IM- PROVEMENTS IN THE MANUFACTURE OF ALKALI FROM COMMON SALT
Year: 1853

page_text: LETTERS PATENT to James Shanks, of Saint Helens, in the County
of Lancaster, Manufacturing Chemist, for the Invention of "IM-
PROVEMENTS IN THE MANUFACTURE OF ALKALI FROM COMMON SALT.".
Sealed the 19th August 1853, and dated the 18th June 1853.
PROVISIONAL SPECIFICATION left by the said James Shanks at
the Office of the Commissioners of Patents, with his Petition, on
the 18th June 1853.
I, JAMES SHANKS, do hereby declare the nature of the said Inven-
tion for "IMPROVEMENTS IN THE MANUFACTURE OF ALKALI FROM COMMON
SALT" to be as follows:-
In the manufacture of alkali from common salt (as this manufacture
is usually conducted) common salt is decomposed by sulphuric acid, so
as to produce sulphate of soda, and this sulphate of soda is decomposed
by fluxing it in mixture with carbonate of lime and small coal, thus
producing "black ash
"black ash" or "rough soda." This black ash or rough
soda is then lixiviated in vats with water, to dissolve out the soluble
compounds of soda which are used for the manufacture of alkali, and

page_text: there remains an undissolved residuum in the vats, which is known as
"alkali waste," and has hitherto been thrown away as a worthless
product. This "alkali waste" contains sulphur combined with lime or
with calcium, the metallic base of lime. The object of my improve-
to the
ments is to apply sulphur contained in such "alkali waste
decomposition of common salt, so as to produce sulphate of soda, which
sulphate of soda, being applied to the manufacture of alkali by its
decomposition with carbonate of lime and coal, occasions a further
production of "alkali waste," which can be also applied in the same
manner to the decomposition of a further quantity of common salt, and
the production of a further quantity of sulphate of soda suitable for
the production of a further quantity of alkali.
"
with
To effect the object of my improvements I mix "alkali waste
common salt, also small coal, and sufficient clay to give such cohesive-
ness to the mass as will provide for its being formed into balls, and I
introduce such balls, preferring to have them about the size of a hen's
egg, into a kiln of a similar construction to the kilns usually employed
by alkali manufacturers for burning pyrites for the production of
sulphuric acid. I cause such kiln to be heated in the first instance by
the combustion of fuel therein, and I introduce the first portion of balls
on such burning fuel, when the balls become ignited, and by the succes-
sive addition of balls I cause the kiln to become filled with balls, some.
or all of which are in a state of ignition.
I withdraw at intervals from the lower part of such kiln the product
which has undergone ignition, and I find that cominon salt previously
contained in such balls has become converted into sulphate of soda. I
supply additional quantities of balls to the kiln or kilns, which I employ
so as to have a continual supply of ignited balls to be withdrawn from
the lower part of such kilns. I separate sulphate of soda from such
ignited balls by lixiviation with water. I cause the solution of sulphate
of soda which I thus obtain to be evaporated so as to produce dry
sulphate of soda suitable to be used for the manufacture of alkali.
The arrangement of the kilns I have herein-before referred to as
being commonly used for burning pyrites in the manufacture of sul-
phuric acid provides for the access of atmospherical air to the pyrites

