Abstract: The present invention is a process for upgrading feedstock prepared from raw phosphate ore. Phosphorus sludge is burned to produce impure phosphoric acid and the acid is combined with beneficiated phosphate ore to prepare anhydrous monocalcium phosphate. Feedstock prepared from raw phosphate ore is blended with anhydrous monocalcium phosphate to upgrade the feedstock.

Abstract: Fluorapatite mineral deposits in middle Tennessee were formerly beneficiated by washing out most of the clay, but some of the clay remained in the beneficiated ore. The ore was agglomerated by heating to temperatures high enough to melt clay remaining in the ore thereby obtaining a fluid phase for agglomeration in rotary kilns. The agglomerated phosphatic material was mixed with silica rock and metallurgical coke and the mixture was smelted in electric furnaces to produce elemental phosphorus. The feedstock had a percent P O in the phosphate-plus-silica of about 25.7.

Abstract: Elemental phosphorus was produced by the Tennessee Valley Authority (TVA) at Muscle Shoals, Ala. by smelting phosphatic material with carbon in electric furnaces. Solid wastes containing elemental phosphorus accumulated at the production facility as a result of TVA's operation at Muscle Shoals. Soil became polluted with elemental phosphorus from contact with phosphorus-containing wastes and remediation of the polluted soil is needed to restore land at the site to usefulness. The present invention entails agglomeration of the polluted soil by nodulizing to prepare feedstock for electric furnaces; reacting phosphoric acid with finely divided phosphate ore forming a porous, monolithic mass of monocalcium phosphate monohydrate; disintegrating the monolithic mass to form lumps; heating lumps to obtain anhydrous monocalcium phosphate; and simultaneous smelting of agglomerated soil and anhydrous monocalcium phosphate with carbon in an electric furnace.

Abstract: Phosphorus furnaces were operated by the Tennessee Valley Authority (TVA) to produce elemental phosphorus beginning over the period 1936-1976. Elemental phosphorus was lost in phosphorus-containing waste throughout the 40 years TVA produced the element. Large quantities of phosphorus-containing wastes remain at the site where TVA produced the chemical.Technology has not been available to treat phosphorus-containing waste so as to recover elemental phosphorus and produce an innocuous waste material. White phosphorus is a dangerous chemical and it is very toxic. Essentially all the elemental phosphorus must be recovered if an innocuous waste is produced. Commercial processes have not been available to recover elemental phosphorus from phosphorus-containing wastes.Elemental phosphorus is produced commercially by smelting phosphatic material in electric furnaces. A process has been invented to prepare phosphatic feedstock from phosphorus-containing waste.

Abstract: Phossy water is a toxic liquid waste that is generated when elemental phosphorus is manufactured, stored, or processed into phosphorus-containing products. Elemental phosphorus may be prsent as a solution, as colloidal particles, and as settleable particles.The primary objects of the invention are as follows:1. To provide a process for the disposal of phossy water stored at the TVA National Fertilizer and Environmental Research Center.2. To provide a process for the recovery of phossy water that will be generated when hazardous wastes stored at the TVA National Fertilizer and Environmental Research Center are recycled.Phossy water can be disposed of by using it to quench and granulate molten slag at electric furnaces used to manufacture elemental phosphorus. The elemental phosphorus content of the phossy water is limited to about 2 parts per million.Phossy water that will be generated during recycling of hazardous wastes can be recovered by using it in the process to produce fluid fertilizers.

Abstract: Phossy water is a toxic liquid waste that is generated when elemental phosphorus is manufactured, stored, or processed into phosphorus-containing products. Elemental phosphorus may be present as a solution, as colloidal particles, and as settleable particles.The primary objects of the invention are as follows:1. To provide a process for the disposal of phossy water stored at the TVA National Fertilizer and Environmental Research Center.2. To provide a process for the recovery of phossy water that will be generated when hazardous wastes stored at the TVA National Fertilizer and Environmental Research Center are recycled.Phossy water can be disposed of by using it to quench and granulate molten slag at electric furnaces used to manufacture elemental phosphorus. The elemental phosphorus content of the phossy water is limited to about 2 parts per million.

Abstract: A process is disclosed for converting precipitator dust obtained during production of elemental phosphorus into feedstock for the submerged-arc electric furnace. Precipitator dust is agglomerated and indurated to prepare furnace feedstock. A binder is made by reacting acidic phosphorus compounds with alkaline substances. The preferred acidic phosphorus compound is phosphoric acid, and the preferred alkaline substance is ground phosphate ore. Precipitator dust is tumbled with the binder to form agglomerates, and the agglomerates are then indurated by heating. Gases evolved during preparation of binder, agglomeration of precipitator dust, and induration of the agglomerates are scrubbed with an aqueous medium having a pH in the range of 5.5 to 6.0. Scrubber effluent is used as feedstock for the production of suspension fertilizer. The indurated agglomerates are smelted in a submerged-arc electric furnace.

