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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Acid Plant Database  April 19, 2020

Owner The National Company for Fertilizers and Chemicals (Agrochem)
Location Alexandria
Background -
Website www.agrochem.com.eg
Plant -
Coordinates* 30° 49' 40" N 29° 54' 50" E
Type of Plant Sulphur Burning
Gas Source Sulphur
Plant Capacity 300 MTPD
Emissions -
Status Operating
Year Built 2012
Technology -
Contractor Nuberg EPC
Engineering, Procurement & Construction (EPC) and Lump sum Turnkey (LSTK) Project
Remarks The company reached out to Nuberg EPC relaying its desire to construct a brand new sulfuric acid plant in Egypt. Nuberg EPC took immediate action with shop drawings and basic and detailed engineering surveys of the proposed site. Afterwards, the company sourced suppliers to procure the best materials for the project. The scope of the project included process, technology know-how, basic and detailed engineering, design, procurement, manufacture and supply of plant equipment including complete erection, construction, project management, commissioning, and startup of the plant. After several months of hard work, the plant was successfully commissioned in 2012 and currently operates on double contact double absorption (DCDA) technology.Equipment/machineryThe scope of the project includes the EPC and LSTK of a 300 tpd sulfuric acid plant. An overview of some of the key equipment and machinery for the project is presented below.Basic engineering packageThese include (but are not limited to) basic engineering packages as follows:
  • Piping material specifications.
  • Painting specifications.
  • Preparation of the list of equipment.
  • Preparation of flow diagrams and configuration finalisation.
  • Sequence diagram; process description; single line diagram; P&I diagram; instrument list, etc.
In addition to the basic engineering packages, details about each individual component and process were also stated with accompanying documents. This section covered key engineering design features such as:
  • Civil and structural engineering.
  • Layout and piping materials (metallic and plastic).
  • Rotary and static equipment.
  • Electrical and instrumental engineering.
  • Mechanical engineering.
  • Site supervision for the erection and commissioning.
  • As-built drawing.
      Project managementNuberg EPC's project managers plan ahead ensuring that every single step is executed to meet the already set out success criteria within the limits of the specified time for the project. Likewise, the same process was applied to the Agrochem project. Some of the major key pointers in the project management processes include the following:
      • Close monitoring of critical activities to ensure compliance.
      • The use of bar charts and critical path method (CPM) to indicate every activity of the project.
      • Coordination with clients and vendors during the detailed engineering.
      • Procurement and delivery progress control.
      • Preparation of monthly progress reports and with comments on compliance or deviations.ConclusionCommissioned in 2012, the Agrochem sulfuric acid plant in Alexandria is the first turnkey project executed by Nuberg EPC in Egypt. Based on DCDA technology, the plant produces sulfuric acid (98%) used mainly in the fertilizer industry in Egpyt. Nuberg EPC provided plant engineering and construction services that helped Agrochem to run a safe, reliable, and environmentally friendly plant. The project scope included engineering, technology know-how, global procurement, and construction of all process facilities, including a sulfuric acid plant, utilities, storage, and other required units.Sulfuric acid is one of the most commonly used industrial chemicals in the world. In the last few years, growth in the sulfuric acid market has been driven by fertilizers using phosphates, such as diammonium phosphate (DAP), monoammonium phosphate (MAP), triple superphosphate (TSP), and single superphosphate (SSP). With the growing demand in agriculture, infrastructure, metal processing activities, and usage in chemical synthesis such as hydrochloric acid, synthetic detergents, nitric acid, dyes and pigments, and sulfate salts, the sulfuric acid market is expected to grow further.
General -
References World Fertilizer, November/December 2018
News -

MTPD - Metric Tonne per Day           STPD - Short Ton per Day
MTPA - Metric Tonne per Annum      STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption

* Coordinates can be used to locate plant on Google Earth