A BASIC METAL HYDROXYSULPHATE COMPLEX IN SOLID FORM AND A METHOD FOR ITS MANUFACTURE

Abstract: A product containing polynucleate basic Me³⁺ hydroxysulphate complex in solid form which when dissolved in water will provide a positively charged polynucle­ ate complex possessing charge neutralizing properties in systems containing suspended or colloidal negatively charged particles, preferably polyaluminium hydroxysulphate complex and polyferrihydroxysulphate complex, and containing calcium sulphate hemihydrate. The invension also relates to a method for produc­ ing the product.

Description: Technical field The present invention relates to a product in solid form containing a basic metal hydroxysulphate, and a method for producing polynucleate basic Me³⁺ hydroxysulphate in solid form which when dissolved in water produces positively charged polynucleate complexes possessing charge neutralizing properties in systems that contain suspended or colloidal negatively charged particles. The object of the present invention is to obtain a rational method for producing industrially polynucleate, basic aluminium hydroxysulphate and/or ferri hydroxysulphate in solid form. Background of the invention There are known to the art a number of aluminium products which contain polynucleate aluminium ions in solution. These products have been produced in response to the demand for more effective chemicals for use, e.g. in water purification, paper sizing, and plant dewatering processes. The products accordingly exhibit considerably improved properties for use within the aforesaid technical fields, due to the higher electrical charge of the metal ions in comparison with the earlier simple compounds. The aluminium products developed with the object of improving efficiency when used in accordance with the foregoing are principally of two kinds, these being a) chloride-based basic aluminium compounds and b) sulphate based basic aluminium compounds. With regard to the first group there was initially developed a polyaluminium chloride (PAC) of the general formula [AlCl x (OH) 3-x ] n where x is <3, normally 1-2. Such compounds and methods for their manufacture are found described, for example, in SE-B-7201333-7, SE-B-7405237-4, SE-B-7412965-1, SE-B-7503641-8, and DE-A-2630768. The other type of aluminium chloride solutions, PALC, which are also based on the same polynucleate complexes have the general formuli which can be written as: [AlCl₃·xAOH] n where A signifies alkali metal, and [AlCl₃· x / 2B(OH)₂] n where B signifies an alkaline earth metal, n is a positive integer, and x is a number in the range 1-2.7. Polynucleate aluminium chloride solutions of the PALC-type are described in FR-A1-7512975, according to which the solutions are prepared by alkalizing aluminium chloride solutions with solutions of alkali hydroxide. According to this publication, however, it has not been possible to produce clear, stable solutions other than in a highly diluted state. By "stable solution" is meant here and in the following a solution which will not change with regard to its composition and properties, even when stored for long periods of time. Thus it is stated in the aforesaid publication that a solution containing up to 0.40 moles of aluminium per litre can be obtained under certain circumstances. The stability of the solution, however, is greatly limited and the solution must be injected directly into the water to be cleansed. It is clearly evident from the publication, and in particular from the working examples that solutions having aluminium concentrations above about 0.1 mole/l cannot be expected to be effective and stable in the known PALC-solutions according to this publication. Sulphate-based basic aluminium compounds have been described in EP-A-79850039-3, EP-A-80850033-4, and SE-A-8101830-1. These products contain polynucleate metal-ions in solutions to a greater or lesser extent, and are thus effective water-cleansing agents. The sulphate-based products can also be used for purposes other than for cleansing water, in which the presence of polynucleate metal-ions favours the effects desired. In certain cases, however, it is highly desirable, and even necessary, to restrict the supply of sulphate-ions to the smallest possible amount in applications within the aforesaid fields of use, and particularly when using the product to produce drinking or tap water. This is particularly important in the case of systems used and cleansed repeatedly in order to eliminate the risk of sulphide accumulation in tissue and in water, this latter with regard to the corrosion of concrete. This thus applies to certain water purifying systems used in areas where there is a water deficiency, necessitating the available water to be used repeatedly for as long as possible, with intermediate cleansing of the water. In water such as this, after cleansing the water ten times with conventional aluminium sulphate or compositions having corresponding sulphate contents (FALS), the sulphate content of the water may reach such high levels as to result in an attack on the water-carrying conduit-system, resulting in troublesome leakages. The problem of enrichment of sulphate ions has now also become manifest in the manufacture of paper, where the water transportation system is, to a large extent, completely closed for environmental purposes. The manufacturing processes are seriously affected by excessively high salt concentrations in the paper stock. US-A-4,238,347 discloses a method of producing sulphate-lean basic aluminium sulphate of the formula: Al(OH) x (SO₄) y (H₂PO₄) z (H₂O) w where x is 0.75 - 1.5; y is 0.7 - 1.07; z is 0 - 