PROCESS FOR THE MANUFACTURING OF CRUDE POTASSIUM CHLORIDE/ CALCIUM SU

FROM BITTERN.

RAW MATERIAL:- BITTERN OF sp gr. 1.25 to 1.26 i.e

source
of bittern
29-30 after
Be remo

process for the manufacturing

sea water which is concentrated to remove salt is crystallized and salt is seperated
the liquid which comes out after salt removal has the sp.gr of 1.25 to 1.26 i.e of 29
this liquid is further evapourated to a density of sp.gr of 1.28 to 1.284 i.e of 32 to 3
at this point the excess salt crystallizes out which is removed
the liquid which comes out after excess salt removal is further evapourated to a dens
at this point carnallite salt i.e KCl. MgCl2. 6H2O Crystallizes out. Along with some s

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
puity of 98% of KCL
which is further purified by hot crystillization and filtration.
the potassium chloirde/ sodium chloride mixture from the purification step is recycled

bittern obtained after removal of carnallite at sp.gr of 1.324 and 35.5 Be is a conce
solution of magnesium chloride and is called end bittern and contains around 400 to

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 hydr
molecular weight of the components
Mol.wt
magnesium chloride 95.31
sodium chloride 58.48
potassium chloride 74.6
calcium chloride 110.99
magnesium sulphate 120.45
potassium sulphate 174.26
sodium sulphate 142.04
calcium sulphate 136.14

MATERIAL BALANCE:-
STEP- 1
note:- for ease of calculation the two ions are considered not present
INPUT brine of 29 Be having the folowing analysis ( desulphated )
atomic mol wt wt % of
g/liter number
Mg2+ 46 24.26 Mgcl2 95.31 Mg2+ 25.50% Mgcl2
Na+ 44 22.99 NaCl 58.48 Na+ 39.31% NaCl
K+ 13.6 39.1 KCl 74.6 K+ 52.41% KCl
Ca2+ 2 40.08 CaCl2 110.99 Ca2+ 36.10% CaCl2
Cl- 197.9 35.5
So42- _
Br- _

STEP -2
this brine is evapurated to sp.gr of 1.28 to 1.284 i.e 32 to 33 Be.
solid
INPUT g/litre % OUTPUT grams
Mgcl2 180.39 55.7 Mgcl2
NaCl 111.93 34.56 NaCl 104.76
KCl 25.95 8.01 KCl
CaCl2 5.54 1.71 CaCl2
323.81
 STEP-3
the liquid brine from step -2 is further evapourted to sp.gr of 1.318 to 1.324

5.5 kgs
liquid
INPUT grams % output
Mgcl2 180.39 82.35 Mgcl2
NaCl 7.16 3.27 NaCl
KCl 25.95 11.85 KCl
CaCl2 5.54 2.53 CaCl2
219.04 water

44.5 kgs

output
Mgcl2
NaCl
KCl
CaCl2
water

step- 4

5.5 kgs of carnallite seperated from 50kgs of initial bittern

solid liquid
input % kgs output output
Mgcl2 28.22 1.55 1.55
NaCl 6.2 0.34 0.1 0.24
KCl 15 0.83 0.67 0.16
CaCl2 0.82 0.05 0.05
water 49.76 2.74 4.94
plus 5.5
water 2.2
KCL out put 0.7677KGS
IMPURE 87%

step-5

KCL INPUT OF 87% OUTPUT

0.7677KGS 0.6600KGS
 97%

THERE FOR OUT OF 50 KGS BITTERN OF 29 Be GRAVITY WILL GIVE

desulphated bittern
kgs
sodium chloride 4.19
potassium chloride 0.66
magnesium chloride 5.5
10.35

entire
solid balance
input 12.95
output 10.35
recycled 2.6

there for for the next cycles

the make up bittern will be
40 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 bittern
440g/litre of calcium chloride at calcium chloride required will be
0.013litres/min 286 gms
0.286 kgs
calcium sulphate produce
7.2796 gms/litre of bittern

