Industry Overview
Phosphoric acid (PA), also known as phosphoric acid (H3PO4), is an important industrial chemical used extensively as an intermediate in the fertilizer industry, for metal surface treatment in the metallurgical industry, and as an additive in the food industry. Its significance is particularly high in the production of phosphatic fertilizers, which influence the growth and composition of agricultural products.
Phosphoric acid can be manufactured from phosphate rock using different process routes. The wet process, based on sulfuric acid attack of phosphate rock, accounts for 90% of current phosphoric acid production according to the report. Other routes include hydrochloric acid attack followed by solvent extraction and the thermal or electric furnace process.
Phosphate rock contains phosphate in an apatite structure, with producers commonly expressing its grade as BPL (bone phosphate of lime). During beneficiation, different techniques may be applied to remove gangue and impurities, resulting in variations in the finished concentrate. These variations affect both the manufacturing process and the characteristics of the resulting acid.
Wet-process phosphoric acid production can involve significant corrosion challenges because of chloride content and interactions involving HF with SiO2, Al2O3, and MgO. Corrosion mechanisms reported in PA plants include erosion-corrosion, selective corrosion, pitting, stress-corrosion cracking, intergranular corrosion, and high-temperature corrosion. The phosphoric acid industry operates worldwide across Europe, Asia, Africa, and America.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 190 MT/Day |
| Land & Building (20 Acre) | Rs. 38.80 Cr |
| Plant & Machinery | Rs. 51.40 Cr |
| Working Capital for 1 Month | Rs. 21.84 Cr |
| Total Capital Investment | Rs. 114.84 Cr |
| Rate of Return | 58% |
| Break Even Point | 38% |
Content Index
- INTRODUCTION
- PROPERTIES
- PHOSPHORIC ACID POSSESSES FOLLOWING PROPERTIES:-
- USES & APPLICATIONS
- THE USES AND APPLICATION IN THE PERCENTAGE CAN BE GIVEN AS FOLLOWS:-
- MARKET OVERVIEW OF PHOSPHORIC ACID
- MANUFACTURERS/SUPPLIERS OF PHOSPHORIC ACID
- MANUFACTURING PROCESS OF PHOSPHORIC ACID USING HCL
- RAW MATERIALS
- REACTION
- SIDE REACTION
- TECHNICAL DETAILS OF TECHNICAL AND FOOD CRUDE PHOSPHORIC ACID MANUFACTURE
- 1. PRETREATMENT
- FLOCCULATION AND SETTLING:
- 2. SOLVENT EXTRACTION
- POST TREATMENT:
- CONCENTRATION:
- DECOLORIZATION:
- HCL STRIPPING AND FINAL CONCENTRATION:
- DEFLUORINATION:
- OXIDATION:
- WASTE TREATMENT:
- MANUFACTURING PROCESS STEPS
- 1. RAW MATERIALS
- PHOSPHATE ROCK
- CALCINATION
- GRINDING
- BALL MILL
- PHOSPHORIC ACID MANUFACTURING PROCESS IN DETAILS
- DETAILS OF PROCESS OF MANUFACTURE (HAIFA PROCESS):-
- A. DISSOLUTION AND SOLIDS SEPARATION:-
- B. EXTRACTION:-
- C. PURIFICATION:-
- D. WASHING:-
- E. STRIPING:-
- F. CONCENTRATION:-
- G. HYDROCHLORIC ACID STRIPPING:-
- H. SOLVENT RECOVERY:-
- I. SOLVENT PURIFICATION:-
- J. EFFLUENT TREATMENT:-
- K. TECHNICAL GRADE ACID:-
- METAL REMOVAL:-
- BLEACHING:-
- ION EXCHANGE:-
- FLOW DIAGRAM
- COMMERCIAL PERODUCTION METHODS FOR PHOSPHORIC ACID
- WET PROCESS ACID PRODUCTION -
- FIGURE: FLOW DIAGRAM OF A WET PROCESS PHOSPHORIC ACID PLANT
- FIGURE: FLOW DIAGRAM OF A WET PROCESS PHOSPHORIC ACID PLANT (CONT.).
