AN INDUSTRIAL TRAINING REPORT ON

COROMANDEL INTERNATIONAL LIMITED

VISAKHAPATNAM

Submitted in partial fulfillment of requirements

Under Internship for the award of
CHEMICAL ENGINEERING
MAHARAJA VIJAYARAM GAJAPATHI RAJ COLLEGE
OF ENGINEERING VIZIANAGARAM-535005

1
 Submitted by
B. AMARESWAR - 20331A0803
CH. GAYATHRI - 20331A0808
G. SUDHEER - 20331A0815
I. RAMESH - 20331A0817
M. RAMAKRISHNA - 20331A0827
P. SRAVANI - 20331A0836
S. SRAVANI - 20331A0842
G. BHARATH SAI SRIRAM - 21335A0805
K.VIJAYA KUMAR - 21335A0807
MD. AZMATULLA SHARIFF – 21335A0808
M. NIHARIKA - 21335A0809
P. SAI CHANDU - 21335A0812

2
 CERTIFICATE
COROMANDEL INTERNATIONAL LIMITED

This is to certify that B. AMARESWAR (20331A0803), CH. GAYATHRI (20331A0808) , G.

SUDHEER (20331A0815) , I. RAMESH (20331A0817), M. RAMAKRISHNA (20331A0827), P.
SRAVANI (20331A0836), S. SRAVANI (20331A0842), G. BHARATH SAI SRIRAM (21335A0805) ,
K.VIJAYA KUMAR (21335A0807) , MD. AZMATULLA SHARIFF (21335A0808) , M. NIHARIKA
(21335A0809) and P. SAI CHANDU (21335A0812) is the Bonafide student of MAHARAJA
VIJAYARAM GAJAPATHI RAJ COLLEGE OF ENGINEERING STUDYING CHEMICAL
ENGINEERING has undergone industrial training at COROMANDEL INTERNATIONAL
LIMITED, Visakhapatnam from 20-05-2023 to 20-06-2023.
During the above period their conductance and performance was found to be
----------------------

Mr. N.Sridhar Mr. D. S. Rajeev Varma

Sr. Manager – HR L&D Sr. Officer- HR L&D
Human Resources Human resources
Coromandel international ltd. Coromandel international ltd.

Mr. M. Sandeep Mr.R.N.V. Chandra Sekhar

Dy- manager Sr. Manager- operations
Human resources complex plant.
Coromandel international ltd. Coromandel international ltd.

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Mr. N.S.V.S.S.R.Phani Kiran Mr. I. Pavan Kumar
Dy.General Manager - Operations Sr.Manager - Operations
Sulfuric acid plant Utilities & AAST
Coromandel international ltd Coromandel international ltd.

Mr. V.Ganesh Kumar Mr. Shanmugam Sundaram

Manager - Operations Manager - Operations
Phosphoric acid plant - I Phosphoric acid plant - II
Coromandel international ltd. Coromandel international ltd.

Mr. Y.V.A. Ganesh Kumar

Dy. Manager – operations
SND
Coromandel international ltd.

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 ACKNOWLEDGEMENT

The success and final outcome of this project required a lot of

guidance and assistance from many people and I am extremely fortunate
to have got this all along the completion of my project work. Whatever I
have done is only due to such guidance and assistance and I would not
forget to thank them.
I respect and thank Mr. N. SRIDHAR (Sr. Manager-HR L&D), Mr.
D.S. RAJEEV VARMA (Sr.Officer-HR L&D), Mr.P.PRAKASH (L&D - Admin
Assistant )for giving me an opportunity to do the project work at
COROMANDEL INTERNATIONAL LIMITED and providing us all such support
and guidance which made me complete the project on time. I am extremely
grateful to all of the Managers, Engineers, operators and all for providing such
guidance.

5
 INDEX

1. PROFILE OF COROMANDEL.

2. PROCESS SAFETY MANAGEMENT SYSTEM.

3. INTRODUCTION TO FERTILIZERS.

4. COMPLEX PLANT.

6
7
 COMPANY PROFILE

COROMANDEL is located spreading over five hundred acres of land, which is leased from port
on renewal basis at Visakhapatnam to the east coast of INDIA.

Coromandel was set as a private limited company on 16th October 1961, with a capital
investment of Rs.60 crores.

Coromandel was jointly promoted by international minerals and Chemicals Corporation and
chevron chemical company, two well-known U.S.A. Corporation and E.I.D.Parry. In 1981 EID
Parry was taken over by MURUGAPPA group, a leading business house in south India. Now
MURUGAPPA group holds 79% of share market of Coromandel.

