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

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Acid Plant Database November 3, 2015


Owner Mosaic Company
Mosaic Fertilizer Company

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3200 Highway 60 West
Bartow, Polk County, Florida

Background Formerly
- Seminole Fertilizer Corporation
1989 - Tosco Corporation acquires Seminole Fertilizer
1993 - Cargill Fertilizer, Inc. acquires Seminole Fertilizer
Website www.mosaicco.com
Plant Bartow Facility
No. 4 Plant No. 5 Plant No. 6 Plant
Coordinates 27° 54' 28" N, 81° 55' 5" W 27° 54' 30" N, 81° 55' 4" W 27° 54' 25" N, 81° 55' 3" W
Type of Plant Sulphur Burning Sulphur Burning Sulphur Burning
Gas Source Elemental Sulphur Elemental Sulphur Elemental Sulphur
Plant Capacity 2600 STPD 2600 STPD 2600 STPD

SO2: 4 lb/ton, 433.3 lb/h, 1898 ton/a
Acid Mist: 0.15 lb/ton, 16.25 lb/h, 71.2 ton/a
NOx: 0.12 lb/ton, 13.0 lb/h, 57.0 ton/a
Opacity: < 10%

Status - - -
Year Built - - -
Technology - - -
Contractor - - -
Remarks Plant equipped with MECS HRS installed in 1992 Plant equipped with MECS HRS installed in 1992 Plant equipped with MECS HRS installed in 1992
General Mosaic-Bartow.jpg (19332 bytes)January 1, 2011 - Most of more than 100 fellow employees raised a hand at Scott Marshall Smith’s retirement party to confirm that they were not yet born when he started working at Mosaic in Bartow.  The Lake Wales resident was around long enough to witness six name changes at Mosaic’s Bartow plant, one of the world’s largest producers of phosphate and potash.  Smith retired on the 57th anniversary of his hire date in 1953 to much fanfare and smiles from co-workers.  The plant once employed up to 1,200 employees, but thanks to technological improvements, now 373 workers toil at a 15 times larger plant.  Prior to automation, and since Smith started as a sulfuric operator testing and filtering sulfur, the 550-ton sulfuric acid plant has grown to three 2,500-ton sulfuric acid plants on the 100-acre site, surrounded by 10,000 acres of company owned reclaimed land and mines.  The retiree witnessed those technological changes first hand. The employees originally counted on pneumatic air tubes to help operate the plant. Now computers run the process.  When the 19-year-old started, safety glasses, steel toed boots and protective headgear were not required on the job.  “There was an operator for every little job,” said Smith, “and many jobs were combined into one.”  Plant Manager Jeff Golwitzer said the plant became much more productive and efficient during Smith’s tenure in order to compete with companies hiring overseas workers at lower wages.  “I just changed with the times,” said Smith. “I never did mind coming to work.  “If I did, I would have left.”  Before safety gear became mandatory, employees didn’t punch a time clock at the phosphate plant.   “We’d trade off if we needed some time off,” said Smith. “They were just happy we got the job done, no matter who did the work. We’d even sign each other’s names.”  Times also changed outside the workplace and in Polk County.   “People were more friendly,” said the 76-year-old. “You knew your neighbors much more then.  “We didn’t lock the house and left the car keys in the car, but you couldn’t do that now.”  Smith is married to Carolyn, father to Scott Jr., and grandfather to Scott III, Julie and Jonathan.  So why did the fisherman and clay target sportsman stay at one job?  At first he intended to get “a real job” when he turned the required 21 years old to work for the telephone or power company.  After working at Publix and for the school board, Smith started out earning $1.67 per hour at the phosphate plant.  “I was paid a fair wage and had job security and stability,” said Smith.  While Smith worked more than a half century at the same place, he’s not an atypical Mosaic employee.  The average employee at the Bartow plant has been on the job for 18 years and is 55 years old.   Hank Crowley worked with Smith.  “Sometimes you spend more time with the employees than you do with your family,” said Crowley.  Bill Scott is a 33 year vet at Mosaic.  “He’s like a fixture,” Scott said about Smith. “It’s kind of like having your family and your grandfather out here.”  Fellow employees seemed in awe of Smith’s endurance and fitness. Plant manager Golwitzer first met his co-worker in the on-site gym. Several fellow workers smiled when they talked about chasing Smith up the facility’s many stairways.  Bernie Kerber has worked with phosphate and Smith for 34 years.   “No way, I’m not in half as good shape,” said Kerber. Most who spoke said they hope to be as healthy when they choose to retire.  Golwitzer presented the retiree with several awards, framed photographs and presented a slide show.   “With his dedication and fortitude, he’s an inspiration for all of us,” said Golwitzer
References -

