Phosphoric Acid Technology Selection

There are three main technology suppliers for Phosphoric Acid.
Some words about each one, as an introduction:
Jacobs
1947:
Joseph J. Jacobs went into business as Jacobs Engineering Co., operating as both an engineering consultant and a manufacturers' representative for process equipment.
1997: Awarded engineering and technical services by Oswal Chemicals and Fertilizers for three 2,000-metric-ton-per-day (MTPD) Diammonium Phosphate/NPK Plants and a 2,650 MTPD Phosphoric Acid Plant--the world's largest--in Paradeep, India.
2011: Corporate Profile: Jacobs Engineering Group Inc. is one of the world’s largest and most diverse providers of professional technical services. With 2011 revenues of over $10 billion, offers full-spectrum support to industrial, commercial, and government clients across multiple markets. Services include scientific and specialty consulting as well as all aspects of engineering and construction, and operations & maintenance.
Technip
Through acquisiton of Spechim-Krebs, inherited intelectual property from Saint Gobain and Rhône Poulenc in the technology for Di-Hydrate Process and proprietary UCEGO® Filter. Has collaboration with YARA for Hemi-Hydrate Process. Sell technology for very large capacity concentration units.
Prayon
Over 60% of the phosphoric acid currently manufactured in the world comes from plants which use Prayon technology.
Prayon Technologies (PRT) sells the know-how and techniques developed by this Group, and also supplies consultancy and support services. PRT has over 50 years' experience in designing and operating phosphoric acid manufacturing units.
PRT's main areas of activity are: phosphoric acid production (fertilizer grade) using various processes, concentrating phosphoric acid, fluorine recovery, purification of gypsum, gas scrubbing, purification of phosphoric acid, consulting, training, etc.
...

Selaata, Lebanon Chemical Company

Using Syrian rock from Palmyra, high chlorides.

Toros - Mersin - Turkey

Mersin production plant, one of the three factories of Toros Tarım that produces chemical fertilizers is located at 5 km in the east of Mersin city center, at a location very close to Mersin Seaport. The plant, which was built in 1968 by Akdeniz Gübre Sanayi A.Ş, a Kuwait-Turkish partnership, started production in 1972 and was largely modified as a result of the rehabilitation that was put into practice between 1984 and 1987. After incorporating in Tekfen Holding in 1990, first, and later merging with Toros Tarım in 2005, trade name of Akdeniz Gübre was changed to “Toros Tarım Mersin Production Plant”.

Mersin production plant consists of 5 main production units producing calcium ammonium nitrate (CAN) and diammonium phosphate (DAP) fertilizers as well as nitric acid, sulphuric acid and phosphoric acid; other supplementary units such as open and closed storage places and a bagging unit. Approximately 135 personnel are employed in the complex that spread on an area of 1 million square meters.

CAN (26% Nitrogen) unit has 594.000 ton/year fertilizer production capacity. Ammonium nitrate with various nitrogen content such as AN 33% can also be produced at the plant. The plant has a share of 38% in the total production capacity of the country in this category.

DAP unit’s production capacity is 150.000 ton/year. The plant has a share of 28% in the total DAP production capacity in Turkey.

363.000 ton/year nitric acid (100% HNO3); 214.500 ton/year sulphuric acid (98% H2SO4) and 71.000 ton/year phosphoric acid (P2O5) can be produced at the acid units of the plant.

Mersin plant is one of the rare industrial organizations that can generate its own electricity. The power generation unit within the body of the plant consists of a steam turbine generator with a capacity of 7,4 MW and a gas turbine generator with a capacity of 4,7 MW.

Khourigba - Jorf Lasfar - OCP phosphate Rock Slurry Pipeline

MOROCCO - OCP SLURRY PIPELINE PROJECT

Tekfen Job No 325

Location Korigba-Jorf Lasfar, Morocco

Client Groupe Chérifien Des Phosphates

Contractor Tekfen Construction and Installation Co., Inc.

Final Project Value US$ 432.991.495

Tekfen Portion 100%

Commencement With the Contract signature

Completion 28 Months after Contrcat signature.

