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| United States Patent |
6,251,352
|
|
Saran
, et al.
|
June 26, 2001
|
Recovery of elemental phosphorus from phosphorus sludge
Abstract
Disclosed is a method of recovering elemental phosphorus from a sludge that
contains water, dirt, and elemental phosphorus. In the first step, the
sludge is melted. A mixture is formed of the melted sludge and about 0.5
to about 3 wt % of an oxidizing agent, based on the weight of said
elemental phosphorus in the sludge, and about 75 to about 400 wt % water,
based on the weight of the sludge. The mixture is stirred until a
continuous elemental phosphorus phase forms. The purified phosphorus phase
is separated from the mixture.
| Inventors:
|
Saran; Mohan S. (Grand Island, NY);
Brooks; James R. (Thompson Station, TN);
Potts; David C. (Franklin, TN)
|
| Assignee:
|
Glenn Springs Holdings, Inc. (Lexington, KY)
|
| Appl. No.:
|
371284 |
| Filed:
|
August 10, 1999 |
| Intern'l Class: |
C01B 025/01 |
| Field of Search: |
423/322,157.2,157.3,158
210/710,737,906
|
References Cited
U.S. Patent Documents
| 3436184 | Apr., 1969 | Hinkebein | 423/322.
|
| 3442621 | May., 1969 | Hinkebein | 423/322.
|
| 3515515 | Jun., 1970 | Hinkebein | 423/322.
|
| 4686094 | Aug., 1987 | Roberts | 423/322.
|
| 4717558 | Jan., 1988 | Beck | 423/322.
|
Primary Examiner: Dunn; Tom
Assistant Examiner: Medina; Maribel
Attorney, Agent or Firm: Fuerle; Richard D., Brookes; Anne E.
Claims
We claim:
1. A method of recovering elemental phosphorus from a sludge that contains
water, dirt, and elemental phosphorus as a discontinuous phase comprising,
in a batch process,
(A) melting said sludge;
(B) forming a mixture of said sludge and about 0.5 to about 3 wt % of an
oxidizing agent, based on the weight of said elemental phosphorus in said
sludge, and about 75 to about 400 wt % water, based on the weight of said
sludge;
(C) stirring said mixture until a continuous elemental phosphorus phase
forms then stopping said stirring before a phosphorus-in-water emulsion
forms; and
(D) separating said continuous elemental phosphorus phase from said
mixture.
2. A method according to claim 1 wherein said oxidizing agent is selected
from the group consisting of chromic acid, hydrogen peroxide, nitric acid,
ozone, and oxygen.
3. A method according to claim 1 wherein said oxidizing agent is chromic
acid.
4. A method according to claim 1 wherein said separated continuous
elemental phosphorus phase is filtered or centrifuged after step (D).
5. A method according to claim 1 wherein said continuous elemental
phosphorus phase is separated by settling.
6. A method according to claim 1 wherein said sludge contains about 5 to
about 80 wt % elemental phosphorus.
7. A method according to claim 1 wherein said dirt is a mixture of carbon
fines, slag, sand, and phosphate rock.
8. A method according to claim 1 wherein said sludge is produced when
phosphate rock, carbon, and sand are heated in an electric furnace.
9. A method according to claim 1 wherein said stirring in step (C) is for
about 15 minutes to about 30 minutes at a rate of about 150 to about 300
rpm.
10. A method of recovering elemental phosphorus from a sludge that contains
water, dirt, and about 5 to about 80 wt % elemental phosphorus as a
discontinuous phase comprising, in a batch process,
(A) melting said sludge at a temperature of about 55 to about 75.degree.
C.;
(B) forming a mixture of said sludge and, in an amount about 1 to about 4
times the amount of sludge, an aqueous solution containing about 0.5 to
about 3 wt % chromic acid;
(C) stirring said mixture until said elemental phosphorus forms a
continuous phase then stopping said stirring before a phosphorus-in-water
emulsion forms; and
(D) separating said elemental phosphorus continuous phase from said
mixture.
11. A method according to claim 10 wherein said separated elemental
phosphorus continuous phase is filtered or centrifuged after step (D).
12. A method according to claim 10 wherein said elemental phosphorus
continuous phase is separated by settling.
13. A method according to claim 10 wherein said sludge contains about 5 to
about 80 wt % elemental phosphorus.
