Industry Overview
Phosphoric acid (H3PO4) is a vital industrial chemical widely used in the manufacture of phosphatic fertilizers, metal surface treatment, and as a food industry additive. Its importance is closely linked to agricultural productivity, as phosphatic fertilizers play a significant role in improving crop growth and quality. Commercial production is primarily based on phosphate rock, making the process economically attractive due to its relatively low manufacturing cost and strong demand from the fertilizer and synthetic detergent industries.
The most widely adopted production route is the wet process, in which phosphate rock is treated with sulfuric acid to produce wet-process phosphoric acid (WPA). Alternative wet processes may use hydrochloric acid followed by solvent extraction, while the electric furnace process is generally reserved for applications requiring elemental phosphorus because of its higher energy requirements. The wet process accounts for the majority of global phosphoric acid production.
The characteristics of phosphate rock vary depending on its mineral composition and impurity levels, requiring manufacturers to continually adapt beneficiation and processing techniques. During production, impurities such as chlorides, fluorides, silica, alumina, and magnesium compounds can influence corrosion behavior and the quality of the final acid. Consequently, phosphoric acid plants employ corrosion monitoring and testing to address issues such as erosion-corrosion, pitting, stress-corrosion cracking, intergranular corrosion, and selective corrosion.
The phosphoric acid industry operates across Europe, Asia, Africa, and the Americas, particularly in regions with phosphate rock reserves. In India, phosphate rock deposits are found in the Udaipur district of Rajasthan, providing an important domestic raw material source for phosphoric acid production.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 5 MT/Day |
| Land & Building (2000 sq.mt.) | Rs. 2.72 Cr |
| Plant & Machinery | Rs. 2.08 Cr |
| Working Capital for 1 Month | Rs. 89 Lac |
| Total Capital Investment | Rs. 5.95 Cr |
| Rate of Return | 60% |
| Break Even Point | 39% |
Content Index
- INTRODUCTION
- PROPERTIES
- PHOSPHORIC ACID POSSESSES FOLLOWING PROPERTIES:-
- USES & APPLICATIONS
- MARKET OVERVIEW OF PHOSPHORIC ACID
- SPECIFICATION OF ORTHOPHORIC ACID
- FOREWORD
- 1. SCOPE
- 2. GRADES
- 3. REQUIREMENTS
- 4. PACKING AND MARKING
- 5. SAMPLING
- METHODS OF TEST FOR ORTHOPHOSPHORIC ACID
- A-1 QUALITY OF REAGENTS
- A-2 DETERMINATION OF RELATIVE DENSITY
- A-3 DETERMINATION OF ORTHOPHOSPHORIC ACID CONTENT
- A-3.1 METHOD A
- A-3.1.1 REAGENTS
- A-3.1.3 CALCULATION
- WHERE
- A-3.2 METHOD B
- A-3.2.1 REAGENTS
- A-3.2.3 CALCULATION
- WHERE
- A-3.3.1 REAGENTS
- A-3.3.1.1 REAGENT A
- A-3.3.2 PROCEDURE
- A-3.3.3 CALCULATION
- A-4 TEST FOR IRON
- A-4.1 APPARATUS
- A-4.3 PROCEDURE
- A-4.3.1 FOR ‘TECHNICAL GRADE’
- A-5 TEST FOR CHLORIDES
- A-5.1 APPARATUS
- A-5.2 REAGENTS
- A-5.3 PROCEDURE
- A-6 TEST FOR SULPHATES
- A-7 TEST FOR ARSENIC
- A-8 TEST FOR ANTIMONY
- A-9 TEST FOR NITRATES
- A-10 TEST FOR HEAVY METALS
- A-11 TEST FOR SILICA
- A-12 TEST FOR CALCIUM AND MAGNESIUM
- A-13 TEST FOR OXYGEN ABSORBED
- A-14 TEST FOR VOLATILE ACIDS
- A-15 TEST FOR MANGANESE
- SAMPLING OF ORTHOPHOSPHORIC ACID
- B-L GENERAL REQUIREMENTS OF SAMPLING
- B-2 SCALE OF SAMPLING
- B-3 PREPARATION OF TEST SAMPLES
- B-4 NUMBER OF TESTS
- B-5 CRITERIA FOR CONFORMITY
- MANUFACTURING PROCESS OF PHOSPHORIC ACID USING SULPHURIC ACID
- REACTION
- PROCESS FLOW DIAGRAM
- PROCESS IN DETAILS
- DIHYDRATE PROCESS
- THE DISADVANTAGES ARE:-
- FIGURE: DIHYDRATE PROCESS
- GRINDING
- REACTION
- FILTRATION
- CONCENTRATION
- FIGURE: PHOSPHORIC ACID CONCENTRATION. FEED CIRCULATION SYSTEM.
- HEMIHYDRATE (HH) PROCESS
- FIGURE: HEMIHYDRATE PROCESS
- CAPITAL SAVINGS
- PURER ACID
- LOWER ROCK GRINDING REQUIREMENTS
- THE DISADVANTAGES OF HH SYSTEMS ARE:-
- FILTRATION RATE
- PHOSPHATE LOSSES
- SCALING
- FILTER CAKE IMPURITY
- PURITY TEST FOR PHOSPHORIC ACID
- GRAVIMETRIC METHOD
- VOLUMETRIC METHOD
- MANUFACTURERS/SUPPLIERS OF PHOSPHORIC ACID
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ROCK PHOSPHATE
- SUPPLIERS OF PHOSPHATE ROCKS
- SUPPLIERS OF HYDRATED LIME (CALCIUM HYDROXIDE)
- ADDRESSES OF PLANT AND MACHINE SUPPLIERS
- 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
- 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 to manufacture phosphatic fertilizers. It is also widely applied in metal surface treatment, food processing, and various industrial chemical processes. Its versatility makes it an important raw material in agriculture and manufacturing, where consistent quality and controlled production methods are essential for achieving the desired product performance.
Commercial phosphoric acid is mainly produced by the wet process. In this process, phosphate rock reacts with sulfuric acid to form phosphoric acid and gypsum. Alternative technologies exist, including hydrochloric acid-based processes and the electric furnace route, but the wet process remains the dominant industrial method because of its economic advantages and widespread adoption.
Phosphate rock quality directly affects process efficiency and product characteristics. Variations in mineral composition and impurity levels influence beneficiation requirements, corrosion behavior, filtration performance, and the purity of the final phosphoric acid. Manufacturers often adjust operating conditions to accommodate changes in raw material quality.
Phosphoric acid plants commonly experience several forms of corrosion. These include erosion-corrosion, pitting, selective corrosion, stress-corrosion cracking, intergranular corrosion, and high-temperature corrosion. Proper material selection, corrosion monitoring, and routine maintenance are important for improving equipment reliability and extending plant life.
The wet process is preferred because it offers a more economical route for large-scale phosphoric acid production. While the electric furnace process can utilize lower-grade phosphate rock, it requires significantly higher energy input and is generally used only when elemental phosphorus is specifically required for downstream applications.
The quality of wet-process phosphoric acid depends on the composition of the phosphate rock, impurity levels, beneficiation methods, reaction conditions, filtration efficiency, and concentration stages. Effective process control helps produce acid with consistent characteristics suitable for fertilizer and industrial applications.
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