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DKL Engineering, Inc.
Handbook of Sulphuric Acid Manufacturing
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Acid Plant Database May 12, 2011
| Owner |
Mosaic Company Mosaic Phosphate Company |
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| Location |
7250 Highway 44 Uncle Sam St. James Parish Louisiana USA 70792 |
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| Background |
In the early 1900s Thomas C. Meadows, an entrepreneur in Tennessee's
phosphate mining business, formed the United States Agricultural
Corporation. The company was established to provide basic fertilizer
nutrients to U.S. growers. 1909 - Meadows and his brother-in-law, Oscar L. Dortch, teamed with Waldemar A. Schmidtmann whose holdings included Kaliwerke Sollstedt - a thriving potash mine in Germany. The three acquired the Schmidtmann holdings in the potash mine and formed the International Agricultural Corporation in New York. 1942 - Company moved its headquarters to the Chicago area and changed its name to International Minerals & Chemical Corporation 1988 - Initial public offering of the fertilizer assets of International Minerals & Chemical Corporation created a new public company called IMC Fertilizer Group 1993 - IMC Global entered into a joint venture that launched IMC Phosphates Company M.P. (originally known as IMC-Agrico Company), a phosphate mining and fertilizer production company in Florida and Louisiana 1994 - Company name changed to IMC Global Inc. to better reflect the worldwide scope of the corporations operations 1997 - IMC Global merged with Freeport-McMoRan Formerly Agrico Chemical Company Formerly IMC-Agrico (2004) |
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| Website | www.mosaicco.com | |||
| Plant | Uncle Sam Plant | |||
| A - Train | D - Train | E - Train | ||
| Coordinates | 30º 2' 20" N, 90º 49' 45" W |
30º 2' 15" N, 90º 49' 44" W |
30º 2' 14" N, 90º 49' 47" W |
|
| Type of Plant | Sulphur Burning | Sulphur Burning | Sulphur Burning | |
| Gas Source | Elemental Sulphur | Elemental Sulphur | Elemental Sulphur | |
| Plant Capacity | 1500 MTPD | 1500 MTPD | 2900 MTPD | |
| SA/DA | SA | 3/1 DA | 3/1 DA | |
| Status | Operating | Operating | Operating | |
| Year Built | 1968 | 1974 | 1992 | |
| Technology | Chemico | Chemico | MECS | |
| Contractor | - | - | - | |
| Remarks |
2004 - Original absorber tower replaced with MECS alloy tower - Cansolv tailgas scrubber unit installed |
2008 - Inter and final absorber tower replaced with MECS alloy towers |
- | |
|
B and C Trains (1500 MTPD each) were constructed at the same time as A-Train
but were shutdown and demolished in 1992. In response to then-current reduced market demand, IMC Phosphates suspended production at its Taft facility in July 1999 and suspended phosphoric acid production at its Faustina facility in November 1999. From January 2001 until August 2001, IMC Phosphates temporarily shut down its Uncle Sam phosphoric acid production as well as its Faustina DAP and GMAP production. The Taft facility and Faustina's phosphoric acid production facilities remain temporarily idled. |
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| Pictures | ![]() |
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| General | The Uncle Sam plant was named for the Uncle Sam Plantation which was once located on the land now occupied by the plant. | |||
| References | - | |||
| News | May 10, 2011 - The Mosaic Company
today announced it will temporarily shut down its
Louisiana operations due to the impact of the Mississippi River
flooding on its electrical power supplies. Operations will resume when river
water levels recede and conditions permit. The Company also noted that its
ammonia plant at this location is temporarily idled for repairs following a
recent incident. Mosaic's
Louisiana
operations include Faustina, which produces diammonium phosphate and
ammonia, and its Uncle Sam facility, which produces phosphoric, sulfuric and
fluosilicic acid. These matters are
not expected to have a material impact on Mosaic's operations or financial
results. November 16, 2009 - The Mosaic Company (Mosaic) has contracted Cansolv Technologies Inc (Cansolv) an affiliate of Shell Global Solutions International B.V., to supply a modular CANSOLV SO2 Scrubbing System. The modular plant will capture SO2 from sulfuric acid plant tail gas at Mosaic’s Uncle Sam fertilizer production facility in Louisiana, USA. The CANSOLV SO2 Scrubbing System will be a key factor in enabling Mosaic to meet the SO2 reductions Mosaic has agreed to implement with its regulators. It is also the first regenerable technology of its kind to be installed in the fertilizer industry in the United States. The project award follows the successful implementation of the CANSOLV SO2 Scrubbing System in a wide range of industrial sectors with operating plants in the petrochemical, metallurgical and power industries. Mosaic has chosen to procure a pre-fabricated modular plant following an engineering study that demonstrated the cost-effectiveness of this approach. The expected delivery date of the modular plant is September 2010. The CANSOLV SO2 Scrubbing System is a new benchmark for environmental performance of sulfuric acid plants in the fertilizer industry. The technology will enable the Mosaic facility to meet SO2 emissions of 1 lb SO2/ton acid, while generating minimal liquid effluent. The Cansolv patented technology uses a regenerable amine to selectively absorb sulfur dioxide from the tail gas stream and recycles the pure SO2 by-product to the acid plant, maximizing productivity and minimizing liquid effluent. 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. |
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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