Professional Documents
Culture Documents
Basic data:
Location of the project:
It is located on the bank of the river Karnaphuli at which is about 4km
from Chittagong Airport & 12km to the south of Chittagong City. This
location is in Patenga Industrial Area having communication facilities by
rail, road & river.
Product Name:
1. Main Product: TSP fertilizer.
2. Intermediate Products: Sulfuric Acid, Phosphoric Acid.
3. By-Product: Gypsum.
Plant Process:
Name of Plant
Reaction Plant
Den Process
Granulation Plant
Stami Carbon
37.25
2. Gypsum field
11.98
3. Housing area
16.69
9.90
5. Others
4.69
total
80.51
Source
Rock Sulphur
Rock Phosphate
Jordan, Morocco,
Algeria, Syria.
Phosphoric Acid
Eqypt,
China,
Process description
The process flow in each of the plants involved in the project is described
as follows:
Water pumped to
clarifier (here, alum
and caustic added)
clear water
passed to
filter bed
Clear
water
(Residue out)
purposes, etc.)
Demineralizer
(cation and anion
exchanger)
Important points:
Reservoir:
Water is collected in 350 Mt reservoirs during low tide period when
amount of salts
in water is low. Water contains about 250 ppm chloride ion is
preferable. Sedimentation occurs here. Sedimented water is transferred
to another tank having same capacity. Four centrifugal pumps at intake
station near jetty are used for water transport.
Clarifier:
Water is clarified by coagulation, floaculation and settling in clarifier. Alum
is used to coagulate and NaOH is used to maintain pH here. From clarifier
water goes to clarified water tank. Two lines are connected to clarified
water tank one goes to cooling water tank and other goes to clean water
tank.
Filter Bed:
A main portion of clear water is sent to filter bed by pumping for filtration.
Filter bed is composed of anthracite, coke and grave.
To remove cation and anion from water, one cation and two anion
exchanger bed are used in water treatment plant. Cation exchanger bed
works based on weak base and anion exchanger bed works on strong
base. Regeneration of cation exchanger bed is done by H 2SO4 and
regeneration of anion exchanger bed is done by NaOH solution.
In the boiler.
MILLING PLANT
For the purpose of uniform mixing and uniform reaction in the plants, it is
very important for the particle size of reactants to be uniform at a
required value. In this plant 200nm size of particle of rock phosphate is
produced which is used for manufacturing TSP fertilizer & phosphoric acid.
The rock phophate which is imported is non-uniform in size and therefore
it must go through the milling plant in order to be processed to the
required uniform size.
Then these rock phosphate are weighed by the rock weigher and
sent to rock feeder through bucket elevator.
Rock feeder is used to feed rock phosphate into the ball mill. Ball
mill consists of four types of balls of different sizes 40mm, 50mm,
60mm, 70mm made of cast iron, mild steel, stainless steel. Hot air &
rock phosphate are charged into rotating ball mill where rock
phosphate is ground into desired size (200nm) & moisture is also
removed from it. The ball mill of this plant is rotated at 18rpm. The
balls hammer the rock phosphate turning it to required form and
wind pressure forces it upwards.
Outlet of ball mill is sent to mill classifier, where over size (>200nm) rock phosphate
is separated from desired size. Over size rock phosphate is recycled into ball mill
through rock feeder and desired size rock phosphate is sent in ground rock cyclone. In
ground rock cyclone more separation of oversize rock phosphate is occurred.
Only desired size of rock phosphate is sent in rock hopper from rock cyclone. And
this rock phosphate is used to manufacturing TSP in TSP plant & phosphoric acid in
PA plant.
amount
99.5% minimum
0.5% maximum
very less
within a required amount
Sulphur Chargin
(Molten sulphur
g
Settlin
Pumpin
g
g
chambe
chambe
r to furnace)
r
sent
chambe
r
Furnace
In this part of the process, molten sulphur is burned in dry air to form
sulphur dioxide at a temperature range of about 900-1000 0C. Molten
sulfur from the melter is sprayed into the furnace by a pump & two
sulphur guns. Fresh air from the drying tower is charged into the furnace.
