1. 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

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

3. 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

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

5. 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

6. 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

7. 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

8. 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)

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

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

12. Upgrading The DCP Recycling System

13. Daily Weighing Hopper System

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

15. 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

16. Mechanical Seals

17. 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

18. Thank You