Sulphur 397 Nov-Dec 2021
30 November 2021
Sulphuric Acid News
UNITED STATES
DuPont to license acid plant for ioneer
Lithium-boron miner ioneer Ltd has awarded DuPont Clean Technologies a contract for the license, engineering, and supply of proprietary equipment for a planned sulphuric acid plant at the company’s Rhyolite Ridge project in Nevada. DuPont will work with engineering partner SNC-Lavalin on the plant design, using MECS® sulphuric acid technology for the 3,500 t/d sulphur-burning unit, as well as controls that limit emissions to among the lowest in the world for this type of facility. DuPont will also supply its latest generation MECSSuper GEAR® ™ catalyst and other critical proprietary equipment. The contract is conditional on a final investment decision by the ioneer board of directors.
The acid will be used to leach lithium and boron from mined rock. The plant will also generate an initial 35 MW of electricity, sufficient to power the entire Rhyolite Ridge operation using primarily co-generated, zero-carbon power. The heat generated will also be used for evaporation and crystallisation processes required to produce lithium carbonate and boric acid. An air quality permit was awarded in June 2021 for what is the first sulphuric acid plant permitted in Nevada.
Rhyolite Ridge is expected to produce 20,600 t/a of lithium carbonate, converting in year four to 22,000 t/a of battery-grade lithium hydroxide, and 174,400 t/a of boric acid. Pending final Department of the Interior (DOI) approval of the plan of operation, the project is expected to begin production in the second half of 2024.
Commenting on the contract, ioneer Managing Director, Bernard Rowe, said: “development of the Rhyolite Ridge lithium-boron project is a critical strategic step to enable US production of lithium-ion batteries for electric vehicles (EV) and renewable energy storage. ioneer’s core commitment is to produce essential materials in an environmentally and socially responsible and sustainable manner through lowered emissions, reduced water usage and a minimal surface footprint. We are delighted to welcome MECS-DuPont to our team.”
Metso Outotec to supply copper leaching plant for Florence
Metso Outotec has signed an agreement with Florence Copper Inc., a subsidiary of Taseko Mines, to supply copper solvent extraction and electrowinning technology for a plant to be built in Arizona. Metso Outotec delivery includes the modular VSFX ® solvent extraction plant and the main process equipment for the electrowinning plant.
“We are very excited to have purchased the key SX/EW process equipment from Metso Outotec, a world leader in mineral processing and hydrometallurgical technologies. The VSFX ® technology is ideally suited for our Florence copper project, which is set to become one of the most energy-efficient and low-carbon copper producers in the world. The modular nature of the equipment will reduce construction time and allow Florence to commence copper production quicker than with other technologies available,” said Stuart McDonald, President and CEO of Taseko Mines.
Smelter shutdown leads to disruption in acid supply
Rio Tinto declared force majeure on shipments of copper cathode and sulphuric acid from its Kennecott mine in late September after the smelter was shut down on September 21st following a release of molten copper materials. According to the announcement, Rio Tinto is assessing the work needed to safely restart operations at the smelter and is working closely with customers to minimise any impacts. Phosphate producer Itafos said that supply of sulphuric acid supply to its Conda, Idaho phosphate plant was disrupted as a result. Conda sources approximately 40% of its acid requirements internally and approximately 60% from a combination of volumes received from Rio Tinto’s Kennecott mine under a long-term supply agreement and volumes procured from other third party producers. Conda produces around 550,000 t/a of mono-ammonium phosphate, superphosphoric acid, merchant grade phosphoric acid and ammonium polyphosphate.
INDIA
Paradeep targeting 2Q 2022 for phosphoric acid expansion
Fertilizers manufacturer Paradeep Phosphates Ltd says that it is looking at 1Q 2022 for an expansion of its phosphoric acid production by 120,000 t/a, as well as the installation of a new evaporator to increase strong phosphoric acid production by 116,000 t/a. The increases are part of a 50% increase in the company’s capacity for producing non-urea fertilizers including diammonium phosphate and NPK by 50% from 1.2 million ta to 1.8 million t/a at its site at Paradeep in Odisha state. The estimated investment on the expansion projects would be close to $64 million. The funding will be partly through internal accruals and partly debt. Paradeep operates 1.3 million t/a of sulphuric acid capacity at the site.
