DAP PLANT SUSTAINABILITY AND DOWN TIME REDUCTION OPERATIONS IRTIZA ALI

OBJECTIVE The main objective is to describe Efforts for Down Time Reduction Modifications for Sustainability As a part of my training plan…………….. Main focus of this presentation is to briefly describe the Plant Sustainability and Down Time Reduction of DAP Plant in the perspective of modifications and suggestions. 1) Efforts for down time reduction 2) Modifications for sustainability

Contents… Process Description Shut Down Requirement Major Modifications Sustainability of Plant Operations Suggestions for Down Time Reduction Conclusion

Process Description

JACOB SLURRY PROCESS DIAGRAM AZF Grande Paroisse 1,350 MTPD Double pipe reactor process Liquid ammonia utilization Low recycle ratio High ammonia loss Jacobs Engineering 2,232 MTPD Slurry process Gaseous ammonia utilization High recycle ratio Low ammonia loss Ammonia BMR: Executed in 2006 & 07 to improve reliability, energy efficiency and capacity by 24%. Project Cost: US$ 68 million. Seven days “Test Run” was conducted successfully in Sept 2007, thereby, achieving the desired objectives. Ammonia plant achieved 1,610 Tons (103%) of revamped capacity on13 Nov 2008. Energy index improved from 10.7 to 9.3 GCal/MT. DAP Revamp: Executed in 2008 to utilize additional ammonia for capacity increase by 50%. Project Cost: US$ 30 million. DAP plant achieved 2,383 Tons (107%) of revamped capacity on 24 Sept 2008.

Shut Down Requirement

REQUIREMENT of SHUT DOWN Shut Down of DAP REQUIREMENT of SHUT DOWN CLEANING ACTIVITIES MAINTENANCE TYPES of SHUT DOWN PLANNED SHUT DOWN UNPLANNED SHUT DOWN

Types of Shut Down Planned Shut Down Turn Around Machinery Maintenance Low Phosphoric Acid Inventory Un-Planned Shut Down Other Factors 24hrs Shut Down Electrical Maintenance Instrument Maintenance Equipment Maintenance Operations Natural Gas Curtailment

Major Modifications UB6 SS316L SS317L SS304L

Efforts for Down Time Reduction Material Up-gradation DT-511 from FRP to SS 317-L DT-5013 from FRP to SS 317-L DD-5031 Portion from FRP to SS 316-L DK-5012 suction & discharge circuits from FRP to SS 316-L DP-5012 A/S Strainers provision DX-4032 Flapper Capacity Enhancement

Sustainability of Plant Operations

Till GRAPH Planned Shut Down Sustainability HOURS Till 20th July YEAR

Suggestions for Down Time Reduction

Suggestions DH-611/612 Replacement Replacement of De-dusting Flappers FRP Duct replacement in Scrubbing area Provision of ID at DK-421 U/P of I/V

CONCLUSION Process Nature suggests Shut Down after regular intervals Shut Down Requirements can be minimized Material Up-gradation has major role in Down Time Reduction Reduction in unplanned shut down is reflection of smooth running of plant

Requirements of Shut Down Cleaning Activities SCRUBBING DE-DUSTING GRANULATION

SCRUBBING REASONS CONIDITONS OUT OF SAFE OPERATING ZONE CHOKING OF WASHING LIQOUR LINES PLUGGING EROSION SCALING CHOKING OF WASHING LIQOUR LINES REASONS CONIDITONS OUT OF SAFE OPERATING ZONE HARD SCALING DUE TO FORMATION OF SALTS PLUGGING OF NOZZLES

DE-DUSTING LUMP FORMATION CHOCKING DUST SETTLING SCALLING

GRANULATION GPR Nozzles Granulator Lumps Dryer Material Elevator Boots Conveyer Structure

PHOSPHORIC ACID IMPURITIES Aluminum Oxide Iron Oxide Suspended Solids Magnesium Oxide Calcium Oxide Suspended Solids Iron Oxide PHOSPHORIC ACID IMPURITIES

SHIPMENTS Shipment# CaO Fe2O3 Al2O3 MgO Solids 321 0.15 0.27 0.26 1.30 0.59 322 0.23 0.38 0.14 1.13 0.24 323 0.01 0.48 0.35 1.40 0.20 324 0.4 0.22 1.24 0.36 325 0.05 0.21 1.1 326 0.1 0.11 1.05 0.3 327 0.12 0.2 1.3 328 0.04 0.49 0.16 1.6 329 0.02 0.47 0.18 1.18 0.17 330 1.56 331 0.03 0.43 1.42 0.28 332 0.94 333 SHIPMENTS

