Process for producing fluorine compounds and amorphous silica

Claim 2

A process consisting essentially of the steps of: (a) reacting in a precipitation zone fluosilicic acid in aqueous solution with a sodium-containing compound selected from the group consisting of sodium hydroxide, sodium carbonate, sodium silicate and combinations thereof, to form an alkaline aqueous slurry comprising silica and dissolved sodium fluoride; by maintaining during said reaction the pH of the alkaline aqueous slurry at a value greater than 7 and up to about 9, the alkaline aqueous slurry at least about saturated with sodium fluoride, and the temperature of the alkaline aqueous slurry substantially equal to its boiling point so that an amorphous silica precipitate is formed; and (b) separating precipitated amorphous silica from the alkaline aqueous slurry leaving an aqueous solution comprising sodium fluoride.

Claim 3

The process of claim 1 in which the alkaline aqueous slurry contains precipitated sodium fluoride, and water is added to the alkaline aqueous slurry, in a dissolving zone, to dissolve substantially all of the precipitated sodium fluoride before the precipitated amorphous silica is separated from the alkaline aqueous slurry.

Claim 4

The process of claim 1 wherein said separating in step (b) is effected by filtering said slurry and the filtrate comprises said aqueous solution comprising sodium fluoride.

Claim 5

The process of claim 3 further comprising recovering solid sodium fluoride from said filtrate.

Claim 6

The process of claim 1 in which solid sodium fluoride is recovered from the filtrate comprising an aqueous solution of sodium fluoride by a process comprising (i) evaporating water from the filtrate in an evaporation zone to form an aqueous slurry comprising solid sodium fluoride and a solution which is saturated with respect to sodium fluoride; (ii) filtering at least a portion of the slurry to recover solid sodium fluoride and a filtrate comprising a solution which is saturated with respect to sodium fluoride; and (iii) converting said solution which is saturated with respect to sodium fluoride into fluoride compounds by reaction with another chemical substance.

Claim 7

The process of claim 3 wherein an aluminum compound is added to said filtrate and converted into a solid, synthetic cryolite.

Claim 8

The process of claim 6 wherein said compound is AlF 3 .

Claim 9

The process of claim 1 in which the precipitated amorphous silica is separated from the alkaline aqueous slurry by filtering the slurry through a filter having an average pore size less than about 15 microns.

Claim 10

The process of claim 1 in which at least 50% by weight of the separated amorphous silica has a diameter greater than about 15 microns.

Claim 11

A process for recovering solid amorphous silica from fluosilicic acid consisting essentially of the steps of: (a) reacting fluosilicic acid with a material selected from the group consisting of MOH, M 2 CO 3 , M 2 SiO 3 , and combinations thereof, where M is selected from the group consisting of sodium, potassium, and ammonium, to form an alkaline aqueous slurry comprising silica and a dissolved fluoride salt MF; wherein during said reacting the pH of the alkaline aqueous slurry is maintained at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry is maintained sufficiently low such that the slurry is at least about saturated with respect to the fluoride salt, and the temperature of the alkaline aqueous slurry is maintained at its boiling point so that an amorphous silica precipitate is formed; and (b) separating precipitated amorphous silica from the alkaline aqueous slurry.

Claim 12

A process for recovering solid amorphous silica from fluosilicic acid consisting essentially of the steps of: (a) reacting fluosilicic acid with a material selected from the group consisting of MOH, M 2 CO 3 , M 2 SiO 3 , and combinations thereof, where M is selected from the group consisting of sodium, potassium, and ammonium, to form an alkaline aqueous slurry comprising silica and a dissolved fluoride salt MF; wherein during said reacting the pH of the alkaline aqueous slurry is maintained at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry is maintained sufficiently low such that the slurry is at least about saturated with respect to the fluoride salt, and the temperature of the alkaline aqueous slurry is maintained at its boiling point so that an amorphous silica precipitate is formed; and (b) separating precipitated amorphous silica from the alkaline aqueous slurry.

