Production From Caustic Potash and Carbon Dioxide.

The
most important process for the manufacture of potassium carbonate begins with
electrolytically produced potassium hydroxide solution. The almost chemically
pure solution obtained by the mercury process is reacted with carbon dioxide or
CO2-containing off-gases (flue gas, lime kiln gas).

2KOH+CO2 −→ K2CO3 +H2O

Figure 2. Production of potassium carbonate by the fluidized-bed process

a) Burner; b) Gas cooler; c) Fluidized-bed reactor; d) Cooler; e) Elevator; f)

Screen; g) Mill; h) Silo; i) Cyclone; j) Exhaust gas scrubber
MATERIAL BALANCE

Plant capacity 100,000 ton / year.

Assuming 330 working days.

 Convert plant capacity into kg/hr

100,000 ton 1 year 1 day 1000 kg

Year 330 day 24 hr 1 ton

= 12626.26 kg/hr

= 91kmol/hr M.wt. of k2co3 = 138.2 kg/kmol

Material balance in C

Main reaction:

2KOH+CO2 −→ K2CO3 +H2O

Assuming 90% conversion is possible in reactor-1. Hence 90% of koh get

converted into k2co3 and 5%
Conversion = 0.90 = reacted / feed

Reacted of KOH = produced of K2co3*2 = 91*2 mol from reaction =182 mol

KOH feed = 182/0.9 =202 kmol/hr

Mwt of KOH=56

Koh feed in Kg = 56*202=11324 kg/hr

koh to co2 feed ratio is 2:1.

Co2 fed = 202/2 kmol/hr=10144*101=4444 kg/h

CO2 material balance

Out= in – reacted in reaction

out co2 = 101– 101*0.9

= 10.1 kmol/hr=444 kg/h

KOH material balance

Out= in – reacted

Out koh = 202– 202*0.9 = 20 kmol/hr=1120 kg/h

H2O material balance

Out= in + produce = 91 mol = 1638 kg/h

Reactor overall material balance

In=11324+4444 =15768 kg

Out=12626+3276+1131+444=15828 kg
Material balance of column i

Unreacted KOH (B)

Reactor
product (A)

Product (C)

KOH material balance

Out= in = product in B =1120 kg

Material balance on gas scrubber

the gas is recycled in the process but first it must be scrubbed with water, the
amount of water needed depend on the gas type . since CO2 is disoved in cooled
water ( < 10oC )and high pressure (>1 atm ) . the solubility of Co2 in water is 0.04
g of CO2/kg of water
444 kg or 444000 g of co2 we need 11100000 kg of water

Since its too large ,the adsorption will take place in a part of the CO2.

KOH make up

Since 1120 kg of KOH is recycled in the process

Make up = feed – recycled = 11324-1120 =10204 kg