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

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Acid Plant Database January 4, 2012

Owner Incitec Pivot Limited

IncitecPivot-Logo.gif (31712 bytes)

Location Mount Isa, Queensland
Australia
Background

Pivot - Phosphate Co-operative Co. of Australia

1988 - WMC acquires Hi Fert, Ltd.
1996 - Queensland Phosphate, Ltd. becomes WMC Fertilizers, Ltd.
2003 -
Incitec Pivot Limited was created on the merger between Pivot and Incitec Fertilizers
2005 -
BHP Billiton acquired WMC Resources Limited
        - WMC's fertilizer business was sold to a joint venture between Elders and AWB in late 2005
2006 - Southern Cross Fertilisers Pty Limited

Website www.incitecpivot.com.au
Plant Mount Isa
Coordinates* 20º 43' 58" S, 139º 28' 58" E
Type of Plant Metallurgical/Sulphur Burner
Gas Source Copper
Isasmelt
23 to 32% SO2
Pierce-Smith Converters
Quantity: 4
5 to 6% SO2
Elemental Sulphur
7 tph minimum, 25 tph maximum
Hot Gas Cleaning Hot ESP - -
Wet Gas Cleaning Quench - Radial Flow Scrubber - Wet Gas Fan Radial Flow Scrubbers (4) - Wet Gas Fan (4)
Gas Cooling Towers (2) - WESP (2 x 2)
Plant Capacity 4200 MTPD
330,120 Nm3/h @ 10.1% SO2
SA/DA 3 SA, 97.4% overall conversion
Status Operating
Year Built 2000
Technology Outotec (Lurgi)
Contractor -
Remarks Xstrata Copper operate the smelter and Incitec Pivot operates the acid plant.  The acid is used for the production of ammonium phosphate fertilizers at Incitec Pivot's facility at Phosphate Hill.

Capital cost of plant: A$130 to A$150 million(1)

One of the world's largest converters: 16 m diameter

NOx Treatment System: De-NOx
Fluoride Treatment System: Sodium Silicate Addition

Pictures    
General Incitec Pivot is a relatively new company, created by the merger of two of the powerhouses of the Australian fertiliser industry in June 2003. Its scale and production capacity was greatly increased in August 2006 with the purchase of Southern Cross Fertilisers, Australia's only manufacturers of MAP and DAP fertilisers.
Personnel Brian-Corrie.jpg (75113 bytes) Brian Corrie - Operations Manager
References (1) Mount Isa Mines Limited Panel Assessment Study – Management of Sulfur Dioxide at Mount Isa
(2) K.H. Daum, "Design, Construction and Commissioning of the World's Largest Smelter Acid Plant", Presented at the AIChE Clearwater Convention 2000
News

December 21, 2011 - Mount Isans should be breathing cleaner air in the New Year now that Xstrata Mount Isa Mines has been made to operate under tougher air and water emission regulations yesterday.  Xstrata MIM will now have to comply with stringent environmental regulations, and is now bound by the Environmental Protection Act.  Since 1985 the mining operations had been exempt from the Act and has operated under its own special legislation.  Under the regulations set down by the Department of Environment and Resource Management (DERM), Xstrata will be required to significantly cut sulphur dioxide emissions and comply with more stringent standards for air and water quality.  DERM environmental services regional manager Rob Lawrence said the transition was part of a wider plan to ensure all Queensland mines operated under the same legislation.  "Mines that previously operated under special agreement acts are now required to have approvals under the Environmental Protection Act. This means the same rules apply across every operation in the state."  Mr Lawrence said DERM was working with Xstrata to ensure the company met its environmental obligations.  "We recognise that considerable work and investment is required to bring the Mount Isa operation up to contemporary standards," he said.  "This will take time. However the Department of Environment and Resource Management is working closely with MIM to ensure the transition to the new standards occurs in a timely fashion while also ensuring the risk to the environment is minimised."  Xstrata Copper North Queensland chief operating officer Steve de Kruijff said Xstrata had spent $275 million on environmental initiatives since the Swiss mining company acquired the operation in 2003.  "We are planning to invest a further $360 million over the next five years to continue improving our performance," he said.  Xstrata plans to close its Mount Isa copper smelter, which emits the sulphur dioxide, by the end of 2016.

May 25, 2011 - Xstrata is due to submit a new environmental management plan to the Qld Government by Friday on its Mount Isa operations.  Mining giant Xstrata says its decision to phase out copper smelting and refining in Mt Isa and Townsville in north Queensland has not been motivated by the Federal Government's carbon tax.  The company will shut down both operations by the end of 2016.   Xstrata has told its 420 staff in the Mount Isa and Townsville facilities it will offer retraining and relocation to retain them.   Xstrata chief operating officer Steve de Kruijff says its Australian operations cannot compete with China, but the carbon tax is not to blame.  "What we've found is that the emerging Chinese metal processing industry is producing copper at a far more marginal rate then we can do that," Mr de Kruijff said. "We don't believe that our smelting and refining processes can be sustained into the future.   "We don't see a turnaround in the profitability of smelters from a global perspective and/or refining."  Xstrata says it will focus on the expansion of existing mines and the development of new mines at Mount Isa and the broader region.  Xstrata says the Ernest Henry Mine at Cloncurry will not be affected by the decision.  It is unclear what the announcement will mean in terms of job losses but the company says it needs to evolve the business to secure its long-term future.  The announcement comes at the same time Xstrata is preparing an environmental management plan to submit to the State Government on its Mount Isa mine operations.  Xstrata is due to submit a new environmental management plan to the State Government by Friday on its Mount Isa operations.   Queensland Resources Council chief executive officer Michael Roche says Xstrata's decision highlights the risk of introducing a carbon tax.  "This just shows you just how vulnerable [the industry] can be to additional cost impost, which is why of course we're trying to fend off the worst of the carbon tax at the moment," he said.  Mr Roche says the move shows how tough the market is becoming for Australian companies.   "Without our competitors also having some sort of carbon pricing mechanism, it's just going to get harder and harder for us to compete," he said.  Mount Isa Mayor John Molony says he thinks uncertainty over the Federal Government's carbon tax may have influenced Xstrata's decision.  "It's a dangerous time of the year for big mining companies like Xstrata when you get the Federal Government announcing a carbon tax without details," he said.  "The mining company will automatically budget for the worst-case scenario.  "It might please [Greens Senator] Bob Brown but it doesn't please the mining operators."  The Townsville Port handles around 600,000 tonnes of copper product a year.  The port exported more than 500,000 tonnes of copper last financial year and imported 100,000 tonnes from South America to be refined in Townsville.  Townsville Port chief executive Barry Holden says it is too early to know if Xstrata's decision will have a major impact on the port because there is scope to export more concentrate from the Ernest Henry mine.  "At this particular point in time we intend to wait and just see what the advices are from Xstrata and some more detail in terms of any changes that will occur in their tonnages through the port," he said.  "As always we will work with them to achieve the best outcome for them."

