Ochure - PRT .2020
Ochure - PRT .2020
PROCESSES Tecfnlogies
FOR PHOSPHORIC
ACID
PRODUCTION
COULEUR 3 DÉGRADÉ
3
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TABLE OF CONTENTS
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PRAYON
PRAYON PROCESSES
PROCESSES
PRAYON TECHNOLOGIES
THE REFERENCE
IN THE PHOSPHORIC ACID WORLD
For over 70 years, PRAYON TECHNOLOGIES s.a.
has been a leader in the licensing of phosphoric acid processes.
+P
lants using the Prayon technology This worldwide success in licensing is not The Prayon Group has 4 production
produce the majority of the world ton- accidental. Rather, it is based on experi- sites, a total of about 1400 employ-
nage of phosphoric acid. ence gained in the area of production. ees, and an annual turnover of about
+P
rayon technology and equipment have Behind PRAYON TECHNOLOGIES s.a. is 700 million EUR.
been used in over 145 plants located its parent company Prayon s.a., a pro-
in over 30 countries. duction company founded in the 19th PRAYON TECHNOLOGIES mission is to
+D
ozens of different phosphate rocks century, which has been manufacturing licence the processes developed in-house,
have been used in plants from 25 to phosphoric acid and phosphates for more “by a producer for producers”.
2000 mtpd P2O5. than seventy years.
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THE CHARACTERISTICS
OF PRAYON
TECHNOLOGIES
PRAYON TECHNOLOGIES offers 6 differ- PRAYON TECHNOLOGIES processes enable These various features have enabled us
ent processes, each one with its own char- plants to achieve higher efficiency than to sell a total of over 130 units, includ-
acteristics. This range ensures that we their competitors, due to the unique de- ing more than 50 repeat orders. The lat-
can provide you with the process which sign of the multi-compartmented reactor. est large scale projects in the world are
best meets your requirements. This design allows the raw materials to based on most advanced Prayon tech-
be introduced at the most effective point nologies.
in the reactor, yielding optimal results.
PRODUCTION-ORIENTED
FLEXIBILITY
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PRAYON PROCESSES
CALCIUM
SULPHATE
CRYSTALLISATION
PHASES
120
Température - °C
HEMIHYDRATE ZONE
100
80
60
40
20
DIHYDRATE ZONE
0
0 10 20 30 40 50 60 80
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PRAYON
TECHNOLOGIES
PROCESSES
DPP DIHY > Dihydrate relatively strong acid (+/- 35% P2O5).
+ W ith two crystals: “Dihydrate then The DA-HF is the newcomer, it ensures a
Hemihydrate” Central-Prayon Process high efficiency with an investment cost
or CPP close to a Dihydrate Process.
CCP DIHY > HEMI > Hemihydrate
SECOND RANGE
+ With two crystals and only one filtra-
tion: “Dihydrate - hemihydrate filtration” Processes with the first reaction as
or DA-HF. “hemihydrate”
DA-HF > DIHY HEMI > Hemihydrate
+ With one crystal: “Hemihydrate” Prayon
For the past 30 years, Prayon’s licensing Process or PH1
activities have been mainly based on PH1 HEMI > Hemihydrate
the DPP - Mark 4 dihydrate process for
phosphoric acid production. Its ability + With two crystals: “Hemihydrate” then
to efficiently convert various types of “Dihydrate” Prayon Process or PH2
PH2 HEMI > DIHY > Dihydrate
phosphates, its flexibility, its ease of
operation and its low maintenance cost
make it the leading process on the market. + With three crystals: “Hemihydrate” then
“Dihydrate” then “Hemihydrate” Prayon
As calcium sulphate is sold at the Prayon Process or PH3
production site at Engis (Belgium), the PH3 HEMI > DIHY > HEMI > Hemi-
purity and quality of the gypsum must be hydrate GAS SCRUBBING TOWER
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PRAYON PROCESSES
In the late 1970s, the increase of oil prices Although a two-stage hemihydrate-di- Under less stringent conditions, where
put pressure on Prayon to develop higher hydrate process would have been more gypsum quality is not so critical, the final
strength processes, and two alternatives efficient, the drying stage would have stage of the PH3 process can be deleted,
were considered. First, the development been costly, compared to the self-drying leading to a hemihydrate-dihydrate pro-
of a process with hemihydrate as the first characteristics of hemihydrate which cess. This type of process was developed
stage, to produce 43-46% P2O5 acid, or cause the free water to be absorbed for licensing purposes and is known as
changing the operating conditions of the during hydration. the “Prayon Hemihydrate 2-crystal pro-
existing Central-Prayon plant to achieve cess” or PH2. This process can yield a
a product acid strength higher than the A novel process was then developed, a 43-46% P2O5 acid and has a process ef-
34-36% obtained at that time. This solu- Hemi-Di-Hemi process with two recrystal- ficiency of over 98.5%.