Requirements of Shut Down Maintenance Types of maintenance Requirement of maintenance

Types of Maintenance Preventive Maintenance (PM) Corrective Maintenance (CM) Improvement Maintenance (IM)

PLANNED SHUT DOWN HISTORY Description 2011 2012 2013 2014 2015 Budgeted 62 93 94 82 60 Planned S/D 40.74 64.97 33.79 48.85 36.93 Number of DAYS YEAR

UNPLANNED SHUT DOWN HISTORY DESCRIPTION  2011 2012 2013 2014 2015 Machinery 4.015 0.808 7.78 0.528 0.36 Equipment 1.09 3.571 0.03 0.017 Instrument 0.26 0.041 0.08 0.361 0.21 Electrical 2.68 0.215 0.34 0.611 Operations 0.71 0.93 1.058 0.832 0.25 DAYS YEAR

HISTORY OF SHUT DOWN DUE TO LOW PHOSPHORIC ACID INVENTORY YEAR 2011 2012 2013 2014 2015 Down Time (DAYS) 22.62 20.14 8.24 8.35 DAYS YEAR

Shut Down Due to NG Curtailment Decription 2009 2010 2011 2012 2013 2014 2015 Down Time 2.57 1.05 3.15 17.46 DAYS YEAR

DT-511 from FRP to SS-317L CRACK EROSION BULGING PITS FORMATION DIS-BONDING SEEPAGE MARKS DETACHMENT Internal surfaces were covered with hard DAP deposits, limiting thorough visual inspection To avoid emergency shutdown To reduce planned shut down time cleaning time Complete internal cleaning of FRP ducts is difficult Continuous leakages at various locations Dis-bonding of chemical barrier leads to damage mechanical barriers Results Unsatisfactory Repair Short Term Maintenance Time Consuming Stainless steel is better than FRP as Easy to clean Higher tensile strength Low inventory Higher temperature resistance Less maintenance, high reliability & durability Appropriate Inspection procedures are available.

DT-5013 from FRP to SS-317L Blisters Erosion Dis-bonding Shell Side Seepage Pin holes in Nozzle Support Under cuts OBSERVATIONS Frequent leakages Damage of internal rubber lining Corrosion damages Extensive repairs

DD-5031 from FRP to SS-316L Seepage from Flange Seepage from Patch Fine Cracks at Floor Pits Formation Eroded Vinyl Ester Seepage at Support Repeated failures Subsequent repairs

DK-5012 suction & discharge circuits from FRP to SS-316L Reason: Failure of FRP ducts and elbows Effects Prolonged Emergency Shutdown in Days resulting in Production loss Result No Down Time Production Loss Efficient Scrubbing DK-5012 suction duct elbow

DP-5012 A/S Strainers Reason: Frequent nozzles choking Result Effects Header blockage leads to Shutdown SS-317L ID : 14” SS-317L ID : 14” Total Height : 45” + 6” Nozzle Dia : 12” In order to increase the flow through the strainers and to reduce the emissions. To reduce chocking intensity in DD-5012 venturi. Nozzle's strainers dismantled and cleaned twice in a shift. Even after frequent cleaning chocking problem of spray nozzle is being faced and restrict smooth operation of DAP plant. Furthermore, dismantling and box up of six sprayer nozzle's strainers is a time consuming activity. In above background, it is proposed to install two simplex strainer (basket type) at discharge of DP-5012 A/S. This modification will enable operator for quick change over of chocked strainer, without involvement of maintenance personnel. Result REDUCED CHOCKING Less Time consumption Efficient scrubbing

DX-4032 Flapper Capacity Enhancement Replacement of Existing double flap valves (type: 200 x 250) for DT-431 & DT433 Cause: Limiting Capacity Modification Type: 250 x 355 Maintain Dust Flow Enhanced Dust Recovery Increased Efficiency

DH-611/612 Replacement TA Temperature diff Ampere Diff Flow Diff Days 2015 -1.82 7.51 3960 28 2014 -0.27 1.67 900 45 2013 -1.04 0.43 360 11 2012 -1.70 6.50 5040 50 2011 -1.22 5.34 1980 22

Replacement of De-dusting Flappers Effectiveness: Dust Load Reduce Chocking Minimum Process Activities Streamline

FRP Duct replacement in Scrubbing area DD-5031 remaining portion of FRP to SS-316L Effectiveness: Reduce Down TIME Minimum Maintenance

ID Provision De-Dusting Fan DK-421 U/P of I/V