CANADA
Metso Outotec to deliver SX plant for First Cobalt
Metso Outotec has signed an agreement with Canadian battery materials recycling company First Cobalt Corporation to deliver solvent extraction technology for First Cobalt’s refinery expansion in Ontario. Metso Outotec’s scope of delivery includes the engineering and supply of a modular VSFX ® solvent extraction plant. First Cobalt aims to produce 25,000 t/a of high-quality, battery-grade cobalt sulphate using a proprietary acid leaching process called Re-2Ox. Their refinery in Ontario is currently the only permitted producer of battery-grade cobalt for the North American electric vehicle market.
“We are happy to be moving forward with Metso Outotec, an industry-leading business partner. Metso Outotec was selected based on its competitive pricing and technically superior bid. The contracted solution involves the latest advancements in solvent extraction in terms of modular design, process control, and ease of installation and start up,” said Trent Mell, president & CEO of First Cobalt.
WORLD
Nickel output forecast to rise by 18% in 2022
The International Nickel Study Group says that it expects global demand for nickel is expected to increase to 3.04 million t/a in 2022 from an estimated 2.77 million t/a in 2021. Production of nickel is forecast to rise to 3.12 million t/a from 2.64 million t/a. The market balance is therefore a net deficit of 134,000 tonnes in 2021, and a surplus of 76,000 tonnes in 2022. The INSG said that an acceleration of the covid-19 vaccination roll-out, the progressive recovery of main economic indicators worldwide, growth in stainless steel production and a continued positive impact on use from the electric vehicle industry through the use of nickel sulphate in batteries were all positive factors for new demand. China now represents 60% of global nickel demand, compared with 5.5% in 2000 and 39% in 2010. The International Stainless Steel Forum (ISSF) has released figures for the first three months of 2021 showing that stainless steel melt shop production increased by 24.7% year-on-year to 14.5 million t/a, and strong growth is anticipated for the full year of 2021, despite announced possible production cuts in China.
On the supply side, the INSG expects new nickel pig iron projects and high pressure acid leaching projects being developed in Indonesia and elsewhere to increase global mine output. However, there is a degree of uncertainty in the figures, particularly for Chinese and Indonesian production. Indonesian exports of unprocessed nickel ore ceased in January 2020 due to a ban imposed by the government. As a consequence, China had less material available to feed its nickel pig iron (NPI) industry resulting in a decrease in Chinese NPI production. New NPI projects in Indonesia ramped up strongly in 2020 and it is anticipated that this trend will continue in 2021 and 2022. World nickel mine production declined in 2020, mainly due to the Indonesian ore ban, but recovered in 2021 and is expected to continue to increase in 2022. Indonesia is the world’s top nickel miner due to its expanding domestic nickel industry. High pressure acid leaching projects being developed in Indonesia and other parts of the world will further increase global mine output.
NEW CALEDONIA
Tesla signs supply agreement with HPAL plant
Nickel producer Prony Resources New Caledonia has struck a deal with the car manufacturer Tesla to supply 42,000 t/a of the metal by 2024 for use in Tesla car batteries. Negotiations had been under way since before the pandemic and were concluded at Tesla’s headquarters last week. The contract is for several years and makes Tesla a key customer.
New Caledonia is home to the Goro nickel mine and associated high pressure acid leach plant. It had been owned by Brazilian mining giant Vale since 2007, but has faced difficulties with local opposition due to dumping of acid-contaminated waste, and failed to reach production targets, eventually being placed on care on maintenance at the end of 2020. After a failed sale to Australia’s New Century Resources, in March this year a buyout was organised by Prony, a consortium including mine employees, three regional provinces, and Singaporean commodity trading group Trafigura, with Tesla described as “a technical and industrial partner”. The car marker is expected to assist with product and sustainability standards at the mine.
