Potassium silicate fertilizer grade were successfully produced by direct fusion of silica (SiO2) and potasium (KOH and K2CO3) in furnaces at temperatures up to melting point of mixture. The geothermal sludge (98% SiO2) and the pyrophyllite (95% SiO2) were used as silica sources. The purposes of the study was to synthesise potassium silicate fertilizer grade having solids concentrations in the range of 31-37% K2O, and silica in the range of 48-54% SiO2. The weight ratio of silicon dioxide/potasium solid being 1:1 to 5:1. Silica from geothermal sludge is amorphous, whereas pyrophylite is crystalline phase. The results showed that the amount of raw materials needed to get the appropriate molar ratio of potassium silicate fertilizer grade are different, as well as the fusion temperature of the furnace. Potassium silicate prepared from potassium hydroxide and geothermal sludge produced a low molar ratio (2.5: 1 to 3: 1). The potassium required quite small (4:1 in weight ratio), and on a fusion temperature of about 900 °C. Meanwhile, the potassium silicate prepared from pyrophyllite produced a high molar ratio (1.4 -9.4) and on a fusion temperature of about 1350 °C, so that potassium needed large enough to meet the required molar ratio for the fertilizer grade. The product potassium silicate solid is amorphous with a little trace of crystalline.Keywords: geothermal sludge, pyrophyllite, fusion reaction, potassium silicate solid, fertilizer
INTRODUCTIONPotassium or sodium water glasses are generally produced on an industrial scale by melting together quartz sand and sodium/potassium carbonate in suitable furnaces at temperatures in the range of 1400° to 1500° C with the splitting-off of carbon dioxide. This high-temperature melt process is, however, very costly both in equipment and as regards the amounts of energy required and leads moreover to not inconsiderable emissions, such as dust, nitrogen oxides, and sulfur oxides (US 5238668 A). The alkali extraction and acid precipitation method, low energy method, has also been successfully used to produce silicate solution (Muljani et al, 2014), but this method is less precise when solid silicate product is desired. The hydrothermal reaction of quartz sand with aqueous potassium hydroxide obtained potassium silicate solutions which have SiO2: K2 O molar ratios of less than 2.75:1. However, in this case, hydrothermal reaction must go through a two-stage process: stage quartz reaction with KOH solution at a temperature of 300 C and quartz reaction stage at a temperature up to melting point (over 1100 °C).SiO2 structural differences between amorphous and crystalline silica can lead to differences in dissolution behavior. But the physical properties of amorphous silica remains elusive in comparison to crystalline silica based on the more comprehensive quartz dissolution studies. There are also known hydrothermal processes for the production of aqueous potassium silicate solutions that are described in a number of patent applications. Gunnarsson, et al (2010) report...