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

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Acid Plant Database    August 29, 2021


Office Chérifien des Phosphates Group (OCP)


Jorf Lasfar

Background 1920 - OCP created
1975 - OCP Group created
Website www.ocpgroup.ma

Maroc Phosphore III-IV

Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Plant 6
Coordinates* 33° 6' 30" N, 8° 36' 5" W 33° 6' 29" N, 8° 36' 2" W 33° 6' 27" N, 8° 35' 59" W 33° 6' 34" N, 8° 36' 2" W 33° 6' 32" N, 8° 35' 59" W 33° 6' 31" N, 8° 35' 56" W
Type of Plant Sulphur Burning Sulphur Burning Sulphur Burning Sulphur Burning Sulphur Burning Sulphur Burning
Gas Source Elemental Sulphur Elemental Sulphur Elemental Sulphur Elemental Sulphur Elemental Sulphur Elemental Sulphur
Plant Capacity

2650 STPD
2404 MTPD

2650 STPD
2404 MTPD

2650 STPD
2404 MTPD

2650 STPD
2404 MTPD

2650 STPD
2404 MTPD

2650 STPD
2404 MTPD

SA/DA 3/1 DA 3/1 DA 3/1 DA 3/1 DA 3/1 DA 3/1 DA
Status Operating Operating Operating Operating Operating Operating
Year Built 1986 1986 1986 1986 1986 1986
Contractor - - - - - -
Remarks - SULFACID (2014) SULFACID (2016) - - -
  CPPE’s first contract with OCP Group was in 2012, for the design, engineering and construction of a SULFACID® gas treatment plant in Jorf Lasfar, Morroco. In this process SO2 from the tail gas of the sulphuric acid production process iscatalytically transformed into diluted sulfuric acid. The sulfuric acid produced is recycled within the installation to produce 98.5% sulfuric acid. The process operates continuously, with input of process water only. No chemicals or steam are required and there are no byproducts requiring disposal. Due to space restraints, the SULFACID process is constructed in a single vertical reactor tower, with central stack, the first of its kind. This technology allows for eliminating polluting SO2 from the atmosphere in the order of 10,800 t/y.After the successful completion of the first SULFACID® installation in 2014, OCP signed a new contract with CPPE to design, engineer and supervise the construction of another, identical SULFACID® installation which was completed in 2016.

Pictures OCP-MPIII-IV-1.jpg (411837 bytes)

Located on the Atlantic coast, 20 km to the South-West of El Jadida, the Jorf Lasfar industrial complex started production in 1986. This new unit allowed OCP Group to double its phosphate processing capacity. The site was selected for its multiple advantages: nearness of the mining areas, availability of a deep water port, access to substantial water reserves and availability of land for future extensions.

This unit, which covers an area of 1,700 hectares, produces annually 2 million tons P2O5 in the form of phosphoric acid, requiring 7.7 million tons of phosphate rock mined out of Khouribga deposits, 2 million tons of sulphur and 0.5 million tons of ammonia. The energy requirements of the complex are met thanks to a 111 MW power station using recovered heat.

The Jorf Lasfar complex is composed of three entities, including the Maroc Phosphore III-IV unit which was created in 1986. With the construction in 1997 of the Emaphos plant, in partnership with Prayon (Belgium) and CFB (Germany), OCP Group entered a new era of diversification of its finished products by producing a high value added acid, i.e. purified phosphoric acid. Two years later, the commissioning of Imacid, a partnership with Indian Birla Group, enabled it to increase its phosphoric acid production capacity by 25% on the Jorf Lasfar site.

Maroc Phosphore III-IV has an annual production capacity of 1.4 million tons P2O5 of phosphoric acid, 850,000 tons of Di-Ammonium Phosphate (DAP) and 850,000 tons equivalent DAP of other fertilizers.

The sulphuric acid plant has 6 production units of 2,650 tons per day. The process used is double absorption Monsanto. The phosphoric acid plant is composed of 8 phosphate rock crushing units, 8 lines of 29% P2O5 phosphoric acid, 20 concentration units, 8 clarification units, 4 54% P2O5 acid filtration units, as well as a pre-treatment unit. Manufacturing is made according to the French Rhone-Poulenc process.

The fertilizer plant includes 4 DAP production units, of which 2 can also produce TSP, granulated MAP and NPK (for the local market). The basic process used is AZF double tubular reactor for DAP and AZF agitated tank with slurry pumping for TSP. This process was replaced by the pre-neutralizer and tubular reactor Jacobs process as part of the revamping programme.

References -
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