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

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

3. 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.

4. 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 mm Kg
2.5
Granular strength
Raw materials
Phosphoric acid
Ammonia
Filler
Sulfuric acid
River sand
Utilities
Natural gas
Antifoam
Coating agent
Industrial water

5. 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

6. 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

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

8. 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

9. 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

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

11. 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.

12. 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
producing MAP (dust), while granulator pipe reactor
operates at mole ratio of producing slurry.
Slurry moisture content low.
Low residence time for reaction.

13. 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.

14. 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

15. 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

16. 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

17. 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.

18. 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.

19. 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.

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

21. 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.

22. 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

23. THANK YOU
Questions????