The following reaction takes place:
S
O2
SO2
Owing to the exothermic nature of the reaction, heat is evoled. The outlet
gas is passed to the waste heat boiler.
Gas filter
The impurities present in the furnace outlet are removed in the gas filter.
Gas filter consists of crushed fire brick that reduce the amount of catalyst
required & increase the life of catalyst. Impurities increase the pressure
drop & decrease the conversion efficiency. Thereofre it becomes vital to
filter them out.
Converter
Converter is one of the major parts of this plant. Here, SO 2 is converted to
SO3 in presence of the catalyst VO. The converter consists of 4 different
beds for better conversion. The beds have different volume, different
amounts of catalyst, pressure, etc. Temperature variation may occur in the
different beds but the overall converter temperature remains fixed at
about 4300C. In first and second beds, gas is leaving at elevated
temperatures so to maintain an adequate level of temperature cold fresh
air is passed through the converter. This air comes from drying tower. In
the third bed, the gas flow is passed into a heat exchanger, where SO 2 &
SO3 given in shell side and cold fresh air passed in tube side. The
following reaction takes place at the converter:
SO2
O2
SO3
10
The main purpose of the two economizers used in this plant is to reduce
the temperature level of the gas stream to an appropriate inlet
temperature for the absorbing tower. Demi water from water treatment
plant is used as the cooling medium. Output hot water (mainly steam) is
sent to waste heat boiler section. The gas stream from the converter
enters 1st economizer at a temperature of 430 0C and leaves at 2300C. The
2nd economizer further reduces the temperature to 170 0C which is the
required inlet temperature for the absorbtion tower.
Absorbing tower
The gas stream from the 2nd economizer at 1700C is passed to the AT
tower (absorbing tower). AT tower is one kind of packed bed that consists
of reaching rings through which SO passes and therefore better mixing
and reaction time possible. This gas is passed at the lower end of the
tower and from the top end of the tower, 98.5% H2SO4 is passed. This is
done as we know SO cannot be absorbed directly into water. Counter
current flow takes place. 98.5% H 2SO4 is circulated continuously and the
reaction produces 99.9% H2SO4. The stack gas is sent to the atmosphere
and the product stream is passed to D.T pump tank.
Drying tower
Drying tower is a scrubber. 98.5% H2SO4 is sent to the tower, where H2 SO4
is spray the top of the drying tower & air passed through the bottom of
the tower. Air is sent to the drying tower from atmosphere by blower &
11
turbine. In this section fresh air is produced, where 98.5% H 2SO4 absorbs
moisture from air. Then this fresh air is sent to furnace for producing gas.
Dilute sulphuric acid is sent to D.T tank.
In TSP plant.
In Iron industry.
In Laboratory.
Process outline:
Acid cooler
98.5% Sulphuric acid and dilution water are mixed and the heat generated
is tranferred to cooling water in the dilution cooler. After cooling , the
temperature of the dilute acid is usually about 70-80%. The flow rate of
the cooling water is regulated by a valve and controlled by the diluted
H2SO4 temperature recording controller.
12
Premixer
Rock phosphate passing from 70% pass 200 meshes (200 mesh means
200 holes per inch), 75%H2SO4 from dilution cooler and phosphoric acid
(20% P2O5) are fed to the premixer. Acid enters at 60C and rock
phosphate enters at 50-60C. Reation starts and around 55% reaction
takes place in the premixer. A temperature of about 98C is maintained in
the premixer.
Digester
The premixer outlet is fed to the digester for further reaction. Roughly a
temperature of around 67C is maintained in the premixer. There are two
digesters. Time, temperature and agitation are maintained in the
digesters for proper reaction. Around 80-85% of the reaction is completed
here.
