A practical approach to produce Mg‐Al spinel based on the modeling of phase equilibria for NH4Cl‐MgCl2‐AlCl3‐H2O system

Based on chemical modeling of phase equilibria for the NH₄Cl‐MgCl₂‐AlCl₃‐H₂O system, a practical approach to produce Mg‐Al spinel (MgAl₂O₄) (widely used as refractory brick, supports in catalysts, and inert material for oxygen carriers) is proposed and proven feasible. This novel process includes coprecipitation of Mg₄Al₂(OH)₁₄·3H₂O from the NH₃‐MgCl₂‐AlCl₃‐H₂O system; calcination of Mg₄Al₂(OH)₁₄·3H₂O to obtain Mg‐Al spinel and recovery of NH₄Cl from NH₄Cl‐rich solutions by feeding MgCl₂‐AlCl₃. A MSMPR reactor was applied to investigate the effect of temperature, feed concentration, and NH₄Cl addition on coprecipitation of precursor Mg₄Al₂(OH)₁₄·3H₂O from MgCl₂‐AlCl₃ solutions with Mg/Al ratio = 2 through gradual addition of NH₄OH. The phase equilibria of the NH₄Cl‐MgCl₂‐AlCl₃‐H₂O system were determined over the temperature range 283.2 to 363.2 K using dynamic method. The experimental solubilities were regressed to obtain new Bromley‐Zemaitis model parameters. These newly obtained parameters were verified by predicting the quaternary system. A chemical model for the NH₄Cl‐MgCl₂‐AlCl₃‐H₂O system has been established with the OLI platform. All the results generated from this study will provide the theoretical basis for Mg‐Al spinel production. The high quality Mg‐Al spinel was prepared by calcination of precursor from 773.2 to 1273.2 K, and the NH₄Cl was successfully recovered through the common ion effect of MgCl₂‐AlCl₃ addition. © 2012 American Institute of Chemical Engineers AIChE J, 59: 1855–1867, 2013