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

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Sulphuric Acid on the Web

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Handbook of Sulphuric Acid Manufacturing
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Acid Plant Database    May 2, 2024

Owner Ma'aden Phosphate Company Maaden-Logo.jpg (10968 bytes)
Location Kingdom of Saudi Arabia
Background Waad Al Shamal Phosphate Project
Website www.maaden.com.sa
Plant Plant 1 Plant 2 Plant 3
Coordinates* 31° 49' 27" N 39° 2' 60" E 31° 49' 27" N 39° 2' 53" E 31° 49' 27" N 39° 2' 47" E
Type of Plant Sulphur Burning Sulphur Burning Sulphur Burning
Gas Source Elemental Sulphur
Refinery, Molten
Elemental Sulphur
Refinery, Molten
Elemental Sulphur
Refinery, Molten
Plant Capacity 5050 MTPD 5050 MTPD 5050 MTPD
SA/DA 3/1 DA 3/1 DA 3/1 DA
Emissions - - -
Status Operating Operating Operating
Year Built 2016 2016 2016
Technology MECS MECS MECS
Contractors SNC-Lavalin/Sinopec Engineering Group (SEG) SNC-Lavalin/Sinopec Engineering Group (SEG) SNC-Lavalin/Sinopec Engineering Group (SEG)
Remarks Power Generation: 2x75 MW
Pictures
     
Tower Replacement - Mammoet
 
General Project Award: February 2014

Storage Tank Design and Fabricator: sasec.com.sa


The total value of the contract is approximately USD$764 million with SNC-Lavalin’s portion estimated at USD$500 million.
Reference -
News April 30, 2024 - US fertilizer company Mosaic is selling its 25% stake in an $8 billion Saudi Arabian phosphate production joint venture to the country’s flagship miner Ma’aden, in a stock deal worth about $1.5 billion.    Ma’aden, which already holds 60% of Ma’aden Wa’ad Al Shamal Phosphate Co. (MWSPC), will issue about 111 million shares to buy Mosaic’s stake in the venture, a partnership that also includes Saudi Basic Industries Corp, with a 15% interest.  Mosaic had warned in February that a significant portion of the revenue generated from the asset was used to decrease debt, and that investing in the venture was not one of the company’s top priorities.  The MWSPC has a phosphate mine, beneficiation facilities, phosphoric acid and sulphuric acid facilities, power plants, and downstream business units. It has an annual production capacity of about 3 million tonnes of phosphate fertilizers products.  Mosaic and Ma’aden have worked together for over a decade. According to the US fertilizer producer’s president and chief executive, Bruce Bodine, the two will continue to work together under the evolved structure.  “This is an important evolution that we believe will create significant benefits for the growth of our phosphate business,” Bob Wilt, CEO of Ma’aden, added. “We look forward to working together with the Mosaic team to strengthen our phosphate business as we continue to build the mining sector into the third pillar of the Saudi economy.”  The deal is expected to close by the end of this year. As part of the agreement, Mosaic is required to hold its Ma’aden shares for a minimum of three years, with one-third of the shares becoming transferable after the third, fourth and fifth anniversary of the closing.

March 28, 2023 - The Ma’aden Waad Al Shamal Phosphate Company (MWSPC), based in Saudi Arabia, is the latest company to have benefitted from Mammoet’s specialised logistics offering.  MWSPC operates some of the largest and busiest fertiliser plants anywhere in the world, including the Umm Wu’al Sulphuric Acid and Power Plant. This plant is in a new industrial city in the extreme northeast of the kingdom. Structured around three sulphuric acid trains containing a total of nine vast process towers, it produces almost 14,000 t/d of fertiliser a day.  When the company was looking to upgrade the facility, and replace the original towers with cleaner, more efficient equivalents, it needed to keep downtime to an absolute minimum. To compound the issue, the towers had originally been stick-built; not designed to be lifted in one piece when they needed to be replaced. The conventional approach for dismantling them piece-by-piece would take several months for each train.  Fluor, the project consultant, reached out to Mammoet to lift out the old towers in one piece. With careful planning, sophisticated computer modelling, the right equipment, and an expert team, Mammoet was able to develop the solution to delicately lift out the old towers intact, then manoeuvre the modular replacements into position.  To convince MWSPC and Fluor that this unlikely operation could be achieved, Mammoet prepared a detailed engineering study. Three dimensional digital models of each tower were supplemented by a series of ultrasonic tests to reveal their true structure and strength. A finite element simulation showed how they would respond to the pressure of being hoisted out of the plant. And a series of bespoke frames and slings were designed to safely cradle the towers throughout the move.  A key requirement was to draft in the right equipment, and Mammoet had two crawler cranes – the 1,600-t capacity CC8800-1 and 1,250-t capacity CC6800 – and the 3,200 t MSG-80 ring crane in place for this. With this combination, it became possible to reach far above the tight confines of the site, extract all nine of the towers, move them to a central staging area, and hoist the replacements into position, according to the company.  Abdullah Terkaoui, Project Manager for Mammoet, explains: “Our methodology enabled our customers to reduce the planned shutdown schedule for each train from 120 days to 45 days. Then, as the operation progressed, further time savings were realised: the complete shutdown of the first train was completed in 30 days; the second shutdown, where the lifts took only seven days, enabled completion in 22 days; and, for the third, the lift took just three days, with a total mechanical completion in 19 days.  “This meant that, thanks to the entire project team and everyone involved, all three shutdowns were completed two months (64 days) ahead of the original schedule – representing a time saving of over 50%.”  Nayef Rowily, Project Director for MWSPC, stated that considerable effort was put into reviewing Mammoet’s plan repeatedly, while keeping in mind the nature of the job, which involved integration in a brownfield and MWSPC’s strong desire to maintain production: “This was accomplished through excellent teamwork, including assessing all risks associated with the scope. Ultimately, we are pleased with Mammoet’s performance across all three SAP train tower replacements. They surpassed our expectations, and the site team did an exceptional job in delivering the project in record time. The MWSPC team takes pride in this significant achievement and recommends Mammoet’s expertise on a global scale.”

