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1996 | Book

Potash

Deposits, Processing, Properties and Uses

Author: Donald E. Garrett, PhD

Publisher: Springer Netherlands

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About this book

Potash is the term generally given to potassium chloride, but it is also loosely applied to the various potassium compounds used in agriculture: po­ tassium sulfate, potassium nitrate or double salts of potassium and magne­ sium sulfate (generally langbeinite, K S0 • 2MgS0 ). Sometimes the var­ 2 4 4 ious compounds are differentiated by the terms muriate of potash, sulfate of potash, etc. When referring to ores, or in geology, all of the naturally­ found potassium salts are called "potash ores". However, originally potash referred only to crude potassium carbonate, since its sole source was the leaching of wood ashes in large pots. This "pot ash" product was generally recovered from near-seacoast plants, such as the saltwort bush, whose ashes were richer in potassium than sodium carbonate. Inland plant's ashes were generally higher in sodium carbonate, giving rise to the word alkali from the Arabic word for soda ash, al kali. The term was then carried over after potassium was discovered to form the latin word for it, kalium. The recovery of potash from ashes became a thriving small cottage industry throughout the world's coastal areas, and developing economies, such as the early set­ tlers in the United States were able to generate some much-needed income from its recovery and sale. This industry rapidly phased out with the advent of the LeBanc process for producing soda ash in 1792, and the discovery about the same time of the massive sodium-potassium nitrate deposits in the Atacama Desert of Chile.