October 1, 2015 - EPA and the U.S. Department of Justice announced a settlement with Mosaic Fertilizer, LLC that will ensure the proper treatment, storage, and disposal of an estimated 60 billion pounds of hazardous waste at six Mosaic facilities in Florida and two in Louisiana. The settlement resolves a series of alleged violations by Mosaic, one of the world’s largest fertilizer manufacturers, of the federal Resource Conservation and Recovery Act (RCRA), which provides universal guidelines for how hazardous waste must be stored, handled and disposed. The 60 billion pounds of hazardous waste addressed in this case is the largest amount ever covered by a federal or state RCRA settlement and will ensure that wastewater at Mosaic’s facilities is properly managed and does not pose a threat to groundwater resources.  The 60 billion pounds of hazardous waste is based on the combined amount of corrosive wastewaters that will be treated at terminal closure of the facilities. Mosaic is one of the fertilizers industry’s best performers in its ability to reduce large volumes of corrosive wastewater in its phosphogypsum stack systems. In addition to recovering valuable phosphate and other compounds, Mosaic is able to reduce terminal closure costs while ensuring that its phosphogypsum stack systems are operated in an environmentally safe manner.  Four Mosaic facilities (New Wales, Bartow, Riverview in Florida and Uncle Sam in Louisiana) will continue to produce phosphoric acid and actively utilize its phosphogypsum stack systems. Mosaic is in the closure process for the Green Bay Complex and South Pierce facility in Florida, and the Faustina facility in Louisiana. However, Faustina will continue to manufacture ammoniated fertilizer. Mosaic operated a small sulfuric acid plant at the Mulberry facility in Florida for a short time. The Mulberry sulfuric acid plant was closed around 2008 and there are no obligations regarding this site in this settlement.  Mosaic has been making major improvements at all its facilities and completed several notable projects: installation of state-of-the-art elementary neutralization units to improve the management of sulfuric acid waste streams, upgrading air scrubbers at its granulation and phosphoric acid plants, and installing automated spill and leak detection systems. All of these projects have been closely monitored by Florida Department of Environmental Protection, and Louisiana Department of Environmental Protection, who provided valuable expertise at each step of the process.

October 10, 2009 - Mosaic Fertilizer agreed this week to give up its permit for a now-closed sulfuric acid production plant in Mulberry in partial settlement of a Clean Air Act action filed in federal court in New Orleans.   It did not, as the Associated Press erroneously reported, agree to close its Bartow chemical plant, which remains in operation.  The confusion, according to Russell Schweiss, public affairs manager for Mosaic, came from a reference to the Mulberry plant as being “near Bartow.”  Mosaic shut down the Mulberry plant in 2008, Schweiss said.  Mosaic, which has its corporate headquarters in Plymouth, Minn., is the last phosphate company still operating in Polk County.  In the settlement, the company agreed to spend about $30 million to improve air pollution controls at its sulfuric acid plant near Baton Rouge, La., as well as to give up its permit for the Mulberry plant.  Since that plant is closed, the settlement has no effect on any Mosaic opertions in Florida, Schweiss said.  He said the upgrades at the Louisiana plant will include state-of-the-art scrubbers to capture sulfur dioxide emissions.   The agreement also requires Mosaic to pay a $2.4 million civil penalty.   Sulfur dioxide is emitted in the production of sulfuric acid, and in sufficient concentrations, can cause respiratory problems.

October 5, 2009 - Plymouth-based fertilizer giant Mosaic reported sharply lower profits for the first quarter amid a global sales slowdown of crop nutrients.  In a release issued after trading closed Monday, the company reported sales of $1.46 billion, or 66 percent below last year's first quarter sales of $4.32 billion. Earnings of $100.6 million for the quarter ending Aug. 31 were 92 percent below last year's $1.18 billion and amounted to 23 cents per share.  Analysts had expected earnings of 35 cents per share on sales of $1.54 billion.  Sharp increases in fertilizer costs beginning last year, along with falling prices for some key agriculture commodities and the global recession, have thrown fertilizer sales into a tailspin. Mosaic's industry rival, PotashCorp. of Saskatchewan, Inc., has scaled back its financial guidance several times this year.   Mosaic, which produces fertilizer ingredients potash and phosphate, earlier this year declined to issue guidance "until market conditions normalize" on significant aspects of its business, including potash sales volumes and selling price.   Cargill, the agribusiness titan and majority owner of Mosaic, warned in August that earnings had dropped at Mosaic. That same month, Mosaic officials said potash sales had fallen 35 to 40 percent, and phosphate sales were off 15 to 20 percent.  The company's long-term outlook remains positive because global demand for food, and thus the fertilizer needed to grow it, remains strong and rising. Projections of both population and calorie consumption show that farmers around the world must sharply increase their production to feed the planet.  "Phosphate fundamentals have improved," said James T. Prokopanko, company president and CEO. "The potash market is evolving and we expect strong demand in calendar year 2010 for both nutrients."

October 5, 2009 - A Minnesota-based company accused of violating the Clean Air Act has agreed to spend about $30 million to improve air pollution controls at its sulfuric acid production plant in Louisiana.  A settlement agreement filed Monday in a New Orleans federal court also calls for Mosaic Fertilizer of Plymouth, Minnesota, to pay a $2.4 million civil penalty.  The Justice Department and U.S. Environmental Protection Agency says Mosaic agreed to install equipment that will limit sulfur dioxide emissions at its plant in Uncle Sam, Louisiana, and will permanently cease sulfuric acid production at its plant in Bartow, Florida.

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