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PERP PROGRAM 1
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117
Phosphate and NPK Fertilizers August 2016 Report Contents
PERP PROGRAM 2
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117
Phosphate and NPK Fertilizers August 2016 Report Contents
Appendix Page
PERP PROGRAM 3
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117
Phosphate and NPK Fertilizers August 2016 Report Contents
Figure Page
1.1 U.S. Gulf Coast Summary of Production Costs ..................................................................... 5
1.2 Chinese Summary of Production Costs ................................................................................. 6
1.3 Middle Eastern Summary of Production Costs ...................................................................... 7
1.4 Global Total DAP, MAP, and TSP Consumption by Region .................................................. 9
2.1 Phosphate Fertilizer Value Chain ........................................................................................... 12
2.2 Cone Mixer ............................................................................................................................. 14
2.3 Manufacture of Run-of-Pile Triple Superphosphate ............................................................... 16
2.4 Dorr-Oliver Process for Granular Triple Superphosphate ...................................................... 17
2.5 Den Process for Single Superphosphate ............................................................................... 19
2.6 TVA Granular Diammonium Phosphate Process .................................................................. 21
2.7 Typical T-shape Inlet Mixer .................................................................................................... 22
2.8 Integrated Nitrophosphate Process ........................................................................................ 24
3.1 Casale Scrubbing System for Dual-Pipe Reactor Process .................................................... 31
3.2 Espindesa Low Recycle DAP Process ................................................................................... 33
3.3 ESPINDESA Phosphoric Acid-Based NPK Process .............................................................. 35
3.4 ESPINDESA Steam Granulation NPK Process ..................................................................... 37
3.5 INCRO DAP/NPK Solid Section ............................................................................................. 40
3.6 INCRO DAP/NPK Liquid Section ........................................................................................... 41
3.7 INCRO TSP Feed Preparation and Reactor Section ............................................................ 46
3.8 Jacobs Process Flow Diagram ............................................................................................... 49
3.9 Jacobs Process Flow for Wet Section of DAP Plant ............................................................. 50
3.10 Yara Nitrophosphate NPK Process ........................................................................................ 52
4.1 Block Flow Diagram for Producing Pure Ammonium Phosphates ......................................... 55
4.2 Block Diagram for Producing Monoammonium Phosphate (U.S. 2015/0360946 A1) ........... 56
4.3 Block Diagram for Producing Diammonium Phosphate ........................................................ 57
4.4 Block Diagram for Producing Sulfate or Phosphate Fertilizers ............................................. 59
5.1 Summary of Monoammonium Phosphate via a Conventional Direct Slurry Granulation
Process................................................................................................................................... 67
5.2 Summary of Diammonium Phosphate via a Conventional Direct Slurry Granulation
Process................................................................................................................................... 72
5.3 Summary of Triple Superphosphate via a Conventional Direct Slurry Granulation
Process................................................................................................................................... 77
5.4 Summary of NPK 16.5-16.5-16.5 via a Conventional Direct Slurry Granulation Process ..... 82
5.5 Summary of NPK 16.5-16.5-16.5 via a Conventional Nitrophosphate Process ..................... 87
5.6 U.S. Gulf Coast Summary of Production Costs ..................................................................... 89
5.7 Chinese Summary of Production Costs ................................................................................. 90
5.8 Middle Eastern Summary of Production Costs ...................................................................... 91
7.1 Global Total DAP, MAP, and TSP Consumption by Region .................................................. 97
7.2 Major Phosphate Rock Producing Countries ......................................................................... 98
PERP PROGRAM 4
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117
Phosphate and NPK Fertilizers August 2016 Report Contents
PERP PROGRAM 5
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117
Phosphate and NPK Fertilizers August 2016 Report Contents
Table Page
PERP PROGRAM 6
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117
Phosphate and NPK Fertilizers August 2016 Report Contents
PERP PROGRAM 7
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117
Phosphate and NPK Fertilizers August 2016 Report Contents
Nexant Thinking™
Process Evaluation/Research Planning
Contact Details:
New York: Marcos Nogueira Cesar, Vice President, Global Products, E&CA: Nexant Thinking™
Phone: + 1-914-609-0324, e-mail: mcesar@nexant.com
Nexant, Inc. (www.nexant.com) is a leading management consultancy to the global energy, chemical, and related industries. For over 38 years, Nexant
has helped clients increase business value through assistance in all aspects of business strategy, including business intelligence, project feasibility and
implementation, operational improvement, portfolio planning, and growth through M&A activities. Nexant has its main offices in San Francisco
(California), White Plains (New York), and London (UK), and satellite offices worldwide.
PERP PROGRAM 8
PERP 2016S9, Phosphate and NPK Fertilizers
A00101.0016.4117