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

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Sulphuric Acid Plant Specifications

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Acid Plant Database  July 17, 2019
Owner Mosaic Company
Mosaic Fertilizer Company

Mosaic-Logo.gif (2654 bytes)

Location 3095 Highway 640
Mulberry, Florida
Background Formerly IMC Phosphates MP, Inc.
Website www.mosaicco.com

New Wales Plant

  Plant No. 1 Plant No. 2 Plant No. 3 Plant No. 4 Plant No. 5

27° 49' 53" N
82° 3' 5" W

27° 49' 53" N
82° 3' 2" W

27° 49' 53" N
82° 3' 0" W

27° 49' 50" N
 82° 3' 6" W

27° 49' 50" N
82° 3' 4" W

Type of Plant Sulphur Burning Sulphur Burning Sulphur Burning Sulphur Burning Sulphur Burning
Gas Source Elemental Sulphur Elemental Sulphur Elemental Sulphur Elemental Sulphur Elemental Sulphur
Plant Capacity

3400 STPD

3400 STPD 3400 STPD 2900 STPD 2900 STPD
Emissions SO2: 3.5 lb/ton (24h), 483.3 lb/h, 2117 ton/a
4.0 lb/ton (3h)
, 567 lb/h, 2172 ton/a
Acid Mist: 0.
05 lb/ton, 7.1 lb/h, 31.1 ton/a
NOx: 0.12 lb/ton,
17 lb/h, 75 ton/a
Opacity: < 10%
SO2: 3.5 lb/ton (24h), 496 lb/h (24h)
4.0 lb/ton (3h)

Acid Mist: 0.
05 lb/ton, 7.1 lb/h
NOx: 0.12 lb/ton,
17 lb/h, 75 ton/a
Opacity: < 10%
SO2: 4 lb/ton, 483.3 lb/h, 2117 ton/a
Acid Mist: 0.15 lb/ton, 1
8.1 lb/h, 79.4 ton/a
NOx: 0.12 lb/ton, 1
4.5 lb/h, 63.5 ton/a
Opacity: < 10%
Status Operating Operating Operating Operating Operating
Year Built - - - - -
Technology - - - - -
Contractor MECS MECS MECS - -
Remarks SAP 1
2009 July - Hydrogen explosion resulting in damage to the converter.  Initial cause was a boiler leak that also cause severe corrosion in an economizer.

2012 - Work done as per Permit 1050059-070-AC
- FAT removed
- IPA changed to FAT
- New HRS
- Sulphur Furnace replaced
- DT replaced
2011 - Equipment Replaced as per Permit 1050059-073-AC
- IPA replaced with HRS
- FAT replaced with IPA, FAT to be removed
- Sulphur Furnace
- Waste Heat Boilers
- DT Mist Eliminator
- 4A/4C Superheater/Economizer
- FAT & DT Acid Cooler replaced with a single combined acid cooler
- IPA Pump Tank
- Repair Stack
- HRS System

Equipment Replaced as per Permit 1050059-063-AC
Sulphur furnace replaced in-kind
Work done as per Permit 1050059-067-AC
- FAT removed
- IPA changed to FAT
- New HRS
Equipment Replaced as per Permit 1050059-073-AC
- DT Mist Eliminator
- 0A & 4A Superheaters
- 3B, 4A & 4C Economizers
- IPA Bottom
- IPA Acid Cooler
- FAT Mist Eliminator

Work done as per Permit 1050059-064-AC
- FAT removed
- IPA changed to FAT
- New HRS
Hydrogen Explosion - Event 1
- No. 1 plant - July 2009
- No. 1 boiler leak and Economizer tube leak
- Hydrogen build up inside converter central core

Hydrogen Explosion - Event 2
- Hydrogen build up at top of Interpass Absorber
General -
References Dougherty, J.W., "Hydrogen Safety Concerns in the Sulphuric Acid Industry", Sulphur 2011, Presentation, November 9, 2011.
Florida Department of Environmental Protection, Permit 1050059-088-AV
Florida Department of Environmental Protection, Permit 1050059-082-AC
Florida Department of Environmental Protection, Permit 1050059-073-AC
Florida Department of Environmental Protection, Permit 1050059-067-AC
Florida Department of Environmental Protection, Permit 1050059-064-AC
Dougherty, J.W., "Hydrogen Safety in the Sulphuric Acid Industry", Sulphur 2014
Sulphuric Acid Today, Spring/Summer 2015, Mosaic's New Wales Plant: Bringing a World-Class Legacy into the 21st Century
News July 16, 2019 - About 200 gallons of sulfuric acid was released Tuesday after a pipeline leaked at a Mosaic facility.  The state Department of Environmental Protection said Tuesday it received a pollution notice about the leak at the New Wales facility. Mosaic said it worked to clean up the leaked acid and neutralize any impact to local soil.  The facility is located at 3095 CR 640 West in Polk County.  Mosaic Fertilizer is the largest phosphate mining company in the world. In 2016, a sinkhole opened up at the New Wales facility and swallowed more than 215 gallons of water. The company admitted the water was slightly radioactive after being contaminated by gypsum, a byproduct of the fertilizer made there.  That contaminated radioactive water got into the Floridan aquifer.  In 2015, the company agreed to pay nearly $2 billion in a federal lawsuit over hazardous waste. It also agreed to improve clean up operations at sites in Florida and Louisiana.  www.wtsp.com

October 1, 2015
- EPA and the U.S. Department of Justice announced a settlement with Mosaic Fertilizer, LLC that will ensure the proper treatment, storage, and disposal of an estimated 60 billion pounds of hazardous waste at six Mosaic facilities in Florida and two in Louisiana. The settlement resolves a series of alleged violations by Mosaic, one of the world’s largest fertilizer manufacturers, of the federal Resource Conservation and Recovery Act (RCRA), which provides universal guidelines for how hazardous waste must be stored, handled and disposed. The 60 billion pounds of hazardous waste addressed in this case is the largest amount ever covered by a federal or state RCRA settlement and will ensure that wastewater at Mosaic’s facilities is properly managed and does not pose a threat to groundwater resources. 
The 60 billion pounds of hazardous waste is based on the combined amount of corrosive wastewaters that will be treated at terminal closure of the facilities. Mosaic is one of the fertilizers industry’s best performers in its ability to reduce large volumes of corrosive wastewater in its phosphogypsum stack systems. In addition to recovering valuable phosphate and other compounds, Mosaic is able to reduce terminal closure costs while ensuring that its phosphogypsum stack systems are operated in an environmentally safe manner.  Four Mosaic facilities (New Wales, Bartow, Riverview in Florida and Uncle Sam in Louisiana) will continue to produce phosphoric acid and actively utilize its phosphogypsum stack systems. Mosaic is in the closure process for the Green Bay Complex and South Pierce facility in Florida, and the Faustina facility in Louisiana. However, Faustina will continue to manufacture ammoniated fertilizer. Mosaic operated a small sulfuric acid plant at the Mulberry facility in Florida for a short time. The Mulberry sulfuric acid plant was closed around 2008 and there are no obligations regarding this site in this settlement.  Mosaic has been making major improvements at all its facilities and completed several notable projects: installation of state-of-the-art elementary neutralization units to improve the management of sulfuric acid waste streams, upgrading air scrubbers at its granulation and phosphoric acid plants, and installing automated spill and leak detection systems. All of these projects have been closely monitored by Florida Department of Environmental Protection, and Louisiana Department of Environmental Protection, who provided valuable expertise at each step of the process.

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."

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