Goro produced only 23,400 tonnes of nickel in 2019 out of a notional capacity of 60,000 t/a. Prony hopes to double this by 2024 to 44,000 t/a, which will make Tesla virtually the sole offtaker. Tesla CEO Elon Musk urged the nickel industry earlier this year to provide more nickel for electric vehicle batteries to avoid a bottleneck in car production.
EGYPT
Nuberg wins acid plant contract
Nuberg EPC has been awarded a contract to supply a 500 t/d sulphur burning acid plant and 5 MW power generation plant by the International Company for Chemical Industry (ICCI) at its site at Gamasa City, west of Damietta, Egypt. The project will use Nuberg’s double contact double absorption process. Nuberg’s scope of services includes process design and technology including product and technology development, process know-how & licensing, basic engineering, front end engineering design (FEED), construction management, operation & maintenance, detailed engineering, project management, commissioning, EPC and lump sum turnkey solutions, heavy fabrication, and start-up of the plant, which is scheduled for 3Q 2023.
BRAZIL
Itafos restarting sulphuric acid plant at Arraias
Phosphate producer Itafos says that it will restart its sulphuric acid plant in Arraias in the state of Tocantins over the next four months, in order to begin sales of sulphuric acid during the first quarter of 2022. “There continues to be significant demand for fertilizer products worldwide, including sulphuric acid in Brazilian markets. Restarting our sulphuric acid plant at Arraias gives us the opportunity to meet market demand with positive margins, while we continue to evaluate strategic alternatives,” said G. David Delaney, CEO of Itafos.
The Arraias sulphuric acid plant has a capacity of 220,000 t/a but, like the rest of the infrastructure associated with Arraias’ vertically integrated phosphate fertilizer business, has been shut down since 4Q 2019.
BELGIUM
Upgrade for PVS Chemicals acid plant
PVS Chemicals Belgium N.V. (PVS) has successfully started up a new MECS® converter and steaming equipment, licensed by DuPont Clean Technologies, at its sulphuric acid plant in Gent, Belgium. The new 4-pass converter, which offers a capacity increase to approximately 300 t/d of sulphuric acid, replaces two parallel converter trains. The converter upgrade, along with new steaming equipment, will allow PVS to double the plant’s saturated steam output. PVS will not only be able to supply steam generated from the new boilers to an industrial neighbour, but will also prevent approximately 11,700 tons of CO2 from entering the atmosphere every year. The PVS sulphuric acid plant in Gent is one of the few sites globally to produce ultra-high purity sulphuric acid, a critical ingredient for the semiconductor chip industry.
David Nicholson, president and CEO of PVS Chemicals Inc. said, “This project and the teamwork, perseverance and hard work shown by all project members, including MECS® field services who worked alongside us through successes and difficulties to deliver the plant, ensure PVS Belgium has a bright future. This project builds on the 126 years of history at this plant and gives it a new heart, so it is ready to run for decades to come.”
Eli Ben-Shoshan, Global Business Leader, DuPont Clean Technologies, said, “Sulphuric acid plants are key sources of carbon-free energy. By capturing that energy, the industry can contribute to decarbonising thermal energy production. We are delighted to be able to assist PVS Chemicals in that aim and to help the plant optimize energy recovery while ensuring reliable, high quality sulphuric acid production so the plant can consistently meet production capacity targets.”
CHINA
Smelters return to production
Copper smelter Tongling Nonferrous Metals has reportedly reduced its output in response to national power rationing and lower demand for sulphuric acid. Its 350,000 t/a Jinlong and 200,000 t/a Jinguan smelters have cut operating rates to about 80% from the second half of October because of high sulphuric acid stocks and depressed demand. Tongling produced 4.4 million t/a of sulphuric acid in 2020, according to Argus.
However, the 100,000 t/a Guorun copper smelter in Shandong province and 300,000 t/a Nanguo smelter in Guangxi province have recently returned to production after extending shutdowns from July into September. Shandong Fangyuan Nonferrous Metals has also restarted its 300,000 t/a refined copper smelter after a long shutdown. The restart of a significant chunk of smelting capacity comes as copper smelters and miners prepare for negotiations on treatment and refining charges (TC/RCs) for 2022. Greater operational smelting capacity means higher demand for copper concentrate, which pushes TC/RCs lower.