tion was intended to produce merchant lisation stages and two filtration stages.
grade gypsum with similar qualities to This process was named the ‘Prayon In cases where lower efficiencies are ac-
that obtained previously. Hemihydrate 3-crystal process” or PH3, ceptable, the removal of the dihydrate
and can produce a 46% P2O5 acid with stage leads to a single-stage hemihydrate
A single-stage HH process could not over 98.5% process efficiency and high process known as PH1. This can yield acid
achieve the gypsum quality required by quality calcium sulphate. 39-45% P2O5, with a process efficiency of
the downstream plaster producer, nor a up to 95%. If lower strengths are accept-
high enough efficiency to produce phos- able, efficiency can be increased. Alterna-
phoric acid economically at the inland tively, higher strengths can be achieved
European site. at the expense of efficiency.
Product acid: % SO3 1.5 0.6 to 1.2 2 to 3% 0.6 to 1.2 0.6 to 1.2 0.6 to 1.2
Crystal H2O % 20.5 6.2 to 6.5 6.2 to 6.5 5.4 to 5.8 18 to 19 6.5
Total P2O5 % 0.8 to 1 0.25 to 0.35 0.35 to 0.65 0.15 to 0.25 0.25 to 0.35 1.2 to 1.8
W.S. P2O5 % 0.2 to 0.3 0.1 to 0.15 0.1 to 0.2 0.05 to 0.1 0.05 to 0.1 0.2 to 0.3
UNR. P2O5 % 0.05 to 0.1 0.05 to 0.1 0.05 to 0.1 0.05 to 0.1 0.05 to 0.1 0.05 to 0.1
Cocryst P2O5 % 0.5 to 0.6 0.1 to 0.2 0.1 to 0.2 0.05 to 0.1 0.15 to 0.25 0.8 to 1.4
F% 0.5 to 0.8 0.4 to 0.6 0.4 to 0.6 0.1 to 0.2 0.5 to 0.7 1 to 1.2
Na2O% 0.4 to 0.8 0.3 to 0.6 0.3 to 0.6 0.1 to 0.2 0.3 to 0.6 1 to 1.2
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FEATURES OF
PRAYON TECHNOLOGIES
DESIGN
In order to improve the overall performance of phosphoric acid plants, PRAYON TECHNOLOGIES
continually updates the design of the equipment used in the process to improve recovery, energy
efficiency and the operability of the plant.
REACTOR DESIGN each loss in the gypsum is a function of to the other can be adjusted depending
several parameters including the sulphate upon the process parameters and the
The PRAYON TECHNOLOGIES reactor concentration in the reactor. When the origin of the phosphate rock.
design is unique. It is proven to be highly sulphate concentration of the reaction
reliable. Its multi-compartments design slurry is high, cocrystallised losses are After leaving the attack section, the slurry
allows flexibility and easy control of the low. When the concentration is low, unre- flows into the digestion section, where it
sulphate in the attack section, which re- acted losses are low. In the reaction tank, will desaturate before being fed to the
duces P2O5 losses in the calcium sulphate rock is added in the first compartment. filter. Consequently, the gypsum crystals
and increases the profitability of the unit. As sulphuric acid is not added to this will be large and the slurry will be desat-
compartment, the sulphate concentra- urated. This feature significantly reduces
tion is low. This results in the dissolution filter scaling, which enables the plant
SULPHATE GRADIENT OF THE of the rock in a media where unreacted to be run for longer periods bet-ween
SLURRY IN THE AT TACK TANK losses are low. In the compartments 2 washes. The increase in stability improves
and 3, sulphate concentration is gradually the overall recovery of the unit and the
Two types of insoluble losses are pro- increased to reduce the cocrystallised onstream time and thus increases the
duced during the production of phos- losses. The design of the reaction tank return on investment.
phoric acid. These are the cocrystallised thus minimises the insoluble losses. The
and the unreacted losses. The level of level of sulphate gradient from one zone
Optional Sulphate
High Sulphate
Low Sulphate
Digestion
R
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PRAYON
PRAYON PROCESSES
PROCESSES
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FEATURES OF
PRAYON TECHNOLOGIES
DESIGN
AGITATORS
Agitation is a key factor in chemical pro- In the digestion section, strong agitation
cesses as it improves the mass transfer of is no longer necessary. Only helicoidal
the reagent and crystallisation conditions blades with low specific power consump-
in the reaction slurry. tion are used.
