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Blast-Furnace Processes for the Production of Phosphatic and Potassic Fertilizer Materials

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Blast-Furnace Processes for the Production of Phosphatic and Potassic Fertilizer Materials TECHNICAL BULLETIN NO. 543 APRIL 1937 BLAST-FURNACE PROCESSES FOR THE PRODUCTION OF PHOSPHATIC AND POTASSIC FERTILIZER MATERIALS P. H. ROYSTER Formerly Chemical Engineer K. G. CLARK Chemical Engineer T. P. HIGNETT Formerly Junior Chemist L. E. BOWE Formerly Assistant Chemist H. I. LANSDON Formerly Assistant Chemical Engineer J. C. SOUTHARD Associate Chemist J. W. TURRENTINE Formerly Senior Chemist Fertilizer Research Division Bureau of Chemistry and Soils UNITED STATES DEPARTMENT OF AGRICULTURE, WASHINGTON, D. C, Technical Bulletin No. 543 April 1937 UNITED STATES DEPARTMENT OF AGRICULTURE WASHINGTON, D. C BLAST-FURNACE PROCESSES FOR THE PRODUC- TION OF PHOSPHATIC AND POTASSIC FERTILIZER MATERIALS By P. H. RoYSTER, formerly chemical engineer; K. G. CLARK, chemical engineer; T. P. HiGNETT, formerly junior chemist; L. E. BOWE, formerly assistant chemist; H. I. LANSDON, formerly assistant chemical engineer; J. C. SOUTHARD, associate chemist; and J. W. TURRENTINE, formerly senior chemist, Fertilizer Research Division, Bureau of Chemistry and Soils ^ ^ CONTENTS Page Phosphate smelting—Continued. rags Introduction 1 Description of experiments and presenta- Work of other investigators 3 tion of data 21 Phosphate smelting 3 Interpretation of results 27 Potash and combined potash-phosphate Determination of material requirements_. _ 38 smelting 3 Potash smelting 47 General features of a blast furnace 4 Applicability of the blast-furnace process.. 47 Furnace stack 4 Description of experiments and presenta- Mechanism of combustion 5 tion of data 48 Temperature of combustion zone 5 Interpretation of results 52 Thermal efíiciency of the blast furnace 7 Determination of material requirements_ _ _ 56 The experimental blast-furnace plant 8 Potash-phosphate smelting 60 Furnace stack _ 8 Applicability of the blast-furnace process.. 60 Blowing equipment 12 Description of experiments and presenta- Hot-blast stoves 13 tion of data 60 Gas-cleaning and gas-cooling system 14 Interpretation of results 62 Handling of materials 17 Determination of material requirements. _ _ 63 Phosphate smelting ^ 17 Summary and conclusions 66 Applicability of the blast-furnace process.. 17 Literature cited 67 Experimental procedure . 19 Appendix 72 INTRODUCTION For more than 2 decades the Department of Agriculture has been investigating methods for the production of fertihzer materials that contain nitrogen, phosphorus, and potassium. An important object 1 The experimental data of this report were obtained under the supervision and direction of P. H. Royster, who was directly in charge of the Bureau's blast-furnace operations. J. W. Turrentine, in charge of the Bureau's potash investigations, initiated the potash phase of this work and in conjunction with P. H. Royster was responsible for its direction. K. G. Clark, who was assistant in charge of the blast-furnace project, is responsible for the compilation and correlation of the data and the writing of this bulletin. The authors express to the American Agricultural Chemical Co. their appreciation for several tons of washed Florida land-pebble phosphate supplied free of charge at Alexandria, Va.; to the Armour Fertilizer Works for a carload of Tennessee blue-rock phosphate supplied free of charge at Washington, D. C; to the Inter- national Agricultural Corporation for 2 carloads of Florida pebble phosphate matrix supplied free of charge at Mulberry, Fla.; to the Chicago & North Western Railway Co. for the free transportation of a carload of wyomingite from Council Bluffs, Iowa, to Chicago, 111.; to the National Carbon Co., Inc., for a carbon- precipitator tube supplied free of charge at Washington, D. C; to the Research Corporation for the use of a high-tension transformer and mechanical rectifier; to the Union Pacific Coal Co. for a carload of Rock Springs coal supplied free of charge at Rock Springs, Wyo.; to the Union Pacific Railroad Co. for permis- sion to mine the wyomingite at Zirkel Mesa and for the free transportation of 2 carloads of wyomingite from Superior, Wyo., and 1 carload of Rock Springs coal from Rock Springs, Wyo., to Council Bluffs, Iowa; to F. G. Cottrell for his many helpful suggestions throughout the course of the investigation; to Mrs. C. E. Rist for the slag analyses; and to C. H. Kunsman, K. D. Jacob, and A. R. Merz for criticism of the manuscript. 2 This investigation was carried out with funds supplied in part by the Wiriter Act, 70th Cong., 2d sess., Public, No. 781, and in part by funds appropriated to the Department of Agriculture for fertilizer investi- gations. 