MAADEN TRAINING

PLANT DESIGN BASIS

MAADEN PHOSPHATE PROJECT Design Basis

CAPACITY

1460 tpd P2O5

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

PRODUCT ACID QUALITY

Ex filter
40% P2O5

Ex evaporator
48% P2O5

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

RAW MATERIALS Phosphate Rock

Al Jalamid

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

ROCK ANALYSIS Chemical Analysis (dry basis) Component P2O5 CaO SO3 Al2O3 Fe2O3 MgO F Design Basis Analysis % wt/wt 32.50 52.0 0.89 0.07 0.09 0.70 4.00 Contract Range Analysis % wt/wt 31.90 34.30 49.73 55.40 0.730 0.939 0.068 0.130 0.077 0.100 0.70 1.00 3.72 4.00

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

ROCK ANALYSIS Chemical Analysis (dry basis) Component Cl SiO2 Na2O K2O CO2 Combined H2O Free H2O Design Basis Analysis % wt/wt 0.01 3.4 0.28 0.02 6.70 0.15 5.0 Contract Range Analysis % wt/wt 0.0069 0.010 0.432 8.21 0.227 0.330 0.012 0.030 4.83 7.10 0.11 0.45 6.0 max

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

ROCK ANALYSIS Size (microns) + 700 + 300 + 212 + 106 + 38 - 38
November 2009

Amount Retained (wt%) 0 2 to 6 21 to 28 50 to 59 12 to 15 2 to 3

MAADEN PHOSPHATE PROJECT Design Basis

RAW MATERIALS Sulphuric Acid

Concentration State Temperature

98.5% H2SO4 Liquid Ambient to 45C

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

RAW MATERIALS Kaolin To promote stable crystallisation of hemihydrate and to suppress the corrosivity Source SiO2 content Al2O3 content MgO content Fe2O3 content CaO content Bulk density Typical Screen analysis Saudi Arabia 39.4% 33.6% 0.2% 1.5% 0.92% 0.46 g/cm (loose) 100% <71 micron

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

RAW MATERIALS Kieselguhr To suppress the corrosivity Type Source SiO2 content Al2O3 content MgO content Fe2O3 content CaO content Diatomaceous Earth Maaden 86.6% 5.0% 0.6% 1.7% 0.4%

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

RAW MATERIALS Defoamer

Type:

Typically alkylene glycolic fatty acid ester Struktol SB 2094 is suitable

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

RAW MATERIALS Anti-Scaling Additive To reduce scaling of filter circuits Type: Form: Total P2O5 Hexametaphosphate Loss on Ignition Chain Length Note Sodium hexametaphosphate Powder or glass chip 68% min. 80% min. 0.7% max. 9 or above Hygroscopic

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

UTILITIES Process Water

Temperature Pressure

35C 275kPa(a)

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

UTILITIES Steam

LP Steam
Temperature Pressure 155C 340kPa(g)

MP Steam
Temperature Pressure 178C 690kPa(g)

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

UTILITIES Electricity

Voltage
above 150kW 0.4-150kW below 0.4kW 4160 V 400 V 230 V

3 phases 60 Hz

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

UTILITIES Air

Plant Air
Temperature Pressure 35C 800kPa(a)

Instrument Air
Temperature Pressure 35C 800kPa(a)

November 2009

MAADEN PHOSPHATE PROJECT Design Basis

UTILITIES Effluents

Gypsum
Quantity 1125 tph (dry weight)

Gaseous
Fluorine (HF) 5mgF/Nm

Liquid Effluent
No Liquid Effluent

November 2009