INDONESIA
Production ramps back up at Grasberg
Freeport-McMoran has nearly doubled copper and gold production at its large Grasberg mine after a lull due to covid. The company says that it produced 448,000 tonnes of copper in the third quarter, up from 384,000 tonnes in the same quarter last year, with output at Grasberg rising to 159,000 tonnes from 100,000 tonnes year-on-year. Production is currently at 90% of the projected level, and is expected to reach maximum by the end of 2021. Milling rates achieved over 177,000 t/d of ore in September, with the company expecting milling rates to average 175,000 t/d in the fourth quarter. Freeport is installing additional milling facilities in 2023, which will increase daily milling rates to 240,000 metric tons of ore per day.
The company has also broken ground on a new $3 billion copper smelter and precious metals refinery in East Java as part of a deal that saw Grasberg’s mining license extended to 2041, with the Indonesian government taking a majority stake in the mine. Speaking at the ground breaking ceremony, Indonesia president Joko Widodo said that the construction of a domestic smelter would strengthen downstream industry in the Gresik Special Economic Zone and would attract other industries to invest. The new smelter will have a capacity of 1.7 million t/a. Chiyoda has been awarded the construction contract. In order to meet its commitment of reaching 2 million tonnes of concentrate smelting capacity by December 2023, the PT-FI joint venture is also planning to fund a $250 million, 30% expansion of its PT Smelting joint venture to take its capacity to 300,000 t/a.
ZIMBABWE
Zimplats plans smelter expansion
South Africa’s Impala Platinum, which owns the Zimplats facility in Zimbabwe, has signed a memorandum of agreement with the Zimbabwean Ministry of Mines and Mining Development for a $1.8 billion upgrade programme for Zimplats over the next seven years. The development plan will include an expansion of the Mupani and Hartley mines, as well as a new $200 million base metal refinery to recover platinum group metals. A 110 MW solar power plant will also form part of the facility, and an expanded smelter which will take concentrate processing from 130,000 t/a to 380,000 t/a, with a sulphur dioxide recovery section and associated sulphuric acid plant. The sulphuric acid plant will have a projected capacity of 100,000 t/a, with the offtake likely to be used in the local production of phosphate fertilizers, replacing current acid imports.
Speaking at the signing ceremony, Zimbabwean president Emmerson Mnangagwa said that Zimplats intention to construct a base metal refinery is a crucial step towards local mineral beneficiation and value addition of the platinum group of metals.
“The sulphuric acid plant will contribute strategic raw materials needed in the local manufacturing of fertilisers and help reduce the importation of sulphuric acid. The adoption and use of smart energy sources by Zimplats through integrating the development of a 110 MW solar power plant is also commendable,” he said.
ETHIOPIA
OCP signs agreement for phosphate fertilizer complex
The Ethiopian government signed a joint development agreement with OCP Group for the implementation of a fertilizer project in Dire Dawa in Ethiopia for a total investment of up to $3.7 billion, according to the Ethiopian Ministry of Finance. The agreement was signed during a visit by a high-level delegation to Morocco, led by Ahmed Shide, Ethiopian Minister of Finance, accompanied by officials of the Ethiopian Chemical Industry Corporation, Ethiopian Agricultural Businesses Corporation, and the Ethiopian Mineral, Petroleum and Biofuel Corporation.
The fertilizer complex will require a $2.4 billion in its first phase for the development of a 2.5 million t/a fertilizer unit including urea and NPK/NPS products, using phosphoric acid shipped in from Morocco, and could reach a capacity of 3.8 million t/a in the second phase.
New acid plant
In separate news, Indian plant constructor Nuberg EPC has been awarded a contract to revamp a 50 t/d sulphur burning sulphuric acid plant and 40 t/d aluminium sulphate plant for the Awash Melkassa Chemical Factory at Oromia. The work will be carried out on a lump sum turnkey basis and is due for completion by the start of 2023.
