In the name of Allah, The most Merciful & Beneficent.

FAUJI FERTIZER BIN QASIM LTD. COMPARISON OF AZF DPR AND JACOBS SLURRY TECHNOLOGY FOR DAP MANUFACTURING BY: MUHAMMAD WASEEM APP. ENGINEER DAP OPERATIONS

OUT LINES DAP formation & plant description. Various methods for DAP manufacturing. Description of AZF double pipe reactor process. Description of Jacobs slurry process. Difference between AZF & Jacobs technology. Advantages of AZF DPR & Jacobs slurry technology.

HOW DAP IS FORMED The main principle of DAP formation is to neutralize phosphoric acid with ammonia and afterwards to granulate the neutralization products. 2NH3 + H3PO4 (NH4)2HPO4 + Q SPECIFICATIONS OF DAP Units Value Description % Min 18.0 Nitrogen 46.0 P2O5 % Max 1.5 Moisture PPM 3900 Coating Agent 0.15 Citrate Insoluble P2O5 93 Granulometry 2 - 4 mm Kg 2.5 Granular strength Raw materials Phosphoric acid Ammonia Filler Sulfuric acid River sand Utilities Natural gas Antifoam Coating agent Industrial water

DESCRIPTION OF DAP PLANT DAP plant consists of Reactors Granulation loop Granulator Dryer Screening & crushing equipment Handling & recycling equipment Product treatment (conditioning) section Cooling Coating Scrubbing section De dusting network

DESCRIPTION OF DAP PLANT Reaction Granulation & Drying Screening Grinding Coating Storage Cooling Scrubbing Feeds Under size & grinded over size Recycle Product GRANULATION LOOP CONDITIONING SECTION Gases De dusting To stack Elevators & conveyors

PROCESSES FOR DAP MANUFACTURING Conventional pre neutralizer process. Single pipe reactor process. Double pipe reactor process. Pre neutralizer with pipe reactor process.

DESCRIPTION OF AZF DPR PROCESS In AZF process two pipe reactors (tubular reactors) are used for neutralization of phosphoric acid with ammonia. Each operates individually, forming slurry & dust. DRYER GRANULATOR H3PO4 LIQ. AMMONIA H2SO4 SCRUBBING LIQUOR AMMONIA SPARGER GPR HOT AIR DPR

DESCRIPTION OF JACOBS SLURRY PROCESS This is the pre neutralizer with pipe reactor kind process. Most of the reaction takes place in pre neutralizer forming slurry. This slurry is sprayed in granulator through pipe reactor where more ammonia and phosphoric acid is reacted for capacity increase. GASEOUS AMMONIA DRYER GRANULATOR H3PO4 LIQ. AMMONIA H2SO4 SCRUBBING LIQUOR AMMONIA SPARGER GPR HOT AIR SLURRY PN

DIFFERENCES B/W JACOBS & AZF TECHNOLOGY Process Reactors Raw material feeding system Recycle ratio Scrubbing system Bag house Ammonia vaporization Environmental impact

ADVANTAGES AZF PROCESS JACOBS PROCESS Saving on Energy. Reduction in Investment. Saving on Maintenance Cost. Great Adaptability for Revamps. Fast startup and shutdown of plant. High service factor of plant. Improved Ammonia Yields. Better pollution control. Flexibility of the Settings. Better scrubbing control.

PROCESS AZF double pipe Reactor Process: Two reactors operates in parallel, one in granulator (granulator pipe reactor) and one in dryer (dryer pipe reactor). Dryer pipe reactor operates at a mole ratio of 1-1.05 producing MAP (dust), while granulator pipe reactor operates at mole ratio of 1.4 - 1.45 producing slurry. Slurry moisture content low. Low residence time for reaction.

PROCESS Jacobs slurry Process : Two reactors operates in series, one is a pre neutralizer (CSTR) and other a pipe reactor which operates in granulator. Pre neutralizer operates at a mole ratio of 1.45 producing slurry. This slurry is sprayed in granulator through granulator pipe reactor where more ammonia & phosphoric acid is reacted for capacity increase. Slurry moisture content high. High residence time for reaction.

AZF REACTORS Granulator pipe reactor Dryer pipe reactor Liq. Ammonia Scrubbing liq. Sulfuric acid Phosphoric acid Hot air Solids recycle Solids to dryer Gases to scrubber Granulator Granulator pipe reactor Dryer pipe reactor Dryer Solids to screening Ammonia sparger

JACOBS REACTORS Granulator pipe reactor Pre neutralizer Ammonia sparger Granulator pipe reactor Liq. Ammonia Gas. Ammonia Scrubbing liq. Sulfuric acid Phosphoric acid Solids recycle Gases to scrubber Solids to dryer Slurry

RAW MATERIAL FEEDS SYSTEM AZF PROCESS JACOBS PROCESS H3PO4 Granulator pipe reactor Dryer pipe reactor Scrubbing first stage Pre neutralizer Scrubbing second stage H2SO4 Scrubbing third stage Liq NH3 Granulator ammonia sparger Gas NH3

RECYCLE RATIO AZF DPR process: Low recycle ratio. Low fuel consumption. Low power consumption. Jacobs slurry process: High recycle ratio. High fuel consumption. High power consumption.

AZF SCRUBBING SYSTEM In AZF process scrubbing consists of two stages. One scrubs the gases of granulator and the other gases from the dryer. A tail gas scrubbing column finally scrubs the gases. High mole ratio & high sp. gravity operation.

JACOBS SCRUBBING SYSTEM In Jacobs slurry process scrubbing system is designed consisting of “dual mole” scrubbing and a tail gas scrubber. Thus reduces the ammonia emissions to atmosphere. Also scrubbing liquor operates at low mole ratio & low sp. gravity.

BAG HOUSE For energy conservation both AZF & Jacobs process used hot de dusting gases as dilution air in hot gas generator flue gases.

AMMONIA VAPORIZATION As compared to AZF process where liquid ammonia is used, Jacobs process designed both the reactors (pre neutralizer and pipe reactor) to operate with gaseous ammonia. Also the cooling provided to the scrubber liquor improves fluorine scrubbing efficiency in the tail gas scrubber.

ENVIRONMENTAL IMPACT AZF PROCESS JACOBS PROCESS Higher ammonia losses from reactor and granulator Low ammonia losses from reactor and granulator Higher dust Low dust Stack analysis: NH3 : 250 mg/nmc P2O5 : 33 mg/nmc F : <1 mg/nmc Particulates : 34 mg/nmc Stack analysis: NH3 : 113 mg/nmc P2O5 : <10 mg/nmc F : <1 mg/nmc Particulates : <10 mg/nmc

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