Phosphates project listing 2022

PROJECT LISTING

Phosphates project listing 2022

Fertilizer International presents a global round-up of phosphate rock, phosphoric acid and finished phosphates projects.

An array of four TOMRA sorting machines at the MWSPC mega project in Saudi Arabia.

PHOTO: TOMRA

Phosphate rock*

*Excluding China. Standalone, non-integrated projects only. At present, there are tens of junior phosphate mining projects globally. However, only capacity developments with a published feasibility study are listed here. In general, these projects have yet to secure the necessary finance and, consequently, none have committed to a firm construction schedule and start-up date currently. Africa is undoubtedly the region with the most potential for phosphate rock expansion – although large uncertainties over individual projects and their timescales remain. OCP Group is, however, pressing on with ambitious plans to increase phosphate rock capacity at Khouribga and Meskala in Morocco. Major expansions in phosphate rock capacity are also expected out to 2024 from established phosphate producers in Russia and Kazakhstan (Acron, EuroChem, PhosAgro), Brazil (EuroChem, Itafos) and Mexico (Fertinal). This extra supply will be largely consumed in integrated, downstream operations. Kropz’s Elandsfontein one million tonne capacity, export-oriented project in South Africa is due to start production in the first-quarter of 2022.

Phosphate fertilizer, phosphoric acid and integrated phosphate rock projects**

KEY FOR BOTH TABLES

FS Feasibility study complete

PL Planned

UC Under construction

C Project completed

n.a. Not available

DAP Diammonium phosphate

DCP Dicalcium phosphate

MAP Monoammonium phosphate

PPA Purified phosphoric acid

SSP Single superphosphate

TSP Triple superphosphate

**Excluding China. The International Fertilizer Association (IFA) expects various production investments by OCP Group to collectively add an additional 3.5 million t/a to Morocco’s finished phosphates capacity out to 2023. OCP is also pursuing large-scale joint venture projects in both Ethiopia and Nigeria. The third phosphates mega project announced by Ma’aden and its partners should eventually ramp-up product capacity in Saudi Arabia by a further 3.3 million t/a. In Egypt, WAPHCO is currently constructing a major phosphate production complex at Abu Tartur.

Phosphate technology and engineering profiles

Equipment market reawakens

Paul-Henri Legros, general manager, Profile, a division of Prayon s.a. provides an update on latest industry developments.

“We actually see the phosphate production market awakening after two years of a lot of studies and projections, yet still with a kind of lethargy in reaching the ‘go’ decision.”

Usually the P2 O5 projects market moves from one continent to another, depending on the business opportunities. But in the last year, projects are blooming in every direction.

Profile and Prayon Technologies are receiving demands from all parts of the world currently – and it makes the future very exciting for our business. Whether on the North and South American continents, from Eastern Europe to Turkey, in the ex-Soviet Union territories of central Asia, in North African and Persian Gulf countries, to India and Far East countries, down as far as Australia, it seems everybody wants to have a shot at P2 O5 and fertilizer production with new factories or capacity increases.

We’re also seeing new companies, usually involved in other chemical industries, showing great interest in P2 O5 and fertilizer production. There’s a general feeling, one that’s growing stronger, that countries want to produce locally for themselves to reduce their dependence on global supply chains.

An EU-based company such as Prayon is holding a strategic central place in that play, thanks to the stability of our European politics and economy. As a company, Profile is well-equipped and ready to face the challenge of conducting multiple projects in parallel, with the proven capacities and reliability of our equipment also helping us to be a quick responder to market demands.

Customer wants to maximize the use of available phosphate rock resources and improve the yields of their installations – those are the actual trends we’re seeing. Indeed, some are now looking for very large treatment and filtration capacities to optimise the use of low-grade rock that was put aside for years.

As a leader in the supply of P2 O5 filtration process equipment, and with our renowned Prayon Tilting Pan Filter© , Profile has the capacity to answer these demands. We are participating in some projects where our new Prayon 36-330 filter design – with its very large 280 m² of useful filtration surface and 330 m² total surface area – is required to meet expectations. Some projects are even considering doubling their filtration capabilities through the installation of new double filtration lines, or adding a new line to their existing plant.

