Management Associate Presentation Presented by Losses Control at DAP PLANT 2 Purpose To reduce the losses and recover into system for optimizing Plant Process 3 Scope of Presentation ID: 568810
Download Presentation The PPT/PDF document "1 SYED MUHAMMAD ALI NAQVI" is the property of its rightful owner. Permission is granted to download and print the materials on this web site for personal, non-commercial use only, and to display it on your personal computer provided you do not modify the materials and that you retain all copyright notices contained in the materials. By downloading content from our website, you accept the terms of this agreement.
Slide1
1Slide2
SYED MUHAMMAD ALI NAQVI
(Management Associate)
Presentation
Presented by:
Losses Control at DAP PLANT
2Slide3
Purpose
To reduce the losses and recover into system for optimizing Plant Process
3Slide4
Scope of Presentation
Reasons and Recovery of Ammonia Loss
Reasons, Effects and Recovery of Dust Loss
Losses Emission Points
Losses at DAP Plant
Background
Stack Losses and comparison of Design & Operating conditions
Suggestion
4Slide5
Background
In any Process industry, Loss of Nutrients (either from Raw material or Product) is the Loss of Money, Loss in Profit and mitigation of Production rate.
5Slide6
Losses at DAP Plant
Losses at DAP Plant
Dust Lost
Ammonia Loss
P
2
O
5
Loss
6Slide7
Recycle Belt Conveyor
Pre neutralizer
Granulator
Dryer
Primary Screens
Oversize Crusher
Product Conveyor
Polishing Screens
F.B.C
Gaseous Ammonia
Scrubbing Liquor
Phosphoric Acid
H
2
SO
4
Liquid Ammonia
GPR
Granulator feed bucket elevator
Primary Screen Feed Elevator
Dedustig
Section
Scrubbing Section
Dust Loss
Ammonia Loss
Stack
Chilled Air
Coater
Polishing screen feed elevator
Recycle Solids
Losses Emission Points
7Slide8
Reasons of Dust Loss
Reasons of
Dust
Loss
Quality of Phosphoric Acid
Limitation of Dedusting Section
8Slide9
Effect of Dust Emission
Continuous reclaiming of dust
Housekeeping
9Slide10
Hopper
Dryer
Dedust
Cyclone
Dryer Exhaust Fan
Dusty gases from Dryer
Dryer Venturi Scrubber
Recycle Belt (DM-223)
Dust
Dust Recovery
Hopper
Dedust
Cyclone
Dedusting Exhaust Fan
Dusty air from Conveyors, Elevators, Screens
Granulator
Bag house
Instrument Air
10Slide11
Reasons of Ammonia Loss
Reasons of
Ammonia Loss
Poor working of Scrubbing
Frequent Shutdown & startup
11Slide12
Schematic diagram for Ammonia Recovery
PRE-SCRUBBER
PN & Granulator Gases
RG SCRUBBER
TAIL GAS SCRUBBER
STACK
Dryer SCRUBBER
PRIMARY SCRUBBER TANK
Phosphoric Acid
Industrial Water
H
2
SO
4
PN Reactor
50-70 %NH
3
recovered
Above 90%NH
3
recovered
From Dryer exhaust fan
Above
95%NH
3
recovered
Maximum NH
3
recovered
Atmosphere
12Slide13
Stack losses
Component
Design Loss
Actual Loss in 2011
Actual loss during 2012Particulate matter150 mg/NM3
<10 mg/NM3
<10 mg/NM3
Ammonia100 mg/NM379 mg/NM373 mg/NM3P2O536
mg/NM
3
<10
mg/NM
3
<10
mg/NM
3
Fluoride
30
mg/NM3
<1 mg/NM3<1 mg/NM3
13Slide14
Suggestion
Good quality of Phosphoric acid should be used.
Size of flappers of Dedusting hoppers should be increased for increasing suction of Dedusting Fans for lowering emission of dust in operating area.
Scrapper system of Recycle belt (DM-223) should be maintained properly.Provision of Dual strainers in the discharge of RG scrubber Pump(DP-5012).14Slide15
Thank You
15Slide16
Comparison of Stack Dust Loss(mg/NM
3
) b/w Operating & Design conditions
16Slide17
Comparison of Stack Ammonia Loss(mg/NM
3
) b/w Operating and Design Conditions
17Slide18
Comparison of Stack P
2
O5 Loss(mg/NM3
) b/w Operating and Design Conditions
18Slide19
Dedust cyclones and Bag house Analysis
Equipment
Date
Component
UnitInlet DuctOutlet DuctDD-431
26/4/12Dust
g/NM3
9066DD-403226/4/12Dustg/NM3
408
4
DD-433
26/4/12
Dust
g/NM
3
322
8
Bag
House
26/4/12Dustg/NM3
5.04
19Slide20
Phosphoric Acid
SHIPMENTS
Composition: Range 111
th
112
th
113
th 114th
P2O5 52.00 – 54.00 54.2 53.4 53.1 53.3
Fe
2
O
3
0.40 – 1.00 0.39 0.43 0.41 0.45
Al
2
O
3
0.50 – 1.00 0.36 0.47 0.48 0.50
F 0.30 – 0.50 0.22 0.33 0.33 0.35
CaO
0.05 – 0.30 0.03 0.02 0.04 0.01
MgO
0.12 – 1.30 0.70 0.76 0.69 0.70
20Slide21
Analysis of three types of phosphoric acid produced by acidulation of different phosphate rocks
Item Acid A (wt%) Acid B (wt%) Acid C (wt%)
P
2O5 50.50 52.14 51.29
Fe2O3 1.250 0.580 0.120
Al2O3 0.981 0.714 0.200
F- 0.640 0.610 0.630
CaO 0.090 0.083 0.104MgO 0.610 0.570 0.552
21Slide22
Comparison of the effects of impurities on the number of
fine particles and granulation quality of produced
DAP
22Slide23
Operating Range of Scrubbing Section
23