1. First of all

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

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

4. 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

5. 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

6. 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…

7. 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 months minimal.
MANPOWER
Additional Manpower was required to run a new plant but after BMR the same no. of persons are operating the plant.

8. 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…

9. 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…

10. 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

11. 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…

12. 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

13. 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…

14. 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

15. 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…

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

17. 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…

18. 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

19. 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

20. QUESTIONS ???

21. THANKS

23. GRANULATOR
DRYER H
NH3

24. SLURRY
DRYER
GRANULATOR
GRANULATOR
DRYER

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

26. PRODUCT RESULTS BEFORE & AFTER REVAMP#
date N2
P2O5 1
19.8
45.0
19.3
48.0 2
19.9
41.7
19.0
47.8 3
46.1 4
46.8
19.1
47.7

27. 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

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

29. WORLD MONTHLY CS PRICES

30. FEEDERS OVERFLOWING

31. OLD & NEW POLISHING SCREENS

32. BAGHOUSE DUST CONVEYOR

33. GRANULATOR BARRING MOTOR

34. BAGHOUSE FILTERS & GRATING