The hemihydrate-dihydrate process was industrialized at Japan Steel-Tube Corporation in June 1961 after the author's investigation and the pilot plant test by coworkers for six years. The characteristics of this process are as follows;
(1) Digesting temperature of phosphate rock must be kept usually in the temperature range at which hemihydrate was stable and also was formed predominantly.
(2) Subsequently, slurry including hemihydrate is cooled from digesting temperature to dihydrate stable temperature due to the mixing of recirculated slurry or by the use of evaporator cooler, and a small amount of dihydrate nuclei is added in it to accelerate growth of crystal during hydration.
(3) The keys of industrial operation are the perfect decomposition of phosphate rock, addition of the active dihydrate nuclei, and of the active silica gel to eliminate effectively obstructive actions by organic impurities and fluorine for the gypsum crystal growth.
To elucidate whether gypsum obtained as byproduct was higher than gypsum for plaster board or not, the titled test was operated.
It was sammerized as follows;
(1) On the washing cake by moving pan filter.
This gypsum contained a small amount phosphoric acid remained on the crystal surface, not in the crystal, because pH valus was in the range 1.95-2.70 and also it was 2.10-2.90 after calcining at 170°C. But the tensil strength was relatively low in the range 3-10 kg/cm
2.
Its color was brown and after calcination at 1000-1100°C, surface of sintered gypsum showed dark bluish gray.
This gypsum is not available as plaster mould's material for porcelain slip casting.
(2) On the rewashing gypsum by the sedimentation washing apparatus.
Byproduced gypsum which is washed again by the devised sedimentation washing apparatus, was white, pH value of it was in the range 3.90-4.60, tensil strength was 9.30-13.3 kg/cm
2 and surface of sintered gypsum after calcining also was white.
(3) It was confirmed that byproduced gypsum has higher qualities enough to use as plaster moulds material for porcelain slip casting.
Especially, qualities of byproduced gypsum that was manufactured from “florida calcined phosphate rock” as raw material, is excellent.
In this process, yield of P
2O5 was 96% and concentrations of phosphoric acid was 32% P
2O
5.
The plant for this process has been operated steadily since it started.
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