OCP Slurry Pipeline project has been designed to deliver several grades of phosphates to Jorf Lasfar Terminal. Project location is between Korigba and Jorf Lasfar.

Project duration is 28 Months after Contract signature.

Phosphate grades and throughputs listed below are based on design data received from OCP. The facilities are designed to handle a throughput of 30 Mt/y initially and 38 Mt/y in the future.

The project scope includes Detail Engineering, Procurement, and Construction (EPC) services to supply, install, and commission the facilities including all associated works .

Project consist of approximately 240 km of pipelines including the feeder lines , Doui Pump station, MEA Head Station, Halasaa pump Station and Jorf Terminal. Feeder pipelines from each wash plant pump station will deliver sequential batches of each grade to segregated tanks at the head station at MEA. From the head station sequential phosphate batches will be pumped through the main pipeline into storage tanks at the terminal. One slurry grade will be supplied to the local acid plants and all slurry grades will be supplied for export purposes.

The pipeline scope consists generally of:
Slurry feeder pump stations and pipelines from the wash plants to the central pipeline

Head Station as summarized below;
Pipeline Head Station
Main slurry pipeline from Head Station to Terminal
Daoui Feeder Pipeline
2. MEA Low Grade Feeder Pipeline
MEA High Grade Feeder Pipeline
Halassa Feeder Pipeline
Pipeline Terminal at Jorf Lasfar
SCADA and telecommunication facilities
Valve stations
Slurry storage and pump stations
Slurry feeder pipelines
Fresh water pipeline

