Hydrometallurgy 84 (2006) 239 – 246 www.elsevier.com/locate/hydromet Dissolution kinetics of celestite (SrSO4) in HCl solution with BaCl2 Salih Aydoğan a,⁎, Murat Erdemoğlu b , Ali Aras a , Gökhan Uçar a , Alper Özkan a a b Department of Mining Engineering, Selçuk University, 42075 Konya, Turkey Department of Mining Engineering, Id nönü University, 44280 Malatya, Turkey Received 12 June 2006; received in revised form 28 June 2006; accepted 30 June 2006 Available online 9 August 2006 Abstract Leaching of celestite (SrSO4) in hydrochloric acid solution with BaCl2 was investigated to produce SrCl2 in solution, which is the main source for SrCO3. The effects of variables such as stirring speed, BaCl2 and HCl concentrations, and temperature and particle size, and also the presence of NaCl in the leaching solution were studied. The leaching was modeled according to the shrinking core model. The activation energy for the leaching process in 8.25 × 10− 3 M BaCl2 solution equilibrated with 0.5 M HCl was found as 68.8 kJ mol− 1. This value reveals that the dissolution of celestite is a chemical reaction controlled process. In agreement with the model, the reaction rate is inversely proportional to the particle size and increases as 0.73, 0.70 and 0.19 powers of the H+, Cl− and Ba2+ concentrations, respectively. © 2006 Elsevier B.V. All rights reserved. Keywords: Celestite; Hydrochloric acid; Barium chloride; Reaction kinetics 1. Introduction Majority of the artificially produced strontium carbonate (SrCO3) has been consumed as an additive in the production of faceplate glass of colour television picture tubes to block X-ray transmission and improve the appearance of the glass. Other end uses of SrCO3 are the production of ferrite magnets for small DC motors, iridescent and special glasses, pyrotechnics, pigments, paints, driers and the production of strontium metal and all other strontium chemicals. There are two different SrCO3 production methods: the black ash process and the direct conversion process. ⁎ Corresponding author. Tel.: +90 332 223 20 60; fax: +90 332 241 06 35. E-mail address: [email protected] (S. Aydoğan). 0304-386X/$ - see front matter © 2006 Elsevier B.V. All rights reserved. doi:10.1016/j.hydromet.2006.06.001 In the black ash process, strontium sulphide (SrS) is obtained by reduction roasting the high-grade celestite (SrSO4) concentrate with metallurgical grade coke at about 1100–1300 °C. The soluble SrS is then leached with water at elevated temperatures. The loaded liquor from leaching is then contacted with either CO2 gas or Na2CO3 to precipitate the chemical grade SrCO3 (Erdemoğlu et al., 1998; Owusu and Litz, 2000). In the direct conversion method, finely ground, washed and thickened celestite concentrate is directly reacted with soda ash and treated with steam at 95 °C for 1 to 3 h to obtain crude strontium carbonate and sodium sulphate. Since the crude SrCO3 is impure and contains undissolved solids, it is then decomposed using HCl solutions to obtain aqueous SrCl2 to be reacted with CO2 or Na2CO3. Therefore, the process is also called as double decomposition process. Iwai and Toguri (1989), 240 S. Aydoğan et al. / Hydrometallurgy 84 (2006) 239–246 Carrillo et al. (1995) and Castillejos et al. (1996) have extensively studied the thermodynamic conditions of the direct conversion process to be able to enhance process efficiency. Because of the problems either originated from the content and grade of celestite concentrate or the problems occurred during the conversion of celestite to SrS in the black ash process or to SrCO3 in the direct conversion process, improvements for the relevant processes have been investigated by many of the researchers. Other carbon sources like petroleum coke were investigated to lower the energy consumption in the black ash process. Contacting the liquor from SrS leaching with CO2 gas together with atmospheric oxygen is another attempt to enhance the SrCO3 precipitation efficiency in the same process (Erdemoğlu and Canbazoğlu, 1998). In the direct conversion process, ammonium carbonate and ammonium bicarbonate were examined by Debuda (1987) and by Cheng and Jiang (1992), respectively, instead