Sulphuric Acid News

Sulphuric Acid News

BRAZIL

Galvani begins phosphate expansion

Brazilian phosphate producer Galvani says that it has begun work on its major phosphate expansion in Bahia state, including a new production plant at Ceará, in partnership with Indústrias Nucleares do Brasil (INB). The company aims to reduce Brazil’s northern and northeastern regions’ reliance on imported fertilizers. The first phase includes $133 million of investment, including $76 million for new phosphate mining at Irecê, and $38 million for Luís Eduardo Magalhães factory, also in Bahia. This expansion will take capacity from 600,000 t/a to 1.2 million t/a by 2026. The expansion at Luís Eduardo Industrial Complex includes expansion of sulphuric acid capacity from 165,000 t/a to 250,000 t/a.

The second stage of the plan involves the project in partnership with INB. Via the Santa Quitéria consortium, the companies will explore associated phosphate and uranium reserves in a deposit in Santa Quitéria, in the state of Ceará. This phase is still awaiting permits, but could begin operating in 3Q 2027. The project foresees an installed capacity of 1 million t/a of phosphate fertilizers, equivalent to around 25% of demand in the North and Northeast regions.

Metso order for Galvani fertilizer plant

Galvani Fertilizante has awarded Metso an order to deliver a lime calcination kiln and cooler package for its fertilizer plant in Irecê, Brazil. Metso says that he total value of the order is over euro 10 million. The Irecê project is a significant step for Galvani in introducing sustainable technological innovations at its industrial plants. The new unit is expected to annually produce 350,000 t/a of phosphate concentrate and 600,000 t/a of agricultural limestone. Metso will supply a rotary kiln, a rotary cooler and ancillary equipment for the project. The kiln and the cooler system are a critical part in the process to remove limestone from the phosphate concentrate. The kiln will be the largest lime calciner Metso has ever delivered, measuring almost six meters in diameter and over 140 meters in length. Metso has installed over 200 lime calcining systems globally.

“The partnership with Metso will bring strategic benefits to Galvani, allowing gains in mineral processing at our new unit in the municipality of Irecê, in Bahia. The laying of the foundation stone for this unit, which took place in May of this year, reinforces the importance of this project for the development of the economy of the state of Bahia, in Brazil, and for the generation of jobs and income. This milestone represents our commitment to innovation and development, boosting our ability to meet the demands of the fertilizer market,” says Galvani’s CEO, Marcelo Silvestre.

“We are proud to partner with Galvani in this project. With Metso’s vast experience in lime calcining and rotary kiln technology and Galvani’s rich history and expertise in phosphate fertilizers, we’re certain the project will be a landmark success for both parties,” says Chris Urban, Vice President, Heat Transfer at Metso.

INDIA

Coromandel starts work on new sulphuric acid plant

In an exchange filing, Coromandel International says that it has begun project activity on its new sulphuric and phosphoric acid complex at Kakinada in Andhra Pradesh. The project is expected to be commissioned in two years’ time and has an estimated cost of $120 million. Coromandel says that the proposed 650 t/d phosphoric acid facility is designed with advanced dihydrate attack-hemihydrate filtration (DA-HF) process technology and an automated DCS system which provide stable supplies of phosphoric acid for its fertiliser manufacturing by replacing more than 50% of the Kakinada plant’s imported acid requirement. The expansion also includes a new 1,800 t/d sulphuric acid plant to supply phosphoric acid production and produce additional power from waste heat.

Haldia refinery completes WSA plant

The Indian Oil Company Ltd (IOCL) has announced the mechanical completion of its new wet sulphuric acid (WSA) plant at its Haldia refinery. The sulphuric acid plant, with a capacity of 325 t/d, takes hydrogen sulphide rich off-gas from the amine regeneration unit and sour water stripper, recovering at least 99.9% of the sulphur as 98.5% sulphuric acid. It forms part of an upgrade to the refinery to produce Bharat-VI quality low sulphur petroleum products. Haldia Refinery is one of two refineries of the Indian Oil Group producing lube oil base stocks at Haldia, 136 km downstream of Kolkata in the Purba Medinipur district, West Bengal, near the confluence of the Hooghly and Haldi rivers.

CANADA

Worley alliance on lithium battery materials

Nano One Materials Corp. and Worley Chemetics have entered into a strategic alliance and license agreement to jointly develop, market and license a process engineering design package for the deployment of cathode active material (CAM) production facilities with potential customers in the lithium-ion battery materials sector. Nano One is a clean technology company with patented processes for the sustainable production of lithium-ion battery cathode active materials. Through Worley Chemetics, Worley offers technology and solutions for sulfuric acid and other specialty chemicals facilities.

“This licensing agreement and global strategic alliance with Worley is another major milestone for Nano One,” said Nano One CEO, Dan Blondal. “It adds to the growing confidence of our shareholders, partners, and government stakeholders. It amplifies the value of our One-Pot process and addresses a growing need for a new generation of scalable battery cathode material production technology and clean, diversified supply chains. Worley has a global network of clients, deep engineering knowledge and a track record of designing and building process facilities that can accelerate our designonce-build-many growth strategy. We have found in Worley a collaborative, insightful and visionary team that is just as passionate about changing how the world makes battery materials as we are.”

