Phosphoric acid commercial processes

White phosphorus also can be produced by a wet process using phosphoric acid, a process that was practiced historically in commercial production. In this method the starting material, phosphoric acid, usually is prepared in large vats by reacting phosphate rock with sulfuric acid ... 

Developments of recent years include plants designed to precipitate the calcium sulfate in the form of the hemihydrate instead of gypsum, hi special cases, hydrochloric acid is used instead of sulfuric acid for rock digestion, the phosphoric acid being recovered in quite pure form by solvent extraction. Solvent-extraction methods have also been developed for the purification of merchant-grade acid, which normally contains impurities amounting to 12 18% of the phosphoric acid content. Processes for recovering part of the fluorine in the phosphate rock are in commercial use. 

There are two basic types of processes for the production of phosphoric acid furnace processes and wet processes. Furnace processes include the blast-furnace process and the electric-furnace process. The blastfurnace process has not been used commercially since 1938. Tlie electric-furnace process is used extensively to make elemental phosphorus, most of which is converted to phosphoric acid for nonfertilizer uses. SirKe it is unlikely that furnace processes wll be competitive for producing phosphoric acid for fertilizer use, except possibly in unusual circumstances, these processes will be described only briefly. 

Ammonium phosphate fertilisers have assumed a greatly increased importance in recent years and have now become the leading commercial product. Mixtures of the mono- and di-salt are obtained from direct reaction of ammonia with wet process phosphoric acid. Commercial production by this method started in the United States in 1917, and about half of the current world production of phosphoric acid is converted to ammonium salts. The tri-ammonium salt is not favoured in fertilisers because of the loss of ammonia on storage. 

Israel Mining Industries developed a process in which hydrochloric acid, instead of sulfuric acid, was used as the acidulant (37). The acidulate contained dissolved calcium chloride which then was separated from the phosphoric acid by use of solvent extraction using a recyclable organic solvent. The process was operated commercially for a limited time, but the generation of HCl fumes was destmctive to production equipment. 

Nitric acid acidulation of phosphate rock produces phosphoric acid, together with dissolved calcium nitrate. Separation of the phosphoric acid for use as an intermediate in other fertilizer processes has not been developed commercially. Solvent extraction is less effective in the phosphoric—nitric system than in the phosphoric—hydrochloric system. Instead, the nitric acid acidulate is processed to produce nitrophosphate fertilizers. 

Triple (Concentrated) Superphosphate. The first important use of phosphoric acid in fertilizer processing was in the production of triple superphosphate (TSP), sometimes called concentrated superphosphate. Basically, the production process for this material is the same as that for normal superphosphate, except that the reactants are phosphate rock and phosphoric acid instead of phosphate rock and sulfuric acid. The phosphoric acid, like sulfuric acid, solubilizes the rock and, in addition, contributes its own content of soluble phosphoms. The result is triple superphosphate of 45—47% P2 s content as compared to 16—20% P2 5 normal superphosphate. Although triple superphosphate has been known almost as long as normal superphosphate, it did not reach commercial importance until the late 1940s, when commercial supply of acid became available. 

The methyl a-hydroxyisobutyrate produced is dehydrated to MMA and water in two stages. First, the methyl a-hydroxyisobutyrate is vaporized and passed over a modified zeoHte catalyst at ca 240°C. A second reactor containing phosphoric acid is operated at ca 150°C to promote esterification of any methacrylic acid (MAA) formed in the first reactor (74,75). Methanol is co-fed to improve selectivity in each stage. Conversions of methyl a-hydroxyisobutyrate are greater than 99%, with selectivities to MMA near 96%. The reactor effluent is extracted with water to remove methanol and yield cmde MMA. This process has not yet been used on a commercial scale. 

Dimersol is a commercial process for the dimeri2ation of propylene, butylenes, or a mixture of both, to and Cg olefins this process produces a more linear olefin than the phosphoric acid process. The reaction is conducted at ambient temperature, using a water-soluble catalyst complex (16). 

