SYED MUHAMMAD ALI NAQVI (Management Associate) Presentation Losses Control at DAP PLANT Presented by: SYED MUHAMMAD ALI NAQVI (Management Associate)

Purpose To reduce the losses and recover into system for optimizing Plant Process

Scope of Presentation Background Losses at DAP Plant Losses Emission Points Reasons, Effects and Recovery of Dust Loss Reasons and Recovery of Ammonia Loss Stack Losses and comparison of Design & Operating conditions Suggestion

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.

Losses at DAP Plant Losses at DAP Plant Dust Lost P2O5 Loss Ammonia Loss P2O5 Loss

Losses Emission Points Ammonia Loss Dust Loss Stack Dedustig Section Scrubbing Section Polishing Screens Gaseous Ammonia GPR Granulator Primary Screens Scrubbing Liquor Phosphoric Acid H2SO4 Dryer Product Conveyor Liquid Ammonia F.B.C Pre neutralizer Polishing screen feed elevator Oversize Crusher Coater Primary Screen Feed Elevator Chilled Air Recycle Solids Granulator feed bucket elevator Recycle Belt Conveyor

Reasons of Dust Loss Quality of Phosphoric Acid Limitation of Dedusting Section

Effect of Dust Emission Continuous reclaiming of dust Housekeeping

Dust Recovery Dusty gases from Dryer Bag house Granulator Dryer Venturi Scrubber Dust Recovery Dusty gases from Dryer Instrument Air Dryer Exhaust Fan Dryer Dedust Cyclone Bag house Hopper Dusty air from Conveyors, Elevators, Screens Dust Dedusting Exhaust Fan Dedust Cyclone Granulator Hopper Recycle Belt (DM-223)

Reasons of Ammonia Loss Frequent Shutdown & startup Reasons of Ammonia Loss Poor working of Scrubbing

Schematic diagram for Ammonia Recovery Atmosphere Above 90%NH3 recovered PN & Granulator Gases From Dryer exhaust fan STACK 50-70 %NH3 recovered Above 95%NH3 recovered TAIL GAS SCRUBBER RG SCRUBBER PRE-SCRUBBER Industrial Water Maximum NH3 recovered Dryer SCRUBBER H2SO4 PN Reactor Phosphoric Acid PRIMARY SCRUBBER TANK

Stack losses Component Design Loss Actual Loss in 2011 Actual loss during 2012 Particulate matter 150 mg/NM3 <10 mg/NM3 Ammonia 100 mg/NM3 79 mg/NM3 73 mg/NM3 P2O5 36 mg/NM3 Fluoride 30 mg/NM3 <1 mg/NM3

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).

Thank You

Comparison of Stack Dust Loss(mg/NM3) b/w Operating & Design conditions

Comparison of Stack Ammonia Loss(mg/NM3) b/w Operating and Design Conditions

Comparison of Stack P2O5 Loss(mg/NM3) b/w Operating and Design Conditions

Dedust cyclones and Bag house Analysis Equipment Date Component Unit Inlet Duct Outlet Duct DD-431 26/4/12 Dust g/NM3 906 6 DD-4032 408 4 DD-433 322 8 Bag House 5 .04

Phosphoric Acid SHIPMENTS Composition: Range 111th 112th 113th 114th P2O5 52.00 – 54.00 54.2 53.4 53.1 53.3 Fe2O3 0.40 – 1.00 0.39 0.43 0.41 0.45 Al2O3 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

Analysis of three types of phosphoric acid produced by acidulation of different phosphate rocks Item Acid A (wt%) Acid B (wt%) Acid C (wt%) P2O5 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 0.104 MgO 0.610 0.570 0.552

Comparison of the effects of impurities on the number of fine particles and granulation quality of produced DAP

Operating Range of Scrubbing Section