Table of Contents

Frontmatter
Chapter 1. Origin of Potash Deposits
Abstract
Large, deeply buried potash deposits are found in many marine evaporite and other formations throughout the world, and occur in every continent and most geological epochs from the Cambrian to the present (Sonnenfeld 1985). The predominant mineral form is sylvite (KCl), found in almost every deposit with halite (NaCl) to form the mixture called sylvinite. In most occurrences fairly pure sylvinite exists with essentially no soluble sulfate or other salts, and in some zones of many deposits carnallite (KCl · MgCl · 6H2O) is also found, occasionally being massive and similarly crystallized with halite nearly free from other soluble salts. In only a few deposits do soluble sulfate salts occur with the potash, such as zones of the Zechstein Basin where “hartsalz” (sylvite with kieserite, MgSO4 · H2O, or anhydrite and halite) is common; double salts such as zones in Sicily and Ethiopia where kainite (KCl · MgSO4 · 2.75H2O) is predominant; and in areas of Carlsbad, New Mexico where langbeinite (K2SO4 · 2MgSO4) occurs extensively. In some deposits various other potash double salts are also present in trace to minor quantities, as well as occasionally quite extensive formations of the insoluble mineral poly halite, K2SO4 · MgSO4 · 2CaSO4 · 2H2O. In a few locations carnallite and some sylvinite occurs with halite and tachyhydrite (CaCl2 · 2MgCl2 · 12H2O.)
Donald E. Garrett
Chapter 2. Potash Deposits
Abstract
The number of potentially mineable and economically exploitable buried potash deposits is surprisingly large, and they are found scattered throughout the world. The “quality” of the deposits, however, varies widely in regard to their size (ore reserves), grade (mineable %K2O), and economic factors such as their location and the cost of mining and processing. The later features include the depth to the ore, thickness and uniformity of the potash bed, its slope, the strength and integrity of the overlying strata (to form a strong roof), the danger of water intrusion (flooding) and the cost of penetrating aquifer zones with the shafts, problems with combustible gasses or “rock bursts”, the amount of insolubles in the ore, the ease of “desliming”, the KCl-NaCl liberation size, and the amount of magnesium chloride (carnallite) or magnesium sulfate (kieserite, etc.) impurities present. The location is very important with respect to the deposit’s distance from the markets, the cost of transportation, Government royalties, taxes or fees, and possible special circumstances in selling the product (i.e., protective tariffs, local or controlled markets, reciprocal trade agreements, etc.). For the state-owned deposits there is often the over-riding desire to create jobs, reduce imports, and obtain foreign currency from exports. Also, there may be investment funds available at low interest rates or without the need for a normal return on the investment in order to promote a local industry.
Donald E. Garrett
Chapter 3. Potash Mining
Abstract
The mining of large underground potash deposits presents an unusual challenge because the quantity of ore to be mined is very large, the value of the ore is relatively low, there is extreme competition, and most dominately, at the depth of many potash mines there are severe stress and creep (plastic flow) problems. There is also the possibility of variable ore thickness, irregular ore zones, changing ore grade, excessive impurities (insolubles, MgCl2, etc.), barren zones, changeable or high slope of the seams, and possibly the practical need to mine non-potash layers. The danger of potential flooding, rock burst from trapped high pressure gas, a weak and/or unstable roof, high temperatures, combustible gas, etc. may also be present. All of these factors, and many more, make mining a very demanding and challenging part of the potash industry. Even so, the fairly well known and similar physical properties of various ores, the general similarity of its companion or adjacent rocks, its geological setting, and of course the demands of economics, have allowed comparatively standard mining techniques, with high efficiency and high capacity equipment, to be employed. Consequently, the operation of most mines have many characteristics in common, but since each ore body is somewhat different, some-to-many unique features also exist at each mine.
Donald E. Garrett
Chapter 4. Solution Mining
Abstract
In 1992 there were only two commercial potash solution mining plants that had been specifically designed for that operation, and each appeared to be using single wells for injection and brine recovery. The oldest was the Kalium mine producing potassium chloride near Belle Plaine and Moose Jaw, Saskatchewan, Canada. A more recent operation near Veedan, Netherlands solution mines carnallite to produce magnesium chloride (and has the possibility of recovering by-product potash) for Billiton, a Shell subsidiary. Two others, Texasgulf at Moab, Utah and PCA at Saskatoon, Canada operate flooded potash mines, while the brine operation at Trona, California uses an indirect solution mining procedure that is specific to their ore body (see the discussion of Searles Lake in the chapter on brines). These operations are reviewed in the following section. For greater detail on the general subject of soluble salt solution mining the reader is referred to the book by Garrett (1992).
Donald E. Garrett
Chapter 5. Sylvinite, Other Potash Ore Processing
Abstract
The modern processing of sylvinite and other potash ores is usually a comparatively simple and standardized procedure, practiced in much the same way at most potash plants. In the early days of the industry, and still with some operations having complex ores or to process fines or waste streams, the ore was given a hot leach, the undissolved salt and insolubles rejected, and the clarified brine crystallized. Now, however, in most plants the ore is first ground to a size where the potash is liberated from the halite, it is “deslimed” to remove the insolubles and fines, and the coarser particles are separated by flotation (although a few plants use a dry electrostatic or wet heavy media separation). After benefication (and possibly a quick leach) the potash is dried, part of it is compacted to a larger size, the fines (and perhaps the slimes) are leached and recrystallized and the rest is sold as is or further processed. As might be expected, differences in the ore, the total recovery achieved, and individual preference among processing steps have resulted in many variations in the details of these procedures. The generalities and some of the typical practices in the industry will be discussed in the following chapter. Again it must be cautioned that the descriptions are of the practice at the time of the listed reference, and might currently be quite different.
