In this paper, a
clean process based on the steam-mediated reactions
for simultaneous HCl and KCl production using the potassium (K)-containing
phosphorous rock as a precursor is proposed. Through hydrochloric
acid (HCl) leaching, not only the generation of H
3
PO
4
and CaCl
2
(via further precipitation) were realized
but also the acid-insoluble residue [phosphorous-rock slag (PS)] rich
in elements, that is, K, Al, Si, and so on, in the form of microcline
(KAlSi
3
O
8
) and quartz (SiO
2
) was
obtained and became readily available for further HCl and KCl generation.
Over 95% of the elements, that is, K, Al, and Si, come into the final
products, and the overall acid consumption (based on HCl) is significantly
reduced (90%) due to recovery of acids. The impacts of the key operational
parameters such as temperature, duration, and reagent impregnate ratio
were rigorously analyzed via a supervised machine learning approach,
and the optimal conditions were determined [reaction temperature,
X
1
, 850 °C; reaction duration, X
2
, 40 min;
and impregnate ratio (PS over CaCl
2
), X
3
, 2.5]
with approximately ±10% uncertainties. Thermodynamic analysis
indicates that the introduction of steam to PS + CaCl
2
not
only enhances the chemical potential for the formation of HCl and
KCl but also provides the transport advantage in continuously removing
the generated products, that is, HCl and KCl, out of the system. Molecular
simulation indicates that the presence of both steam and SiO
2
in the PS matrix plays critical roles in decomposing PS + CaCl
2
at high temperature. The shrinking core model shows that
both the intrinsic kinetics and transport are influential with the
activation energy being around 14.63 kJ/mol. The potential reaction
pathway is postulated.