Abstract: There is disclosed a process for producing a potassium sulfate electrochemically. The process involves the use of sodium sulfate which is electrolyzed in an electrolytic cell and which results in the production of sodium hydroxide and ammonium sulfate. The process carried out in a two or three-compartment electrolytic cell and the ammonium sulfate is converted by ammoniation and treatment of the ammoniated mixture with potassium chloride to produce potassium sulfate. Potassium sulfate may then also undergo electrochemical treatment to produce potassium hydroxide and ammonium sulfate.

Abstract: A process for the preparation of potassium sulfate, sodium bicarbonate and sodium carbonate. The process involves the treatment of potash brines by the reaction of sodium chloride and potassium chloride with calcium sulfate and sodium sulfate. Syngenite precipitate (CaSO4.K2SO4&khgr;H2O) is produced and a first filtrate containing sodium chloride and potassium chloride. The syngenite precipitate is reacted with ammonium bicarbonate at between 70° C. and 100° C., with the result being calcium carbonate precipitate and a second filtrate containing ammonium sulfate and potassium sulfate. The second filtrate is cooled to a temperature of between 20° C. and 50° C. and treated with potassium chloride. A potassium sulfate precipitate results. The sodium bicarbonate is precipitated from the first filtrate by the addition of ammonium bicarbonate to the first precipitate. The sodium bicarbonate may be calcined to form sodium carbonate.

Abstract: A method of wet granulation of fertilizer and other materials into granules. The method involves formation of the granule directly on the pan from the feedstock without intermediate steps or the use of seed materials. The result is a product having a completely uniform cross section. The feedstock is initially in the size distribution of −150 mesh with 90% or greater in the size range of 200 mesh. Moisture is maintained to facilitate a steady process without cycling. The method has the advantage of allowing granulation of materials either known to be hazardous or inherently difficult to granulate in a safe and expedient manner.

Abstract: A process is provided for producing potassium sulfate by reacting ammonium sulfate and potassium chloride at a temperature of about 30 to 40° C. to produce a slurry containing K2SO4·NH4·2SO4 double salt, and reacting this double salt with an aqueous solution containing potassium chloride at a temperature of about 30° C. to produce a slurry containing potassium sulfate. The slurry containing potassium sulfate is subjected to a solids/liquid separation step to obtain potassium sulfate crystals having a size in the range of about 20 mesh to about 150 mesh.

Abstract: Granulated particles by making use an initial feedstock having particle size of −150 mesh and 90% or greater particle size of 200 mesh. The feedstock may be contacted in a pan granulator which includes a minor amount of nucleating material of about −35 mesh. Binder is introduced into the pan granulator to progressively layer the feedstock material onto the nucleating to form a final granular fertilizer or other product in any desired size distribution. The method by which the granules are formed is interruptible and is particularly useful for forming granules having a plurality of layers of differing material. The granules, by formation with dust feedstock and in the absence of seed material, lack a core and therefore include the maximum amount of tightly packed feedstock. This results in substantial increases in the break strength of the granules with uniform homogeneous cross-sections.

Abstract: Fertilizer granulation method for incorporating urea directly into the matrix of fertilizer pellets. The process involves introducing the urea in a liquid form into the matrix and then progressively cooling the mixture of pellet and urea to recrystallize the urea within the matrix of the pellet. The result is a substantially harder particle relative to pretreatment hardness, reduced solubility for longer lasting pellets and substantially reduced dust and other handling problems of the formed pellets.

Abstract: A method of wet granulation of fertilizer and other materials into granules. The method involves formation of the granule directly on the pan from the feedstock without intermediate steps or the use of seed materials. The result is a product having a completely uniform cross section. The feedstock is initially in the size distribution of -150 mesh with 90% or greater in the size range of 200 mesh. Moisture is maintained to facilitate a steady process without cycling. The method has the advantage of allowing granulation of materials either known to be hazardous or inherently difficult to granulate in a safe and expedient manner.

Abstract: A process is provided for recovering sodium bicarbonate and ammonium sulfate from a solution containing sodium sulfate derived from a process for removing sulfur contaminants out of a gas with sodium bicarbonate reagent. Sodium bicarbonate is precipitated and removed from the solution. Sodium sulfate or ammonium bicarbonate is added to the solution to form a second precipitate of sodium bicarbonate, which is removed from the solution. The solution is conditioned by either heating the solution to 95.degree. C. to liberate ammonia and carbon dioxide or by adding sulfuric acid to the solution to decompose any carbonates. The solution is cooled to a temperature between -2 to 2.degree. C. to form a third precipitate of sodium bicarbonate. Sulfuric acid is added to the solution to decompose any carbonate minerals, and purified ammonium sulfate solution is recovered.

Abstract: An apparatus and method for uniform granulation is disclosed. The method involves the use of an initial feedstock having particle size of -150 mesh and 90% or greater particle size of 200 mesh. The feedstock may be contacted in a pan granulator which includes a minor amount of nucleating material of about -35 mesh. Binder is introduced into the pan granulator to progressively layer the feedstock material onto the nucleating to form a final product having a size distribution -8 mesh to +4 mesh. The method is designed to be interruptible and is particularly useful for forming granules having a plurality of layers of differing material. The method has marked improvement over the prior art methods since a particularly fine granule can be formed in a relatively expedient process to result in a granule having high commercial value and high break strength. These factors are achievable in addition to 100% product usage with no waste.