14. A method according to claim 10 wherein said dirt is a mixture of carbon
fines, slag, sand, and phosphate rock.
15. A method according to claim 10 wherein said sludge is produced when
phosphate rock, carbon, and sand are heated in an electric furnace.
16. A method according to claim 10 wherein said stirring in step (C) is for
about 15 minutes to about 30 minutes at a rate of about 150 to about 300
rpm.
17. A method of recovering elemental phosphorus from a phosphorus sludge
comprising, in a batch process,
(A) melting a phosphorus sludge that contains about 5 to about 80 wt %
elemental phosphorus in a discontinuous phase in a reactor at a
temperature of about 55 to about 75.degree. C.;
(B) forming a mixture of said sludge and, in an amount about 1 to about 4
times the amount of sludge, an aqueous solution containing about 0.5 to
about 3 wt % chromic acid;
(C) stirring said mixture for about 15 minutes to about 30 minutes at about
150 to about 300 rpm whereby said elemental phosphorus forms a continuous
phase but does not form a phosphorus-in-water emulsion;
(D) permitting said mixture to settle;
(E) separating said lemental phosphorus continuous phase from said mixture;
and
(F) filtering or centrifuging said separated elemental phosphorus
continuous phase.
18. A method according to claim 17 wherein said dirt is a mixture of carbon
fines, slag, sand, and phosphate rock.
19. A method according to claim 17 wherein said sludge is produced when
phosphate rock, carbon, and sand are heated in an electric furnace.
20. A method according to claim 16 wherein said separated elemental
phosphorus continuous phase is filtered.
Description
BACKGROUND OF THE INVENTION
This invention relates to a method of recovering elemental phosphorus from
phosphorus sludge. In particular, it relates to such a method where the
sludge is melted, an oxidizing agent and water are added, and the sludge
is stirred to coalesce phosphorus globules into a pure phosphorus
continuous phase which separates from the dirt in the sludge.
Elemental phosphorus can be made by heating phosphate rock, carbon, and
sand in an electric furnace. Phosphorus vapors given off in the furnace
contain solid impurities, such as slag, phosphate rock, sand, and coke,
which cause the formation of sludge when the phosphorus vapors are
condensed to the liquid form. Gradually, phosphorus sludge accumulates on
top of this liquid phosphorus layer.
Phosphorus sludge is often stored in outdoor ponds. Periodically, it is
necessary to reduce the amount of stored sludge either by recovering
phosphorus or by converting the sludge into useful products. Such
treatment may require the separation of phosphorus from the impurities.
In U.S. Pat. Nos. 3,436,184 and 3,515,515 there is described a process for
reducing the phosphorus content of phosphorus sludge by adding chromic
acid to the sludge. That process removes only a portion of the phosphorus
in the sludge.
SUMMARY OF THE INVENTION
We have discovered that when an aqueous solution of an oxidizing agent is
added to a heated phosphorus sludge followed by stirring, a continuous
phosphorus phase forms which separates from the dirt in the sludge. Thus,
unlike the prior process, in the process of this invention close to the
entire amount of elemental phosphorus in the sludge can be recovered.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of this invention is applicable to any phosphorus sludge that
contains about 0.5 to about 90 wt % elemental phosphorus (usually present
as P.sub.4), about 2 to about 80 wt % water, and about 2 to about 60 wt %
"dirt," which is typically a mixture of various solids such as carbon
fines, slag (calcium-aluminum silicates), sand, and phosphate rock. The
process of this invention is particularly applicable to phosphorus sludges
that contain about 5 to about 80 wt % elemental phosphorus.
Phosphorus sludge has been described in the literature as being a
phosphorus-in-water emulsion. While we do not wish to be bound by any
theories, we believe that the phosphorus in a phosphorus sludge is a
discontinuous phase consisting of phosphorus globules. The globules may
also contain water and fine dirt. They do not coalesce because their
surfaces may be partially oxidized and may carry electrical charges as
well as dirt and water. In our invention, when an oxidizing agent is added
followed by vigorous stirring, the oxidizer cleans the surfaces of the
phosphorus globules, allowing them to coalesce. During purification the
phosphorus separates from dirt and water. The process must be performed as
a batch process because over-stirring causes the cleaned phosphorus to
form an emulsion of fine phosphorus particles suspended in an aqueous
solution. It is difficult to separate the phosphorus from this emulsion.