Equally, Profile in collaboration with its sister division Prayon Technologies is becoming more and more involved in double crystallisation projects. Many phosphoric acid plants that already use the dihydrate process are wishing to switch to a hemihydrate-dihydrate process by installing a second filtration and conversion unit.

“In the last year, projects are blooming in every direction. Profile and Prayon Technologies are receiving demands from all over the world.”

Above: Profile’s model 30-220 tilting pan filter with a total surface area of 220 m². Installed at OCP’s Jorf Lasfar phosphates production complex in Morocco.

PHOTO: PRAYON/PROFILE

Double crystallization can really boost phosphoric plant yield, even if the running of the plant operations are more ‘touchy’ and therefore need to be more carefully managed with a better control of process parameters. This is where our motto – “a producer developing processes and equipment for other producers” – makes senses, as Prayon has been operating its proprietary double crystallization process at our Engis plant in Belgium for years.

Currently within Profile, we are finalising a two-year project that will completely switch the design and conception of our equipment from 2D to 3D – something we strongly believe will help us to further improve the design and performance of our Prayon Tilting Pan Filter© .

This 3D design capability will also help us push to make our equipment more sustainable, while minimising our exposure to the impact of high stainless-steel prices. Maintaining our leading position and edge in the equipment market is a challenge that all the Profile team is ready to meet.

Our main hope for 2022 is for the easing of Covid restrictions worldwide to bring back the possibility of traveling again. There is a real feeling and desire in our commercial and technical teams that we do need to be on-site to fully meet customer needs. We also need to re-build our existing network of relationships if we are to pursue new solutions and projects with full force.

At the end of the day, let’s all keep in mind that fertilizers do feed the world – and it is therefore a great privilege to be part of this industry!”

Alsys International

Alsys International has been developing robots, optimising chemical processes, manufacturing parts and writing software for nearly 30 years, having been founded by the chemical engineer Marc van Beelen in 1992. Marc started developing robotic systems to tackle and overcome the many problems he encountered during his decade-long experiences in the laboratory sector. One particular problem – eliminated by the use of robots – is the high margin of human error in extremely accurate measurements.

Alsys currently has four product lines on the market:

• Fertilizer robot
• End-group (oleochemical) robot
• Compact robot
• Soil robot.

The main benefits of these robots versus manual analysis are:

• Automated sample preparation
• Perfectly integrated analysis techniques
• Reliable analytical results
• Modern data processing
• A safe working environment
• Four-day run time without the need for an analyst.

Alsys has specialised in building lab robots for the sample preparation and analysis of fertilizer industry raw materials and end products for 20 years. Its fertilizer robot (Alsys RB-247) analyses for potassium and other key nutrients in fertilizers. This fully automated laboratory unit uses Metrohm titrators, Mettler moisture analyser and Metrohm ion chromatography. Its main functions and operations include:

• Autonomous assessment of solid and liquid samples
• Sample dissolution in water (both cold and boiling) and acid.
• The unit has the ability to analyse both raw materials and processed samples. Options include:
• Titration and potentiometric determinations
• Moisture analysis
• Ion chromatography
• ICP
• Flow Injection Spectrometry.

The latest development from Alsys is the soil robot. By measuring soil nutrients, this will be able to give fertilization advice based on the analytical results obtained. Currently, the company is looking to offer a robot with the capacity to prep and analyse 1,000 soil samples per day. Soil analysis is potentially a lucrative, large-scale market due to the large difference in unit price between manual analysis and that performed robotically.

Desmet Ballestra

Milan-headquartered Desmet Ballestra SpA has extensive experience in the design and supply of chemical plants.

For the fertilizer industry, the engineering company offers production plants for sulphuric acid, merchant-grade and purified phosphoric acid (MGA and PPA), single superphosphate (SSP), triple superphosphate (TSP), potassium sulphate and granulated NPK compound fertilizers.

From initial design through to plant start-up, Desmet Ballestra offers support to clients during all of the following project phases:

• Feasibility studies
• Process design
• Detailed engineering
• Material supply
• Project implementation
• Plant start-up phases.

Desmet Ballestra phosphoric acid plants are highly flexible. The design of each plant is bespoke, being specifically tailored to individual client needs. To maximise process efficiency, for example, plants are customised to accommodate different types of phosphate rock.

