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The traditional way of producing DCP requires to produce or to buy phosphoric acid on the market.
That phosphoric acid needs to be purified prior to the neutralisation to DCP. Another option is to buy high-quality phosphoric acid on the market, but the price will be high and the margins on the final product DCP will be low.
Prayon offers a unique process to produce a feed-grade DCP with the highest possible margin on the variable costs and two valuable co-products. The “Ecophos” process starts from the rock phosphate (that can be either low- or high- grade) and uses diluted hydrochloric acid possibly recovered from other industries. The purification of the raw material is integrated into the process as the impurities are removed through the rock and CCP residues.
These are the process conditions of the Module 1A that will define the quality of the final product by selective removal of the impurities. Sulfuric Acid may be added at Module 4 so that CaCl2 is converted back to HCl reducing accordingly the Hydrochloric Acid consumption.
The first valuable co-product from the Ecophos process is the Calcium Chloride that can be recovered as a de-icing or dedusting salt or used for oil drilling.
The second valuable co-product is the Calcium Sulfate or “Pure Gypsum” that is raw material of choice for any plaster producer.