page_text: undergoing combustion. In the same manner it is essential that
atmospherical air should have access to the balls composed of alkali
waste, common salt, and other matters undergoing ignition in the kilns
employed for effecting the objects of my improvements. I prefer also
to introduce a supply of steam together with such atmospherical air to
assist the decomposition of common salt in such balls.
Alkali waste in the dry state usually contains about sixteen per cent.
of sulphur; and assuming this to be its composition, I add to 100 parts
of such alkali waste 60 parts of common salt, 100 parts of small coal,
and sufficient clay and water to give the requisite adhesiveness to the
mixture. I vary the proportion of common salt employed relatively to
the alkali waste according to the sulphur contained in such waste,
preferring to use 60 of common salt for cach 16 parts of sulphur present
in the alkali waste.
I have herein-before stated that pyrites is used by alkali manu-
facturers for the production of sulphuric acid. One of the results of
such use of pyrites is the production of an oxide of iron commonly
called burnt pyrites. When I have a convenient supply of such
material, I prefer to add some of this to the mixture of alkali waste,
common salt, and other matters herein-before referred to, and I prefer
to add about 25 parts of burnt pyrites for each 100 parts of alkali waste
employed.
SPECIFICATION in pursuance of the conditions of the Letters l'atent,
filed by the said James Shanks in the Great Seal Patent Office, on
the 17th December 1853.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I,
JAMES SHANKS, of Saint Helens, in the County of Lancaster, Manu-
facturing Chemist, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her
Letters Patent, bearing date the Eighteenth day of June, in the year
of our Lord One thousand eight hundred and fifty-three, in the
sixteenth year of 1er reign, did, for Herself, Her heirs and successors,
give and grant unto me, the said James Shanks, Her special licence

page_text: that I, the said James Shanks, my executors, administrators, and
assigns, or such others as I, the said James Shanks, my executors,
administrators, and assigns, should at any time agree with, and no
others, from time to time and at all times thereafter during the term
therein expressed, should and lawfully might make, use, exercise, and
vend, within the United Kingdom of Great Britain and Ireland, the
Channel Islands, and Isle of Man, an Invention for "IMPROVEMENTS IN
THE MANUFACTURE OF ALKALI FROM COMMON SALT," upon the condition
(amongst others) that I, the said James Shanks, by an instrument in
writing under my hand and seal, should particularly describe and ascer-
tain the nature of the said Invention, and in what manner the same
was to be performed, and cause the same to be filed in the Great Seal
Patent Office within six calendar months next and immediately after
the date of the said Letters Patent.
NOW KNOW YE, that I, the said James Shanks, do hereby
declare the nature of my said Invention, and in what manner the same
is to be performed, to be particularly described and ascertained in and
by the following statement (that is to say):
In the manufacture of alkali from common salt (as this manufacture
is usually conducted) common salt is decomposed by sulphuric acid, so
as to produce sulphate of soda, and this sulphate of soda is decomposed
by fluxing it in mixture with lime and small coal, thus producing
"black ash," or "rough soda." This "black ash" or "
rough soda"
is then lixiviated with water to dissolve the soluble compounds of soda
which are used for the manufacture of alkali, and there remains an
undissolved residuum which is known as "alkali waste," and has
hitherto been thrown away as a worthless product. This "alkali
waste" contains sulphur combined with lime, or with calcium, the
metallic base of lime.
The object of my improvements is to apply sulphur contained in
such "alkali waste" to the decomposition of common salt, and thereby
to produce sulphate of soda, which sulphate of soda, being applied to
the manufacture of alkali by fluxing it with lime and coal, occasions
a further production of "alkali waste," which can be also applied in
the same manner to the decomposition of a further quantity of common

page_text: salt, and the production of a further quantity of sulphate of soda
suitable for the production of a further quantity of alkali.
To effect the object of my improvements I mix alkali waste" with
common salt, and add thereto small coal, and such a quantity of clay
(mixed with sufficient water) as will give cohesiveness to the mass, and
thereby provide for its being formed into balls or masses, which I prefer
to make about the size of a hen's egg; and I introduce such balls (after
being well dried) into a kiln, of a similar construction to the kilns
usually employed by alkali manufacturers for burning pyrites for the
production of sulphuric acid. I cause such kiln to be heated in the
first instance by the combustion of fuel therein, and I introduce the
first portion of balls on such burning fuel, when the balls become
ignited, and by successive additions I cause the kiln to become nearly
filled with balls, some or all of which are in a state of ignition. I
withdraw at intervals from the lower part of such kiln the product
which has undergone ignition, and I find that common salt previously
contained in such balls has become converted into sulphate of soda,
and calcium previously combined with sulphur in the "alkali waste"
lias become converted into lime.
I supply additional quantities of balls to the kiln or kilns, which I
employ so as to have a continued supply of balls which have under-
gone ignition to be withdrawn from the lower part of such kiln or
kilns.
I have herein-before stated, that in effecting the objects of my
Invention I mix alkali waste" and common salt with small coal, and
form the mixture into balls or masses, as herein-before described. My
object in adding small coal is to communicate heat by its combustion
to the mixture of "alkali waste" and common salt, and thereby to
determine the re-action of these two compounds upon each other (in
the presence of atmospheric air), which is requisite for the production
of sulphate of soda. I prefer also to assist the said re-action by heat
derived from the combustion of fuel not forming part of the composi-
tion of such balls. For this purpose I provide a furnace, so connected
with each of the kilns in which I am causing the said balls to undergo
ignition that flame and heated air (proceeding from fuel undergoing
combustion on the grate of such furnace) can be conducted into the

