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Merchant Grade Acid (M.G.A.), the market standard phosphoric acid quality, is the basis for fertilizer production (MAP, DAP, NPK’s, TSP).

Prayon offers five processes for Phosphoric Acid Production (Dihydrate, DA-HF, Central-Prayon, Hemihydrate, Hemi-Dihydrate) from either a phosphate rock or a DCP super-rock (Upgraded Rock- Ecophos, Upgraded Rock-GetMoreP). The selection of the suitable process is based on the quality requirements for the co-product gypsum and on the availability and cost constraints regarding raw material and utilities.

Based on preliminary discussions about your project, Prayon will guide you to the optimum process. During the pilot test phase, the process conditions will be adjusted to improve P₂O₅  recovery and filtration rate in order to design a robust and economically-optimized plant.

DCP – Dicalcium Phosphate Fertilizer or DCP “Super-Rock”, is a key intermediate in phosphate production that can be used in the production of high-quality low-cadmium fertilizers (SSP, TSP, CSP, WPPA).

DCP Super-Rock can also be converted into high-quality phosphoric acid directly suitable for fertigation and the production of water-soluble fertilizers (NPK, MAP, DAP). Instead of requiring a high-quality or treated phosphoric acid, a low-grade rock phosphate can be directly converted into a DCP fertilizer or super-rock. That process acts as a chemical beneficiation of the initial rock.

Based on the rock quality and project specifities, Prayon offers two solutions :

• Upgraded rock – Ecophos
• Upgraded rock – GetMoreP

Our experts will support you to select the best option for your project.

DCP, Dicalcium Phosphate, a pure and concentrated form of phosphate, is highly bio digestible (up to 82%) and ensures a healthy bone structure.

Instead of requiring a high-quality or treated phosphoric acid, Prayon processes enable to convert a low-grade rock directly into a DCP animal feed-grade.

Based on the rock quality and project specifities, Prayon offers two solutions :

• DCP – Ecophos
• DCP – GetMoreP 

MCP, Monocalcium Phosphate Monohydrate, Ca(H₂PO₄)2. H₂O, a granular phosphate source, makes cattle and poultry food more digestible and improves their bone structure.

Prayon offers a solution to produce MCP by neutralising phosphoric acid by a calcium source (calcium carbonate or calcium hydroxide) or by acidulating DCP with phosphoric acid.

With a clear focus on the circular economy, our teams keep innovating day in, day out to make a valuable product from gypsum, the main co-product from the phosphoric acid production.

Prayon provides no less than three processes to produce phosphoric acid and, at the same time, a gypsum co-product suitable for the cement or plaster industry.

Depending on the phosphogypsum target market and the project constraints, Prayon offers:

• Self-drying gypsum for cement industry through DA-HF process 
• Self-drying gypsum for cement and plaster industry through Central-Prayon process 
• Gypsum for cement and plaster industry through Hemi-Dihydrate process

Additionally, our DCP – Ecophos and Upgraded rock – Ecophos enable the production of DCP and recycled hydrochloric acid by adding sulfuric acid – leading to a pure gypsum co-product.

Solid calcium chloride is used in various applications such as de-icing, dedusting or oil drilling.

The Calcium chloride, a pure co-product from the DCP – Ecophos and Upgraded rock – Ecophosprocesses, is first concentrated to a solution of 35% CaCl₂. After further concentration and drying, it is turned into 76% CaCl2 flakes or 96% CaCl₂ granules.

To protect the environment from undesirable pollutants (liquid effluents or gaseous emissions), Prayon has developed an efficient way to clean the gases from the various sections of a phosphoric acid plant.

Additionally, a part of the fluorine from the rock can be recovered at the concentration stage of the acid. Prayon offers a technology for this purpose that recovers the fluorine as a fluosilicic acid solution from 14 to 25%, depending on the anticipated application.

Depending on the source of fluorine gases, Prayon offers two technologies:

– From low-vacuum streams (close to atmospheric pressure), Gas Scrubbing process is applied fitted with Profile scrubber equipment.

– From high-vacuum streams, Fluorine Recovery process is applied fitted with Profile spraying equipment.