O Porto de Nacala

Maaden´s Ras az Zawr Complex

Key Figures of Maaden´s Phosphoric and Chemical Complex

Saudi Arabia Mining Company (Ma'aden), Saudi Arabia

8


Key Data

Saudi Arabian Mining Company (Ma'aden) started-up an integrated fertiliser production complex which is based on phosphate reserves located at Al-Jalamid, in the north of Saudi Arabia.
The phosphate concentrate produced at the mine is transported by rail to Ras Az Zawr where it is processed to produce the feedstock required for the production of 3mtpa of diammonium phosphate (DAP) fertiliser. It is about 10% of the global demand for the fertiliser.
The phosphate fertiliser complex, which includes sulphuric acid, phosphoric acid and DAP, was built at Ras Az Zawr in 2011.
Besides fertiliser production facilities, the project includes the construction of power and desalination plants. Production from the phosphoric acid and sulphuric acid was started in June 2011.
Partners
During the second half of 2007, Sabic, a leading producer of petrochemicals based in Saudi Arabia, announced that it had finalised a joint venture agreement with Ma'aden.
"The facilities will represent the world's largest fully integrated fertiliser production operation."
Under the terms of the agreement Sabic has a 30% equity share in the fertiliser production operation, with Ma'aden retaining the remaining 70%.
It is owned and operated by Ma'aden Phosphate Company (MPC). It is said that the facilities represent the world's largest fully integrated fertiliser production operation.
Ma'aden provided its expertise in the phosphate industry, while Sabic provided the technology and expertise in the area of nitrogen fertilisers. Ma'aden will market about 33% of the production, while Sabic will market the other 77%.
Financing
The total cost of the project was $5.5bn. During the early part of 2008, Ma'aden had approached banks to arrange a syndicated loan of $2.3bn.
Advisers
During the second half of 2007, the global law firm Baker and McKenzie announced it had provided Ma'aden with advice on the development of the phosphate mine and fertiliser production project including the signing of engineering, procurement and construction contracts with three international contractor groups for the development of process plants.
Engineering and project management
US-based WorleyParsons was appointed by Ma'aden to provide engineering and project management and consulting (PMC) services for the phosphate project.
Power and desalination plants
During December 2007, Ma'aden announced it had awarded contracts to Chinese and Korean companies for the construction of the power and desalination plants. The contracts had a total value of $630m.
Guizhou Hongfu Industry and Commerce Development Company was awarded a $350m contract to provide a beneficiation plant. This removes calcium and magnesium carbonates from the phosphate deposit ore to produce 4.6mtpa of dry phosphate concentrate.
"The total cost of the project is put at $4.5bn."
At the same time Korea's Hanwha Engineering and Construction Company was awarded a $280m contract to provide the power and desalination plants. These facilities are located at the phosphate fertiliser complex in Ras Az Zawr.
The power plant consists of 2 × 66% Siemens Condensing Steam Turbines and Generators with an output of 126.76MW base load and 145.53MW peak load. Depending on final load examination the phosphate project is expected to be a net exporter to the grid.
The desalination plant processes up to 40,000m³ of water each day.
Ammonia plant
Samsung Engineering was awarded an engineering, procurement and construction (EPC) contract during May 2007 for Ma'aden's ammonia plant. The contract was valued at $950m.
In October 2007 Samsung awarded Uhde a contract which covered the process licence and basic engineering as well as the supply of specialist equipment for a single-train ammonia plant.
The facility has a capacity of 3,300t/day. Uhde did not disclose the value of its contract. Uhde supplied its dual-pressure process technology for the ammonia plant. The process is said to be particularly reliable and environmentally friendly.
Phosphoric acid plants
Three world-scale phosphoric acid plants, with a combined capacity of 1.5mtpa, are built by Litwin Europe Middle East, a company based in the Netherlands.
The three facilities were built in Ras Az Zawr in 2011. Litwin selected Tekfen Construction and Installation Company to provide construction services for the plant under a consortium agreement. The three production lines are based on the yara semi-hydrate process technology.
The total value of the engineering, procurement and construction contract was put at $525m.
Sulphuric acid plant
Finland's Outotec provided Ma'aden with EPC services for what is said to be the world's largest sulphuric acid production facility with an output of 13,500t/day.
The value of the lump sum turnkey contract, awarded in 2006, was $270m. All of the acid is used for the production of phosphate fertiliser.
Diammoinium phsophate (DAP) plant
Spain's Dragados was awarded a contract to provide the 3mtpa diammonium phosphate fertiliser production plants. The value of the contract was not disclosed.
Dragados also awarded Nesma and Partners the main subcontract package for the DAP plant. Under the subcontract package the company was responsible for the total construction of the project and other services including all civil and infrastructure, heavy foundations, piping fabrication, electrical instrumentation and final commissioning.
Electric substations
During February 2008, Ma'aden announced it had signed a $100m contract with ABB Contracting for two electrical substations that connects the phosphate project at Ras Az Zawr to the national grid.
The contract covered engineering, procurement, construction, testing, commissioning and completion of 380kV and 115kV gas insulated switch gear substations.

Construction FActs of Maaden´s Phosphoric ACid -Fertilizer Complex (by TEfken)

SAUDI ARABIA - WET PHOSPHORIC ACID PLANT

Tekfen Job No 306
Location Ra’s Az Zawr, Saudi Arabia
Client Saudi Arabian Mining Co. - Ma’aden
Contractor Tekfen Construction and Installation Co., Inc. - Litwin Consortium
Final Project Value US$ 525.000.000
Tekfen Portion 35,5%
Commencement 31/05/2007
Completion 30/06/2010

Tekfen signed Contract for Ma’aden Wet Phosphoric Acid Plant in consortium with Litwin. The project covers LSTK contract for the engineering, procurement, construction and erection of Wet Phosphoric Acid Plant with a capacity of 4.380 t/day P2O5 as 48% concentrated Phosphoric Acid, together with neutralization unit, its sludge pond and phosphoric acid / sulphuric acid truck and railway car loading station nearby the plant area.
Tekfen was responsible for the whole construction and erection works as consortium partner and was implementing all construction and erection works at site.

