In areas where bedded deposits can be solution-mined, evaporated salt is recovered from these solutions with artificial heat. Some evaporated salt also is made from natural brine or solar salt. Formerly, brine was concentrated in open pans over fire. More recently, steam-jacketed vessels have been used. The largest amount of salt produced in the colder climates is rock salt. The largest amount of evaporated salt is produced by multiple-effect vacuum evaporators, and an important quantity is made in so-called open crystallizers or grainers that produce a type of crystal preferred for use in some of the food industries. The brine, natural or artificial, is first pumped into settling tanks, where calcium and magnesium compounds may be removed by chemical treatment. In grainer operations the settled and filtered brine is delivered to the grainer, a long open trough heated with steam coils. The brine is fed into the grainer at approximately the same rate at which evaporation is taking place and at a temperature only slightly below that of the brine in the grainer. The residue of brine, or bitterns, may be removed continuously, once a day, or less often. Evaporation occurs at the surface of the liquid, and the crystals originate there. They remain at the surface, held up by the surface tension of the brine. The crystal grows at the top edges, becoming a small inverted hollow pyramid, or hopper. Eventually the hopper sinks and ceases to grow. When the crystals are recovered, the salt is largely in the form of flakes, hence the name flake salt.
When multiple-effect evaporators are used, the vacuum in each vessel is adjusted so that the vapour from the first vessel is hot enough to boil the brine in the second, the vapour from the second supplying the heat to operate the third vessel or effect. The brine is usually sent through the stages or effects in succession, although in the case of salt manufacture fresh brine may be fed to each stage if desired. With open pans, 4,500 to 5,400 kg (10,000 to 12,000 pounds) of steam are required to produce 900 kg (1 ton) of salt. With triple-effect evaporation, 630 kg (1,400 pounds) of steam produce 1 ton of salt.
The Alberger process is partially a vacuum-pan and partially a grainer operation in which cubic crystals are formed in the solution fed to the grainer pans by a partial vacuum-pan evaporation. These seed crystals in the grainer produce a salt that is a mixture of the grainer-type flake and the flake grown on seed crystals. About 1,360 kg (3,000 pounds) of steam are required to produce one ton of salt. Salt from the Alberger process is centrifuged (spun) from the brine and then dried. Table salt may have small amounts of aluminum calcium silicate, calcium silicate, magnesium silicate, tricalcium silicate, magnesium carbonate, or tricalcium phosphate added to keep it free-flowing. Iodized salt has potassium iodide added. In some countries yellow prussiate of soda, to prevent caking, is added in minute amounts as regulated by the government.
Frank Osborne Wood Robert H. Ralston