At present Coromandel producing high analysis of fertilizers, urea ammonium phosphate

(28:28:0), ammonium phosphate sulphate (20:20:0:13), (24.24.0.8) under brand name of
“GROMOR”.

Coromandel is originally an integrated fertilizer complex plant where the raw materials like
sulfuric acid, urea, phosphoric acid and ammonia are prepared. At present urea and ammonia
plants are not in production due to incompatible production cost with the international market
rates and we are importing ammonia from gulf countries and urea fromlocal fertilizer industries.

For the production of required sulfuric and phosphoric acids, we are also importing rawsulfur and
rock phosphate from countries like JAPAN, SENEGAL, etc.

Coromandel installed Ammonia importation facility consisting of 5 km length pipe line in the
year 1999.

Coromandel products are marketed mainly in A.P. and also in the neighboring states of
Orissa, West Bengal and Madhya Pradesh with turnover crossing 800 crores. Coromandel
also offers extensive farmer friendly AGRO services by analyzing the soil samples for nutrients
and advising the farmers from time to time on optimum usage of fertilizers mix suitable to
the fields.

8
Coromandel has constantly taken up modernization and up gradation programmer’s to enhance
production levels. These modernizations are helped to increase the volume of production of
fertilizers from the original level of 2, 50,000 MT per annum to the current level of 7, 70,000 MT
per annum. Coromandel has also installed a new complex plant (C-train) which increased its
fertilizer production to about 10, 00,000 MT per annum.

ACHIEVEMENTS OF COROMANDEL:
It has the credit of being the first in INDIA to import molten sulfur as a part of eco-friendly and
energy conservation measures.
 It has the credit of “THE BEST PHOSPHORIC ACID” plant in the fertilizer for the last 10
years.
 Coromandel received BRITISH SAFETY COUNCIL FIVE STAR RATING for health and
safety management system.
 Coromandel has taken initiative to implement process safety management system
level four of occupational safety and health administration (OSHA), USA to bring the
company at par with international standards in operating chemical plants.
 Coromandel has recognized as the 8th most profitable company in fertilizers industry.

 Coromandel has certified under the ISO: 9001:2000 and ISO: 14001:1996 for its
environmental management activities.

 Coromandel recently got great place to work certificate.

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 COROMANDEL MANUFACTURING FACILITIES

SECUNDERABAD (MAIN BRANCH)- CORPORATE OFFICE

1. FERTILIZER INDUSTRIES

 KAKINADA

 VISAKHAPATNAM

 ENNORE

 RANIPET 1

2. PESTISIDE INDUSTRIES

 RANIPET 2

 THANE

 JAMMU

 ANKELESHWAR

Mission of coromandel fertilizers limited:

To enhance the prosperity of farmer through the supply of quality farm inputs
and related services to ensure value for money.

Vision of coromandel fertilizers limited:

To be the leader in the phosphatic fertilizer industry, producing high quality
fertilizers at low cost and giving satisfaction to all stakeholders.

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RAW MATERIALS AND THEIR SOURCES:

RAW MATERIALS SOURCE

Raw sulfur From gulf countries
Rock phosphate Togo, Israel, Udaigarh, Russia & Morocco.
Liquid ammonia Bangladesh, Indonesia
Urea China
Raw MAP Kakinada

Products:
 Ammonium phosphate sulphate (20:20:0:13), (24.24.0.8)
 Urea Ammonium phosphate (28:28:0)
 Water soluble fertilizers
1) 24-24-0
2) 28-28-0
 Bentonite sulfur, sulfomax, bosmax & sulfo zinc
 Novozin

By products:
 Gypsum (CaSO4.2H2O)
 Hydroflurosilicic Acid (H2Sif6)
 Steam (Internally used in plant)
Production facilities:
 Sulfuric acid plant ─ for internal use
 Phosphoric acid plant ─ for internal use
 Granulation plant ─ main product for use
 Product handling and bagging ─ infrastructure
 Utilities ─ infrastructure
 Captive power generation ─ infrastructure
 WSF plant ─ specialty product for sale
 G-sulfur . ─ specialty product for sale
 Sulpho zinc pilot plant ─ specialty product for sale

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  Wharf ─ infrastructure-RM imports

Production plant facilities:

 Complex plant
A-train ─ 1000MTPD
B-train ─ 1000MTPD
C-train ─ 2000MTPD
 Pilot plant
Fertilizer pilot plant ─ 1MTPH
Phosphoric pilot plant ─ 30kg/hr
 Water solubility fertilizer ─ 10MTPD
 G-sulfur ─ 100MTPD

PROCESS SAFETY MANAGEMENT SYSTEM

SAFETY PRACTICES IN COROMANDEL FERTILIZERS:

As the Chemical process plant deals with certain hazardous chemicals like ammonia,
phosphoric acid and sulfuric acid along with the flammable products like LPG, LSHS, HSD and
LDO. Safety management plays a crucial role in every plant under vital situation. Also this
organization has to comply with various statutory requirements under factories act and
environmental production act.