Phosphates are the principal catalysts used in polymerization units the commercially used catalysts are Hquid phosphoric acid, phosphoric acid on kieselguhr, copper pyrophosphate pellets, and phosphoric acid film on quartz. The last is the least active and has the disadvantage that carbonaceous deposits must occasionally be burned off the support. Compared to other processes, the one using Hquid phosphoric acid catalyst is far more responsive to attempts to raise production by increasing temperature. 

Manufacture. Phosphoric acid, H PO, is the second largest volume mineral acid produced sulfuric acid is the first. The greatest consumption of phosphoric acid is in the manufacture of phosphate salts, as opposed to direct use as acid. Markets are differentiated according to the purity of the acid. Phosphoric acid is produced commercially by either the wet process or the thermal (furnace) process. Thermal acid, manufactured from elemental... 

Modem commercial wet-acid purification processes (see Fig. 4) are based on solvents such as C to Cg alcohols, ethers, ketones, amines, and phosphate esters (10—12). Organic-phase extraction of phosphoric acid is accompHshed in one or more extraction columns or, less frequently, in a series of countercurrent mixer—settlers. Generally, 60—75% of the feed acid P2 s content is extracted into the organic phase as H PO. The residual phosphoric acid phase (raffinate), containing 25—40% of the original P2O5 value, is typically used for fertilizer manufacture such as triple superphosphate. For this reason, wet-acid purification units are almost always located within or next to fertilizer complexes. 

Commercial condensed phosphoric acids are mixtures of linear polyphosphoric acids made by the thermal process either direcdy or as a by-product of heat recovery. Wet-process acid may also be concentrated to - 70% P2O5 by evaporation. Liaear phosphoric acids are strongly hygroscopic and undergo viscosity changes and hydrolysis to less complex forms when exposed to moist air. Upon dissolution ia excess water, hydrolytic degradation to phosphoric acid occurs the hydrolysis rate is highly temperature-dependent. At 25°C, the half-life for the formation of phosphoric acid from the condensed forms is several days, whereas at 100°C the half-life is a matter of minutes. 

Phosphorus [7723-14-0] is a nonmetaUic element having widespread occurrence in nature as phosphate compounds (see Phosphoric acid and phosphates). Fluorapatite [1306-03-4], Ca F(P0 2> is the primary mineral in phosphate rock ores from which useful phosphoms compounds (qv) ate produced. The recovery from the ore into commercial chemicals is accompHshed by two routes the electric furnace process, which yields elemental phosphoms and the wet acid process, which generates phosphoric acid. The former is discussed herein (see Furnaces, electric). Less than 10% of the phosphate rock mined in the world is processed in electric furnaces. Over 90% is processed by the wet process, used primarily to make fertilisers (qv). 

Currently, almost all cumene is produced commercially by two processes ( /) a fixed-bed, kieselguhr-supported phosphoric acid catalyst system developed by UOP and (2) a homogeneous AlCl and hydrogen chloride catalyst system developed by Monsanto. 

Catalysts. Nearly aU. of the industrially significant aromatic alkylation processes of the past have been carried out in the Hquid phase with unsupported acid catalysts. For example, AlCl HF have been used commercially for at least one of the benzene alkylation processes to produce ethylbenzene (104), cumene (105), and detergent alkylates (80). Exceptions to this historical trend have been the use of a supported boron trifluoride for the production of ethylbenzene and of a soHd phosphoric acid (SPA) catalyst for the production of cumene (59,106). 

Acid-Gatalyzed Synthesis. The acid-catalysed reaction of alkenes with hydrogen sulfide to prepare thiols can be accompHshed using a strong acid (sulfuric or phosphoric acid) catalyst. Thiols can also be prepared continuously over a variety of soHd acid catalysts, such as seoHtes, sulfonic acid-containing resin catalysts, or aluminas (22). The continuous process is utilised commercially to manufacture the more important thiols (23,24). The acid-catalysed reaction is commonly classed as a Markownikoff addition. Examples of two important industrial processes are 2-methyl-2-propanethiol and 2-propanethiol, given in equations 1 and 2, respectively. 