Crystallizer
The major difficulty in the phosphoric acid plant is the crystal production
and seperation of soild and liquid part. To enhance crystal formation, there
are 3 crystallizers with a relative decrease in their temperature levels
having temperatures of 58C, 57C and 55C respectively. Slurry
proceeding form the decomposition stage, containing hemihydrate of
CaSO4 is recrystallized and thereby hydrated to from gypsum. The slurry
decomposed phosphate rock is introduced into the three crystallizers.
Near the point of entry, the slurry is mixed with the seed recycled from
the crystallizer. Proper agitation and settling time maintained in the
crystallizers so that about 98% of reaction is completed at the end of the
3rd crystallizer. It takes about 16 hrs (reaction time) for the slurry to cross
the whole area.
Filter
13
Concentrator
The product acid of 30% P2O5 is then concentrated to 50% P2O5 acid in a
concentrator (calendria) by heating the material with steam under forced
vacuum circulation system. This is done because 50% P 2O5 is required to
produce TSP of the required 46% P2O5. Low pressure steam is used in the
shell side where phpsphoric acid is passed through tube side. Here two
stage ejectors are used with barometric condenser to create vacuum in
the evaporation section. The evaporator is kept half filled for the purpose
of evaporation. The equipments here are made of graphite tube which is
appropriate for phosphoric acid handling. 50% P 205 content PA is sent to
TSP plant. About 135MT of phosphoric acid is produced per day.
Uses of Gypsum:
14
In fertilizers
As an additive in cement
In Wall board
In Plaster products
15
Dilution cooler
98% H2SO4 is produced in sulphuric acid plant but to produce TSP fertilizer
only 70% H2SO4 is required. Therefore, 98% H2SO4 is diluted by mixing D.M
water (maintaining H2SO4 & D.M water ratio) in dilution cooler. Dilute H2SO4
(70% H2SO4) is stored in storage tank. From this tank 70% H 2SO4 is fed to
cone mixer for producing TSP fertilizer.
Cone mixer
Cone mixer contains a simple cone box in which ground rock phosphate
from ground rock bin & 70% H2SO4 from & 50% phosphoric acid from PA
plant are fed. Cone mixer mixes the entire compound uniformly & the
mixer is charged into continuous den.
Continuous den
Reaction mixture from the cone mixture is dropped to the continuous den
consisting of a conveyor belt upon which the product dries & proceeds
towards the outlet. The retention time of den is 20 minutes and there is a
rotary cutter which slices the product and the belt conveyor transports the
product to the curing house before it is sent to the granulation plant.
Unreacted rock phosphate & some gas produced in continuous den
containing rock phosphate is fed to scrubber. From scrubber, recycled rock
phosphate is fed to cone mixer.
GRANULATION PLANT
16
The cured TSP from the curing house is taken to the granulation plant.
Granulation is a process by which granular TSP is produced from powder
TSP. In this Granulation plant, 1-3.3mm size of TSP fertilizer is produced
through the Stamicarbon process. The capacity of this Granulation plant is
500 ton/day. For reducing waste, this plant needs to be inactive for 4
hours in a day. The plant consists of a drum-like granulator. Here, granules
are formed through the principle of agglomeration with steam and process
water.
17
Bucket elevator
A bucket elevator is used for transporting TSP from rotary drum dryer to
coarse screen (it is also required for the transport of the green TSP from
conveyor belt to granulator).
Coarse screen
Outlet from the rotary drum dryer is fed to coarse screen by a bucket
elevator via a conveyor belt for separating over (>3mm) & under (<1mm)
size granular TSP from standard size (1-3.3mm) TSP. over size is then sent
in crusher & standard & under size TSP sent in fine screen.
Crusher
Over size granular TSP is fed to crusher where it is crushed into desired
size of TSP. Then crushed TSP is sent back to coarse screen.
Fine screen
Under size TSP is separated from standard size TSP in fine screen section.
Standard size TSP is sent in bagging plant and under size TSP is sent back
in granulator.