of soda ash. Erdemoğlu et al. (2006) studied the leaching of celestite in sodium sulphide solution to convert the sulphate to water-soluble sulphides at ambient temperatures. They found that celestite can be converted to strontium disulphide, but the reaction rate is too slow, depending on reaction products deposited at the surface of the unreacted mineral. Xu and Zhu (2005) developed a new flow sheet for direct conversion process of continual reaction between CO2 and SrCl2 by means of neutralizing the produced HCl or removing it to another phase. They found that coupling the reaction with solvent extraction is a way to lower the acidity of the aqueous solution and to allow the reaction to proceed continually. Suárez-Orduña et al. (2004) have investigated the exchange of SO42− ions with CO32− ions in natural celestite single crystals under alkaline hydrothermal conditions. Recently, Obut et al. (in press) have investigated the direct conversion of celestite to strontium carbonate by mechanochemical processing in sodium carbonate solution at ambient temperatures. It is expected that investigations about the conversion of celestite to strontium carbonate will not be stopped since there are still certain drawbacks of the relevant methods, such as high energy consumption in the black ash process and high temperature leaching and acid costs in the double decomposition process. In this present study, an attempt was made to convert the celestite directly to soluble SrCl2 by leaching the celestite in acidic barium chloride (BaCl2) solutions. By this way, crude strontium carbonate production stage in the direct conversion method may be discarded from the process flow sheet. During the dissolution investigation, effects of such main leaching parameters as stirring speed, HCl concentration, BaCl2 concentration, temper- ature and particle size, and effect of NaCl addition to the leaching medium were investigated. For modeling the celestite dissolution, a kinetic analysis was also performed using shrinking core model. 2. Material and methods 2.1. Material In this study, samples of the celestite concentrate purchased from Barit Maden Türk A.Ş. Concentrator (Sivas, Turkey) were used. The samples were wet sieved to obtain 106 × 75, 75 × 45, and 45 × 38 μm particle size ranges. According to mineralogical and XRD analysis together with chemical analysis, celestite is the major mineral in the sample with minor gypsum (CaSO4·2H2O) and trace barite (BaSO4), while other minerals vary only from 1.49 to 1.02%. Chemical analyses of different size fractions of the sample are listed in Table 1. 2.2. Experimental procedure A Pyrex beaker of 1 L was used as a leaching reactor with a rubber cover. Temperature of the leach solution in the reactor was provided by a thermostatically controlled water bath with ± 0.2 °C sensitivity. Stirring was carried out by Heidolph Mark RZR 2021 model mechanical stirrer equipped with propeller. During the set up of the experiments, solid content of the solution was held constant at 0.4% (w/v). Stirring speed was altered in the range of 100–600 rpm; temperature was varied in the range of 40–80 °C; HCl concentration was in the range of 0.05–0.75 M. BaCl2 concentrations were 10, 25, 50, 75 and 100% BaCl2 (1.1 × 10− 3, 2.75 × 10− 3, 5.5 × 10− 3, 8.25 × 10− 3 and 1.1 × 10− 2 M, respectively) with respect to the stoichiometric amount required for dissolution of 1 g of celestite. Particle size fractions were as 106 × 75, 75 × 45 and 45 × 38 μm. For element analysis, 1 mL of solution was withdrawn from the reactor at various time intervals. The sample solution was diluted with distilled water to 100 mL in a volumetric flask. Strontium and barium in the leach solution Table 1 Chemical analysis of the different size fractions of the celestite sample (wt.