizes out. Along with some sodium chloirde.

puity of 98% of KCLthe potassium chloirde/ sodium chloride mixture from the purification step is recycled back to the brines

bittern obtained after removal of carnallite at sp.gr of 1.324 and 35.5 Be is a concentrated solution of magnesium chloride and is called end bittern and contains around 400 to 430 g/litre of mgcl2

the end bittern is calcined at 500 to 600 degree c to get magnesium oxide and hydrochloric acid as the end product.

40 litres of bittern taken for recoverysp.gr is 1.2550 kgs

50 kgs will containg/litre % gms

180.39 55.7 7215.6111.93 34.56 4477.2

25.95 8.01 10385.54 1.71 221.6

323.812 12952.48total 12.9524kgs

liquid after removing sodium chlorideOUTPUT grams gmsMgcl2 180.39 7215.6

NaCl 7.16352 286.8KCl 25.95 1038CaCl2 5.54 221.6

8762total 8.762

the liquid brine from step -2 is further evapourted to sp.gr of 1.318 to 1.324 i.e 35 TO 35.5Be

of carnallite seperated from 50kgs of initial bittern

% kgs28.22 1.5521

6.2 0.34115 0.825

0.82 0.045149.76 2.7368

5.5

end bittern after recovery of carnallite

kgs5.6635

nil0.213

0.176538.447kgs

0.7677KGS

calcium chloride required will be

PRODUCTION PLANT FOR 100 TONNE OF POTASSIUM CHLORIDE PER MONTH

a) raw materials required1 bittern from sea water after removing salt baving sp. Gr of 1.244 and 28.5Be2 calcium chloride of 440 gram / litre strenght. in water

b) process as described in the sheet no 1

c) reactions only one reaction taken place during the desulphation of the bittern

SO4+ ADD CaCl2 gives CaSO4 and respective chloride

d) by products are calcium sulphatemagnesium chloridesodium chloride

e) process flow chartsea water

`water out

bittern of 29-30 Besp.gr 1.25 to 1.26

calcium chloride

evapouration-1sp.gr 1.24

25 Be

desulphationof bittern

of 440g/l concentration

desulphated bittern of29-30 Besp.gr - of 1.25 to 1.26

liquid out is a concentrated solution of magnesium chloride

effluent to sea

desulphationof bittern

evapouration-2to 1.28 to 1.284

32-33 Be

evapouration-3to 1.318 to 1.324

35 to 35.5 Be

seperation of magnesium chloride

( 4 TONNE / DAY)

tonnequantity

bittern from sea water after removing salt baving sp. Gr of 1.244 and 28.5Be 303.034.9518

respective chloride

2.2053233.33

25.3914total 64.9244 with product quantity

21.4% solids

salt out

calcium sulphate

sodium chloride

water

water

carnallite KCl. MgCl2.6H2O

water

potassium chloridea concentrated solution of magnesium chloride of 87 % purity

water

magnesium chloride

potassium chloride 97% purity

carnallite decomposition

crude purification

project economicsEconomicsfor raw material

input:- sea water bittern 303.3 tonne transportation chargescalcium chloride 4.918tonne

outputsodium chloride 25.3914potassium chloride 4magnesium chloride 33.33calcium sulphate 2.2053

energy cost

water to be evapourated 136 tonne215102 rupees per day

economics will change if we get the carnallite form the salt pans itself.

energy cost will decrease to 50%107551 rupees per day

project cost:-building and equipment cost only

21400000 rupees

working capital per month required9268200 rupees

generation of productsgroup -1 kcl/mgcl2 37.44 tonne per day

1048.32tonne per month

powerworking capital includes fuelmaintanancelabourpackingotherstotal 15000000

cost/ kgs 14.3 rs/kgs

profitibility gives 15.8 rs/kgs for kcl and mgcl2at 10%

profit1572480 rs/kgs

payback period 14 month for project cost building and machinery

rupeesat 400/ tonne 121200 per dayat 7RS/KGS 34426 per day

total 155626

at 0.5RS/KGS 12695.7at 7 RS/KGS 28000at 10Rs/Kgs 333300at 1RS/KGS 2205.3

total 376201 per daymarket value

group-2 nacl and caso4sales of the same will meet the day to day expencesof the unit.

selling price of kcl and mgcl2.