18
BAGGING PLANT
For the purpose of sending the final product to the market, TSP
fertilizer from granulation plant is sent to the bagging section through
the conveyor belt and bucket elevator. In this section, TSP is charged
into a hopper where a measuring device is used to measure the weight
of TSP fertilizer. 50kg of TSP fertilizer is charged in every bag. After
bagging these are sent to storage house via conveyor belt. The bag
consists of a layer of polythene inside and a layer of polypropylene
outside. The capacity of this bagging plant is bagging of TSP 16-18
bag/min. The final product granular TSP has the following composition:
Amount
Moisture content
5% Maximum
Total P2O5
46.0% Minimum
40.0% Minimum
3.0% Maximum
Size
Design Basis
To produce 97200 Metric ton per year (MTY) granular TSP of 1
3.3mm sizes.
19
Milling Plant
( fine
ones pass out)
BALL MILL
(wind takes away the
(Rock phosphate
grinded
by balls)
FURNAC
E
(dry air
added)
CONVERTER
AT
TOWER
HSO
(sulphuric
acid
added)
PAN
PREMIX
ER
DIGEST
ER
FILTE
R
CRYSTALLI
ZER
CONCENTRA
TION
UNIT
Reaction Plant
CONE
CONTINUOUS
DEN
MIXER
Green TSP
(recycled rock
phosphate)
SCRUBBE
R
Material Balance
For Sulphuric Acid Plant:
To Design 400 MTD (120 000 MTY) capacity sulphuric acid plant :
( how to calculate Back cal.)
400 MTD = 16666.67 kg/hr of acid (considering 300 days a year
plant is running)
With 98.5% purity, the acid per hour = (0.98*16666.67) kg/hr =
16333.34 kg/hr
Kmol/hr of Sulphuric acid to be produced = (16333.34 /98)
=166.67 kmol/hr
Absorption of the acid is 100%
Therefore, SO3 = 166.67 kmol/hr (SO3 + H2O = H2 SO4)
Overall conversion of SO2 to SO3 in reactor is 99.8% (SO2
= SO3)
O2
(S
O2
SO2 )
22
kmol/hr
23
13185.23 kg/hr
For 127.6 kmol/ hr, water required = (2*127.6) kmol/hr
= 255.2 kmol/hr
= (255.2 * 18) kg/hr
= 4593.6 kg/hr
For Gypsum production:
(Ca(PO) + 3HSO +6HO 2HPO + 3 CaSO.2HO)
3 kmol H2SO4 reacts to produce 3 kmol gypsum,
Then, 127.6 kmol/hr H2SO4 reacts to produce 127.6 kmol/hr
gypsum
24
= (127.6 * 172)
kg/hr
= 21947.2
H3PO4 required
Also, to produce 756 kg/hr TSP, 54 kg/hr H2O required (from
stoichiometry)
Therefore, 13500 kg/hr TSP from (54/756 * 13500) kg/hr
25
= 964.3 kg/hr
H2O required
Energy Balance
Equipment List
For Sulphuric Acid Plant
Melter
Furnace
Waste heat boiler
Gas filter
Converter
1st and 2nd Economizers
AT Tower
Drying tower
Pump
Dilution Cooler
26
Equipment Design
27
P & I Diagram
Plant Layout
28
Costs (Taka)
Percenta
ge
Of TFCI
Direct costs
Purchased Equipment
2289008400
40%
Purchased Equipment
installation
572460000
10%
343476000
6%
Piping
457968000
8%
Electrical
286230000
5%
Buildings
171738000
3%
Yard improvements
114492000
2%
Service facilities
457968000
8%
57246000
1%
Land
4551418000
Indirect costs
Engineering & supervision
343476000
6%
Construction expense
228984000
4%
Contractors fee
114492000
2%
Contingency
286230000
5%
973182000
5724600000
Taka
29
Production Cost:
Component
Rock Sulphur
Rock
Phosphate
Amount
(MTY)
Price per MT
Costs
(Taka/Y)
38670
7000
270690000
134790.696
10000
Total
1347906960
1618596960
Utilities:
The Cost of Utilities = 294660000 Taka
General Expenses:
Administrative costs:
30
Local Taxes:
3% of the total fixed capital investment
So, Local Taxes = 171738000 Taka
Insurance:
Insurance costs = 50000000 Taka
Other costs:
Costs = 200000000
Name of
product
Amount
(MTY)
Income
(Taka/Y)
TSP fertilizer
97200
2138400000
Sulphuric Acid
6750.3
101254500
Gypsum
158019.84
1106138880
Total
(from selling
product)
3345793380(Ta
ka/Y)
Economic Analysis:
Gross Income = Total income total production cost
= 3345793380 2924994960
= 420798420 Taka
32
HAZOP Analysis
A HAZOP analysis is a procedure for the systematic, critical, examination
of the operability of a process. Techniques considered are:
(a) Failure modes and effects analysis (FMEA).