- THERMAL PROCESS ACID PRODUCTION -
- FIGURE: FLOW DIAGRAM OF A THERMAL PROCESS PHOSPHORIC ACID PLANT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ROCK PHOSPHATE
- SUPPLIERS OF PHOSPHATE ROCKS
- SUPPLIERS OF HYDRATED LIME (CALCIUM HYDROXIDE)
- SUPPLIERS OF HCL (HYDROCHLORIC ACID)
- SUPPLIERS OF SODIUM HYDROXIDE (NAOH)
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF DRYERS
- SUPPLIERS OF MIXERS
- SUPPLIERS OF AGITATORS
- SUPPLIERS OF EVAPORATOR
- SUPPLIERS OF PRESSURE VESSEL
- SUPPLIERS OF STORAGE VESSELS
- SUPPLIERS OF FILTER PRESS
- SUPPLIERS OF CENTRIFUGE MACHINE
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Phosphoric acid is primarily used in fertilizer, metallurgical, and food applications.
It is an important intermediate for producing phosphatic fertilizers and can also be used for metal surface treatment and as a food additive. Its industrial importance is closely associated with fertilizer manufacturing because phosphatic fertilizers contribute to agricultural plant growth and affect the composition of agricultural products.
Phosphoric acid can be manufactured from phosphate rock through wet, hydrochloric acid, or thermal process routes.
In the wet process, phosphate rock is attacked with sulfuric acid to produce phosphoric acid. The report also describes hydrochloric acid processing followed by solvent extraction and purification. The thermal route uses electrical energy to produce elemental phosphorus as an intermediate stage and has become less common except where elemental phosphorus is specifically required.
The wet process produces phosphoric acid by chemically attacking phosphate rock with sulfuric acid.
The process generally involves preparation and beneficiation of phosphate rock, reaction with sulfuric acid, separation of solids, and subsequent concentration and treatment of the acid. The composition of the phosphate ore strongly influences the process because many of its impurities remain associated with the resulting acid. The report identifies the wet process as the dominant commercial production route.
Phosphate rock is the principal mineral raw material from which phosphoric acid is produced.
Commercial phosphate rock contains phosphate in an apatite structure, while its quality and impurity profile can vary considerably. Beneficiation may be required to remove gangue and associated impurities before processing. These variations affect the manufacturing technology, operating conditions, corrosion behavior, and characteristics of the phosphoric acid produced.
Phosphoric acid is a corrosive acid whose physical form varies with concentration.
The report states that anhydrous phosphoric acid can form colourless crystals with a melting point of 42.35oC. Commercial grades contain 50-90% acid, while phosphoric acid is syrupy at about 85% concentration. It decomposes at 250oC, producing pyrophosphoric acid and, with further heating, metaphosphoric acid. Depending on concentration, it can occur as a clear, colourless, odourless liquid or as a transparent crystalline solid.
Phosphoric acid plants can experience several forms of corrosion, particularly localized corrosion.
The report identifies chloride content and interactions involving HF formed in the reaction slurry with SiO2, Al2O3, and MgO as important factors affecting corrosivity. Reported mechanisms include erosion-corrosion, selective corrosion, pitting, stress-corrosion cracking, intergranular corrosion, and corrosion at high temperature. Laboratory and plant corrosion tests can be used to identify and assess these mechanisms.
The main commercial production routes are the wet process and the thermal process, with hydrochloric acid processing also described in the report.
The wet process uses sulfuric acid to attack phosphate rock and is the principal route discussed in the report. Hydrochloric acid processing can incorporate solvent extraction and purification stages. The thermal or electric furnace process produces elemental phosphorus before phosphoric acid manufacture and is generally associated with applications requiring elemental phosphorus.
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