In the first step of the process of this invention, the phosphorus sludge
is melted. As the phosphorus melts the sludge becomes more fluid. A
temperature of about 55 to about 75.degree. C. is usually satisfactory as
lower temperatures may not melt the sludge and higher temperatures are
unnecessary.
In the second step of the process of this invention, an oxidizing agent is
added to the melted sludge. Examples of oxidizing agents that can be used
include chromic acid, hydrogen peroxide, nitric acid, ozone, and oxygen.
The preferred oxidizing agent is chromic acid as it has a fast,
controllable reaction rate. Chromic acid is preferably added as a solution
of CrO.sub.3 in water as it is easier to handle as a solution. A 1 to 4 wt
% chromic acid solution is preferred. The amount of oxidizing agent used
should be about 0.5 to about 3 wt % of the amount of elemental phosphorus
that is present in the sludge. Less oxidizing agent may not be effective
and more is unnecessary. The preferred amount of oxidizing agent is about
1 to about 3 wt %.
It is also necessary to add water to the sludge to help float the dirt away
from the elemental phosphorus. The water can be added separately or it can
be added with the oxidizing agent. The amount of water added should be
about 75 to about 400 wt %, based on the weight of the sludge, as the
removal of dirt from the sludge is facilitated by water, but too much
water is unnecessary and provides no additional benefit. The preferred
amount of water is about 90 to about 150 wt %.
In the third step of the process of this invention, the melted sludge and
oxidizing agent solution are stirred. This is a critical step as stirring
is necessary to clean the phosphorus, remove the dirt, and form a
continuous elemental phosphorus phase. That is, the sludge is stirred
enough to liberate the dirt, producing clean elemental phosphorus, but not
so much that a phosphorus-in-water emulsion forms. Stirring to produce
that result typically requires about 15 minutes to about 30 minutes at
about 150 to about 300 rpm. Once a continuous phosphorus phase forms, the
stirring should be stopped as additional stirring may break the elemental
phosphorus into droplets and form a phosphorus-in-water emulsion,
preventing the recovery of pure elemental phosphorus.
After the stirring is finished, the reaction mass is allowed to settle for
at least 30 minutes to allow the phosphorus to settle as a separate phase.
The heavy dirt (e.g., pebbles, slag, etc.) settles to the bottom of the
reactor. The next layer is the elemental phosphorus, which has a density
of about 1.8 g/cc. On top of the elemental phosphorus is the finer dirt,
suspended in water. The various components of the sludge can then be
separated. The resulting elemental phosphorus is typically about 90 to
about 99 wt % pure and, if it is centrifuged or filtered, its purity can
rise to 99.9 wt %. Instead of settling, the entire reaction mass can be
filtered or centrifuged to recover the phosphorus, but settling is
preferred because it makes it easier to handle the phosphorus phase only.
The following examples further illustrated this invention. Analytical data
was obtained by separating the phosphorus as a frozen layer from the rest
of the reaction mass.
EXAMPLES 1 to 6
A weighed sample of P.sub.4 sludge (molten or solid) containing 49.4 wt %
phosphorus, 23.3 wt % dirt, and 27.3 wt % water (average of 4
determinations) was added to 500 g of a chromic acid solution of various
concentrations in a 2-liter resin flask equipped with a stainless steel
stirrer (2 inches long curved paddle) having a variable speed capability.
The flask was placed in a large Pyrex water bath which was heated with an
immersion heater to 65 to 75.degree. C. and stirred at 100 rpm for 15
minutes with a magnetic stirrer. The sludge, when solid, was allowed to
melt before stirring began. After the stirring was stopped, the reaction
contents were allowed to settle for 1/2 hour. Phosphorus settled at the
bottom as a separate layer, heavier dirt settled under the phosphorus
layer, lighter dirt on top of the phosphorus layer, and fine dirt stayed
suspended in the aqueous layer.
The settled phosphorus layer was allowed to freeze and removed from the
aqueous dirt suspension or it was removed as a molten layer and filtered
or centrifuged. The following table gives the conditions used and the
results:
Sludge CrO.sub.3 Phosphorus Phase
Example (g) (wt %) Amount (g) Dirt (wt) %
1 97.8 0 101 20.9
2 85.5 1 63 17.8
3 104.2 2 81 12.8
4 94.3 3 58 7.8
5 99.0 4 61 6.7
6 106.2 5 66 6.4
the above examples show that chromic acid concentrations of about 3 to 4 wt
% are optimal and that using higher concentrations of chromic acid does
not offer any advantage.