%) Mineral Particle size, μm 106 × 75 75 × 45 45 × 38 SrSO4 BaSO4 CaSO4.2H2O Others 96.67 0.35 1.49 1.49 97.32 0.33 1.33 1.02 97.24 0.33 1.33 1.10 S. Aydoğan et al. / Hydrometallurgy 84 (2006) 239–246 241 samples were determined by ICP AES. In calculating the fraction of strontium leached, a volume correction formula was used — which includes in itself correction factors to account for the volume losses due to sampling (Georgiou and Papangelakis, 1998). i−1 i−1 P P V− vi CM;i þ vi CM;i i¼1 i¼1 XM;i ¼ ð1Þ mðcM =100Þ Ba 2+ ions from BaCl2 into the solution, BaSO4 immediately precipitates, leaving the Sr2+ in the solution with chloride ions where V is the initial volume (mL) of the solution, vi is the volume (mL) of the sample i withdrawn each time, CM,i is the concentration of M (Sr, Ba) in sample i (mg L− 1), m is the initial mass of celestite in g (on a dried basis) added into the reaction vessel and cM is the concentration of M in celestite sample (wt.% dried solids). Distilled water and reagent grade chemicals were used to make up all required solutions. Each experiment was repeated at least three times and the arithmetic mean of the results was used in the discussion of experimental results. SrSO4 ðsÞ þ BaCl2 ðaqÞ ¼ BaSO4 ðsÞ þ SrCl2 ðaqÞ 3. Results and discussion 3.1. Thermodynamic considerations When celestite is introduced into an aqueous solution, dissolution occurs with the formation of Sr2+, SrOH+, SrSO4(aq), HSO4− and SO42− species depending on the pH of the solution (López-Valdivieso et al., 2000). The concentration of the chemical species in solution is well represented in the pH-log solubility diagram using the available thermodynamic data for formation constant of the species and solubility of strontium sulfate (Fig. 1). From this diagram, it is possible to intend the following equilibrium reactions together with the solubility products (log Ksp) of the species, in the broad pH range of 2–14, SrSO4 ðsÞ ¼ Sr2þ þ SO2− 4 log Ksp ¼ −6:62 ð2Þ SrSO4 ðaqÞ ¼ Sr2þ þ SO2− 4 log K ¼ −2:29 ð3Þ Ba2þ þ SO2− 4 ¼ BaSO4 ðsÞ log Ksp ¼ −9:96 ð5Þ According to these equilibrium reactions occurred in SrSO4–BaCl2–H2O system, one can easily suggest the following dissolution reaction, ð6Þ The driving force for this reaction is the relatively low solubility of BaSO4 (log Ksp = − 9.96 at 20 °C) compared with SrSO4 (log Ksp = − 6.62). Preliminary experiments showed that during the leaching of celestite in barium chloride solution at high acidic conditions (pH = ∼ 1), Sr2+ concentration increased with respect to decreasing Ba2+ concentration with the course of time (Fig. 2). Initial concentration of Ba2+ from BaCl2 in 0.5 M HCl solution containing 2 g celestite sample was 8.25× 10− 3 M. After 240 min of leaching, final Ba2+ and Sr2+ concentrations were measured as 2.64× 10− 4 M and 8.17 × 10− 3 M, respectively, meaning that almost all of the Ba2+ was consumed. Both the chemical analysis performed by XRF and mineralogical analysis performed by XRD method revealed the presence of nearly 71% BaSO4 in the leaching residue. These experiments also confirmed that the pH of the solution kept constant at pH 0.7 throughout the leach as expected. From this point of view, H+ ion acts as a catalyst in order to increase the dissolution rate of celestite. Similar Sr2+ extraction recoveries were obtained in repeated experiments using other acid types like HNO3 and HClO4, confirming the catalytic effect of H+ ion. Additionally, in the pH range below 7, sulfate ion gains one proton and bisulfate ion appears, − SO2− 4 þ H ¼ HSO4 log K ¼ 1:91 ð4Þ As seen from Fig. 1, concentrations of SO42− and HSO4− species at pH 2 are almost identical. During the dissolution in acidic aqueous solutions, if one adds Fig. 1. Solubility of celestite in aqueous solutions closed to the atmosphere at 25 °C (after López-Valdivieso et al., 2000). 242 S. Aydoğan et al. / Hydrometallurgy 84 (2006) 239–246 Fig. 2. Variations of Ba2+ and Sr2+ concentrations during the leaching of celestite (BaCl2: 8.25 × 10− 3 M; HCl: 0.5 M; S/L ratio: 1/250 w/v; T: 60 °C; Particle size 45 × 38 μm; Stirring speed: 400 rpm). 