Production Process of Di-Calcium Phosphate in ARASCO Chemicals King Fahd University of Petroleum and Minerals Mechanical Engineering Department Presented by Ra’ad M. Al-Ghamdi 986821 22/04/2004

Outline The Company Overview Production Process. Case Study. Conclusion.

The Company Overview Production: Types: DCP, MCP. Capacity: 30,000 MT/Year DCP. Location: Dammam second industrial city. Manpower: Engineers: 18 Administrative: 12 Operators: 17 Technicians: 15

Production Process Tank Farm Area (TFA). Filtration Area. DCP Area.

TANK FARM AREA T101 A/B/C Flocculent Clarifier Raw Acid Storage area Caustic Soda 50% NaOH (Sodium Hydroxide) Silica Powder 98% SiO2 Silicon Dioxide T101 A/B/C Flocculent Clarifier Raw Acid Storage area T301/T302 Pure Acid Tank Raw Acid Reactor Crystallizer Sludge P101:Raw Acid Unloading Pump P301 Clarifier Feed Pump P102 Reactor Feed Pump Clarifier Discharge Pump Filter P302 Acid to DCP Feed Pump Pure Acid to DCP Area

FILTERATION AREA Sludge Clarifier Bond Filter Sludge (rich in F) 1st cake wash 2nd cake wash Clarifier Sludge Bond Filter Sludge (rich in F) Sludge Bucket Sludge Bond T301/T302 Pure Acid Tank Clarifier Discharge Pump Pure Acid

DCP AREA CaCO3 Bag Silo Filter DCP Silo DCP Mixer HOT AIR GENERATOR Clean Exhaust Air Tank Farm Area Daily Weighing Hopper CaCO3 Silo Bag Filter Cyclone Pure Acid DCP Silo DCP Mixer Wet DCP Bulk Loading HOT AIR GENERATOR Primary Disintegrator Hot Air Bagging Machine

Material Storage and Handling Raw Acid Storage (785 m3) CaCO3 Silos (S 201 A/B/C) (32.39m3) Pure Acid Storage (T301-T302) (140m3 – 18m3) Process DCP Silos (S 501 A/B/C) (245m3)

Case Studies Screw Feeder Replacement. Upgrading DCP Recycling System. Upgrading Daily Weighing Hopper System Replacing the Packing Gland with Mechanical Seals

Screw Feeder Replacement Replacing the screw feeder with belt conveyor. DCP Mixer Wet DCP DCP Mixer Wet DCP Belt Conveyor Screw Feeder

Upgrading The DCP Recycling System

Daily Weighing Hopper System

Replacing the Packing Gland with Mechanical Seals Cost of the product : 12000 SR Bearings Packing sleeves Power consumption (packing consumes six times the power ) Pollution Reliability Safety Seals are self-adjusting Manpower

Packing Gland VS Mechanical Seals 12000 SR/year Bearings Packing sleeves Power consumption (packing consumes six times the power ) Pollution Reliability Safety Seals are self-adjusting Manpower 800 SR/year Less bearing damage Less power consumption Prevent pollution More reliable More safer

Mechanical Seals

Conclusion I have gained: Experience of work in such industry. Value of time and commitment. Value of team work. I have learned how production processes works. I have experienced working on machines in terms of maintenance and overhauling. I have given the opportunity to manage a group of team. I contributed to enhance the performance of the production by suggestion and study

Thank You