Under a long-standing agreement with technology licensor Prayon, the company offers phosphoric acid plants based on the following processes:

• DH : Di-Hydrate (single crystallisation)
• HH: Hemi-Hydrate (single crystallisation)
• CPP: Central Prayon Process (double crystallisation DH-HH)
• HDH: Hemi-hydrate to Di-Hydrate (double crystallisation HH-DH)
• DA-HF: Di-hydrate attack, Hemi-Hydrate filtration (double crystallisation DH-HH).

These versatile, well-proven and market-leading processes are widely employed in many phosphoric acid projects around the globe. The most suitable process is selected based on a range of factors, such as rock quality, performance parameters and production economics. All the above processes enable the production of 52-54 percent concentration phosphoric acid, an intermediate in the manufacture of phosphate fertilizers.

Plants can also be configured to allow the recovery of fluosilicic acid (FSA). This is obtained as a process by-product – in concentrations up to 18 percent – and can be sold to market, or converted into valuable anhydrous hydrofluoric acid (AHF) or AlF3 under a technology collaboration with Buss ChemTech. Alternatively, it can be neutralised for disposal.

Desmet Ballestra has offered a phosphoric acid purification option as part of its chemicals technology portfolio since 2015. The purification process involves a sequence of several steps to remove impurities – typically arsenic, gypsum, heavy metals, fluorine and chlorine – and achieve the target quality at the required yield.

Desmet Ballestra is also an established supplier of SSP and TSP powder plants. These have been developed through a technology partnership with Italy’s Industrie Chimiche Puccioni and incorporate proprietary Kuhlman-Den or Broadfield-Den type reactors. These production processes involve reacting phosphate rock with either sulphuric or phosphoric acid, respectively, to generate SSP or TSP.

Granulation plants for SSP/TSP/DAP/ MAP and NPK are also available, based on in-house or Incro pipe-reactor technology. The company also offers plants for water-soluble MAP/DAP production through a strategic partnership with leading technology provider GEA.

GEA Group

GEA is emerging as a leading technology and equipment provider to the phosphates industry. The Dusseldorfheadquartered group is one of the world’s largest production technology and equipment suppliers and employs about 18,500 people across the globe. GEA generates around 70 percent of its revenues from the food and beverages sector – and is the technology leader in this market.

With more than 100 years of experience in crystallisation alone, the company offers a range of production plant technologies able to meet the diverse requirements of the phosphate and fertilizer industries. They include:

• Evaporators
• Crystallisers
• Membrane filtration units
• Centrifugal decanter and separators
• Spray and fluid bed dryers for drying crystals or granulation.

Operational GEA crystalliser at a fertilizer production plant.

PHOTO: GEA

“GEA’s technology for water-soluble MAP production has already been successfully implemented by an Eastern European customer.”

GEA specialises in the production of water-soluble monoammonium phosphate (MAP) from phosphoric acid. The innovative production technology offered by the company is capable of manufacturing high-quality water-soluble MAP from lower-quality merchant grade acid (MGA). This ground-breaking process reduces opex and/ or capex costs as it avoids the need to purchase more expensive purified phosphoric acid (PPA), or integrate a purification line within the fertilizer production plant.

GEA’s process firstly produces a clarified liquid stream after an initial reaction and filtration step. Dry, pure and highly water-soluble MAP crystals are eventually generated as an end-product, after a series of further crystallisation and purification steps. Waste from the various purification and filtration steps, in the form of sludges or purges, still contains some valuable P2 O5 . This can be captured by further processing – for example, via the fertilizer plant’s blending or granulation units.

GEA’s manufacturing process can typically deliver a yield (i.e. the amount P2 O5 recovered to the crystalline end-product vs the P2 O5 contained in the feed acid) of between 50-70 percent. The exact yield depends on the impurity levels in the MGA and the purity/quality requirements (non-soluble content) of the final MAP product.

GEA’s technology for water-soluble MAP production has already been successfully implemented by an Eastern European customer. The new plant avoided considerable capital and operational expenditure by allowing non-purified MGA to be used as the phosphoric acid feed, while still delivering a pure MAP fertilizer with a high market value as the end-product. As a fertilizer, the crystalline end-product offers the following key benefits:

• High-quality fully water-soluble MAP (typically 12-61-0) with a low insoluble content
• Avoids clogging problems on spray systems and pumps
• Suitable for fertigation, foliar applications and the production of fertilizer blends and nutrient solutions
• Low turbidity after dissolution in water
• High-throughput processing
• Free of chlorine, sodium and other deleterious elements
• Moderate solution pH – safer and less corrosive
• Access to excellent laboratory back-up, support and expertise.

