We are an acknowledged leader in the design of phosphoric acid plants and have achieved an unbroken involvement within the phosphate industry since the 1930s.

Our reactor has been under continual development over the decades and its current configuration provides for the best process and mechanical solutions in the industry.

Superior sulfate control results from high recirculation ratios provided by the integrated geometry. We offer three different wet process technologies utilizing the same concepts that make our reactor an industry leader, DH, HH and HDH.

Recent completed projects include 6 world-scale (~1,500 MTPD each) plants for OCP at Jorf Lasfar, Morocco and 3 world-scale plants (1615 MTPD) for Ma’aden at Wa’ad Al Shamal, Saudi Arabia.

33 Operating Units

15 Countries

14 Ore Sources

PHOSPHORIC ACID PROCESSES

Di-Hydrate (DH)

The Di-Hydrate (DH) process is the most common process. The largest production capacity plants are using the DH process. DH plants are also more stable to operate.

It is preferred when the investment is coupled to fertilizer production. Further, DH plants have taken advantage of the economies of scale lowering the unit costs. Global recovery at the feed stock is higher for this technology.

FEATURES AND BENEFITS

  • The DH Process offers higher on-stream times which results in higher annual production capacity and reduced maintenance (reduced OPEX).
  • DH Plants operate at a lower temperature which reduces the problems with rubber lining and corrosion allowing a lower grade of stainless steel (reduced CAPEX).
  • The DH Process is more forgiving to variations in rock quality, which offers flexibility to accept different rock qualities. Especially for producers who import rock phosphate.
  • The DH Process generally requires smaller filters due to the higher filtrations rates (reduced CAPEX).
  • The DH Process does not require dry rock nor anti-scaling agents (reduced CAPEX and OPEX).
  • The DH Process results in the highest on-stream operating factors in the industry.
  • Simplicity in design makes operations easier than other technologies.
  • A properly designed DH plant will have the highest global recoveries of the other technologies.

Hemi-Hydrate (HH)

The Hemi-Hydrate (HH) process is sometimes selected when the plant is located close to a mine owned by the operator and steam is costly (for example no adjacent sulfuric acid plant). It allows production of 38-48% P2O5 acid directly, with consequent valuable savings in energy. 

 

FEATURES AND BENEFITS

  • The HH Process can accept coarse rock grind which reduces the overall power consumption associated with grinding (reduced CAPEX and OPEX).
  • The HH Process produces 38-48% P2O5 acid directly from the filter which reduces the steam/water consumption associated with the evaporators (reduced OPEX).
  • The HH Process requires less cooling which impacts the design of the flash cooler (reduced CAPEX) .
  • No 40% acid clarification required (reduced OPEX). Acid from the HH process tends to contain substantially less free sulphate and suspended solids and lower levels of aluminum and fluorine.

 

Hemi-Hydrate (HH) is the second most used wet process after the Di-Hydrate (DH).

Hemi-Di-Hydrate (HDH)

The Hemi-Di-Hydrate (HDH) process is a double crystallization process which allows the recovery of P2O5 losses that are trapped in the crystal lattice. This not only raises the overall efficiency of the process but also gives a much cleaner calcium sulphate.

The HDH process is used for medium size plants when no steam and sulfuric acid plants are onsite.

 

FEATURES AND BENEFITS

  • The HDH Process produces 38-48% P2O5 acid directly from the filter which reduces the steam/water consumption associated.
  • The HDH Process has a typical P2O5 recovery of 98.5% compared to 95% for DH and 92% for HH.
  • The HDH Process can accept coarse rock grind which reduces the overall power consumption associated with grinding (reduced CAPEX and OPEX).
  •  The HDH Process produces 38-48% P2O5 acid directly from the filter which reduces the steam/water consumption associated with the evaporators (reduced OPEX).
  • The HDH Process requires less cooling which impacts the design of the flash cooler (reduced CAPEX) .
  • No 40% acid clarification required (reduced OPEX). Acid from the HDH process tends to contain substantially less free sulphate and suspended solids and lower levels of fluorine.
  • The HDH Process produces a significantly cleaner gypsum than the DH or HH processes.
 

Equipment Features

The major feature of the JT process is the annular reactor.

  • The reactor has many advantages versus other reactor configurations.
  • Each reactor is custom built based on the ore source and process goals. Sturdy reinforced concrete construction with an inner support wall for proven long life.
  • Circular with few dividing walls. The configuration minimizes downtime during normal maintenance clean outs and provides the highest on-stream factors in the industry.
  • Agitators, rock feed, sulfuric, recycle feed and flash cooler feed generate recirculation while the agitators provide mixing and wall velocities to keep all solids entrained and minimize scaling. This keeps the total reaction volume available year-round.
  • If an agitator fails and it must be removed for maintenance, the others keep the process going and a shutdown is not necessary.
  • Agitation is optimized utilizing state of the art techniques which minimizes CAPEX/OPEX and maximizes dissolution, gas dispersion and internal recirculation.
 
  • The reactor provides a controlled combination of slurry recirculation by means of cooler circulating pumps and back-mixing from the geometric configuration of the annular reactor. The combination provides the least capital and operating costs for obtaining a high yield and extremely filterable gypsum.
  • Stable reaction system with very easy sulfate control. Variations in rock feed streams are easily handled.
  • Proprietary mixing tee for sulfuric acid addition eliminating hyper- saturation zones producing a highly filterable gypsum.
  • Rock dissolving area completely separated from the maturation area for crystal growth and desaturation.
  • Defoamer consumption per ton P2O5 has been shown to be low at high throughputs.
  • Low-level, low-energy flash coolers for process temperature control and slurry recirculation. Designs minimize entrainment and potential carryover and provide a means to recover any P2O5 lost through the vapor duct as well as removing silica from the system if that is a process goal.

Research & Development

We are continually looking at new ideas to address current industry issues and for process innovations. Many patents have been filed in recent years and more concepts are being developed. Research in our world class laboratory is ongoing with multiple projects moving forward. Some of our efforts are client specific but are not commercially available, others are collaborations, but most are generated in-house. Be sure to stay apprised as announcements for commercialization of new technologies will be forthcoming. 

Iron Removal

Other R&D efforts have produced a patent for iron removal from phosphoric acid. Iron removal is for ores with high iron content. A slip stream can be treated reducing the size of equipment necessary to bring the content low enough to improve yields and grades in granulation.