Donald E. Garrett
Chapter 6. Brine Processing Operations
Abstract
Scattered throughout the world there are a large number of brine sources that contain commercial tonnages of potash. A few of them have been operated since the earliest days of the industry, but often for only short periods and/or on a limited scale. A problem with their production has been that the potash content is always weak (usually only about 1–2% KCl), and thus a solar evaporation, or expensive plant evaporation step, was first required. Also, the brines always contain many other ions, thus complicating the separation of potash from the evaporated brine or crystallized salts. Potential operators until fairly recently have been reluctant to become involved with the weather-dependent solar evaporation step, but since it has become evident that the Israeli Dead Sea operation probably produces the world’s lowest cost potash, there has recently been a renewed interest in these brine deposits. However, since the technology required for such production is far different than the standard mining-crushing-flotation steps required for buried deposits, they have usually only been developed by non-mining companies. This includes, as of 1993, large new brine operations being planned for China, Chile, Argentina (solar evaporation of solution mined brine), and elsewhere, as well as smaller tonnages as a byproduct from a number of other facilities (from lithium, soda ash, salt, or other primary products).
Donald E. Garrett
Chapter 7. Non-Chloride Products
Abstract
Potassium sulfate can be produced in many ways, and with a number of compounds supplying the sulfate ion. These include brine, epsomite, glaubers salt, gypsum, kainite, langbeinite, kieserite, salt cake, sulfur dioxide or sulfuric acid. Each has been, or is currently being used to produce this product (Table 7–1), depending upon its local availability and the economics involved. Each source will be discussed below.
Donald E. Garrett
Chapter 8. Utilization of Potash in Agriculture
Abstract
By far the majority of the world’s potash production is utilized in agriculture. Over 97% of all potash is sold to improve the world’s food, fiber and other farm output. Potassium is one of the three major plant nutrients, and as such must be added to all intensive farming soils in comparatively large amounts for high crop production. Once the soil becomes depleted of any of the 16 or so necessary plant nutrients each must be added in equal amounts to the plants’ uptake. With all but the three major nutrients, nitrogen, phosphorus and potassium, however, the quantities are somewhat less, or very small (they are called secondary or micronutrients). Nitrogen may be provided to the soil through crop rotation and the action of legumes with their root nodules’ nitrogen (from the air)-fixing bacteria. However, the phosphate and potassium must either be in the soil or supplied externally in the amount required by the plant. Many potash-containing minerals such as clay, feldspar and mica are found naturally in soils. Some of their potassium content becomes available to plants with weathering, and consequently many soils have been slow to become depleted in potash. Consequently, the addition of potash may not be as demanding as the other nutrients with some crops or soils. Also, the placement of the potash is important in many soils since the potassium may be ion exchanged with clays or organic matter near the surface, and thus not be very mobile.
Donald E. Garrett
Chapter 9. Potash Sales and Marketing
Abstract
The estimated world’s potash production between the period 1970–1991 is listed in Table 9–1. Many of the individual country estimates must be considered as quite uncertain because of the lack of detailed reporting data, or perhaps due to being inflated for political reasons. However, the general trends are probably quite valid. Figure 9–1 shows a plot of this production from 1962–1991, indicating a rapid increase through the 1960’s to the mid-1970’s, and then very slow continued growth. With the break-up of the Iron Curtain countries the Eastern Block consumption and production has dropped dramatically, and a simultaneous general worldwide recession has caused a reduction in production from 1988–1993. The annual growth rate had been 5.7% from 1962–1978, and 2% from 1978–1988. For the entire period 1962–1991 the average increase in production was 3.1%/yr. Prior to the first period most of the world’s potash came from Germany, France, or United States plants, and there was not a large export movement. However, during the 1960’s and early 1970’s the very large Canadian and Russian mines opened, and they developed extensive new markets. Russia and the Eastern Block became essentially the total consumers of the greatly increased supply of USSR and East German potash. The new Canadian mines largely developed the Asian and (with others) the Brazilian markets, thus utilizing much of their capacity.
Donald E. Garrett
Chapter 10. Physical, Thermodynamic and Solubility Data
Abstract
This chapter will attempt to present some of the basic physical and thermodynamic data for potassium chloride and its simple aqueous solutions. However, only a limited amount of data will be given for other potash salts and solutions because of the immense amount of information that would be required to cover all of the potassium compounds and their mixtures. Since potassium chloride is such a common and basic compound it has been extensively studied, and data is available from the late 1800’s to the present. In some respects this is a mixed blessing since the data in many cases is inconsistent. The early data was often presented as tables in centigrade and weight percent units, later it was reported in molar (moles/liter) concentrations, but now it is almost always expressed as molal (moles/1,000 g water) solutions with quite limited and random molal and temperature values for each series of tests. This is the result of the present fairly universal objective of using the data to form very large polynomial equations, and present them instead of the more useable tables of data. The new polynomial equations are then compared to previous researcher’s polynomials, but unfortunately discrepancies of 4–20% for some of the data is either ignored or brushed-off as the new values being better than the old ones.
Donald E. Garrett
Backmatter
Metadata
Title
Potash
Author
Donald E. Garrett, PhD
Copyright Year
1996
Publisher
Springer Netherlands
Electronic ISBN
978-94-009-1545-9
Print ISBN
978-94-010-7189-5
DOI
https://doi.org/10.1007/978-94-009-1545-9