Abstract: New processes and equipment are disclosed for producing elemental phosphorus and thermal phosphoric acid. Benefits are listed below.1. Phosphorus-containing solids are recycled to smelting furnaces thus eliminating hazardous waste generation.2. Phosphorus furnace feedstock is upgraded and this permits unbeneficiated phosphate ore to be smelted.3. Energy is conserved during manufacture of elemental phosphorus and phosphoric acid.4. Electric energy is produced by cogeneration.5. Fluorine in phosphate ore is recovered as ammonium fluoride.6. Phosphorus-containing liquids are used as feedstock for production of suspension fertilizers.Benefits are achieved by agglomerating phosphate ore with monocalcium phosphate binder by a method which upgrades the ore. Phosphorus-containing solids are fluidized and burned to form an impure phosphoric acid mixture which is reacted with small sized phosphate ore to form monocalcium phosphate binder.

Abstract: Fluorine in phosphate ores is present as the mineral fluorapatite. When the ores are digested with sulfuric acid a slurry is formed which can be filtered to make wet-process phosphoric acid. But fluorine compounds are discharged into the surrounding air during digestion and filtration. The fluorine-containing air is scrubbed with water to prevent air pollution. Scrubber water is cooled in ponds and is recycled to the scrubber. However, fluorine compounds are emitted from the cooling ponds and cause air pollution. In the present invention, processes are disclosed for treating fluorine-containing gases without use of cooling ponds thereby eliminating the air pollution problem. A facility is provided for treating fluorine-containing gases wherein fluosilicic acid or fluosilicate salts are converted to a fluoride salt by the addition of an alkaline substance. A slightly acidic scrubber water is concentrated in an absorption tower.

Abstract: The invention discloses processes for preparing matched sizes of electric furnace feed materials. With the matched sizes, components of the feed mixture do not separate inside the furnace and this decreases the electric energy for smelting. Preparation of matched sizes of materials is made possible by low-temperature agglomeration followed by drying to indurate the agglomerates. Fuel requirements for induration are substantially reduced, and environmental problems associated with high-temperature agglomeration are eliminated. Phospahte ores can be agglomerated and simultaneously the ores are upgraded by increasing the P.sub.2 O.sub.5 content. Unbeneficiated phosphate ores heretofore considered unsuited for smelting can be used as phosphate sources for the production of phosphorus. A combustible gas consisting mainly of carbon monoxide and hydrogen is generated when ores are smelted. Processes are disclosed for cleaning the gas to permit it to be burned in a facility for the cogeneration of electric energy.

Abstract: Processes are disclosed for recovering solid wastes containing elemental phosphorus. The wastes may cause serious environmental problems at phosphorus furnaces because elemental phosphorus is toxic to marine animals. Recovery of the wastes was considered for the following.1. At phosphorus furnace plants making phosphoric acid as one of the products, when the objective is to produce only high-quality phosphoric acid.2. At phosphorus furnace plants making elemental phosphorus as a final product, and the objective is to provide only high-quality phosphorus.3. At plant sites where neither phosphoric acid nor phosphorus is produced.The processes include recycling the wastes to phosphorus furnaces. All of the phosphoric acid produced in 1 can be highly concentrated with low impurities content. In 2, all the low-quality phosphorus is recycled to the phosphorus furnaces and all the produce is high grade. In 3, phosphorus furnaces are not available at the plant site and recycling the solid wastes is impractical.

Abstract: Processes are disclosed for recovering solid wastes containing elemental phosphorus. The wastes may cause serious environmental problems at phosphorus furnaces because elemental phosphorus is toxic to marine animals. Recovery of the wastes was considered for the following.1 At phosphorus furnace plants making phosphoric acid as one of the products, when the objective is to produce only high-quality phosphoric acid.2. At phosphorus furnace plants making elemental phosphorus as a final product, and the objective is to produce only high-quality phosphorus.3. At plant sites where neither phosphoric acid nor phosphorus is produced.The processes include recycling the wastes to phosphorus furnaces. All of the phosphoric acid produced in 1 can be highly concentrated with low impurities content. In 2, all the low-quality phosphorus is recycled to the phosphorus furnaces and all the product is high grade. In 3, phosphorus furnaces are not available at the plant site and recycling the solid wastes is impractical.

Abstract: Fluorine in phosphate ores is present as the mineral fluorapatite. When the ores are digested with sulfuric acid a slurry is formed which can be filtered to make wet-process phosphoric acid. But fluorine compounds are discharged into the surrounding air during digestion and filtration. The fluorine-containing air is scrubbed with water to prevent air pollution. Scrubber water is cooled in ponds and is recycled to the scrubber. However, fluorine compounds are emitted from the cooling ponds and cause air pollution. In the present invention, processes are disclosed for treating fluorine-containing gases without use of cooling ponds thereby eliminating the air pollution problem. A facility is provided for treating fluorine-containing gases wherein fluosilicic acid or fluosilicate salts are converted to a fluoride salt by the addition of an alkaline substance. A slightly acidic scrubber water is concentrated in an absorption tower.