3.2. Effect of stirring speed The effect of stirring speed on the dissolution of celestite was investigated at different stirring rates from 100 to 600 min− 1 in 8.25 × 10− 3 M BaCl2 (i.e. 75% stoichiometric amount) equilibrated with 0.5 M HCl at 60 °C. It was found that at stirring rates of 400 rpm and higher, the dissolution rate was independent of the stirring speed. Slow dissolution was evident at 100 rpm due to the inability to keep the particles in suspension and sustain a realistically homogeneous solution. A stirring rate of 200 rpm may be considered as boundary between insufficient and sufficient mixing. Therefore, the stirring rate was kept constant at 400 rpm to investigate the effect of other parameters on the dissolution. Fig. 3. Rate curves for the dissolution of celestite for different BaCl2 concentrations with respect to 10, 25, 50, 75 and 100% stoichiometric amount required to dissolve the celestite according to Eq. (6) (HCl: 0.5 M; S/L ratio: 1/250 w/v; 400 rpm; T: 60 °C; Particle size 45 × 38 μm). these low concentrations. The change in the dissolution rate to slow at high concentrations may be due to more limited diffusion of H+ ions through a boundary layer of BaSO4 which is precipitating at the shrinking celestite particle surface. The strontium extraction after 240 min of leaching in 1.1 × 10 − 3 and 1.1 × 10 − 2 M of Ba 2+ concentrations was 54.4% and 91.3%, respectively. 3.4. Effect of HCl concentration The effect of HCl concentration on the celestite dissolution was investigated by varying the HCl concentration in the 0.05–0.75 M range in 8.25 × 10− 3 M BaCl2 3.3. Effect of Ba2+ concentration Fig. 3 shows the dissolution curves obtained when celestite was reacted at 60 °C with different BaCl2 to SrSO4 ratios. The BaCl2 concentrations were 10, 25, 50, 75 and 100% the stoichiometric amount required to dissolve the entire celestite sample according to Eq. (6). Excess amounts of BaCl2 were not tested to avoid contamination of the SrCl2 in the leach solution with unused BaCl2. As seen from Fig. 3, dissolution of celestite is dependent on the Ba2+ concentration. It is interesting to observe that when 1.1 × 10− 3 or 2.75 × 10− 3 M BaCl2 solution was tested, the initial dissolution rate was faster than the other higher concentrations but then reached a plateau and kept unchanged. This behavior may be attributed to the fast dissolution of celestite with the aid of acid, without the formation of solid BaSO4, since there are not enough Ba2+ ions to exceed the solubility product at Fig. 4. Rate curves for the dissolution of celestite for different HCl concentrations (BaCl2: 8.25 × 10− 3 M; S/L ratio: 1/250 w/v; 400 rpm; T: 60 °C; Particle size 45 × 38 μm). S. Aydoğan et al. / Hydrometallurgy 84 (2006) 239–246 243 solution at 60 °C. As shown in Fig. 4, the strontium extraction increases with increasing HCl concentration. The strontium extractions after 240 min of leaching with 0.05 M and 0.75 M HCl are 22.3% and 88.3%, respectively. These results reveal that HCl has significant effect on the celestite dissolution by forming HSO4− ions, according to Eq. (4), and minimizing the equilibrium concentration of SO42− ions released from celestite that can back-react. 3.5. Effect of temperature Experiments were conducted to determine the effect of temperature on the dissolution of celestite in the temperature range of 40–80 °C, using 0.5 M HCl and 8.25 × 10− 3 M BaCl2 solution. As seen in Fig. 5, as the temperature is increased, the rate of dissolution of celestite increases. It is known that the solubility of celestite in pure water decreases with increasing temperature (Reardon and Armstrong, 1987) — likewise barium sulfate. The celestite solubility in pure water is small, less than 6.6 × 10 − 4 M. Although the solubility of celestite in water increases as the ionic strength or salt concentration of solution increases, the increment with concentration is limited (Risthaus et al., 2001). The rapid decrease in the dissolution rates observed during leaching at 70 and 80 °C after 60 min is not surprising as only 75% of the required amount of Ba2+ ions were initially present and were rapidly consumed leaving unreacted celestite. As can be seen in Fig. 6, Ba2+ concentration decreased from 8.25 ×10− 3 to 5.75 ×10− 4 and 7.05× 10− 4 M within 120 and 90 min of leaching at 70 and 80 °C, respectively. Fig. 5. Rate curves for the dissolution of celestite at different leaching temperatures (BaCl2: 8.25 × 10− 3 M; HCl: 0.5 M; S/L ratio: 1/250 w/v: 400 rpm; Particle size 45 × 38 μm). Fig. 6. Decrease in Ba2+ concentration during the leaching at various temperatures. 