page_text: lower part of such kiln, and caused to percolate through the mass of
balls contained therein. I prefer to burn such a quantity of fuel on
the grate of such furnace as I find to be sufficient to keep the balls
through which the products of combustion are caused to percolate at a
full red heat, but taking care that such heat shall not be sufficient to
cause the balls to become fluxed.
I separate sulphate of soda from such ignited balls by lixiviating the
same with water. I cause the solution of sulphate of soda which I
thus obtain to be evaporated, so as to produce dry sulphate of soda
suitable to be used for the manufacture of alkali. Or, in place of
separating sulphate of soda from the said balls by lixiviation, I add to
the mixture of sulphate of soda and lime obtained by the ignition of
such balls an additional quantity of sulphate of soda, lime, and small
coal in suitable proportions, and flux the mixture so as to make "black
ash" or "rough soda."
The arrangement of kilns I have herein-before referred to as being
commonly used for burning pyrites in the manufacture of sulphuric
acid provides for the access of atmospheric air to the pyrites under-
going combustion. In the same manner it is essential that atmospheric
air should have access to the balls containing "alkali waste" and
common salt undergoing ignition in the kilns employed for effecting the
objects of my improvements.
I prefer also to introduce a supply of steam, together with the atmo-
spheric air, to assist the decomposition of common salt in the balls.
"Alkali waste" (in the dry state) usually contains about sixteen per
cent. of sulphur; and assuming this to be its composition, I add one
hundred parts of such "alkali waste," sixty parts of common salt, one
hundred parts of small coal, and sufficient of clay and water to give
the requisite cohesiveness to the mixture. I vary the proportion of
common salt employed relatively to the "alkali waste," according to
the sulphur contained in such waste, preferring to use sixty of common
salt for each sixteen parts of sulphur present in the "alkali waste."
I have herein-before stated that pyrites is used by alkali manufac-
turers for the production of sulphuric acid. One of the results of such
use of pyrites is the production of an oxide of iron, commonly called
"burned pyrites." When I have a convenient supply of such material,

page_text: I prefer to add some of this to the mixture of "alkali waste," common
salt, and other materials herein-before referred to; and I prefer to add
about twenty-five parts of "burned pyrites" for each one hundred
parts of alkali waste" employed.
I have herein-before described and ascertained certain means by
which I prefer to carry into effect my Invention of producing sulphate
of soda by the use of common salt and alkali waste" (which "alkali
waste" is one of the results of the manufacture of alkali from common
salt, and has heretofore been considered as a worthless product), and
which sulphate of soda I employ for the production of alkali; but I do
not confine myself to the employment of the exact means herein
described, nor to the precise proportions of materials herein indicated,
as these may be varied to some extent without deviating from the
nature of my Invention.
I claim as my Invention the production of sulphate of soda (for
the purpose of using this for the production of alkali), by exposing a
mixture of common salt and alkali waste," together with small coal
(made into balls or masses), to the action of atmospheric air and heat
in kilns, by means of such arrangements as I have herein-before
described, or by such modifications thereof as may provide for the
proper application of heat and of atmospheric air to such balls or
masses.
In witness whereof, I, the said James Shanks, have hereunto set
my hand and seal, this Fifteenth day of December, One thou-
sand eight hundred and fifty-three.
JAMES (L.S.) SHANKS.
Witness, ROBERT SLATER,
of Saint Helens.