1 Presentation Losses Control at DAP PLANT Presented

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Presentation Losses Control at DAP PLANT Presented by: SYED MUHAMMAD ALI NAQVI (Management Associate) 2

Purpose To reduce the losses and recover into system for optimizing Plant Process 3

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 4

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. 5

Losses at DAP Plant Dust Lost Ammoni a Losses at DAP Plant P 2 O 5 Loss 6

Losses Emission Points Ammonia Loss Dust Loss Stack Dedustig Section Scrubbing Section Gaseous Ammonia Polishing Screens GPR Primary Screens Granulator Scrubbing Liquor Phosphoric Acid H 2 SO 4 Pre neutralizer Dryer Liquid Ammonia Product Conveyor Oversize Crusher Primary Screen Feed Elevator Polishing screen feed elevator F. B. C Coater Chilled Air Recycle Solids Granulator feed bucket elevator Recycle Belt Conveyor 7

Reasons of Dust Loss Quality of Phosphoric Acid Reasons of Dust Loss Limitation of Dedusting Section 8

Effect of Dust Emission Continuous reclaiming of dust Housekeeping 9

Dusty gases from Dryer Dedust Cyclone Dryer Venturi Scrubber Dust Recovery Instrument Air Dryer Exhaust Fan Bag house Hopper Dusty air from Conveyors, Elevators, Screens Dedust Cyclone Dedusting Exhaust Fan Granulator Hopper Recycle Belt (DM-223) 10

Reasons of Ammonia Loss Frequent Shutdown & startup Reasons of Ammonia Loss Poor working of Scrubbing 11

Schematic diagram for Ammonia Recovery Atmosphere PN & Granulator Gases 50 -70 %NH 3 recovered Above 90%NH 3 recovered From Dryer exhaust fan 95%NH 3 recovered RG SCRUB BER TAIL GAS SCRUBBER Industrial Water Dryer SCRUBBE R PRESCRUBBER STACK Above Maximum NH 3 recovered H 2 SO 4 PN Reactor Phosphoric Acid PRIMARY SCRUBBER TANK 12

Stack losses Component Design Loss Actual Loss in 2011 Actual loss during 2012 Particulate matter 150 mg/NM 3 <10 mg/NM 3 Ammonia 100 mg/NM 3 79 mg/NM 3 73 mg/NM 3 P 2 O 5 36 mg/NM 3 <10 mg/NM 3 Fluoride 30 mg/NM 3 <1 mg/NM 3 13

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). 14

THANK YOU 15

Comparison of Stack Dust Loss(mg/NM 3) b/w Operating & Design conditions 160 150 150 150 150 140 120 100 80 Operating 60 Design 40 20 10 10 11. 4 10 10 0 4/6/2012 26/4/12 30/3/12 31/12/11 26/10/11 29/9/11 5/8/2011 20/7/11 9/6/2011 5/5/2011 29/4/11 29/3/11 8/2/2011 16

Comparison of Stack Ammonia Loss(mg/NM 3) b/w Operating and Design Conditions 120 100 100 100 100 89 80 73 63 60 50 50 43 40 30 59 51 45 Operating Desgin 30 21 20 0 4/6/2012 26/4/12 30/3/12 31/12/11 26/10/11 29/9/11 5/8/2011 20/7/11 9/6/2011 5/5/2011 29/3/11 8/2/2011 17

Comparison of Stack P 2 O 5 Loss(mg/NM 3) b/w Operating and Design Conditions 40 36 36 36 36 35 30 25 20 Operating 15 10 Design 10 10 10 10 5 0 4/6/2012 26/4/12 30/3/12 31/12/11 26/10/11 29/9/11 5/8/2011 20/7/11 9/6/2011 5/5/2011 29/4/11 29/3/11 8/2/2011 18

Dedust cyclones and Bag house Analysis Equipment Date Component Unit Inlet Duct Outlet Duct DD-431 26/4/12 Dust g/NM 3 906 6 DD-4032 26/4/12 Dust g/NM 3 408 4 DD-433 26/4/12 Dust g/NM 3 322 8 Bag House 26/4/12 Dust g/NM 3 5 . 04 19

Phosphoric Acid Composition: SHIPMENTS Range � P 2 O 5 52. 00 – 54. 00 � Fe 2 O 3 0. 40 – 1. 00 � Al 2 O 3 111 th 54. 2 112 th 113 th 114 th 53. 4 53. 1 53. 3 0. 39 0. 43 0. 41 0. 45 0. 50 – 1. 00 0. 36 0. 47 0. 48 0. 50 �F 0. 30 – 0. 50 0. 22 0. 33 0. 35 � Ca. O 0. 05 – 0. 30 0. 03 0. 02 0. 04 0. 01 � Mg. O 0. 12 – 1. 30 0. 76 0. 69 0. 70 20

Analysis of three types of phosphoric acid produced by acidulation of different phosphate rocks Item Acid A (wt%) Acid B (wt%) Acid C (wt%) P 2 O 5 50. 50 52. 14 51. 29 Fe 2 O 3 1. 250 0. 580 0. 120 Al 2 O 3 0. 981 0. 714 0. 200 F- 0. 640 0. 610 0. 630 Ca. O 0. 090 0. 083 0. 104 Mg. O 0. 610 0. 570 0. 552 21

Comparison of the effects of impurities on the number of fine particles and granulation quality of produced DAP 22

Specific Gravity Operating Range of Scrubbing Section N/P 23