During the reaction period of phosphoric For a few years now, PRAYON T E C H -
acid production, agitation is used for the NOLOGIES has been using a Computer-
following purposes: ized Fluid Dynamics software in order to
further improve the design of its agitators.
+ To keep the solids suspended.
+ To renew the liquid layer (reagent) on
the phosphate grains.
+ To break the foam on the surface of
the reactor.
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PRAYON
PRAYON PROCESSES
PROCESSES
FILTERS
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PRAYON TECHNOLOGIES
PROCESSES WITH INITIAL
DIHYDRATE REACTION
THE MARK 4 DIHYDRATE PRAYON THE MAIN CHARACTERISTICS OF RECOMMENDED FOR LOCATIONS
PROCESS (DPP) THE PROCESS ARE
This process has undergone major in- + low investment and running costs + with low to medium cost rock
novation every ten years or so, up to the + the ability to process all types of phos- + with low-cost energy (steam)
achievement of the highly efficient Mark phates (sedimentary and igneous) + with gypsum disposal possibility
4 version, which is a favourite with pro-
+ accepts phosphate slurry feeding (wet
ducers due to its reliability, simplicity of
grinding)
operation and the use of tried-and-tested
+ water balance is easy to control (recy-
equipment.
cling of pond water, reduction and/or
elimination of liquid effluent)
+ dihydrate route
+ good P2O5 recovery
Vacuum
H2SO4
Flash Cooler
Phosphate
Water
Filter
Calcium
Sulphate
Dihydrate
Reaction Digestion
Recycled Acid
DIHYDRATE
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PRAYON PROCESSES
THE CENTRAL-PRAYON PROCESS dihydrate solids into hemihydrate liberating + it produces CaSO4.1/2H2O which is self-
most of insoluble losses. The slurry produced drying due to its chemical properties
The Central-Prayon Process was developed is then filtered and the cake washed. All and is purer than dihydrate, and can
to produce a calcium sulphate (phospho- filtrates from the second filter are recycled therefore be used directly as a merchant
gypsum) which could replace the natural to the reaction tank, while solids can be grade raw material (phosphate selec-
gypsum in different applications. neutralised and used as a raw material for tion may be important)
gypsum products.
This process is a dihydrate-hemihydrate RECOMMENDED FOR LOCATIONS
process. During the first stage, slurry con- T H E M A I N C H A RACT E R I S T I C S O F
taining dihydrate crystals is produced. From THIS PROCESS ARE + with medium - high-cost rock
that flow, the quantity corresponding to the + with high-cost energy
product acid is sent to storage, the remaining + it produces a higher acid strength than + with disposal limitation and/or with a
quantity being sent with the solids to the DPP with much higher P2O5 recovery potential market for this purer gypsum
conversion tank. In this reactor, sulphuric + it can process both types of phosphates:
acid and steam are added to transform the sedimentary and igneous
Vacuum
H2SO4
Flash Cooler
Phosphate
Steam
Hemihydrate Water
Filter
DIHYDRATE HEMIHYDRATE
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TWO-CRYSTAL PROCESS OR DA-HF (DI ATTACK AND HEMI FILTRATION) THE MAIN CHARACTERISTICS OF
THE PROCESS ARE
The Prayon DA-HF process© for producing This process has been developed to
phosphoric acid by sulphuric acid attack produce phosphoric acid with a high P2O5 + high strength phosacid
of natural phosphate rocks is a modern content (about 32 -35%) while only one + high P2O5 recovery (97-98%)
process leading to high P2O 5 yield and filtration step is required. + reduced CAPEX for high efficiency process
giving, as a by-product, hemihydrate calcium + self-drying gypsum
sulphate. Dihydrate calcium sulphate is
produced in the attack section where the RECOMMENDED FOR LOCATIONS
phosphate is attacked by sulphuric acid.