91740°—37 1 1 2 TECHNICAL BULLETIN 543, U. S. DEPT. OF AGRICULTURE of the investigations is to assist in the development of improved methods for the commercial production of fertilizer materials. The present bulletin describes a phase of this research concerned with an investigation, by means of small-scale apparatus, of the technical feasibility and commercial practicabihty of producing phosphatic and potassic fertihzer materials by blast-furnace processes. Extensive deposits of phosphate ores that contain sufficient phos- phorus to be considered commercial sources of fertilizer occur in Florida and Tennessee. As the phosphate occurs in the ground, from 5 to 12 tons of material must be mined for each ton of phosphorus pentoxide (P2O5) obtained. More extensive and in general higher grade deposits occur in Idaho, Montana, Utah, and Wyoming. These deposits yield ores that contain approximately 25 to 35 percent P2O5 as mined. The present market for fertilizer in this country, however, is so largely centered in the Southern and in the Middle Atlantic States {ISy J^J^af that the cost of rail transportation from the western fields to the present eastern market has Hmited the development of these deposits. Potash-bearing sihcates in sufiicient quantities to merit considera- tion as sources of potash are widely distributed in the United States. Notable among the deposits are the leucitic rocks of Wyoming, the greensands of New Jersey, and the shales of Georgia. The potash (K2O) content of these rocks ranges from 3 to 7 percent in Georgia shale, from 4 to 7 percent in New Jersey greensands, and from 8 to 12 percent in wyomingite (7^). The principal remaining constituents are largely sifica, alumina, and iron, with smaller amounts of lime and magnesia. Each ton of K2O is accompanied, therefore, by from 7 to 32 tons of materials that must be mined, handled, treated, and dis- carded as waste or converted to marketable byproducts in any process proposed for potash production. In attempting to develop an improved process for the commercial production of marketable phosphate or potash from the minerals available, the large tonnage of raw materials to be handled assumes primary importance. This is one of the reasons that the blast furnace was so early and so frequently suggested as an apparatus for the pos- sible production of phosphates and potash. The blast furnace (ßS) as such has been used for many centuries for the production of pig iron, and more recently in a smaUer way for the production of man- ganese aUoys. The modern blast furnace is chiefly characterized by its abihty to smelt enormous tonnages of raw materials at a low labor cost and with a relatively inexpensive fuel. In such a smelting process the volatile constituents of the charge are removed from the furnace in the exhaust gas; the reducible oxides in the charge are reduced to their respective chemical elements; and the irreducible oxides are converted into molten slag and discharged from the bottom of the furnace in the liquid state. The blast furnace thus provides a general furnace process adapted to volatihzation, reduction, and melting. Shortly after the Bureau of Chemistry and Soils was estabfished in 1927, investigations of blast-furnace methods for the smelting of phosphate rock and potash minerals were undertaken. These inves- tigations were continued until October 1933. From October 1933 to April 1934 the experiments on phosphate smelting were continued by the Tennessee Valley Authority, with use of the Bureau's personnel 3 Italic numbers in parentheses refer to Literature Cited, p. 67. PROCESSES FOK PRODUCTION OF FERTILIZER MATERIALS 6 and equipment. The blast-furnace experiments reported here cover the results obtained prior to October 1933. WORK OF OTHER INVESTIGATORS PHOSPHATE SMELTING The proposal to smelt phosphate rock in the blast furnace for the production of elementary phosphorus was made as early as 1868 by Brison (5). From this date on, patents covering various furnace processes for the production of phosphorus and phosphoric acid have appeared with considerable frequency {57, 74, 75). In 1915 the Bureau of Soils initiated an investigation of electric- furnace processes for the smelting of phosphate rock, and in 1916, in cooperation with the R. B. Davis Co., erected a semicommercial plant for the production of phosphoric acid (9, 76). In 1920-21 the first commercial furnace for the production of this acid was installed by the Federal Phosphorus Co. at Anniston, Ala. (57, 38, 69). So far as the writers know, the first attempt actually to smelt phosphate rock in a fuel furnace for the production of phosphorus or phosphoric acid was undertaken experimentally by the Bureau of Soils nearly half a century after Brison's proposal. The results of these experi- ments were reported by Waggaman, Easterwood, and Turley in 1923 {75). xllthough these results were not sufl&ciently conclusive to point the way immediately to the commercial adoption of furnace smelting as an economic process, suflBcient progress was made to indicate the desirability of continuing and extending the investigation. Easterwood {14y 15) reported that the experimental smelting of phosphate rock in the blast furnace was undertaken by the Victor Chemical Works at Chicago Heights, 111., in 1924 and that a com- mercial installation was put in operation at Nashville, Tenn., in 1929. This installation was later replaced by a larger and improved plant.
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