0.3639kgs
for 50 kgs of bittern

output products will be now

kgs
sodium chloride 4.19
potassium chloride 0.66
magnesium chloride 5.5
10.35
calcium sulphate 0.36
total 10.71
 M CHLORIDE/ CALCIUM SULPHATE / MAGNESIUM CHLORIDE.

source bittern after removal of salt.

zed and salt is seperated

r of 1.25 to 1.26 i.e of 29-30 Be
1.28 to 1.284 i.e of 32 to 33 Be

ther evapourated to a density of sp.gr of 1.318 to 1.324 i.e 35 to 35.5 Be

zes out. Along with some sodium chloirde.

a liquid and a solid layer.

of 98% of KCL
purification step is recycled back to the brines

324 and 35.5 Be is a concentrated

nd contains around 400 to 430 g/litre of mgcl2

actor of 3

magnesium oxide and hydrochloric acid as the end product.

 40 litres of bittern taken for recovery
sp.gr is 1.25
50 kgs
50 kgs will contain
g/litre % gms
180.39 55.7 7215.6
111.93 34.56 4477.2
25.95 8.01 1038
5.54 1.71 221.6
323.81 ###
total 12.9524kgs

i.e 32 to 33 Be.
liquid after removing sodium chloride
OUTPUT grams gms
Mgcl2 180.39 7215.6
NaCl 7.16 286.8
KCl 25.95 1038
CaCl2 5.54 221.6
8762
 total 8.76

to sp.gr of 1.318 to 1.324 i.e 35 TO 35.5Be

of carnallite seperated from 50kgs of initial bittern

% kgs
28.22 1.55
6.2 0.34
15 0.83
0.82 0.05
49.76 2.74
5.5

end bittern after recovery of carnallite

kgs
5.66
nil
0.21
0.18
38.447kgs

0.7677KGS
AVITY WILL GIVE

e required will be
PRODUCTION PLANT FOR 100 TONNE OF POTASSIUM CHLORIDE PER MONTH

a) raw materials required

1 bittern from sea water after removing salt baving sp. Gr of 1.244 and 28.5Be
2 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 sulphate
magnesium chloride
sodium chloride

e) process flow chart

sea water
`
water out

bittern of 29-30 Be
sp.gr 1.25 to 1.26

calcium chloride
of 440g/l concentration
desulphated bittern of
29-30 Be
sp.gr - of 1.25 to 1.26

liquid out is
a concentrated solution of magnesium chl

effluent to sea
 ( 4 TONNE / DAY)

tonne
quantity
sp. Gr of 1.244 and 28.5Be 303.03
4.95

lphation of the bittern

respective chloride

2.21
33.33
25.39
total 64.92 with product quantity
21.4% solids

salt out
 calcium sulphate

sodium chloride

water

water

carnallite KCl. MgCl2.6H2O

water

potassium chloride
solution of magnesium chloride of 87 % purity

water

magnesium chloride

potassium chloride
97% purity
 project economics
Economics
for raw material

input:- sea water bittern303.3 tonne transportation charges

calcium chloride 4.918tonne

output
sodium chloride 25.39
potassium chloride 4
magnesium chloride 33.33
calcium sulphate 2.21

energy cost

water to be evapourated 136 tonne

215102 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
### rupees

working capital per month required

### rupees

generation of products
group -1kcl/mgcl2 37.44 tonne per day
 1048.32tonne per month

power
working capital includes fuel
maintanance
labour
packing
others
total 15000000

cost/ kgs 14.3 rs/kgs

profitibility gives 15.8 rs/kgs for kcl and mgcl2

at 10%

profit
1572480 rs/kgs

payback period 14 monthfor project cost building and machinery

 rupees
at 400/ tonne 121200 per day
at 7RS/KGS 34426 per day
total ###

at 0.5RS/KGS ###
at 7 RS/KGS 28000
at 10Rs/Kgs 333300
at 1RS/KGS 2205.3
total ### per day
market value

ans itself.

group-2 nacl and caso4

 sales of the same will meet the day to day expences
of the unit.

selling price of kcl and mgcl2.

and machinery