Abstract: Processes and compositions of matter are disclosed for the production of liquid fertilizers wherein wastewater from a phosphorus smelting furnace is incorporated in liquid fertilizer processes. The wastewater replaces water evaporated and the wastewater dissolves fertilizer salts. A serious water pollution problem is avoided when wastewater is incorporated in liquid fertilizers. The invention discloses a process for making orthophosphate suspension fertilizer wherein impure phosphoric acid is neutralized in the condensing system, water from the condensing system is bled off, and a suspending clay is added to produce orthophosphate suspension fertilizer. In this process, phosphorus sludge made at phosphorus furnaces is used to produce suspension fertilizer, and wastewater from phosphate smelting furnaces is recovered. New compositions of matter are disclosed.

Abstract: Fluorine in phosphate ores is present as the mineral fluorapatite. When the ores are digested with sulfuric acid a slurry is formed which can be filtered to make wet-process phosphoric acid. But fluorine compounds are discharged into the surrounding air during digestion and filtration. The fluorine-containing air is scrubbed with water to prevent air pollution. Scrubber water is cooled in ponds and is recycled to the scrubber. However, fluorine compounds are emitted from the cooling ponds and cause air pollution. In the present invention, processes are disclosed for treating fluorine-containing gases without use of cooling ponds thereby eliminating the air pollution problem. A facility is provided for treating fluorine-containing gases wherein fluosilicic acid or fluosilicate salts are converted to a fluoride salt by the addition of an alkaline substance. A slightly acidic scrubber water is concentrated in an absorption tower.

Abstract: Processes are disclosed for recovering solid wastes containing elemental phosphorus. The wastes may cause serious environmental problems at phosphorus furnaces because elemental phosphorus is toxic to marine animals. Recovery of the wastes was considered for the following.1. At phosphorus furnace plants making phosphoric acid as one of the products, when the objective is to produce only high-quality phosphoric acid.2. At phosphorus furnace plants making elemental phosphorus as a final product, and the objective is to produce only high-quality phosphorus.3. At plant sites where neither phosphoric acid nor phosphorus is produced.The processes include recycling the wastes to phosphorus furnaces. All of the phosphorus acid produced in 1 can be highly concentrated with low impurities content. In 2, all the low-quality phosphorus is recycled to the phosphorus furnaces and all the product is high grade. In 3, phosphorus furnaces are not available at the plant site and recycling the solid wastes is impractical.

Abstract: Processes and compositions of matter are disclosed for the production of liquid fertilizers wherein wastewater from a phosphorus smelting furnace is incorporated in liquid fertilizer processes. The wastewater replaces water evaporated and the wastewater dissolves fertilizer salts. A serious water pollution problem is avoided when wastewater is incorporated in liquid fertilizers. The invention discloses a process for making orthophosphate suspension fertilizer wherein impure phosphoric acid is neutralized in the condensing system, water from the condensing system is bled off, and a suspending clay is added to produce orthophosphate suspension fertilizer. In this process, phosphorus sludge made at phosphorus furnaces is used to produce suspension fertilizer, and wastewater from phosphate smelting furnaces is recovered. New compositions of matter are disclosed.

Abstract: The invention discloses processes for preparing matched sizes of electric furnace feed materials. With the matched sizes, components of the feed mixture do not separate inside the furnace and this decreases the electric energy for smelting. Preparation of matched sizes of materials is made possible by low-temperature agglomeration followed by drying to indurate the agglomerates. Fuel requirements for induration are substantially reduced, and environmental problems associated with high-temperature agglomeration are eliminated. Phosphate ores can be agglomerated and simultaneously the ores are upgraded by increasing the P.sub.2 O.sub.5 content. Unbeneficiated phosphate ores heretofore considered unsuited for smelting can be used as phosphate sources for the production of phosphorus. A combustible gas consisting mainly of carbon monoxide and hydrogen is generated when ores are smelted. Processes are disclosed for cleaning the gas to permit it to be burned in a facility for the cogeneration of electric energy.

Abstract: Processes and compositions of matter are disclosed for the production of liquid fertilizers wherein wastewater from a phosphorus smelting furnace is incorporated in liquid fertilizer processes. The wastewater replaces water evaporated and the wastewater dissolves fertilizer salts. A serious water pollution problem is avoided when wastewater is incorporated in liquid fertilizers. The invention discloses a process for making orthophosphate suspension fertilizer wherein impure phosphoric acid is neutralized in the condensing system, water from the condensing system is bled off, and a suspending clay is added to produce orthophosphate suspension fertilizer. In this process, phosphorus sludge made at phosphorus furnaces is used to produce suspension fertilizer, and wastewater from phosphate smelting furnaces is recovered. New compositions of matter are disclosed.

Abstract: Processes and compositions of matter are disclosed for the production of liquid fertilizers wherein wastewater from a phosphorus smelting furnace is incorporated in lqiuid fertilizer processes. The wastewater replaces water evaporated and the wastewater dissolves fertilizer salts. A serious water pollution problem is avoided when wastewater is incorporated in liquid fertilizers. The invention discloses a process for making orthophosphate suspension fertilizer wherein impure phosphoric acid is neutralized in the condensing system, water from the condensing system is bled off, and a suspending clay is added to produce orthophosphate suspension fertilizer. In this process, phosphorus sludge made at phosphorus furnaces is used to produce suspension fertilizer, and wastewater from phosphate smelting furnaces is recovered. New compositions of matter are disclosed.