Abstract: A process for preparing concentrated, high-grade, nitrogen-phosphate (N--P.sub.2 O.sub.5) base suspension fertilizer from wet-process or other impure orthophosphoric acids. The process involves a new procedure for the direct ammoniation of orthophosphoric acid in stages for production of fluid, high-analysis, N--P.sub.2 O.sub.5 suspension fertilizer with good physical properties. The new process contains a novel method for prevention of settling of crystals in the suspension during vibration, such as that which occurs during shipment. Settling is avoided by producing small, thin crystals of diammonium phosphate through control of the N:P.sub.2 O.sub.5 ratio and temperature in the second and third ammoniation stages.

Abstract: A process for the production of a granular fertilizer material from sludge materials discharged from scrubbing processes that remove pollutants from boiler flue gases. Waste sludge discharged from flue gas scrubber systems often contain large amounts of calcium and sulfur as well as lesser amounts of other compounds known to have plant nutrient value. The sludge is treated with an acid such as phosphoric, sulfuric or nitric, or a mixture of these, and ammonia. The resulting sludge-ammonia-acid salt mixture is combined with partially dried, previously processed solid material (recycle) in a horizontal rotating vessel. Additional ammonia and/or acid is added to the rotating vessel to cause the sludge-salt mixture to solidify and granulate. Other plant nutrients may be added to the rotating vessel during granulation. The granulated material discharged from the rotary vessel is further processed (dried, cooled, and screened) to obtain desirable moisture content and particle size.

Abstract: Ammonium polyphosphates are prepared by a process which comprises heating melamine orthophosphate prepared from impure wet-process phosphoric acid in a stream of gaseous ammonia at a temperature between 150.degree. C and 210.degree. C to produce a mixture of melamine and relatively pure short-chain ammonium polyphosphates. The solid product is extracted with water to remove the ammonium polyphosphates and free the insoluble, crystalline melamine for recycle. Thus, the only starting materials consumed in the process are phosphoric acid and ammonia.

Abstract: Heretofore waste rubber, a substantial amount of it in the form of used automobile tires, has been buried, burned, or otherwise disposed of in manners and by means totally inconsistent with good ecological practices and considerations. Now, such waste or scrap rubber, both natural and synthetic, can readily be converted in the presence of molten acidic halide Lewis salt catalysts to useful products, including fuels comprising a naptha-like oil, a burnable solid carbonaceous material, and a mixture of gases. The most promising salts are zinc chloride, tin chloride, and antimony iodide. Also, an extremely active catalyst can be prepared by adding up to about 60 percent by weight of sodium chloride to the zinc chloride catalyst. The burnable carbonaceous material has been shown to be a carbon black of moderate quality and is believed to be suitable for reuse in tires if blended with high-quality fresh carbon black.

Abstract: The apparatus provides a homogeneous (with respect to particle size), dense, mass of sized particles in random motion so that highly uniform coatings of the same or of different solids can be applied to each particle by conventional spray-coating with the liquified coating material(s). The apparatus is a horizontal rotary drum containing lifting flights. A novel deflector pan is fixed in space inside the upper section of the drum which deflects particles falling from the lifting flights to the side of the drum where they form a narrow, dense falling cascade. The coating material is sprayed onto the cascading particles, preferably as they free-fall after leaving the lower edge of the pan. However, if desired, some or most of the coating material may be directed onto the top edge of the moving bed including the juncture of the cascade therewith.

Abstract: Process for the production of granular mixed fertilizer in which ammonium phosphate melt is prepared in a pipe reactor and dispersed through a plurality of apertures in the wall of the pipe to bind small particles of fertilizer materials into granules. Wet-process phosphoric acid is ammoniated to an NH.sub.3 :H.sub.3 PO.sub.4 mole ratio of about 1.0 and the steam formed by the heat of reaction atomizes the ammonium phosphate melt resulting in proper distribution of the melt for granulation. Up to about 30 percent of the P.sub.2 O.sub.5 in the melt may be polyphosphate. The ammonium phosphate is essentially anhydrous and the granules of mixed fertilizers do not require drying. Elimination of drying greatly decreases investment, dust and fume evolution, and fuel requirement.

Abstract: Our invention relates to an improved process for the partial purification of wet-process phosphoric acid with co-production of impure phosphoric acid or solid fertilizer materials containing most of the impurities originally present in the crude acid. The crude acid is treated with methanol and ammonia to precipitate most of the metallic and fluorine impurities as solid ammonium metallic phosphates and fluorine compounds that filter and settle rapidly. The solids are separated from the reaction mixture and methanol is distilled from the resulting clarified solution to form concentrated partially purified acid. The solid ammonium metallic phosphates are fertilizer materials. Alternately, the reaction slurry is separated into a clarified liquid fraction and a settled slurry fraction. Methanol is distilled from the settled fraction which causes most of the impurities to redissolve yielding an impure phosphoric acid.