Nano One brings its patented One-Pot process to the alliance as well as its innovation hub in Burnaby, British Columbia, and its LFP CAM demonstration facility in Candiac, Quebec. The One-Pot process makes cathode materials by combining the processes for precursor CAM and CAM, enabling a smaller physical footprint than incumbent processes and up to 50-60% fewer carbon emissions than other battery cathode processes, as well as using 80% less process water. It also eliminates wastewater and harmful sodium/ ammonium sulphate by-products, a major disposal and permitting challenge in current cathode material production processes.

UNITED KINGDOM

CRU’s new Battery Technology and Cost Service now available

The Energy Transition is driving unprecedented demand for batteries, with new chemistries emerging each year, aimed at reducing costs, improving performance, or both, staying informed is imperative to capitalise on emerging trends, navigate technological advancements effectively, manage procurement and risk and grow financially and strategically. CRU’s Battery Technology and Cost Model offers unparalleled data and analysis capabilities, empowering businesses within the battery space to make strategic decisions.

It model hundreds of battery technology combinations, and allows users to benchmark battery technologies, comparing energy density and production cost over a ten-year forecast, including next-generation cells. Users can also review forecasts for key metrics, including raw material prices, over a 10-year forecast using CRU data. The service covers all key markets, including China, USA, Europe, South Korea, Japan, the UK and Canada, comparing labour rates, labour cost, electricity cost and production yield by country. Enquiries can be made to sales@crugroup.com.

SERBIA

Elixir to decarbonise phosphate production

The Elixir Group plans to install a solar power plant, a wind farm, a battery storage facility, and start using waste for the production of steam, as part of a e300 million investment plan, according to Matthias Predojević, Vice President for Corporate Development. The new investments will help push forward the decarbonisation process in Elixir Group. Elixir operates at two locations in Serbia at Elixir Prahovo and Zorka Šabac, with a capacity of 1 million t/a of mineral fertilizers and phosphoric acid. At Prahovo the firm intends to invest in a new phosphoric acid plant, using steam from non-recycled waste, and electricity from wind and solar energy production.

SAUDI ARABIA

Acid imports down 50% in Q1

Saudi Arabia imported 96,141 tonnes of sulphuric acid during January-March 2024, down 50% from the equivalent period in 2023, according to Global Trade Tracker (GTT). Imports from Japan climbed from nothing to 40,400 tonnes, while the volume from South Korea was down 38% at 25,846 tonnes. The volume from China was down 84% at 19,394 tonnes, while acid received from Taiwan, China was roughly stable at 10,501 tonnes.

Saudi phosphates producer Ma’aden first purchased spot acid in November 2020, buying a cargo from Chinese sulphur burner Two Lions via a trader. The buyer then made a range of acid purchases through 2021 and 2022. Saudi imports for January-December 2023 were up 14% year on year at 565,488 tonnes, according to GTT, while annual imports for 2022 were up 53% at 493,954 tonnes. The company typically bases its production off its own acid output, produced using Saudi sulphur from Aramco. Ma’aden enquired about acid purchases several times throughout 2020, but no deal was concluded until the November purchase.

Ma’aden to buy out Mosaic’s share of phosphate JV

Saudi Arabian mining company Ma’aden has announced the acquisition of Mosaic’s 25% stake in the two companies’ phosphate joint venture Ma’aden Wa’ad Al Shamal Phosphate Company. Ma’aden finalised a stock purchase and subscription agreement with Mosaic. Under the terms of the agreement, Ma’aden will issue nearly 111 million new shares, worth a total of $1.49 billion, to acquire the 25% stake. The deal will increase Ma’aden’s stake in Wa’ad al Shamal from 60% to 85%, and also significantly expand its phosphate production capabilities.

UNITED STATES

New alkylation complex

Next Wave Energy Partners has selected Elessent Clean Technologies to provide STRATCO® alkylation technology at the world’s first stand-alone alkylation complex in Pasadena, Texas. The complex operates as an ethylene-to-alkylate facility, eliminating the need for crude oil and significantly reducing carbon intensity compared to traditional methods.

“We are immensely proud to announce our part in the launch of this groundbreaking alkylation complex. Collaborating closely with the Next Wave team over the past decade has been an honour. As we forge ahead, we eagerly anticipate further collaboration, aiding Next Wave in expanding horizons and diversifying feedstocks, all while relentlessly pushing the boundaries of industry norms,” said Eli Ben-Shoshan, CEO, Elessent Clean Technologies.

Asarco to restart copper smelter

Grupo México says that its Asarco subsidiary will restart its mothballed copper smelter in the United States due to high copper prices. Asarco bought the Hayden smelter in Arizona and associated copper mines in 1999. The US currently has only two domestic copper smelters; Freeport McMoRan’s Miami smelter in Arizona, and Rio Tinto’s Kennecott smelter in Utah. Asarco is now said to be in negotiations with miners and staff over the restart, and has extended its air quality permit. The US produced 880,000 t/a of refined copper in 2023, according to the International Copper Study Group, although it imported 770,000 t/a and consumed more than 1.6 million t/a of refined copper.