HIGHLIGHTS

Excavation: 170.000 m3
Backfilling: 175.000 m3
Piles: 4.200 Nos
Structural Reinforced Concrete: 50.000 m3
Structural Steel Installation: 9.000 t
Piping: 2.100 t
CS Pipes: 340 t
RLCS Pipes: 1.200 t
SS Pipes: 130 t
Others: 430 t
Equipment Installation: 6.500 t
Storage Tanks: 900 t
Reactor: 1.100 t
Others: 4.500 t
Cables: 490.000 m
Cable Trays: 380.000 kg

Official Inauguration of Bunge Maroc Phosphore

Rabat -
HM King Mohammed VI inaugurated on Thursday (12-22-2011) the new plant «Bunge Maroc Phosphore» to produce phosphoric acid and phosphate fertilizers in the industrial platform of Jorf Lasfar, completed for a total cost of 2.7 billion dirhams.
22 December 2011- HM the King enquires about structuring projects launched in Jorf Lasfar, for a total cost of 40 billion dirhams.
- The Sovereign learns about the Economic Interest Grouping in Jorf Lasfar.
- HM the King visits the Jorf Lasfar industrial platform.
- The Monarch lays foundation stone for a sea water desalination plant, worth 720 million dirhams.
- The Sovereign decorates with Royal Wissams representatives of foreign partners as well as OCP’s executives and employees.

The new plant is established in partnership between Morocco’s state-run group, Office Chérifien des Phosphates (OCP) and Brazil’s leading international fertilizers distributers, Bunge Fertilizantes.
The new project will help produce 375,000 tonnes of phosphoric acid and 610,000 tonnes of fertilizers annually.
The plant will cover 70% of Bunge Fertilizantes imports, which will be distributed in Latin American markets.
The new plant, which will spawn 340 direct jobs, is part of OCP’s long-term strategy to reinforce its trade ties with clients and international partners, and enhance the added value of its products.
The project is also intended to give a fresh impetus to the national economy.
The Monarch was also briefed on large scale projects launched in the platform of Jorf Lasfar for an estimated total cost at 40 billion dirhams.
In this respect, HM the King was provided with details about a 2.1 billion dirham plan to extend a fertilizers plant, a 10 billion dirham project to develop storage and utility units, a 22 billion dirham project to set up four new factories for the production of acid fertilizers, a 2.7 billion dirham seawater desalination plant and a 3.3 billion dirhams extension of port infrastructure.
On this occasion, the Monarch was briefed on the Jorf Lasfar’s Economic Interest Grouping, which brings together the province of El Jadida along with five other operators notably the OCP, the National Ports Agency, Jorf Lasfar Energy Company and the National Steel Industry Company.
The Grouping aims at improving economic activity linked to the Jorf Lasfar’s industrial platform, protect the environment and preserve security and to promote a development that benefits the region.
Afterwards, the Monarch visited the Jorf Lasfar industrial platform to oversee the already operating and the underway phosphoric acid and fertilizers units.
The platform also houses, inter alia, a pipeline terminal station which comprises 10 tanks of a storing capacity of 5,500 cubic meters each.
The 240-km long pipeline, worth 4.5 billion dirhams, will be completed in 2013 by Turkish group, Tekfen, and will help create 110 direct jobs.
The Monarch also laid the foundation stone for the construction of a sea water desalination plant, to be completed for 720 million dirhams.
With an annual treatment capacity of 25 million cubic meters, the new facility will cover the water needs of the Jorf Lasfar platform.
The new facility, to be ready by 2013, is designed to cover the water needs of the Jorf Lasfar platform and will have an annual treatment capacity of 25 million cubic meters.
As part of the OCP’s strategy to preserve water resources, Sidi Masaoud dam will be built for a total cost of 1.1 billion dirhams as well as a sewage water treatment plant in Khouribga (226 million dirhalms).
On the same occasion, HM King Mohammed VI decorated representatives of foreign partners and executives and employees of OCP with Royal Wissams.
In this regard, HM the King decorated with the Alaouite Wissam with the rank of Officer the Chairwoman of Toros Administrative Board Meté Esin, President & CEO of the Tekfen Group Erhan Öner, Former Vice-President of Bunge Fertilizantes Olavio Massao Takenaka.
The Monarch awarded the Wissam of national merit with the rank of Officer CEO of the industrial Pole of OCP group Amar Drissi, Director of the Financial pole of the OCP group Mohamed El Hajjouji, Industrial Development Director El Moutawakil El Baraka, Sales director for Central and Latin America and Africa at the OCP Rachid Rtal Bennani, and Head of the social affairs service at the OCP Bouchra Aâmrou.
HM the King also decorated OCP workers Abdelkader Hossini and Mohamed Traibi and employees Rachid Soufiane and Ahmed Zouhir with Wissams with the rank of Knight.
Last modified : 22 December 2011