0.2, and w is 2.0 - 4.2, wherein x + 2y + z is equal to 3. The compounds are prepared by reacting aluminium sulphate with comminuted calcium carbonate, optionally in the presence of phosphoric acid, and passing the reaction mixture through a filter to isolate the gypsum formed. It has been found, however, that the carbon dioxide leaving the reaction process with the calcium carbonate together with the gypsum creates certain technical problems. EP-A-0 069 718 and EP-A-0 069 719 describe an improved method for producing sulphur lean polynucleate aluminium hydroxide complexes of the formula: [Al(OH) x (SO₄) y (H₂O) z ] n where n is an integer x is 0.75 - 2.0; y is 0.5 - 1.12; x + 2y is 3; z is 1.5 - 4, z being ≦ 4 when the product is in solid form, and z is >>4 when the product is in solution, wherein aluminium sulphate is reacted with one or more compounds taken from the group CaO, Ca(OH)₂, BaO, Ba(OH)₂, SrO, Sr(OH)₂ in aqueous solution to form the aforesaid compound, thereafter the resultant earth alkali metal sulphate precipitate is isolated and the residual solution optionally evaporated. The resultant solution has splendid properties and can be obtained with a high basicity, OH/Al ≦2.0. Manufacture is complicated, however, since isolation of the earth alkali metal sulphate is difficult to achieve and places specific demands on the technical equipment used. These references also teach that these complexes are unstable but can be stabilized by adding different organic complex formers to the solution of the polynucleate complexes. No economical route of preparing a stable solid form product is given. Another method of producing these complexes is described in SE-A-8206206-8, this method comprising cooling a solution containing a polynucleate hydroxide sulphate complex of the formula: Al m (OH) n (3m-n)+ in which the anion is where m and n are integers, and which has been prepared by alkalizing aluminium sulphate with an alkali from the group NaOH, and Na₂CO₃, so as to crystallize out Na₂SO₄·10H₂O, which is then separated out and the residual solution optionally concentrated or dried to solid form by evaporation. Still a further method of producing this complex is described in SE-A-8206207-6, in which a solution of an aluminium salt is neutralized to pH 5-7 to precipitate amorphous aluminium hydroxide which is isolated and thereafter contacted with sulphate ions in the form of aluminium sulphate and/or sulphuric acid to a y-value of 0.5-1.12, preferably 0.5-0.75, this product being optionally converted to a solid form. The conversion of the solution to a solid form in order to maintain the stability of the complex in those circumstances when the presence of costly stabilizing agents are not desired is both complicated and expensive, such that the final product is not truly competitive with standard aluminium sulphate (BOLIDEN R ALG) or aluminium-ferri sulphate (BOLIDEN R AVR), for use in water cleansing processes. Water cleansing processes, drinking water, and then in particular domestic sewage purification processes require the presence of large quantities of flocculating agents for precipitating out the impurities present, such as, inter alia, phosphorous, and the cost of the water cleansing chemicals required in sewage purification in particular is very high. Demands have therefore been made for more effective and relatively inexpensive chemicals. Disclosure of the present invention It has now surprisingly been found possible to eliminate these technical problems in a simple and an efficient manner with the aid of the product according to the present invention, which product contains a sulphate-lean basic metal hydroxysulphate of the general formula [Me³⁺(OH) x (SO₄) y (H₂O) z ] n wherein Me is Al and/or Fe, n is an integer; x is 0.75-2.0, preferably 1.0-2.0, more preferably 1.5-2.0; y is 0.5-1,12; x+2y is 3; and z 1.5-4, the product in addition to said complex the product also contains calcium sulphate hemihydrate, the mole ratio Ca, expressed as Ca(OH)₂, and Me³⁺, expressed as Me₂³⁺(SO⁴)₃, being at most 2, and the product containing water in an amount, expressed as water of crystallization per mole Me₂³⁺(SO₄)₃, of at most 6H₂O. The mole ratio Ca(OH)₂ to Me₂³⁺(SO⁴)₃ is suitably 1.0-2.0, although preferably 1.5-2.0. The product is also produced in accordance with the invention in a simple and rational manner, the method being characterized by mixing to molten aluminium sulphate, Al₂(SO₄)₃·14H₂O and/or aluminium sulphate-ferri sulphate, Al₂(SO₄)₃·14H₂O; Fe₂(SO₄)₃·9H₂O, with a calcium compound taken from the group Ca(OH)₂, CaO, CaCO₃, CaMg(CO₃)₂; optionally expelling water from the mixture; and cooling the mixture to obtain a comminutable, or grindable solid product containing polyaluminiumhydroxide sulphate complex and optionally polyferri hydroxy sulphate complex and calcium sulphate hemihydrate. Further characteristic features of the method and the product produced thereby are set forth in the following claims. It has not been possible previously to prepare a complex of the aforegiven formula at temperatures higher than 70°C when practising the known methods, due to decomposition of the complex at said higher temperatures. It is therefore particularly surprising that the claimed product can be produced successively by means of the method according to the present invention. Particularly preferred compounds produced are those in which x is 1.6-1.8; y is 0.6-0.7. The compound exists in the form of a polynucleate complex in aqueous solution and has the same form when solid. The solid product obtained in accordance with the invention dissolves relatively quickly in water (<2 