Enhanced acidolysis of phosphate rock and controlled phosphogypsum crystallization via high shear reactor

Phosphoric acid, vital for fertilizers and new energy materials, is produced via sulfuric acidolysis of phosphate rock (PR). Conventional dihydrate processes suffer from slow acidolysis rates, low phosphorus yield, high slurry recirculation and high residual phosphorus in phosphogypsum (PG). Herein,...

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Bibliographic Details
Published in:Separation and purification technology Vol. 380; p. 135463
Main Authors: Shan, Guixuan, Yang, Xinhui, Huo, Xinyi, Ma, Kangkang, Abrar, Laiba, Li, Xiaoning, Yao, Long, Zhao, Yu, Chi, Ru'’an, Long, Bingwen, Li, Wei, Zhang, Jinli
Format: Journal Article
Language:English
Published: Elsevier B.V 07.02.2026
Subjects:
Acidolysis
High shear reactor
Intensification mechanism
Phosphate rock
Phosphogypsum
Phosphogypsum
Intensification mechanism
Acidolysis
Phosphate rock
High shear reactor
ISSN:1383-5866
Online Access:Get full text
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Summary:Phosphoric acid, vital for fertilizers and new energy materials, is produced via sulfuric acidolysis of phosphate rock (PR). Conventional dihydrate processes suffer from slow acidolysis rates, low phosphorus yield, high slurry recirculation and high residual phosphorus in phosphogypsum (PG). Herein, Jet-flow high shear reactors (JF-HSRs) with novel configurations were designed to intensify the acidolysis process, enhancing PR leaching and modulating the crystallization of PG. Experiments and computational fluid dynamics (CFD) simulations demonstrated that JF-HSRs' intense turbulence and shear forces improve solid-liquid mass transfer, suppress PR encapsulation, and shift rate-limiting steps from diffusion to interfacial reactions. Optimized JF-HSR operation achieved >98 % P2O5 conversion across PR grades (28.5–32.8 % P2O5), surpassing traditional methods by ∼3 %, while reducing cocrystal P2O5 in PG to 0.23 % (vs. 0.61 % conventionally). An optimization model integrating the ‘flow fields-reaction-crystallization’ framework was developed, with a dimensionless correlation predicting P2O5 conversion, guiding dihydrate process optimization and advancing efficient phosphorus utilization. [Display omitted] •>98 % P2O5 conversion achieved with HSR than conventional methods.•Using HSR significantly reduces reaction time in wet dihydrate process.•Shear forces accelerated mass transfer and suppressed PR encapsulation.•Two-stage process (HSR mixing + ripening) refines crystal morphology.
ISSN:1383-5866
DOI:10.1016/j.seppur.2025.135463