Thailand's Flooding to Push down China's Export Volume of Purified Phosphoric Acid

In the remainder of 2011, the China's export volume of phosphoric acid is to reduce due to the recent flood in Thailand as estimated, according to CCM's November issue of Phosphorus Industry China Monthly Report.
At the end of Nov.8th, the impact of flood damage in Thailand has spread to over seven large industrial estates. According to the official warnings, it is predicted that the flood will last for at least one month. This flood is the worst in Thailand in decades that began in July 2011. It is threatening many manufacturing chains which need a long-term to recover.
In accordance with the export data of China, the food grade phosphoric acid exported to Thailand has confronted a serious recession in Sep., decreasing by 89.17% compared with the same period of last year.
Thailand is the second largest importer of food grade phosphoric acid for China. It has imported over 60,000 tonnes of food grade phosphoric acid each year since 2008. During 2008-2011, Thailand imported more and more food grade phosphoric acid from China. In 2010, over 95% of its total import volume was from China.
For China, it has exported over 450,000 tonnes of food grade phosphoric acid annually since 2009. The export food grade phosphoric acid is sold to over 20 countries. And about nearly 50% of that is supplied to the five prime purchasers—South Korea, Thailand, Japan, Indonesia and Taiwan. Overall, the export destination is relatively scattered.
Basically, China exports 10% of total export food grade phosphoric acid to Thailand annually. By Sep. 2011, Thailand has purchased 48,598 tonnes of food grade phosphoric acid from China, decreasing by 3.12% compared with the same period of last year.
According to the past import data of Thailand, it is impossible to achieve this amount in the remainder three months of this year, as the Thailand flooding has hit most of its manufacturing.

Source:Phosphorus Industry China Monthly Report 1111
http://www.cnchemicals.com/Newsletter/PhosphorusIndustryChinaMonthlyReport.shtml

Fosbrasil S.A. - Cajati - São Paulo - Brazil - Brazilian Producer of Purified Phosphoric Acid

Some names that made the history: from Monsanto: Ken Wulfert, Steve Domahidi, Aristides Boeira, David Gard, Bill Compton, Antônio Queiroz; from Quimbrasil Serrana: José Luiz Marini, Saulo Meda, João de Brito, Gunther Drewes, Walter Cover, Mário Barbosa; from Prayon Rupel: Michel Peeterbroeck, Bernard Heptia, Marcel Nicolay, Paul Smith, Philippe Renier, Armand Davister, Denis Leruth, to be short. The "ins" were Mário Cerqueira, Vinicius Pergamo, Júlio Awane, Armando Mastandrea, José Maria Zacari, Sérgio Haddad, and more two or three hundreds (counting the turn over...), most of them friends.
Quimbrasil was "inherited" by Vale. Monsanto Phosphates by ICL. Prayon is still the old and good Prayon.
In 1980 they started talking with partners to a Phosphoric Acid Purification Plant (Solvent Extraction with DIPE plus TBP). The process is exquisitelly complex, as Coca Cola (to cite an important client) is very restrictive, requiring a "special food grade" phosphoric acid with 99,98% purity in a 85% H3PO4 water clear solution (61,5% P2O5).
Ingenious technical financial agreement was made (the project almost was sent to Uberaba).
Erected at 230 km south of São Paulo City, started up in 1987 and is still a Brazil's and South America's market leader.
As this joint venture is located inside Vale´s Chemical Complex, we can see in the right Vale´s Tank Farm and some DCP´s facilities around.
I worked there from 1990 to 2006!

Mosaic - Mulberry - Florida - USA

Homs- Syria

JPMC - Aqaba - Jordan

ICL - Arad - Israel

Salt Ponds in the South of Dead Sea (Israle/Jordania)

Al Qaim - Iraq

Gujarat Alkalies & Chemicals - Vadodara - Índia