First of all . . . . .

DAP REVAMP MUHAMMAD SHAKEEL PRESENTED BY: APPRENTICE ENGINEER DAP OPERATIONS FAUJI FERTILIZER BIN QASIM LIMITED

An integral part of Apprenticeship at FFBL OBJECTIVE An integral part of Apprenticeship at FFBL Self study for more detailed exposure

CONTENTS Purpose Why not a new plant instead of BMR? Problems faced in old plant. Major additions made in Revamp Modifications made in Revamp From AZF dual pipe reactor to JACOBS’ PN technology Problems emerging after Revamp Conclusion

PURPOSE FOLLOWING WERE THE PURPOSES TO BE ACHIEVED BY DAP REVAMP To utilize the increased NH3 production To enhance plant capacity by 50% To uplift the country’s economy by reducing the DAP imports as FFBL is its sole manufacturer in Pakistan

WHY NOT A NEW PLANT INSTEAD OF BMR Following main factor lead FFBL management to go for revamp of existing plant instead of installing new plant. COST According to JACOBS budgetary estimate the company would have to spend 13.1 Million USD for Revamp while the total installed cost of new plant was ~ 24 Millions USD. CONTINUE…

WHY NOT A NEW PLANT INSTEAD OF BMR TIME Time was one of the most important factors. Revamp project was to be completed in 14 months while new plant completion requires 24 - 26 months minimal. MANPOWER Additional Manpower was required to run a new plant but after BMR the same no. of persons are operating the plant.

PROBLEM FACED IN OLD PLANT GRANULATOR Frequent rubber panels replacement due to short life i.e. approx. 1~2 months only High frequency of Granulator outlet chute (DM-122) rubber panels damaging. Damage to grizzly CONTINUE…

PROBLEMS FACED IN OLD PLANT DRYER High noise from hammers Plugging of inlet spiral plates & lifters Frequent plant shutdowns for impeller washing due to dust deposition on Dryer off-gases fan CONTINUE…

PROBLEMS FACED IN OLD PLANT HGG Frequent blockage of discharge duct FRP PIPING Frequent blockages, failures and seepages DUST GENERATION MAP formation in powdered form in DPR COATER High vibration Frequent failure of Hydraulic Coupling

MAJOR ADDITIONS MADE IN REVAMP PRE-NEUTRALIZER A new reactor system to take a significant load of reaction. AMMONIA VAPORIZER Removes heat from the circulating tail gas scrubber liquor. The cooling provided to the scrubbing liquor improves its Fluorine scrubbing efficiency. AIR CHILLERS Additional state-of-the-art feature is an air chiller for product cooling & Ammonia Vaporization. CONTINUE…

MAJOR ADDITIONS MADE IN REVAMP PRE SCRUBBER & RG SCRUBBER Utilize a “dual mole” ratio Scrubbing system for Pre Neutralizer & Granulator off gases. Recovers maximum NH3 & Fluorine from off gases BAG HOUSE A dedust bag House installed in series with cyclones to minimize dust carryover to Hot Gas Generator outlet duct

MODIFICATIONS MADE IN REVAMP GRANULATOR Slope increase from 3% to 6.23% Exit chute replaced Grizzly has been changed to a stronger design GPR replaced NH3 sparger replaced Barring device added DRYER Slope increased from 2.5% to 5% Speed increased from 2.2 to 3.8 RPM Hammers replaced with balls in tube CONTINUE…

MODIFICATIONS MADE IN REVAMP MATERIAL HANDLING CAPACITY Dryer exit belt upgraded from11.5 to 16 kW Product conveyor power increased from 8 to 11.5kW Recycle conveyor drive system has been upgraded from 16 to 30 kW Screen feed elevator & Granulator feed elevator internals changed

FROM AZF TO JACOBS AZF DUAL PIPE REACTOR Water fed to Granulator: 6~8% Low recycle ratio Low fuel consumption MAP is formed in powdered form Less residence time PN SLURRY PROCESS Water fed to Granulator 20% High recycle ratio High fuel consumption No MAP is formed More residence time CONTINU…

FROM AZF TO JACOBS Less NH3 fixation More emissions More NH3 fixation Less emissions

PROBLEMS EMERGING AFTER REVAMP BAGHOUSE Dust conveyor safety pin breaking Dust accumulation on grating Passage of dust through Bags Baghouse Inlet Damper passing VIBRATING FEEDERS Material spillage Overflowing of material from one compartment to the other CONTINUE…

PROBLEMS EMERGING AFTER REVAMP NEW POLISHING SCREEN Less efficiency to segregate the material DEDUSTING Frequent blockage of new dedusting chutes High dust formation Limitations of Crushers

CONCLUSION The plant capacity has been increased by 50%. Majority of the problems faced prior to Revamp has been overcome. Enhanced Ammonia production finds its usage to produce more DAP, hence increasing the company profit

QUESTIONS ???

THANKS

GRANULATOR DRYER H NH3

SLURRY DRYER GRANULATOR GRANULATOR DRYER

STACK ANALYSIS BEFORE & AFTER REVAMP # COMPONENT 07.12.07 27.03.07 02.05.08 22.04.08 1 TPM 113 70 <10 2 P2O5 107 33 3 NH3 712 1050 98 4 F <1

PRODUCT RESULTS BEFORE & AFTER REVAMP # date N2 P2O5 1 01.11.07 19.8 45.0 01.04.08 19.3 48.0 2 26.10.07 19.9 41.7 31.05.08 19.0 47.8 3 22.11.06 46.1 19.05.08 4 29.08.06 46.8 30.03.08 19.1 47.7

POLISHING SCREEN INLET & OUTLET ANALYSIS # SIZE RANGE INLET (%) OUTLET(%) 1 +4.5mm 2 +4.0mm 5 3 +2.0mm 78 81 4 +1.0mm 14 <1

BAGHOUSE INLET & OUTLET ANALYSIS # DATE COMPONENT INLET DUCT OUTLET DUCT 1 02.07.08 DUST 69 1.74 MOISTURE 38 31 2 04.07.08 96 1.75 32 27.4

WORLD MONTHLY CS PRICES

FEEDERS OVERFLOWING

OLD & NEW POLISHING SCREENS

BAGHOUSE DUST CONVEYOR

GRANULATOR BARRING MOTOR

BAGHOUSE FILTERS & GRATING