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

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Acid Plant Database May 31, 2011

Owner Vale Fertilizantes

Vale-Logo.gif (2341 bytes)

Location Av. Eng. Plínio de Queiroz, s/nº
Bairro Jardim São Marcos - Cubatão (SP)
CEP 11570-900
Background Fertilizantes Fosfatados S.A.
Ultrafertil S.A.

1965 - Ultrafertil S.A. is incorporated
1970 - Fertilizer complex at Cubat
ão opens
1977 - Fabrica de Fertilizantes de Cubat
ão (Fafer) is merged with Ultrafertil
1993 - Ultrafertil privatized and acquired by Fosfertil
1995 - Ultrafertil is merged into Goiasfertil, a wholly owned subsidiary of Fosfertil.   After the merger the name is changed back to Ultrafertil.
2004 - Each company maintain separate corporate names but they adopt a single corporate indentity

Fosfértil was originally a state owned company, a subsidiary of Cia. Vale de Rio Doce and was named Valefertil.  Following government policies the company was privatized and shares were purchased by several small fertiliser blending companies, who formed the group Fertifos, to ensure their supply of intermediates.  The other fertiliser companies that are shareholders, besides Fertifos, are Bunge Fertilizantes and Fertibrás whilst nearly 25% is owned by individuals, banks and investment companies.
2010 - Formerly Fosfertil 
Fosfertil-Logo.gif (4069 bytes)

Website www.valefertilizantes.com
Plant Piaçaguera Industrial Complex
Sulphuric Acid Plant (U-7400)
Coordinates* 23° 50' 9" S, 46° 22' 41" W
Type of Plant Sulphur Burning
Gas Source Sulphur
Plant Capacity 1970: 694 MTPD
1986: 900 MTPD - Convert to double absorption
1996: 1200 MTPD - Revamp
2009: 1300 MTPD - Revamp
2011: 1400 MTPD - Revamp (superheater and turbine)
SA/DA 1970: Single Absorption
1986: 2:2 Double Absorption
Status Operating
Year Built 1970
Technology Dorr Oliver Engineering Ltd.
Contractor -
Remarks 1996: Blower revamp and DCS installation
1999: New Interpass absorption tower (designed for 1500 MTPD)
2003: New Drying tower (designed for 1500 MTPD) (MECS)
2009: New Final absorption tower (designed for 1500 MTPD)(5.1 m I.D. Brick, Flexeramic 88+)
         New sulphuric acid coolers
         New blower, heat recovery and sulphur filter revamp
Pictures General

    Fosfertil-Piacaguera-3.jpg (29450 bytes)  Fosfertil-Piacaguera-4.jpg (34768 bytes)  Fosfertil-Piacaguera-5.jpg (78563 bytes) 

Fosfertil-Piacaguera-6.jpg (35265 bytes)  Fosfertil-Piacaguera-18.jpg (35732 bytes)  Fosfertil-Piacaguera-19.jpg (27649 bytes)  Fosfertil-Piacaguera-20.jpg (37912 bytes)

Sulphur System
Fosfertil-Piacaguera-7.jpg (45323 bytes)  Fosfertil-Piacaguera-8.jpg (28795 bytes)
Acid Cooling System Revamp

Fosfertil-Piacaguera-14.jpg (35768 bytes)  Fosfertil-Piacaguera-15.jpg (40167 bytes)  Fosfertil-Piacaguera-16.jpg (37886 bytes)  Fosfertil-Piacaguera-17.jpg (43753 bytes)

Heat Recovery System Revamp
Fosfertil-Piacaguera-9.jpg (32965 bytes)  Fosfertil-Piacaguera-10.jpg (35471 bytes)  Fosfertil-Piacaguera-11.jpg (16384 bytes)  Fosfertil-Piacaguera-12.jpg (17180 bytes)  Fosfertil-Piacaguera-13.jpg (35781 bytes)
General -
References Sulphuric Acid Plant Optimization - Piaçaguera Industrial Complex, Cobras VI

January 27, 2010 - Vale SA agreed to buy Bunge Ltd.’s fertilizer assets in Brazil for $3.8 billion in cash as the South American nation, the world’s biggest producer of coffee, sugar and orange juice, seeks to cut its dependency on imports.   Vale will acquire 100 percent of Bunge Participacoes e Investimentos SA, which owns phosphate rock mines and assets in Brazil, and Bunge’s 42.3 percent stake in Brazilian fertilizer producer Fertilizantes Fosfatados SA, or Fosfertil, the Rio de Janeiro-based company said today in an e-mailed statement.   Vale, the world’s biggest iron-ore producer and second- largest nickel miner, is seeking to diversify from iron ore and boost investments in fertilizers throughout Latin America as Brazil aims to reach self-sufficiency in crop nutrients after prices surged. The company plans to become a global fertilizer supplier, Chief Financial Officer Fabio Barbosa said Aug. 4.  “Today’s acquisition adds value to Vale’s existing potash and phosphate mine assets, and is a positive diversification,” Gilberto Cardoso, a Rio de Janeiro-based analyst with Banif Securities, said in an interview. “Vale’s strategy is in line with the trend by the world’s big mining companies, including BHP Billiton and Rio Tinto, to invest in fertilizers.”  Vale sid that once the transaction gains approval from regulators, the company will start a mandatory offer to buy out the common shares held by minority shareholders of Fosfertil. Bunge said in a statement that it will use part of the net proceeds of $3.5 billion from the deal to reduce debt.

“This transaction is instrumental to the consolidation of Vale’s strategy on focusing on Brazil as the main market for its production of phosphates, given the potential of the acquired mines,” Vale Chief Executive Officer Roger Agnelli said in today’s statement.  Vale fell 85 cents, or 2 percent, to 41.75 reais as of 1:04 p.m. in Sao Paulo. Bunge, based in White Plains, New York, rose 36 cents to $62.38.  Fosfertil is Brazil’s biggest supplier of phosphate and nitrogen-based products for fertilizers production, currently supplying about 11.3 million tons a year of these materials, according to its Web site. The company, with phosphate rock mines in Goias and Minas Gerais states, has proven and probable reserves of 1.19 billion metric tons of phosphates, Vale said.  Vale is currently Brazil’s sole producer of potash, a raw material used in fertilizer production, at the Taquari-Vassouras mine in Sergipe state, where it produces 800,000 metric tons a year.

Brazil currently imports 91 percent of its potash needs, 49 percent of its phosphates needs and 75 percent of its nitrogen- based fertilizer raw materials, according to the national mining department’s fertilizer minerals coordinator, Joao Cesar de Freitas Pinheiro.  Vale plans to start in 2013 the 4.3 million-tons-a-year Rio Colorado potash mine in Argentina, bought last year from Rio Tinto Group. Other projects may boost the company’s output of potash to 12 million tons a year, Rubens Fernandes, head of Vale’s fertilizers business, said in an Dec. 14 interview. The company also aims to produce 9 million tons of phosphate rock.  Brazil’s potash consumption, now 6 million tons a year, is rising 5 percent a year, about double the world average, he said. Bunge said its share in Fosfertil, together with the other phosphate rock assets it’s selling to Vale, have an annual capacity of about 3 million tons.  Vale is also developing a phosphate rock mine at Bayovar, Peru, which is scheduled to start up this year.   Cash availability for the Bunge purchase is “no problem” for Vale, Banif’s Cardoso said, following its July 2008 share- sale, when it raised more than $12 billion.  “Vale’s got strong investment capability, it’s got a lot of cash reserves,” he said.

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