EXAMPLES 7 AND 8
Example 4 was repeated at different stirring rates. The following table
gives the results:
Sludge Stirring Rate Phosphorus Phase
Example (g) (rpm) Amount (wt) Dirt (wt %)
4 94.3 100 58 7.8
7 100.1 280 64 1.2
8 101 472 45 1.1
the above examples show that a better separation of the dirt from the
phosphorus obtained at the higher stirring rates.
EXAMPLES 9 TO 14
Examples 4, 7, and 8 were repeated using different stirring times. The
following table gives the results:
Stirring Stirring
Sludge Rate Time Phosphorus Phase
Example (g) (rpm) (min) Amount (g) Dirt (wt %)
4 94.3 100 15 58 7.8
9 102 100 60 62 1.3
10 97.7 100 120 50 0.7
11 102 280 5 59 2.2
7 100.1 280 15 64 1.2
12 103.6 280 30 78 0.3
13 105.7 280 55 *
8 101 472 15 45 1.1
14 107.7 472 30 *
*Fluffy homogeneous emulsion. No P.sub.4 layer separated even after 10
months. These examples show that a better separation of the dirt from the
phosphorus product was obtained as the stirring time was increased, until
a critical stirring time when the phosphorus did not separate.
EXAMPLES 15 TO 23
Examples 4 and 7 were repeated using different amounts and concentrations
of the chromic acid solution. The following table gives the results:
Chro-
mic
Ex- Acid Stirring Phosphorus Phase
am- Sludge Solution CrO.sub.3 CrO.sub.3 Rate Amount
ple (g) (g) (wt %) (g) (rpm) (g) Dirt (%)
4 94.3 500 3 15 100 58 7.8
15 103.4 500 3 15 200 60 0.5
16 100.3 500 0.5 2.5 280 63 18.2
17 99.8 500 1.0 5 280 56 8.3
18 100.5 500 1.5 7.5 280 59 0.8
19 92.5 500 2.0 10 280 47 0.3
20 102.8 500 2.5 12.5 280 51 0.7
7 100.1 500 3.0 15 280 64 1.2
8 101 500 3.0 15 472 45 1.1
21 100.8 150 3.0 4.5 280 63 4.4
17 99.8 500 1.0 5.0 280 56 8.3
22 100.3 250 2.0 5.0 280 54 6.7
23 100.3 200 2.5 5.0 280 58 4.2
The above examples show that a higher stirring rate results in less dirt in
the phosphorus product and that at these higher stirring rates a chromic
acid concentration of 1.5 to 3.0 wt % is more effective than a 3 to 4 wt %
concentration of chromic acid at lower stirring rates.
EXAMPLES 24 TO 38
The same procedure was used as in the previous examples on various
different sludges using 150 g of different chromic acid solutions. A
stirring rate of 280 rpm was used in these examples. The following table
gives the results:
Sludge Treated P.sub.4 Phase
Example grams % P % Dirt % CrO.sub.3 grams % P % Dirt
24 100 6.5 60.8 3 6.2 99.8 0.02
25 100.3 6.5 60.8 2 6.9 99.8 0.16
26 100 6.5 60.8 0.5 4.4 94.7 5.3
27 100 6.5 60.8 0.33 12.9 94.1 5.9
28 100 17.6 54.0 1.4 14.7 98.75 1.25
29 100 17.6 54.0 1.07 14.0 98.3 1.7
30 100 17.6 54.0 0.5 36.6 96.1 3.9
31 100 38.1 23.1 3.0 53.8 99.8 0.2
32 100 46.5 28.4 3.0 53.3 98.5 1.5
33 100 46.5 28.4 2.0 64.8 96.7 3.3
34 100 66.0 20.5 0.5 73.7 94 6.0
35 100 66.0 20.5 1.07 62.2 95.2 4.8
36 100 68.6 11.5 1.07 73.7 95.8 4.2
37 100 66.6 11.5 1.5 70.2 98.2 1.8
38 100 68.6 11.5 3.0 66.9 99.5 0.5
The above experiments show that sludges having very different phosphorus
and dirt compositions can be successfully treated with this process.
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