Then, the gypsum slurry recrystallizes + to adapt current Dihydrate process plant
into hemihydrate calcium sulphate in the and improve profitability
conversion section before being filtered to + with medium high-cost rock
produce the phosphoric acid. + with potential market for gypsum
Vacuum
Flash Cooler
Phosphate H2SO4
Steam Water
Calcium
Filter Sulphate
Hemihydrate
Reaction Conversion
RPA
Phosphoric Acid 32-35% P2O5
DIHYDRATE HEMIHYDRATE
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PRAYON
PRAYON PROCESSES
PROCESSES
H H CRYSTALS
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PRAYON TECHNOLOGIES
PROCESS WITH INITIAL
HEMIHYDRATE REACTION
After the first reaction in hemihydrate + high-strength phosacid + with medium - high-cost rock
mode, the product acid is separated as + high P2O5 recovery (> 98.5%) + with high-cost energy
a 46% P2O5 with low SO3 content. The + with easy gypsum disposal
remaining α-hemihydrate, washed with
recycled liquor, is further processed
with sulphuric acid in conditions in
which α-hemihydrate is unstable and
recrystallises as gypsum, releasing
cocrystallised and unreacted P2O5.
Vacuum Vacuum
Flash H2SO4
Cooler Optional
Flash Cooler
Phosphate
Water
Dihydrate
Filter
Recycled Acid
Phosphoric Acid
40 to 46% P2O5
Hydratation tanks
HEMIHYDRATE DIHYDRATE
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PRAYON PROCESSES
The reaction takes place in two stages. + simple and low-cost process + with low-cost rock
The first stage takes place with a low but + high-strength acid + with low-cost sulphuric acid
positive sulphate level, while the second + with high-cost energy
stage operates with a higher sulphate + where gypsum disposal is not a problem
level. Perfect sulphate and temperature
control permit the filtration of a slurry
containing a highly stable hemihydrate
with low scaling properties.
Vacuum Vacuum
Flash H2SO4
Cooler Optional
Flash Cooler
Phosphate
Water
Filter
Calcium
Sulphate
Hemihydrate
Reaction Digestion
Recycled Acid
HEMIHYDRATE
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DCP
PRODUCTION TECHNOLOGY
In front of the growing world population and to optimize earth’s resources, phosphate industry must be innovative and keep
on providing technologies to face those challenges. Prayon Technologies developed and patented a new route to process
phosphate raw material with low P2O5 content or with high level of impurities. Moreover, this process is suitable to consume a
waste stream of sulfuric acid. P2O5 is extracted from rock and finally recovered by precipitation as di-calcium phosphate (DCP).
Level of impurities in the final product is It consists of two main steps: + w ith low-grade phosphate rock or
reduced through the new process. containing specific impurities to be
+ Attack of the rock in diluted acidic removed or with other P 2O5 sources
DCP produced is pure compared to the conditions by addition of sulfuric acid (tailings, slimes, ashes…)
original rock. It can be further processed + Precipitation as DCP by addition of + with low-grade sulfuric acid or with
through a conventional acidulation route calcium source waste stream of sulfuric acid to be
to produce phosphoric acid (fertilizer consumed
quality) and purified gypsum. Impurities from the rock/ sulfuric acid + where gypsum disposal is not an issue
are removed with the gypsum produced + where use of low-cost building mate-
It can also be used directly for animal through new process by a pH modification. rial for equipment is a key as process
feeding applications as DCP or be con- is operated under diluted conditions
verted to MCP with addition of phos- Specific chemical agent can be added to
phoric acid. remove heavy metals.
DILUTED GYPSUM
DCP PRODUCT
SULFURIC ACID & IMPURITIES CAKE
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PRAYON
PRAYON PROCESSES
PRAYON
RELATED TECHNOLOGIES
ACID CONCENTRATION
FLUORINE RECOVERY
GYPSUM PURIFICATION
stream processes as cement plant.
ACID PURIFICATION
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PROCESS
LICENSING
CONSULTING
If requested by the customer, Prayon + Technical support for existing units
Technologies can provide the following + Training of operators
services: + Phosphate rock evaluation
+ Agitation optimisation
+ Long-term collaborative program for assistance
(P2gether)
+ Plant operation simulator tool
Payon
Tecfnlogies
PRAYON TECHNOLOGIES S.A.
LICENSING DIVISION OF PRAYON
www.globulebleu.com