KAZAKHSTAN

Agreement for copper smelter project

Kazakhstan has signed an agreement with China to build a new copper smelter with a capacity of 300,000 t/a of copper. The agreement was signed between KAZ Minerals Smelting LLP, China Nonferrous Metal Industry’s Foreign Engineering and Construction Co., Ltd. (NFC), and NFC Kazakhstan LLP. The smelter, costed at $1.5 billion, will be built near the village of Aktogai in the Abai Region near one of the world’s largest copper mines, and will supply Kazakhstan’s domestic demand for copper for in the power industry and other industrial sectors. The complex will also include a new sulphuric acid plant. It is scheduled to be commissioned by the end of 2028.

EuroChem signs agreement for phosphate expansion

EuroChem has signed an agreement with China National Chemical Engineering Co. (CNCEC) for the design, construction and commissioning of a chemical complex in Janatas in Kazakhstan’s Jambyl region. Combined total investment to date and planned capital expenditure will exceed

$1 billion. The project is the third phase of EuroChem’s phosphate development. The first phase involved building and commissioning a phosphate mine. As part of Phase II, a contract has been signed and the company has started construction of a sulphuric acid facility to be commissioned in 2026. Following the completion of Phase III, in 2027, EuroChem will commission a chemical complex with a total annual output in excess of 1 million t/a of mineral fertilizers and associated industrial products, with distribution in Kazakhstan and Central Asia, as well as China, Russia and Europe. According to EuroChem, the new plant’s technology will enable it to avoid phosphogypsum waste, replacing it with more eco-friendly synthetic gypsum and calcium chloride – by-products used in construction materials and as reagents for the road construction, coal and hydrocarbon industries.

MOROCCO

US raises duty on Moroccan phosphates

The US Department of Commerce (DoC) has announced an increase on import duties for fertilizers from Morocco. The move relates to a request from US fertilizer producer Mosaic received in May 2023. In June last year the DoC published a notice of initiation of an administrative review of the countervailing duty (CVD) order on phosphate fertilizers from Morocco, and it has twice extended the deadline for the preliminary results of this review, which was finally completed in April 2024. The determination is backdated to imports from January-December 2022, and increases import duties on Moroccan fertilizers from 2.12% to 14.21%, while lowering duties on Russian phosphate fertilizers to 18.83% from 28.5%.

INDIA

HURL concludes SSP distribution agreement

Hindustan Urvarak & Rasayan Limited (HURL) has entered into an agreement with fertilizer producers in India for distribution of single superphosphate (SSP). The agreement covers the supply of 500,000 tonnes of SSP for distribution across 13 Indian states in 2024-2025. The product will be supplied by companies including Agro Phos India Ltd, Khaitan Chemicals & Fertilizers Ltd, and Rama Phosphates Ltd.

Aramco’s Jazan refinery, Saudi Arabia

PHOTO: SAUDI ARAMCO

CHILE

Copper output down at Codelco

Copper production at Chilean miner Codelco was reportedly 484,500 tonnes in the first five months of the year, 6.1% under the company’s target. May’s output of 103,100 tonnes was 8.6% below the goal, according to Reuters, while April production of 95,100 tonnes was the first time a month’s output was below 100,000 tonnes in at least 18 years. The state-owned company lost production when it suspended activity at Radomiro Tomic to enable an inspection following a fatal accident in March. A workers’ strike at the mine added to the company’s woes. As lower ore grades across all operations is the underlying reason for reduced output, Codelco has embarked on a multi-billion dollar investment programme to return production to the historic level of around 1.7 million t/a.

FINLAND

Metso technology for quenching of off-gas

Metso is reintroducing the OtoVentTM off-gas treatment technology for the quenching of various types of off-gases in non-ferrous and ferrous metallurgical processes and in oil, gas and chemical plants. OtoVent technology is used, for example, at the most modern copper smelters. It incorporates high quenching and pre-dedusting capability, and the design ensures lower maintenance effort. Metso says that its compact size also makes it suitable for both greenfield and brownfield installations and it is an exceptional replacement for existing quenchers

SAUDI ARABIA

Acid imports down 50% in Q1

Saudi Arabia imported 96,141 tonnes of sulphuric acid during January-March 2024, down 50% from the equivalent period in 2023, according to Global Trade Tracker (GTT). Imports from Japan climbed from nothing to 40,400 tonnes, while the volume from South Korea was down 38% at 25,846 tonnes. The volume from China was down 84% at 19,394 tonnes, while acid received from Taiwan, China was roughly stable at 10,501 tonnes.

Saudi phosphates producer Ma’aden first purchased spot acid in November 2020, buying a cargo from Chinese sulphur burner Two Lions via a trader. The buyer then made a range of acid purchases through 2021 and 2022. Saudi imports for January-December 2023 were up 14% year on year at 565,488 tonnes, according to GTT, while annual imports for 2022 were up 53% at 493,954 tonnes. The company typically bases its production off its own acid output, produced using Saudi sulphur from Aramco. Ma’aden enquired about acid purchases several times throughout 2020, but no deal was concluded until the November purchase.