3.6. Effect of particle size Effect of particle size was investigated by using the particle size ranges of 106 × 75, 75 × 45 and 45 × 38 μm in solution containing 1.1 × 10− 2 M Ba2+ equilibrated with 0.5 M HCl at 60 °C. The strontium extraction increased with decreasing particle size, as shown in Fig. 7, reaching to 55.1% and 91.4% after 240 min of leaching of 106 × 75 and 45 × 38 μm particle size fractions, respectively. 3.7. Effect of NaCl addition There are many reports on the solubility of sulfate minerals like gypsum, barite and celestite in NaCl Fig. 7. Rate curves for the dissolution of celestite with various particle size ranges (BaCl2: 1.1 × 10− 2 M; HCl: 0.5 M; 400 rpm; S/L ratio: 1/250 w/v; T: 60 °C). 244 S. Aydoğan et al. / Hydrometallurgy 84 (2006) 239–246 solutions. Nearly all of these studies have investigated the thermodynamics of those scale forming minerals in oil and gas production. The effects of temperature, pressure and, ideal and non-ideal solutions have been analyzed (Macdonald and North, 1974; Reardon and Armstrong, 1987; Raju and Atkinson, 1989; Howell et al., 1992; He et al., 1995; Atkinson and Mecik, 1997; Krumgalz et al., 1999; Risthaus et al., 2001; Freyer and Voigt, 2003). Solubility of celestite at the 25–50 °C temperature range increases with NaCl concentration up to 3 M and then slows down and decreases (Reardon and Armstrong, 1987). The most possible chemical reaction for celestite in NaCl solution can be written as, − SrSO4 þ 4Cl ¼ ½SrCl4 2− þ SO2− 4 ð7Þ with the formation of strontium tetrachloride complex, [SrCl4]2−. By introducing Ba2+ ions in acidic medium, BaSO4 immediately precipitates from the solution, according to Hþ SrSO4 þ 4Cl− þ Ba2þ Y½SrCl4 2− þ BaSO4 ð8Þ The curves with solid lines in Fig. 8 represent the effect of NaCl concentration on the dissolution of celestite in solutions containing 8.25 × 10− 3 M BaCl2 equilibrated with 0.5 M HCl at 60 °C. For a comparison, the result of one separate leaching test performed with 1 M NaCl and 8.25 × 10− 3 M BaCl2 in the absence of HCl in the solution (Fig. 8: dashed line). It is easily observed that celestite dissolution is negligible in the absence of H+ ions. But it is significantly enhanced by the presence of both NaCl and HCl in the leach solution. This increase can be interpreted Fig. 8. Rate curves for the dissolution of celestite for different NaCl concentrations (BaCl2: 8.25 × 10− 3 M; 0.5 M; 400 rpm; S/L ratio: 1/250 w/v; T: 60 °C; Particle size: 45 × 38 μm). as synergistic effect of H+ ions protonating the sulfate ion and Cl− ions from HCl, BaCl2 and NaCl forming a strontium chloro-complex and lowering strontium ion activity for dissolution of celestite. 3.8. Kinetic analysis The dissolution of celestite can be explained by a shrinking core model. Hence, diffusion and surface reaction control models were investigated. If reaction is controlled by diffusion the following equation can be used (Levenspiel, 1972): 2 2MB DCA 1− X −ð1−X Þ2=3 ¼ t ¼ kd t 3 qB ar02 ð9Þ If reaction is controlled by surface reaction: 1−ð1−X Þ1=3 ¼ kc MB CA t ¼ kr t qB ar0 ð10Þ Where X is the fraction reacted, kc is the kinetic constant, MB is the molecular weight of the solid, CA is the concentration of the dissolved lixiviant A in the bulk of the solution, a is the stoichiometric coefficient of the reagent in the leaching reaction, r0 is the initial radius of the solid particle, t is the reaction time, D is the diffusion coefficient in the porous product layer, ρB density of the solid and kd and kr are the rate constants, respectively, which are calculated from Eqs. (9) and (10) respectively. Eq. (9) reveals that if the diffusion through the product layer controls the leaching rate, there must be a linear relation between the left side of equation and time. The slope of the line is the rate constant kd, it must be directly proportional to 1/r02. If the surface reaction controls the rate, the relation between the left side of Eq. (10) and time must be linear. The slope of this line is called the apparent rate constant kr and must be directly proportional to 1/r0. Eqs. (9) and (10) were applied from obtained results from each temperature value. The plot of