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

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Acid Plant Database April 20, 2021

Owner Apatit

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Location Cherepovets
Vologda Region
Background Part of Phosagro Holding Company
Website www.phosagro.com
Plant Plant No. 1 Plant No. 2 Plant No. 3 Plant No. 4 Plant No. 5
Coordinates* 59° 10' 45" N, 37° 42' 11" E 59° 10' 43" N, 37° 42' 19" E 59° 10' 43" N, 37° 42' 23" E 59° 10' 43" N, 37° 42' 26" E 59° 10' 43" N, 37° 42' 30" E
Type of Plant - - - - -
Gas Source - - - - -
Plant Capacity - - - - -
SA/DA - - - - -
Status - - - Dismantled  Dismantled
Year Built - - - - -
Technology - - - - -
Contractor - - - - -
Remarks - - - - -
Plant Plant No. 6 SK1100 - Plant No. 7      
Coordinates* 59° 10' 37" N, 37° 42' 15" E  59° 10' 40" N, 37° 42' 27" E       
Type of Plant - Sulphur Burning      
Gas Source - Elemental Sulphur      
Plant Capacity - 3300 MTPD      
SA/DA - DA      
Status - Operating      
Year Built - 2020      
Technology - NIUIF      
Contractor - -      
Remarks - Total Investment: RUB 10.6 billion      
Pictures 2008 -
2014 -
2020 -

The PhosAgro holding company was established along with the PhosAgro AG management company, which assumed the management of current production and business activities and developed the production capacities of recently acquired Apatit, Voskresensk Mineral Fertilisers and Balakovo Mineral Fertilisers. 

PhosAgro is a Russian vertically integrated company and one of the world’s leading producers of phosphate-based fertilisers. Its core line of business is the production of phosphate-based fertilisers, high-grade phosphate rock  (P2O5>35.7%), and also feed phosphates, nitrogen fertilisers and ammonia.  PhosAgro’s primary assets include Apatit, PhosAgro-Cherepovets (established as a result of the merger of Ammophos and Cherepovetsky Azot), Agro-Cherepovets, Balakovo branch of OJSC Apatit, Metachem, PhosAgro-Trans, PhosAgro-Region and NIUIF.  The Company is Europe’s largest producer of phosphate-based fertilisers, the world’s largest producer of high-grade phosphate rock and the world’s second largest producer (excluding China) of MAP and DAP (according to Fertecon), Russia’s only producer of feed monocalcium phosphate (MCP), and also the sole producer of nepheline concentrate in Russia. 

The arrangement of pollution-free production of sulphuric acid is based on shifting the production systems to “short sulphur scheme” with intensification of sulphuric acid production process due to increase of concentration of sulphur dioxide in the production gas from 8.5 to 12.0%. Due to this technology, after accomplishment of reconstruction of the production lines (in 2007), generation of slag in sulphuric acid production will be stopped at the plant. As a result, the sludge accumulators will be gradually withdrawn from operation taking into account discharge of accumulated waste and thus the pollution source will be eliminated. In the course of reconstruction in June of 2003 and in September of 2004, two new installations on production of sulphuric acid from lumpy and granulated sulphur were put into operation, resulting in reduction of generation for 220 thousand tons. Annual shipping of more than 400 tons of pyrite cinder for the needs of cement industry and reconstruction of sulphuric acid production will make it possible to considerably improve the environment due to cessation of generation of pyrite cinders.

In 2003, the Group launched the first of the four new sulphuric acid production lines at Ammophos.

2004 - 2nd sulphuric acid plant built

2007 - 3rd sulphuric acid plant built

In 2009, as part of the modernisation programme, the last of the four new sulphuric acid production lines at Ammophos became operational, which made Ammophos the largest sulphuric acid production facility in Europe, according to the European Commission.

In the fourth quarter of 2018, the Group commissioned an upgraded SK-600/3 sulphuric acid production unit and a terminal for storing raw materials with a capacity of - 163 - 30 thousand tonnes at Cherepovets. The production capacity of the SK-600/3 unit increased from 680 thousand tonnes to 1 million tonnes of sulphuric acid per year. Given the current market shortage of sulphuric acid (which is one of the key components for fertiliser production). The enterprise is expected to ensure the Group's selfsufficiency in sulphuric acid supplies and thus reduce its dependence on external suppliers. The total capital expenditure relating to this project amounted to approximately 2.1 billion roubles.

In the end of 2019, the Group completed construction of a new sulphuric acid plant SK1100 at Cherepovets with a capacity of 3.3 tonnes per day (1,100 thousand tonnes per year) which was launched in 2017 ("Cherepovets Sulphuric Acid Plant"). Cherepovets Sulphuric Acid Plant is expected to start its operations in the first quarter of 2020. The launch of Cherepovets Sulphuric Acid Plant is expected to reduce the Group's need for the purchase of sulfuric acid in the market and increase feedstock production of sulphuric acid from 3.3 million tonnes in 2019 (representing 87 per cent. of the Group's sufficiency in sulphuric acid) to 4.2 million tonnes in 2020 (increasing the Group's sufficiency in sulphuric acid to 100 per cent.) and further to 4.3 million tonnes in 2021. Total investments in the project, which the Group will finance with own funds, is estimated at RUB 10.6 billion, 70 per cent. of which was spent as of 30 September 2019.

References -
November 1, 2017 - PhosAgro one of the world’s leading vertically integrated producers of phosphate-based fertilizer and high-grade phosphate rock, announces the completion of the merger of JSC PhosAgro-Cherepovets into JSC Apatit (Cherepovets).  As of today, 1 November 2017, JSC PhosAgro-Cherepovets ceases its activities as a legal entity. All property, obligations and rights under contracts, and income from the sale of goods are now the property of JSC Apatit. On 2 June 2017, JSC Apatit was re-registered in Cherepovets in the Vologda region from the city of Kirovsk in the Murmansk region, where the Kirov branch of JSC Apatit was established.  PhosAgro CEO Andrey Guryev said: "We believe that the merger should contribute to further improving efficiency and the competitiveness of our products, as well as to PhosAgro’s busienss as a whole.”  The merger does not entail significant changes in the structure of tax payments to the budgets of the Murmansk and Vologda regions, where JSC Apatit and JSC PhosAgro-Cherepovets are among the largest taxpayers. Optimisation of production personnel at both sites in connection with the reorganisation is not planned, and all social obligations will be fulfilled as before.  After evaluating the functioning of the merged entity, PhosAgro may consider merging JSC Metakhim with JSC Apatit, thus completing the merger of the Company’s production assets into one legal entity. The transition to a single entity for the Company’s production assets and PJSC PhosAgro is currently not being considered.

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