February 9, 2011 - Queensland’s wild weather will wipe $36 million from chemicals company Incitec Pivot's earnings, the group says.  Cyclone Yasi, which ripped through far north Queensland last week, halted production at its Phosphate Hill fertiliser plant and the Mount Isa sulphuric acid factory, the company told the stock exchange.  While Phosphate Hill is well inland, about 160 kilometres south of Mount Isa, most of its workers live on the coast and the company flew many of them home before the cyclone hit so they could prepare their homes and families for the crisis.  ''The Phosphate Hill and Mount Isa plants have returned to normal operation,'' the company said.  Operations in cyclone-ravaged Townsville were also disrupted, with ''minor damage'' to port facilities and the company's distribution centre, Incitec Pivot said.  The $36 million figure includes the effect of the floods that swamped much of Queensland and also hit New South Wales and Victoria in December and January.

October 13, 2010 - A mechanical problem at Incitec Pivot's Mount Isa acid plant has resulted in more visible emissions from Xstrata's copper smelter in recent days.  The acid plant extracts metalliferous gases from the copper smelter, including sulphur dioxide, however only two thirds of the normal level of extracted gases were being removed due to a breakdown in one of the plant's two blowers, an Incitec Pivot spokesperson said.  The acid plants produces sulphuric acid which is transported to Phosphate Hill, south of Mount Isa, to produce fertiliser.  The spokesperson said the breakdown was not having any impact on fertiliser production because the company could supplement acid from other sources.   The spokesperson said Xstrata were notified of the equipment failure when the blower first stopped working.  Xstrata's 2009 sustainability report said sulphur dioxide emissions went up in the reporting year due to downtime at the acid plant.   The repairs to the damaged blower are expected to be complete by mid next week.

March 5, 2010 - INCITEC Pivot's sulphuric acid plant has a new operations manager.  Brian Corrie has moved to Mount Isa from Sydney to take on the new role.  Mr Corrie said he was excited about his new position.  "It was a good opportunity from a job point of view. I have the knowledge and experience to do the job well," he said.  "The new job is very exciting. It's a challenge and an opportunity to grow in a big company."  But Mount Isa is more than just a rung on the ladder for Mr Corrie, who said he had no intention of leaving anytime soon.  "I'm settling into Mount Isa and I'm going to be here for the long term," he said.  Mr Corrie has a background in metallurgy and spent 24 years in the platinum industry in South Africa.  He also worked with Cement Australia in Gladstone, which he said helped him to prepare for Mount Isa.  The plant Mr Corrie is in charge of employs about 50 people and uses metgas from the neighbouring Xstrata copper smelter as the main feedstock to produce sulphuric acid.  The acid is transported by rail to Incitec's plant at Phosphate Hill, where it is used to manufacture fertiliser for Australia and export markets.  www.northweststar.com.au

February 26, 2010 - The shutdown of copper operations at Xstrata Mount Isa Mines and Incitec Pivot Limited's Phosphate Hill fertiliser and Mount Isa sulphuric acid plants for maintenance will inject millions of dollars into the community.  Final preparations are being made for the shutdowns which start next Tuesday at the three operations. It should be completed by March 31.  For Incitec Pivot the shutdown will cost $56 million in goods and services and will involve more than 900 fly-in contractors from more than 75 companies working across both sites.    About 250 of the contractors will work on projects at the acid plant and live in Mount Isa for between two and three weeks. They will be housed at four caravan parks.  Another 625 extra personnel will be engaged at Phosphate Hill during the course of the shutdown and will live on site.  For Xstrata the shutdown is the final stage of a $34million dollar project, this stage will cost about $28million.  The company said the copper smelter had engaged several local and outside contractors who were specialists in maintenance shutdowns. Collectively they would provide about 330 contractors to work on the copper smelter re-brick.  The re-brick will involve replacing the refractory (brick) linings of the vessels which convert concentrate to anode through a series of smelting processes.  The copper smelter re-brick will use about 1000 tonnes of special thermal bricks which are sourced from Europe. They are not made in Australia.  340 tonnes of bricks will be used in the Rotary Holding Furnace, 240 tonnes of bricks in Anode Furnace 2 and about 420 tonnes of bricks in the Copper ISASMELT Furnace.  At Xstrata, the shut down will affect mainly the copper smelter maintenance and operational employees. Some engineering personnel will be involved in the Xstrata project. The Incitec Pivot Limited (IPL) shutdown is planned as is the Xstrata shutdown and will have no impact "on upstream or downstream parts" of Xstrata's operations.

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