Claim 13

A process for recovering a low silica content fluoride solution and solid amorphous silica from phosphate plant scrub liquor containing at least about 15% by weight fluosilicic acid, consisting essentially of the steps of: (a) combining the scrub liquor with sodium carbonate in a precipitation zone to form an alkaline aqueous slurry comprising precipitated amorphous silica and sodium fluoride by maintaining the pH of the alkaline aqueous slurry at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry sufficiently low such that the slurry contains solid sodium fluoride, and the temperature of the alkaline aqueous slurry substantially equal to its boiling point; (b) adding sufficient water to the alkaline aqueous slurry in a dissolving zone to dissolve substantially all of the solid sodium fluoride; and thereafter (c) separating precipitated amorphous silica from the alkaline aqueous slurry leaving an aqueous solution comprising sodium fluoride.

Claim 14

A process for recovering a low silica content fluoride solution and solid amorphous silica from phosphate plant scrub liquor containing at least about 15% by weight fluosilicic acid, consisting essentially of the steps of: (a) combining the scrub liquor with sodium carbonate in a precipitation zone to form an alkaline aqueous slurry comprising precipitated amorphous silica and sodium fluoride by maintaining the pH of the alkaline aqueous slurry at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry sufficiently low such that the slurry contains solid sodium fluoride, and the temperature of the alkaline aqueous slurry substantially equal to its boiling point; (b) adding sufficient water to the alkaline aqueous slurry in a dissolving zone to dissolve substantially all of the solid sodium fluoride; and thereafter (c) separating precipitated amorphous silica from the alkaline aqueous slurry leaving an aqueous solution comprising sodium fluoride.

Claim 15

A process for recovering solid amorphous silica from fluosilicic acid consisting essentially of the steps of: (a) reacting fluosilicic acid with MOH, where M is selected from the group consisting of sodium and potassium to form an alkaline aqueous slurry comprising silica and a dissolved fluoride salt MF; wherein during said reacting the pH of the alkaline aqueous slurry is maintained at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry is maintained sufficiently low such that the slurry is at least about saturated with respect to the fluoride salt, and the temperature of the alkaline aqueous slurry is maintained substantially equal to its boiling point so that an amorphous silica precipitate is formed; and (b) separating precipitated amorphous silica from the alkaline aqueous slurry.

Claim 16

A process for recovering solid amorphous silica from fluosilicic acid consisting essentially of the steps of: (a) reacting fluosilicic acid with MOH, where M is selected from the group consisting of sodium and potassium to form an alkaline aqueous slurry comprising silica and a dissolved fluoride salt MF; wherein during said reacting the pH of the alkaline aqueous slurry is maintained at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry is maintained sufficiently low such that the slurry is at least about saturated with respect to the fluoride salt, and the temperature of the alkaline aqueous slurry is maintained substantially equal to its boiling point so that an amorphous silica precipitate is formed; and (b) separating precipitated amorphous silica from the alkaline aqueous slurry.

Claim 17

A process for recovering solid amorphous silica from fluosilicic acid consisting essentially of the steps of: (a) reacting fluosilicic acid with a material selected from the group consisting of M 2 CO 3 , M 2 SiO 3 , M 2 CO 3 , M 2 CO 3 and M 2 SiO 3 and combinations thereof with MOH, where M is selected from the group consisting of sodium, potassium, and ammonium, to form an alkaline aqueous slurry comprising silica and a dissolved fluoride salt MF; wherein during said reacting the pH of the alkaline aqueous slurry is maintained at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry is maintained sufficiently low such that the slurry is at least about saturated with respect to the fluoride salt, and the temperature of the alkaline aqueous slurry is maintained at its boiling point so that an amorphous silica precipitate is formed; and (b) separating precipitated amorphous silica from the alkaline aqueous slurry.

Claim 18

A process for recovering solid amorphous silica from fluosilicic acid consisting essentially of the steps of: (a) reacting fluosilicic acid with a material selected from the group consisting of M 2 CO 3 , M 2 SiO 3 , M 2 CO 3 , M 2 CO 3 and M 2 SiO 3 and combinations thereof with MOH, where M is selected from the group consisting of sodium, potassium, and ammonium, to form an alkaline aqueous slurry comprising silica and a dissolved fluoride salt MF; wherein during said reacting the pH of the alkaline aqueous slurry is maintained at a value greater than 7 and up to about 9, the water content of the alkaline aqueous slurry is maintained sufficiently low such that the slurry is at least about saturated with respect to the fluoride salt, and the temperature of the alkaline aqueous slurry is maintained at its boiling point so that an amorphous silica precipitate is formed; and (b) separating precipitated amorphous silica from the alkaline aqueous slurry.