Prayon Technologies (PRT)

Prayon Technologies (PRT) is the technology arm and subsidiary of parent company Prayon s.a. With experience dating back more than 60 years, PRT is a global leader in phosphoric acid production technology.

Uniquely, Prayon is both a leading commercial manufacturer of phosphoric acid and its derivatives – purified acid, technical- and food-grade phosphates – and a licensor of phosphoric acid production technology. This provides the Belgium-headquartered company with considerable advantages when it comes to understanding the needs of its technology customers.

A major proportion of the worldwide phosphoric acid production relies on Prayon’s process technology. In fact, Prayon Technologies has designed, developed and helped construct more than 135 phosphoric acid plants in more than 30 different countries globally. These plants consume more than 40 different types of phosphate rock and have P2 O5 production capacities ranging from 25 tonnes up to 2,000 tonnes per day.

Prayon offers flexible production technologies able to respond optimally to the requirements of phosphoric acid producers, offering:

• Reduced energy consumption
• Increased yield,
• Lower production costs
• Excellent environmental performance.

Prayon Technologies essentially offers two types of service: technology licensing and consultancy. Its licensing activities cover:

• Phosphoric acid production – including a full range of processes (DH, HH, DA-HF, CPP, PH2 ) producing hemihydrate or dihydrate calcium sulphate with one or two filtration step(s)
• Phosphoric acid concentration
• Fluorine recovery
• Gas scrubbing systems – for F, dust and H2 S reduction
• Phosphoric acid purification – SO3 , Cd, As, F, Al2 O3 , Fe2O3 and MgO reduction technologies
• Phosphogypsum purification
• Uranium recovery from phosphoric acid
• DCP production from low-grade rock and dilute sulphuric acid – the GetmoreP process.
• Prayon’s consultancy activities cover:
• Audits of existing plants with specific objectives
• Phosphate rock evaluations
• Plant operator training.

JESA Technologies

JESA Technologies (JT), based in Lakeland, Florida, has proudly served the global phosphate industry for over a half century. The company, part of Worley Group, offers licensed technology to the phosphates industry covering the whole production process, from mine to market. The company is a leading licensor for three process steps in particular: phosphate rock beneficiation, phosphoric acid production and granular fertilizer manufacture.

Additionally, JT offers on-site pilot plants, for both beneficiation and phosphoric acid, supported by a fully equipped analytical laboratory. The ability to combine in-house technical and engineering design know-how – from mined rock all the way through to the finished product – with on-site pilot plants makes JT unique as a licensor.

Since its establishment in 1974, JT has been responsible for the design of over 150 process facilities for the phosphate fertilizer industry in 29 countries. The plants designed by JT include the largest single-train phosphate operations in the world. Notably, these include a phosphoric acid plant with a demonstrated capacity above 3,000 tonnes per day – plus numerous examples of DAP/NPK plants with capacities in excess of one million tonnes per year.

In addition to designing new plants, JT has an extensive track record in revamping operational plants. These revamps have successfully delivered a range of desired outcomes for customers – including increased production capacity, product quality improvements, energy savings and higher environmental performance.

Through its parent company Worley Group, JT is also backed by one of the world’s largest engineering and project delivery firms, with proven strengths in resource, energy, and infrastructure markets globally. JT and Worley’s combined capabilities offer clients a full spectrum of support covering all aspects of engineering, procurement, programme and construction management, as well as operations and maintenance.

JT’s extensive test facilities in Lakeland, Florida, include:

• A comprehensively equipped analytical laboratory
• A bench-scale metallurgical laboratory, capable of testing ore samples obtained from core drilling or pits
• A fully-equipped pilot plant capable of batch or continuous operation
• A continuous phosphoric acid pilot plant.

These test facilities make a vital contribution to feasibility studies. By developing process design data, they enable JT to offer its customers process guarantees. They are also engaged in contract research for clients.

Two case studies of phosphate industry projects recently awarded to JT are provided below: