Located on the Atlantic coast, 20 km to the South-West of El Jadida, the Jorf Lasfar industrial complex started production in 1986. This new unit allowed OCP Group to double its phosphate processing capacity. The site was selected for its multiple advantages: nearness of the mining areas, availability of a deep water port, access to substantial water reserves and availability of land for future extensions.
This unit, which covers an area of 1,700 hectares, produces annually 2 million tons P2O5 in the form of phosphoric acid, requiring 7.7 million tons of phosphate rock mined out of Khouribga deposits, 2 million tons of sulphur and 0.5 million tons of ammonia. The energy requirements of the complex are met thanks to a 111 MW power station using recovered heat.
The Jorf Lasfar complex is composed of three entities, including the Maroc Phosphore III-IV unit which was created in 1986. With the construction in 1997 of the Emaphos plant, in partnership with Prayon (Belgium) and CFB (Germany), OCP Group entered a new era of diversification of its finished products by producing a high value added acid, i.e. purified phosphoric acid. Two years later, the commissioning of Imacid, a partnership with Indian Birla Group, enabled it to increase its phosphoric acid production capacity by 25% on the Jorf Lasfar site.
Maroc Phosphore III-IV has an annual production capacity of 1.4 million tons P2O5 of phosphoric acid, 850,000 tons of Di-Ammonium Phosphate (DAP) and 850,000 tons equivalent DAP of other fertilizers.
The sulphuric acid plant has 6 production units of 2,650 tons per day. The process used is double absorption Monsanto. The phosphoric acid plant is composed of 8 phosphate rock crushing units, 8 lines of 29% P2O5 phosphoric acid, 20 concentration units, 8 clarification units, 4 54% P2O5 acid filtration units, as well as a pre-treatment unit. Manufacturing is made according to the French Rhone-Poulenc process.
The fertilizer plant includes 4 DAP production units, of which 2 can also produce TSP, granulated MAP and NPK (for the local market). The basic process used is AZF double tubular reactor for DAP and AZF agitated tank with slurry pumping for TSP. This process was replaced by the pre-neutralizer and tubular reactor Jacobs process as part of the revamping programme.
New joint ventures came later: Imacid revamped 450 ktP2Oy in early 2000's, PMP (Pakistan Maroc Phosphore, 375 ktP2O5y) started in 2007 and BMP (Bunge "or Brazil" Maroc Phosphore) with the same 375 ktP2O5 in 2009.
OCP will soon build a new PhosAcid unity to join that team!
The Office Chérifien Phosphates built a new a new fertilizer production plant at Jorf Lasfar, with a capacity of 1 1 million tonnes per year. They said it is the first in a series of 4 new plants to be built between 2013 and 2015.