(b) Failure modes, effects and criticality analysis
(FMECA).
(c) Hazard and operability studies (HAZOP).
(d) Event tree analysis (ETA).
(e) Fault tree analysis (FTA).
(f) Probabilistic hazard analysis
A HAZOP analysis should be carefully examined for any plant with a large
number of equipments which may have risks of hazards. Smooth
operation can be done by prevention of possible accidents. Let us take the
sulphuric acid plant for example and study the HAZOP analysis on it for
enhanced safety.
Guid
e
wor
Deviati
on
Causes
Consequences
Actions
33
No
Temp.
Less
Temp.
More
Level
No
Less
Rever
se
Deviat
ion
Flow
Flow
Level
Causes
Fully failure
pump
Consequences
of
Overflow
sulphur
of
Actions
34
Guid
e
wor
d
Deviati
on
Causes
Low
Temp
More
Temp.
More
Flow
Consequences
Reducing
Pressure
Loss of Heating
Faulty
Instrumentatio
n and Control
Reaction
Control
Failures
Heater Control
Failure
Faulty
Instrumentatio
n and Control
Ratio controller
mis-operation
Actions
SO2
combustion
will not occur
Resulting in
incomplete
combustion
and possible
after burning
and flame
impingement
on
tubes
Higher
percentage of air
& gas content,
increase Furnace
temperature
Increase
the
temperat
ure up to
desired
level.
Procedure
s to limit
fuel firing
to air
availabilit
y
Automati
c heater
shutdown
Replace or
repair ratio
controller
Guid
e
wor
d
Deviatio
n
Flow
Less
As
well
as
compositi
on
Causes
Consequences
Actions
Gas
or
Gas
35
Guid
e
wor
d
No
More
Deviati
on
Flow
Flow
Causes
Actions
Less
Consequences
Temp.
or
controller Excess
air Replace
or
consumed in the repair
ratio
Converter
controller
&reduce temp.
Guide
word
Deviati
on
Causes
Consequence
s
Actions
36
High
Pressure
High
Tempera
ture
Surge
Problems
Inadequate
Volume of
Vents
Incorrect Vent
Set Pressure
for Vents
Failed Open
PCV
thermal
expansion/cont
raction
between tubes
and shell
resulting in
tube
leak/rupture
Procedural
control of
introduction
of process
fluids on
start-up and
shutdown
Periodic
inspection
Fouled or
Failed
Exchanger
Tubes
Cooling D.M.
Water Failure
Faulty
Instrumentati
on and
Control
Loss of
mechanical
integrity of
tube
High
temperatur
e indication
with alarm
External fire
Repair
necessary
equipment
Guide
word
Deviati
on
Less
flow
Causes
High
Flow
If SO3 is not
available from
2nd
economizer
98.5% H2SO4is
not available
from drying
tower.
Control Faults
Greater Fluid
Density
Cross
Connection of
Consequence
s
Contact
process for
the
production
of sulphuric
acid is
hampered.
Less
production
Create a high
pressure
Actions
Operator
action in
response to
low flow
indication
High speed
alarm and
overflow
shutdown
37
Systems
system
38
39