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

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

4. 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

5. 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.

6. Losses at DAP Plant Losses at DAP Plant Dust Lost P2O5 Loss
Ammonia Loss
P2O5 Loss

7. Losses Emission Points
Ammonia Loss
Dust Loss
Stack
Dedustig Section
Scrubbing Section
Polishing Screens
Gaseous Ammonia
GPR
Granulator
Primary Screens
Scrubbing Liquor
Phosphoric Acid
H2SO4
Dryer
Product Conveyor
Liquid Ammonia
F.B.C
Pre neutralizer
Polishing screen feed elevator
Oversize Crusher
Coater
Primary Screen Feed Elevator
Chilled Air
Recycle Solids
Granulator feed bucket elevator
Recycle Belt Conveyor

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

9. Effect of Dust Emission
Continuous reclaiming of dust
Housekeeping

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

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

12. Schematic diagram for Ammonia Recovery
Atmosphere
Above 90%NH3
recovered
PN & Granulator Gases
From Dryer exhaust fan
STACK
50-70 %NH3
recovered
Above 95%NH3
recovered
TAIL GAS SCRUBBER
RG SCRUBBER
PRE-SCRUBBER
Industrial Water
Maximum NH3
recovered
Dryer SCRUBBER
H2SO4
PN Reactor
Phosphoric Acid
PRIMARY SCRUBBER TANK

13. Stack losses Component Design Loss Actual Loss in 2011
Actual loss during 2012
Particulate matter
150 mg/NM3
<10 mg/NM3
Ammonia
100 mg/NM3
79 mg/NM3
73 mg/NM3
P2O5
36 mg/NM3
Fluoride
30 mg/NM3
<1 mg/NM3

14. 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).

15. Thank You

16. Comparison of Stack Dust Loss(mg/NM3) b/w Operating & Design conditions

17. Comparison of Stack Ammonia Loss(mg/NM3) b/w Operating and Design Conditions

18. Comparison of Stack P2O5 Loss(mg/NM3) b/w Operating and Design Conditions

19. Dedust cyclones and Bag house Analysis
Equipment
Date
Component
Unit
Inlet Duct
Outlet Duct
DD-431
26/4/12
Dust
g/NM3
906 6
DD-4032
408 4
DD-433
322 8
Bag House 5
.04

20. Phosphoric Acid SHIPMENTS
Composition: Range th th th th
P2O –
Fe2O –
Al2O –
F –
CaO –
MgO –

21. Analysis of three types of phosphoric acid produced by acidulation of different phosphate rocks
Item Acid A (wt%) Acid B (wt%) Acid C (wt%)
P2O
Fe2O
Al2O F
CaO
MgO

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

23. Operating Range of Scrubbing Section