January 8, 2016 - The Saudi Arabian Mining Co. (Ma’aden) has announced the approval of a Saudi Industrial Development Fund loan of Saudi Arabian riyal 4bn ($1bn*) for the Ma’aden Waad Al Shamal Phospahte Co. (MWSPC).  The loan is split into four facilities, each of which provides separately for the construction of an ammonia plant in Ras Al Khair, a diammonium phosphate (DAP) plant in the same city, a sulphuric acid plant in Waad Al Shamal and a phosphate plant, likewise in Waad Al Shamal.  Ma’aden said that the loans would complete the debt financing of its phosphate joint venture. Saudi Basic Industries Corp. (SABIC) and US-based Mosaic Co. retain 15% and 25% stakes in the business, respectively.

March 4, 2014 - DuPont Sustainable Solutions is pleased to announce that MECS, Inc., a wholly owned subsidiary of DuPont, has been awarded the sulfuric acid technology license by the Saudi Arabian Mining Company (Ma’aden) for its Waad Al Shamal Phosphate Project. MECS, Inc. will provide the sulfuric acid technology and proprietary equipment for this three-line, 15,150 metric-tonne-per-day sulfuric acid facility. Ma’aden has selected a consortium led by long-time MECS licensee, SNC Lavalin Group Inc., to perform engineering, procurement and construction of the sulfuric acid and power segments of the complex.  When operational in 2016, the facility will be one of the largest world-class phosphate fertilizer complexes, positioning Ma’aden as a significant global producer of fertilizers and other phosphate-based products. “We are proud to partner with Ma’aden and SNC on this landmark project and look forward to supporting Ma’aden in its endeavor to be a world-class minerals enterprise,” said Kirk Schall, vice president of Licensing, MECS, Inc.

February 4, 2014
- SNC-Lavalin in consortium with Sinopec Engineering Group (SEG), has signed a contract with Ma'aden in Saudi Arabia to provide engineering, procurement, construction, commissioning and start-up services for a three-line 15,150-metric-tonne-per-day sulphuric acid plant. Also included in the agreement are two 75-MW power plants that will recover heat generated by the acid plant operations. The total value of the contract is approximately USD$764 million with SNC-Lavalin's portion estimated at USD$500 million.The project was awarded as part of Ma'aden's Waad Al Shamal Phosphate Project, which involves the conversion of phosphate ore from the Al Khabra mine into various end products, primarily for the agricultural sector. The contract signing was formalized at a ceremony held in Turaif, Saudi Arabia today with the participation of the Saudi Royal Family, Government Ministers and various dignitaries.The sulphuric acid plant will use industry leading technology from MECS, Inc. (a wholly-owned subsidiary of DuPont) to produce acid and generate power through the efficient recovery of process waste heat. The project, scheduled to be operational in the fourth quarter of 2016, will be one of the largest complexes of its kind."We are honoured to be part of a project that will support Ma'aden in its mandate to develop its mineral resources and increase industrial development in the Northern Province and Al-Jouf areas of Saudi Arabia," said Dale Clarke, Executive Vice-President, SNC-Lavalin Group Inc.SNC-Lavalin is a longstanding leader in the sulphuric acid industry, having successfully installed more than 60 plants around the world over the past 25 years.  Maaden also signed the contract for building a phosphoric acid plant worth SR3,506 million ($935 million) to Hanwha Engineering & Construction Co. Ltd & Hanwha Saudi Contracting Co. Ltd. The phosphoric acid plant which will consist of three phosphoric acid lines when completed will have a production capacity of 1.5 million tons.

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