Phosphoric Acid from Phosphate Rock (Hydrochloric Acid Route)
Phosphoric Acid Production Costs Report | Issue E | Q3 2024
Report Details |
100 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 100 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Phosphoric Acid production from phosphate rock in the United States via a hydrochloric acid route similar to the one developed by the Israel Mining Industry (IMI). In this process, phosphate rock is dissolved by hydrochloric acid, resulting in an aqueous solution of calcium chloride and Phosphoric Acid. The Phosphoric Acid is separated from the solution via solvent extraction and further concentrated to obtain a final product containing 69 wt% of P2O5.
The report provides a comprehensive study of Phosphoric Acid production and related Phosphoric Acid production cost, covering three key aspects: a complete description of the Phosphoric Acid production process examined; an in-depth analysis of the related Phosphoric Acid plant capital cost (Capex); and an evaluation of the respective Phosphoric Acid plant operating costs (Opex).
The Phosphoric Acid production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Phosphoric Acid plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Phosphoric Acid plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Overview

Product
Phosphoric Acid. Phosphoric Acid is a colorless, odorless, and non-volatile inorganic compound, soluble in both water and ethanol. It is not considered a strong acid, but aqueous solutions can severely irritate the skin and damage the eyes.
Raw Materials
Hydrochloric Acid. Hydrogen Chloride (HCl), commonly found as hydrochloric acid (a.k.a. muriatic acid) when dissolved in water, is a highly important industrial chemical. Hydrochloric acid has widespread applications in various industries, with major uses in steel pickling, pH control, water treatment, and as a catalyst in chemical synthesis. It is also employed in the production of chlorides, fertilizers, dyes, and in food processing. Hydrogen chloride is primarily produced through the direct synthesis of hydrogen and chlorine, or as a by-product of chlorination reactions in various organic processes. The HCl gas can be absorbed in water to produce aqueous hydrochloric acid, which is the form most widely used industrially.
Rock Phosphate. Rock phosphate is a naturally occurring mineral used primarily as a raw material in the production of phosphoric acid and fertilizers. It is also used in animal feed supplements and industrial chemicals. Rock phosphate is mined from deposits and is stored as a solid. Its phosphate content is essential for plant growth, making it crucial for global agricultural production and soil health management.
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Production Process Information
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Production Process Information
Process Consumptions
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Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Phosphoric Acid production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Phosphoric Acid process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Phosphoric Acid production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Phosphoric Acid plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Phosphoric Acid Production Cost Reports
Phosphoric Acid from Phosphate Rock (Dihydrate Wet Process)
This report presents the economics of Phosphoric Acid production from phosphate rock in the United States via a dihydrate wet process. In this process, phosphate rock is digested with sulfuric acid to producing Phosphoric Acid with the precipitation of calcium sulfate dihydrate. Phosphoric acid is further concentrated to a final product containing 54 wt% of P2O5.
Details: 1,200 kta United States-based plant | Q3 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 1,200 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Phosphoric Acid from Phosphate Rock (Hemihydrate Wet Process)
This report presents the economics of Phosphoric Acid production from phosphate rock in the United States via a hemihydrate wet process. In this process, phosphate rock digestion with sulfuric acid proceeds in two distinct zones, with the precipitation of calcium sulfate hemihydrate. The Phosphoric acid produced is subjected to a further concentration step to obtain a final product containing 54 wt% of P2O5.
Details: 900 kta United States-based plant | Q3 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 900 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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Other Related Production Cost Reports
Phosphoric Acid from Phosphate Rock (Dihydrate Wet Process)
This report presents the economics of Phosphoric Acid production from phosphate rock in the United States via a dihydrate wet process. In this process, phosphate rock is digested with sulfuric acid to producing Phosphoric Acid with the precipitation of calcium sulfate dihydrate. Phosphoric acid is further concentrated to a final product containing 54 wt% of P2O5.
Details: 1,200 kta United States-based plant | Q3 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 1,200 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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