Polymer Gasoline. Refinery trends tend to favor alkylation over polymerisation. Unlike the alkylation process, polymerisation does not require isobutane. The catalyst is usually phosphoric acid impregnated on kieselghur pellets. Polymerisation of butylenes is not an attractive alternative to alkylation unless isobutane is unavailable. The motor octane number of polymer gasoline is also low, and there is considerable shrinkage ia product volume. The only commercial unit to be built ia recent years is at Sasol ia South Africa. The commercial process was developed by UOP ia the 1940s (104). 

Phosphogypsum [13397-24-5] is the name given to the by-product gypsum residue when phosphate ore is acidulated to extract phosphoric acid. There are several processes commercially used. AH of them digest or acidulate tri-calcium phosphate. 

CP esters are generally prepared as the ammonium salt [9038-38-4] by the reaction of cellulose with phosphoric acid and urea at elevated temperatures (130—150°C). The effects of temperature and urea/H PO /cellulose composition on product analysis have been investigated (33). One of the first commercially feasible dameproofing procedures for cotton fabric, the Ban-Flame process (34,35), was based on this chemistry. It consists of mixing cellulose with a mixture of 50% urea, 18% H PO, and 32% water. It is then pressed to remove excess solution, heated to 150—175°C for 5—30 minutes, and thoroughly washed (36). 

Activated alumina and phosphoric acid on a suitable support have become the choices for an iadustrial process. Ziac oxide with alumina has also been claimed to be a good catalyst. The actual mechanism of dehydration is not known. In iadustrial production, the ethylene yield is 94 to 99% of the theoretical value depending on the processiag scheme. Traces of aldehyde, acids, higher hydrocarbons, and carbon oxides, as well as water, have to be removed. Fixed-bed processes developed at the beginning of this century have been commercialized in many countries, and small-scale industries are still in operation in Brazil and India. New fluid-bed processes have been developed to reduce the plant investment and operating costs (102,103). Commercially available processes include the Lummus processes (fixed and fluidized-bed processes), Halcon/Scientific Design process, NIKK/JGC process, and the Petrobras process. In all these processes, typical ethylene yield is between 94 and 99%. 

The extractant is a commercial mixture of mono- and dioctyl phenyl phosphoric acid (OPPA). It is used in conjuction with tributyl phosphate (TBP). Stripping is by ammonium carbonate solution. The mixture shows synergism. Uranium is extracted in the tetravalent state. The process is much less expensive and possesses a higher extracting power than D2EHPA-TOPO combination. 

The most important acid containing phosphorus is orthophosphoric acid, H3P04. This is the acid usually indicated when the name phosphoric acid is used in most contexts. Approximately 30 billion pounds of this acid are produced annually. The commercial form of the acid is usually a solution containing 85% acid. The process used to produce phosphoric acid is related to the intended use of the acid. If the acid is intended for use in foods, it is prepared by burning phosphorus and dissolving the product in water. 

DEPA-TOPO [di (2-ethylhexyl) phosphoric acid and trioctylphosphine oxide] A process for recovering uranium from wet-process phosphoric acid, by solvent extraction with a mixture of the two named reagents. Developed at Oak Ridge National Laboratory and first commercialized in 1978 by Freeport Minerals Corporation and Wyoming Mineral Corporation. 

Wet Process A process for making phosphoric acid by treating phosphate rock with an acid. The acid is usually sulfuric acid, but hydrochloric and nitric acids are used commercially in special circumstances — in Israel where by-product hydrochloric acid is available, and in Norway and Switzerland where nitric acid is made by cheap hydroelectric power. The basic process with sulfuric acid is ... 

Zincex [Zinc extraction] A process for extracting zinc from pyrite cinder leachate, using organic solvents. The chloride leachate is first extracted with a secondary amine, and then with di(2-ethylhexyl)phosphoric acid to remove iron Developed by Tecnicas Reunidas, first commercialized in 1976, and now used in Spain and Portugal. 

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