Abstract: Particulate carbonaceous matter in ammonium polyphosphate liquid made from impure wet-process phosphoric acid is removed by intimately mixing the liquid with a combination of selected organic flocculating agents and then transferring the mixture to a separation vessel where the particulate carbonaceous matter floats rapidly to the surface. Clarified liquid that contains essentially no particulate carbonaceous matter is withdrawn from the bottom of the separation vessel. The particulate carbonaceous matter and a minor portion of the input ammonium polyphosphate liquid are withdrawn from the top of the separation vessel and processed into fluid or solid fertilizers.

Abstract: My invention relates to a new method for purification of wet-process phosphoric acid with co-production of nitrogen solution. The crude acid is treated with urea by known processes to form urea phosphate free of most of the impurities in the crude acid. The urea phosphate is treated with concentrated nitric acid to form solid urea nitrate and phosphoric acid. The purified phosphoric acid is separated from the urea nitrate and withdrawn as product. The urea nitrate is washed with concentrated nitric acid and the wash soluton then is used for reaction with urea phosphate. The washed urea nitrate is then treated with ammonia and water to form nitrogen solution.

Abstract: A process for the production of fertilizers from phosphoric and sulfuric acids, liquid anhydrous ammonia, and water. The ammonia is premixed with a small quantity of water in a common pipe; the resulting mixture is subsequently mixed downstream of said common pipe with the acids introduced to the pipe through a pipe cross. The acids and aqua ammonia react in the pipe cross and extension of the pipe beyond the cross. Overall length of the pipe reactor is 7 feet and it is cooled by a water jacket. In another variation of the process, the cooling water jacket is not used and the reaction tube is made of either Hastelloy C metal or Teflon-lined mild steel pipe. Slurry from the reactor is granulated with recycle fines, additional phosphoric and sulfuric acids, and ammonia in a rotary drum. Product from the granulator is cooled and screened for product size removal. Equipment is uncomplicated, easy to operate, and inexpensive.

Abstract: A process for the production of a granular fertilizer material from sludge materials discharged from scrubbing processes that remove pollutants from boiler flue gases. Waste sludge discharged from flue gas scrubber systems often contain large amounts of calcium and sulfur as well as lesser amounts of other compounds known to have plant nutrient value. The sludge is treated with an acid such as phosphoric, sulfuric or nitric, or a mixture of these, and ammonia. The resulting sludge-ammonia-acid salt mixture is combined with partially dried, previously processed solid material (recycle) in a horizontal rotating vessel. Additional ammonia and/or acid is added to the rotating vessel to cause the sludge-salt mixture to solidify and granulate. Other plant nutrients may be added to the rotating vessel during granulation. The granulated material discharged from the rotary vessel is further processed (dried, cooled, and screened) to obtain desirable moisture content and particle size.

Abstract: A process for preparing concentrated, high-grade, nitrogen-phosphate (N--P.sub.2 O.sub.5) base suspension fertilizer from wet-process or other impure orthophosphoric acids. The process involves a new procedure for the direct ammoniation of orthophosphoric acid in stages for production of fluid, high-analysis, N--P.sub.2 O.sub.5 suspension fertilizer with good physical properties. The new process contains a novel method for prevention of settling of crystals in the suspension during vibration, such as that which occurs during shipment. Settling is avoided by producing small, thin crystals of diammonium phosphate through control of the N:P.sub.2 O.sub.5 ratio and temperature in the second and third ammoniation stages.

Abstract: dicalcium phosphate is prepared from phosphate rock by a process which comprises reacting phosphate rock with sulfur dioxide and an organic carbonyl compound for 0.5 to 10 hours while maintaining the temperature of the reaction mixture below 50.degree. C. The reaction yields a mixture of gangue, solid calcium .alpha.-hydroxy sulfonate and soluble dicalcium phosphate. The solids are separated from the liquid and P.sub.2 O.sub.5 values adhering to the solid are washed free with a mixture of carbonyl, water, and sulfur dioxide. The wash effluent is recycled to the process and both carbonyl and some sulfur dioxide are recovered from the filter cake by heating it. The offgas from the heated filter cake is recycled to the process and the dry filter cake, now largely calcium sulfite hemihydrate, is discarded.Dicalcium phosphate is precipitated from the reaction mixture filtrate in high yield by partially distilling sulfur dioxide from the filtrate.

Abstract: processes for preparing concentrated phosphate rock-water suspension fertilizer with exceptionally satisfactory handling and storage properties are disclosed. Although there are various parameters in the processes that can be varied, they may, for the sake of convenience, be categorized in two embodiments. In the first embodiment, the process involves the blending together of water, fine-ground phosphate rock, and a small amount of a particle dispersant in proportions so that the final product contains 70-78 percent by weight of phosphate rock. In the second embodiment, the process involves the use of specialized procedures in the blending of water, fine-ground phosphate rock, gelling-type clay, and small amounts of dispersant and gelling agents in preparation of final product suspension containing 60 percent by weight of phosphate rock.