Commodity Production Costs Report
Phosphoric Acid from Phosphate Rock (Dihydrate Wet Process)
Phosphoric Acid Operating Costs & Plant Construction Costs
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.
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.
Key reference(s): ?
The process under analysis comprises three major sections: (1) Reaction; (2) Separation; and (3) Scrubbing system.
Reaction. Initially, the phosphate rock is ground in a ball mill, resulting in a particle size capable of being digested in the reactor. The reaction occurs in a compartmentalized reactor, where the ground rock is fed in the first compartment along with recycled Phosphoric Acid, and sulfuric acid is added in the second compartment in order to avoid the formation of an insoluble layer of calcium sulfate on the rock.
Separation. The slurry formed in the reactor proceeds to filtration to separate calcium sulfate dihydrate from Phosphoric Acid. In the filter, gypsum separated is washed to improve the Phosphoric Acid recovery. Filtered acid proceeds for the first clarification step, where most of the remaining solids are precipitated by gravitation settling. The clarified overflows to the first vacuum evaporator, where it is concentrated to 40% P2O5, and then to a second evaporator that further concentrates the acid to reach the desired 54% P2O5 concentration. Finally, the concentrated Phosphoric Acid proceeds to a second clarification tank to remove residual solids that were formed in concentration and the final product is sent to storage facilities.
Scrubbing system. All gas produced in the reaction and concentration areas is directed to a scrubbing system to be washed with water. The scrubbing system is comprised of two separate sections. The first one is designed to wash the reaction gas that comes in part from the reaction. The second one is designed to condense the evaporated water from the concentration and to separate fluorine (which is present in the phosphate rock raw material) in the form of fluorosilicic acid.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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
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Other Phosphoric Acid Production Cost Reports
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
Phosphoric Acid from Phosphorus
This report presents the economics of Phosphoric Acid production from phosphorus in the United States via a typical thermal process. In this process, elemental phosphorus is burned in a combustion chamber forming phosphorus pentoxide, which is then hydrated to produce Phosphoric Acid containing 54 wt% of P2O5.
Details: 250 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $999 USD
Phosphoric Acid from Phosphate Rock (Thermal Process)
This report presents the economics of an integrated process for the production of Phosphoric Acid from phosphate rock involving: (1) the production of elemental phosphorus from phosphate rock; and (2) the production of Phosphoric Acid from elemental phosphorus via a thermal process. The final product obtained in this process is Phosphoric Acid containing 54 wt% of P2O5. The economic analysis performed is based on a plant constructed in the United States.
Details: 250 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD
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NPK Fertilizer Production (Phosphonitric Process)
This report presents the economics of a typical phosphonitric process for NPK Fertilizer production in the United States from rock phosphate, phosphoric acid, ammonia, and nitric acid. Initially, rock phosphate is digested with nitric acid and phosphoric acid. The NP solution generated is then neutralized with gaseous ammonia. To produce NPK potassium chloride or sulfate is finally admixed. The product formulation is 15-15-15 (15% N, 15% P2O5, 15% K2O).
Details: 300 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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