Knowledge for the Sulphuric Acid Industry
Sulphuric Acid on the Web
Acid Plant Database
Boiler Feed Water
Materials of Construction
DKL Engineering, Inc.
Acid Plant Database April 23, 2016
|Owner||Foskor Richards Bay|
1970’s - Triomf Fertilizer establishes fertilizer production at Richards Bay
|Plant||Plant A||Plant B||Plant C|
|Coordinates*||28° 46' 21" S, 32° 2' 6" E||28° 46' 19" S, 32° 2' 7" E||28° 46' 17" S, 32° 2' 8" E|
|Type of Plant||Sulphur Burner||Sulphur Burner||Sulphur Burner|
|Gas Source||Elemental Sulphur||Elemental Sulphur||Elemental Sulphur|
Original: 1650 MTPD
Upgraded: 1800 MTPD
Original: 1650 MTPD
Upgraded: 1800 MTPD
|2722 MTPD (3000 STPD)|
Sulphos - Joint venture formed between:
As one of the world’s largest producers of phosphate and phosphoric
acid, Foskor is proudly South African, but internationally focused. At
Foskor, we are determined to unlock value for all our stakeholders through
the profitable, responsible and sustainable beneficiation of phosphates for
local and international markets.
The Indian Ocean Fertiliser Company (IOF), a subsidiary of Foskor, received final approval in 1999 to expand its Richards Bay-based phosphoric acid and granular fertiliser production plant. IOF believes that the expansion will raise the plant turnover from $120 million to $217 million. The IOF plant produces phosphoric acid mainly for export. As well as the actual fertiliser plant itself, the project also requires the construction of raw materials storage, conveyor systems, the export tank farm and utilities.
The project will take place on a brown-field site where the new facilities will be accommodated. This will require some early site works to institute a re-routing of services and the demolition of certain existing site facilities. The upgrade meets the KwaZulu-Natal Department of Traditional and Environmental Affairs' environmental approval conditions.
According to the company, the expansion had been necessitated by IOF's inability to meet demands from its growing list of international customers. IDC funding would result in a 77% increase in IOF's production capacity. The expansion project will increase Indian Ocean Fertilizer's present production capacity of 450,000 tons of phosphate per annum by 330,000 tons to around 780,000 tons per annum of phosphate.
Various services and utilities are being constructed and in some cases existing facilities are being moved or demolished to make way for the new plant. The following facilities are being constructed: a sulphuric acid plant with a capacity of 3,000 tons per day. A phosphoric acid plant with a capacity of 11,000 tons per day. Work is also being done on related infrastructure and utilities.
2016 - At full capacity, Foskor Richards Bay is able produce per
annum 2.2 million tons of sulphuric acid, 720,000 tons of phosphoric acid
and 300,000 tons of granular fertiliser. Strike action and plant
failures last year left phosphates and phosphoric acid producer Foskor’s
Richards Bay plant in KwaZulu-Natal with its lowest production results since
it was established in 1976. At the Mhlathuze Effluent Pipeline Forum
meeting held earlier this week, Foskor Environment, Quality and Systems
Superintendent Karel du Plessis said the company’s local acid division faced
considerable concerns and challenges during 2015, Zululand
Observer reported. “Our
production challenges also included major equipment replacements and
failures as well as troubles with efficiency and plant balance. Production
was down to 300 000 tons last year,” Du Plessis said. At full
capacity, Foskor Richards Bay is able produce per annum 2.2 million tons of
sulphuric acid, 720,000 tons of phosphoric acid and 300,000 tons of granular
fertiliser. “We do, however, have a number of capital expenditure
projects lined up that will increase environmental compliance, improve plant
processes and boost production,” In the short term, the company will
purchase an in-plant P205 (phosphate) analyser, separate high P205 streams
from clean streams, control the reactor level at 70% and analyse individual
streams to the buoyant line.
August 7, 2012 - Jacobs Engineering Group was awarded two
contracts by Foskor Ltd. to design and fabricate two final acid towers and
one acid cooler for Foskor’s sulfuric acid plants in Richards Bay, South
Africa. The contract value was
not disclosed. Under the terms
of the deal, Jacobs is designing the equipment and process for two final
acid towers using Jacobs' proprietary Chemetics alloy SARAMET.
Jacobs is also designing and
fabricating a proprietary anodically-protected sulfuric acid cooler, which
will be manufactured at Jacobs' facility in Pickering, Ontario, Canada.
Meanwhile, the company
plans to manage local fabrication and site
coordination from Jacobs' operations in South Africa.
“This project builds on a successful acid cooler replacement that
Jacobs completed for Foskor in 2009,” said Jacobs vice president Andy
Kremer. “We look forward to many
more opportunities to enhance Foskor's competitive advantage through
superior technical solutions."
Jacobs has supplied more than 1,600 proprietary acid coolers to clients over
more than 40 years, according to the company .
November 25, 2010 - Aker Solutions has been awarded a contract for the supply of an anodically protected, proprietary sulphuric acid cooler to Foskor Ltd, one of the world's largest producers of phosphate and phosphoric acid. The acid cooler is a proprietary design of Aker Solutions and will be supplied to Foskor's phosphoric acid facility in Richards Bay, South Africa. Aker Solutions has supplied more than 1400 proprietary acid coolers over the last 40 years. This valuable operating experience coupled with ongoing design and materials has positioned Aker Solutions' patented acid coolers at the forefront of sulphuric acid cooling technology. Developed out of the customer need to improve plant reliability and reduce plant foot print, Aker Solutions' acid coolers deliver long periods of uninterrupted plant operation; compact plant layout; vastly reduced maintenance; greatly improved acid quality and the ability to recover sizeable quantities of valuable low grade energy. The acid cooler will be manufactured at Aker Solutions' Pickering, Canada facility. Johan Cnossen, Senior Vice President, Europe, Middle East & Africa region with Aker Solutions' Process and Construction business area said, "Aker Solutions' position as the leading supplier of sulphuric acid cooling technology has emanated from our focus on every quality detail during fabrication and our understanding of the plant operators' requirements. Through our Johannesburg operation we can extend supply of this successful product into Southern Africa, whilst ensuring a strong local service."
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