PROCESS 2: MANUFACTURING OF PHOSPHORIC ACID FROM PHOSPHATE ROCK

USING BLAST FURNACE

PROCESS NARRATIVE:

The phosphate rock is first dried and pulverized to make the mixing easier and effective.
Grounded phosphate rock is then mixed with coke powder and silica sand and is compressed to
5000psi which results to briquettes. It is then dried and fed continuously from the top of a blast
furnace. At the bottom of the blast furnace, a preheated air at about 1000 0C to 11000C is
charged using a tuyere. The briquettes are burned due to the preheated air which causes the
temperature to rise up to 13700C. At these temperature, a reaction between silica and calcium in
the rock takes place, phosphate is freed from the rock and also forming a calcium silicate
molten slag. The coke acts as reducing agent that reduces the rock phosphate content to
diphosphorus vapor and carbon monoxide. On sophisticated plants, the vapors and entrained
dust pass through an electrostatic precipitator to reduce the solid load. The remaining unreacted
coke undergoes combustion with air to generate heat. Reaction is completed in the furnace
itself producing phosphorus pentoxide, P2O5. The reaction in the blast furnace is shown below:
(Gilmour, 2014)

Ca3(PO4)2 + 3SiO2 + 5C 2P + 5CO + 3CaSiO3

H = - 364.8 kcals

2P + 5CO + 5O2 P2O5 + 5CO2

The next process is to purify and separate impurities. Cyclone separator and
phosphorus condenser are used collect and separate P2O5 from elemental phosphorus. P2O5 is
cooled in the heat exchanger which produces superheated steam; part of the gas produced can
be taken into regenerative blast furnace. The purified P2O5 is then fed to the hydrating towers.
The reaction in the tower is shown below: (Patel)

P2O5 + 3H2O 2H3PO4

H = - 44.9 kcals

The phosphoric acid, H3PO4, produced using blast furnace process is usually 75% - 85%
pure. Purification of phosphoric acid includes removal of arsenic by hydrogen sulfide treatment
followed by filtration. (Walton, 1993)

PROCESS 2: MANUFACTURING OF PHOSPHORIC ACID FROM PHOSPHATE ROCK

USING BLAST FURNACE

PROCESS FLOW DIAGRAM

Availability of Raw Materials

Phosphate rock
There are currently two mining company here in the Philippines which produces
phosphate rock, one of them is APH Phosphate Fertilizers Inc. which is located at Negros
Occidental. The production of phosphate here in the Philippines is fluctuating. Since there are
only two companies that produces phosphate rock there is a need for import. Data of import and
export is as follows: (UN Comtrade)
Year
2007
2008
2009
2010
2011
2012
2013
2014
2015

Import (kg)
77,406,654
63,965,299
51,639,918
46,407,612
47,910,129
53,196,878
51,317,377
61,434,422
71,729,396
Table : Import and export of phosphate rock

Export (kg)
1,494,433
63,552
696,630
136,754
18,782
242,804
16,404
87,222
1,707

Import
Export

Figure : Graphical representation of import and export of phosphate rock

Silica Sand
There are certain companies that manufacture silica sand here in the Philippines, one of
them is JFMF Retail & Trading located at Lapu-lapu City. There was a great decline on the
export of sand during the recent year, however after the decline the export immediately rose on
the succeeding year. The data for import and export based on UN Comtrade are as follows:
Year
2007
2008
2009
2010
2011
2012
2013
2014
2015

Import (kg)
126,433,591
94,173,331
121,992,453
82,898,364
129,909,219
72,268,060
171,591,835
105,604,033
113,838,941
Table : Export and import of silica sand

Export (kg)
1,670,197
2,279,068
2,787,651
3,537,046
23,535,652
640
8
8,820
25,000,000

Import
Export

Figure : Graphical representation of import and export of silica sand

Powder Coke
Powder coke is being imported since there is no company that produces it here in the
Philippines. The main importer and supplier here in the Philippines is India Phil Minerals & Gen,
Trade, Inc. located at Binondo, Manila. China is the major country the imports the Silica sand.
Based on UN Comtrade the data for import are:
Year
Import (kg)
2007
8,098,830
2008
7,942,833
2009
26,396,660
2010
48,228,899
2011
12,722,902
2012
20,020,222
2013
13,570,711
2014
21,558,743
2015
58,953,567
Table : Import of powder coke

Import

Figure : Graphical representation of the import of powder coke

Reactions Involved
Production of phosphoric acid using blast furnace consist of two main reaction. The first
reaction happens within the blast furnace where phosphorus pentoxide, P2O5, is being
produced. (The Essential Chemical Industry Online, 2013)
2P + 5CO + 5O2 P2O5 + 5CO2
The second process is the conversion of P2O5 to Phosphoric acid by hydration.
P2O5 + 3H2O 2H3PO4

Number of Equipment
The equipment used in manufacturing of phosphoric acid using blast furnace are as
follows:
Quantity
Equipment
1
Blast Furnace
1
Dust Collector
1
Boiler
1
Hydrator
1
Blast Stove
1
Briquetic Press
1
Precipitator
1
Compressor
TOTAL
8
Table : Equipment used summary

Raw Material Cost

Price cost of each raw material based on Alibaba
Raw Material

Cost per Ton

Phosphate rock

Php 4,950

Silica sand

Php 1,575

Powder coke

Php 4,500

Charcoal Briquette

Php 22,050

Table : Prices of raw material in Php

Product Yield
During the thermal process, phosphorous is burned in a combustion chamber and then
reacted with water to produce Phosphoric acid that contain 75% to 85% P2O5. (Walton, 1993)

By-product
Reaction of phosphate rock and silicon produces Carbon Monoxide then reacting
Phosphorus, Carbon Monoxide and Oxygen produces Carbon Dioxide.

Process Capability
Phosporic Acid produced via thermal process is highly concentrated and contains fewer
to almost no impurities. However, this process is not used anymore because there are other
methods which are better and much easier which has the same yield.

Process Usage
Process was used by the Victor Chemical works in 1929 to 1938, now Stauffer Chemical
Company. The plant was located at Nashville, Tennessee (Gilmour, 2014)

Bibliography
Gilmour, R. (2014). Phosphoric Acid: Purification, Uses, Technology and Economics.
Taylor & Francis Group, LLC.
Patel, D. N. (n.d.). Module 4: Phosphoric Acid. NPTEL.
The Essential Chemical Industry Online. (2013, march 18). Retrieved from
http://www.essentialchemicalindustry.org/chemicals/phosphoric-acid.html
Walton, T. G. (1993). Phosphoric Acid and Phosphatic Fertilizers.