Eq. (10) gave a straight line (Fig. 9). It must be noted here that the data points after 90 and 60 min of leaching time were excluded from the curves plotted for 70 and 80 °C, respectively. This part of the data does not represent the actual dissolution behavior of celestite since the required amount of BaCl2 (i.e., 1.1 × 10− 2 M) was not used in these tests. The apparent rate constants (kr) were calculated as slopes of the straight lines. Using the apparent rate constants obtained by application of Eq. (10), the Arrhenius plot was obtained (Fig. 10). S. Aydoğan et al. / Hydrometallurgy 84 (2006) 239–246 Fig. 9. Plot of 1 − (1 − χ)1/3 versus time for different temperatures (BaCl2: 8.25 × 10− 3 M; HCl: 0.5 M; S/L ratio: 1/250 w/v; 400 rpm; Particle size: 45 × 38 μm). The activation energy was calculated as 68.8 kJ mol− 1. This value clearly confirms that this process is controlled by chemical reaction at the celestite surface, which is the rate-determining step in the dissolution of celestite by Ba2+ in HCl (Habashi, 1999). In addition, the kinetic curves for particle size results were linearized by means of Eq. (10) and the apparent rate constant (kr) were drawn as a function of the inverse of the particle radius. Direct relationship between kr versus 1/r0, which can be formulized as kr = 0.09/r0 with a correlation coefficient of 1.00, confirms the chemical reaction on the celestite surface as the rate-controlling step. In order to decide the specific effect of H+ and Cl− ions, the results on the effect of HCl and NaCl concentrations were applied to this kinetic model. Total Cl− ion concentrations of the test solutions with NaCl were calculated and found as 0.617, 1.017 and 1.517 M with respect to 0.1, 0.5 and 1 M NaCl concentrations. The kr values for each H+ and Cl− concentration were deter- Fig. 10. Arrhenius plot of reaction rate against reciprocal temperature. 245 Fig. 11. Plots representing the order of reaction with H+, Ba2+ and Cl−concentrations. mined. From the corresponding kr and H+ and Cl− concentration values, plots of ln kr versus ln [H+] and ln [Cl−] were obtained. As seen from Fig. 11, the order of reaction with respect to H+ and Cl− is proportional to 0.73 power of H+ concentration ([H+]0.73) and 0.70 power of Cl− concentration ([Cl−]0.70) with a correlation coefficient of 1.00, respectively. It was also computed by the same way that the order of the reaction with respect to Ba2+ concentration is proportional to 0.19 power of Ba2+ concentration ([Ba2+]0.19) with a correlation coefficient of 0.99. 4. Conclusions Leaching of celestite in hydrochloric acid solution in the presence of BaCl2 was investigated to produce SrCl2 in the solution, over a broad range of experimental conditions. The effects of variables such as stirring speed, HCl and BaCl2 concentrations, temperature, particle size and also the presence of NaCl in the leaching solution were studied. According to the thermodynamical considerations, celestite solubility increases in BaCl2 solutions with H+ ion which acts as a catalyst to enhance the formation of bisulfate ion (HSO4−) and with Cl− ion which reacts with Sr2+ ion to produce strontium tetrachloride complex, [SrCl4]2−. The reaction of celestite obeys the shrinking core model, incorporating chemical reaction of Sr2+ and SO42− ions with Cl− and H+, respectively, as the rate determining step. As presented by the model, the reaction rate is inversely proportional to the particle size and increases as 0.73, 0.70 and 0.19 powers of the H+, Cl− and Ba2+ concentrations, respectively. The leaching rate of celestite increases with temperature, the apparent activation energy being 68.8 kJ mol− 1. Under well-mixed conditions, in the solution of 0.5 M HCl, 246 S. Aydoğan et al. / Hydrometallurgy 84 (2006) 239–246 8.25 × 10− 3 M BaCl2 (75% stoichiometric amount) and 1 M NaCl at 60 °C, celestite was entirely dissolved within 180 min at a solid/liquid ratio of 1/250. Acknowledgement This study was supported by The Research Foundation of Selçuk University under Project No. BAP-2004/098. References Atkinson, G., Mecik, M., 1997. The chemistry of scale prediction. 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