min), even when ground or comminuted to a relatively coarse particle size. The gypsum present is suspended in the resultant solution, while the metal hydroxysulphate complex is dissolved therein. The water cleansing properties of the obtained suspension have been found to be far superior to those of conventional aluminium sulphate products (BOLIDEN R ALG, AVR). The reason why the respective constituents of the product rapidly suspend and dissolve in a water phase is probably due to the fact that the gypsum present, which has a hemihydrate form in the solid product is rearranged to dihydrate therewith causing an increase in volume and temperature such as to accelerate the dissolution reaction. The present invention will now be described more in detail with reference to a number of working examples. Example 1 A product having a high mole ratio OH/Me (1.7) was prepared from 100 grams of molten aluminium sulphate-ferri sulphate (BOLIDEN R ARV, Al₂(SO₄)₃·14H₂O; Fe₂(SO₄)₃·9H₂O, 7% Al, 3% Fe). The temperature of the melt was 115°C and the melt was held at this temperature while mixing 15.0 g CaO with the melt over a period of 2 minutes. The resultant product reaction mixture was then cooled to room temperature, the molten product gradually transforming into a solid, comminutable product. The final product was analysed and found to contain water in an amount corresponding to 6H₂O per mole (Al, Fe)₂(SO₄)₃. The polynucleate aluminium sulphate-ferri sulphate complex present in the product contains 1.7 OH per mole Me (Al, Fe). The product comprised CaSO₄·0.5H₂O, calcium sulphate hemihydrate. Example 2 100 g Al₂(SO₄)₃·14H₂O having a temperature of 115°C were admixed with 15.5 g CaO, there being obtained in a manner similar to Example 1 an end product having an OH/Al ratio of 1.65 in the resultant polyaluminium hydroxysulphate complex. In those cases where calcium hydroxide is used, it is necessary to evaporate off larger quantities of water, in order to obtain a comminutable product. This can be effected by maintaining the product at an elevated temperature, or by reacting the product in a vessel of large surface area so as to rapidly evaporate the water present. It has been found that with a dry solids content of 69% or thereabove in Me₂(SO₄)₃·xH₂O measured by expelling water in a conventional domestic microwave oven for five minutes at maximum power, it is necessary to expel water during the reaction between Me₂(SO₄)₃ and CaO. In order to obtain a comminutable or grindable product, the Me₂O₃-content of the polymetal hydroxy complex of the end product shall be in excess of 14% by volume, the calcium sulphate being precipitated out as hemihydrate. As beforementioned, this means that the crystallization water present per mole of ingoing Al₂(SO₄)₃ or (Al,Fe)₂(SO₄)₃, about 14H₂O, is reduced to 6H₂O in the end product. A product according to Example 1 (PAV) above was tested with regard to its ability to clarify turbid sewage water. The test also includes a comparison test using standard aluminium sulphate-ferri sulphate (AVR). The starting turbidity was >100 FTU. As will be seen from the following table, the product according to the present invention gave a far better result than the standard product. As shown by the Table, the product according to the invention exhibits a highly linear, flat register and overdosing does not increase the turbidity in any way.

Claims: A solid product containing a polynucleate basic Me³⁺ hydroxysulphate complex of the formula [Me³⁺(OH) x (SO₄) y (H₂O) z ] n wherein Me is Al and/or Fe, n is an integer; x is 0.75-2.0, preferably 1.0-2.0, more preferably 1.5-2.0; y is 0.5-1,12; x+2y is 3; and z=1.5-4, said product when dissolved in water giving a positively charged polynucleate complex possessing charge neutralizing properties in systems containing suspended or colloidal negatively charged particles, characterized in that in addition to said complex the product also contains calcium sulphate hemihydrate, the mole ratio Ca, expressed as Ca(OH)₂, and Me³⁺, expressed as Me₂³⁺(SO⁴)₃, being at most 2, and the product containing water in an amount, expressed as water of crystallization per mole Me₂³⁺(SO₄)₃, of at most 6H₂O. A polynucleate complex containing product according to claim 1, wherein the mole ratio Ca(OH)₂ to Me₂³⁺(SO⁴)₃ is 1.0-2.0, preferably 1.5-2.0. A method for producing a polynucleate basic Me³⁺ hydroxysulphate complex containing product in solid form, which product when dissolved in water will provide a positively charged polynucleate complex possessing charge neutralizing properties in systems containing suspended or colloidal negatively charged particles, characterized by adding to molten aluminium sulphate and/or aluminium sulphate-ferri sulphate a calcium compound taken from the group Ca(OH)₂, CaO, CaCO₃ and CaMg(CO₃)₂ and permitting ingoing constituents to react to form said basic Me³⁺ hydroxysulphate complex and calcium sulphate hemihydrate; and by cooling the resultant product reaction mixture to ambient temperature to form a comminutable or grindable solid product containing polyaluminium hydroxysulphate complex and/or polyferri hydroxysulphate complex and calcium sulphate hemihydrate. A method according to claim 3, wherein the melt has a temperature of 100-115°C. A method according to claim 3, wherein the dry solids contents of the metal sulphate present, is at least 69%, determined by heating the product in a conventional domestic microwave oven for 5 minutes at maximum power output.

Inventors: KVANT, MAGNUS BIRGER
Applicants: KEMIRA KEMI AKTIEBOLAG
Application year: 1987
Main classification: C01F7
IPC codes: C01G49, C01F7, C02F1, C01B17