The main objectives of the safety department are:

 To ensure safety of men, material and machinery.
 To achieve accident free productivity
 Training the employees to increase the awareness towards safety among them.

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Function:-
Following are some of the important activities of safety department.

 Carrying of safety inspections.

 Coordinating safety audits.
 Organization safety seminars.
 Carrying out accident investigation, analysis & reporting.
 Conducting safety classes on different aspects.
 Implementation of safe work permits.
 Procurement and inspection of safety equipment.
 Distribution of safety pamphlets.
General equipment’s used for safety purpose
are Clothing:

The body fully clothed to prevent from possible hot oil, steam, hot water and
chemicals splashed in unprotected skin. Long trousers and sleeves are caught in moving
machinery.

Gloves:
When handling hot equipments gloves (asbestos) must be used. When working in
chemical area rubber gloves must be worn.
Goggles:
Before start any job which may involve any possible hazards to the eye, obtain and
wear approved type of goggles.

Helmets:
To protect head from flying particles, falling objects and electric shock, safety helmets
must be worn.

Safety shoes:
Safety shoes with steel toe are far general protection against falling materials, rolling
objects, accidental kicking of sharp objects. Gum boots for protection against acid and alkali
splashes or where water spillage is there.

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Walk ways:
We walk ways stairs and ladders present shortcuts across pipe trunches and railways
track must be taken. When wearing a gum shoe take care in walking place, where oil on
ground may present a hazard.

Fire protection:
When a fire occurs it must be put of and necessary protection must be chosen.

Then portable extinguishers are

 Soda ash fire extinguishers
 Dry powder extinguishers
 CO2 type extinguisher
 Portable ABC fire extinguishers

Emergency communication:
Emergency phone number 111 if it is not responding dial 444 or communicate through walkil
talkie emergency phone located at 6 places.
 Fire station
 Laboratory
 Security plant gate
 Atmospheric ammonia storage tanks.
 Telephone operator room.
 Ambulance (OHC)

Of the above 6 locations who ever lifts the phone first only will receive the
emergency message who in turn should communicate the emergency message to the other 5
places by dialing # 1 of the emergency phone & should inform by the speaker phone.
During the emergency call, all the people must be at their respective nearer assembly
points.

Assembly points are located at:

 Plant gate
 Contract work man entry gate.
 Gypsum pond entry gate.
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  Dock road entry gate.
 At berth gate area north. as wharf silo entrance gate
Assembly points are to be selected based on their wind direction.
Siren:
 During emergency one minute wailing sound for on site emergency declaration.
 One & half minute, continuous siren for all clear signal.

15
 INTRODUCTION TO FERTILIZER

INTRODUCTION TO FERTILISER
Any organic or inorganic, natural or synthetic material that provides one or more
chemical elements require for plant growth is broadly classified, as a fertilizer.16 elements
are essential for plant growth. Of the 16 elements C, O, H2, is supplied by air and H2O. Hence
they are not considered as nutrients. The main concern of the fertilizer industry is to provide
the primary and secondary nutrients required in macro quantities and other elements are
required in micro quantities.

Elements essential for plant growth:

Natural Nutrients: C, H2, O2
Primary nutrients: N 2, P, K
Secondary nutrients: Ca, Mg, S
Micro nutrients: Zn, Ba, Cl, Fe, Mn, Mb, B

ORGANIC NUTRIENTS:
Some of the Nutrients are provided by organic manures such as farmyard manure,
Green manure, Oil seed cakes, Animal wastes such as urine, blood, bones and sewage sludge.
Organic nutrients contain very low preparation of plant nutrients and hence or not considered
to provide the primary nutrients in sufficient quantities for the proper growth of plants.

Chemical Fertilizers and Their Nutrient Content:

The primary nutrients are normally supplied through chemical fertilizers. They are
chemical compounds containing one or more primary nutrients and are generally produced
by chemical reactions. What ever be the chemical, the most important ingredient of it is the
nutrient content of it, which is important for the plant growth.
The primary nutrients are N, P, K. However their concentration in a chemical fertilizer
is expressed as the percentage of N, P2O5, K2O.

The grade of fertilizer is expressed as set of three numbers in the order of percent
total Nitrogen, available Phosphate as P2O5 and soluble potash as K2O
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Fertilizers Produced In India:
India produces a wide variety of fertilizers having different nutrient contents.
The names of fertilizer, their nutrient content, and the names of manufactures are shown.

Fertilizers:

These are those substances that must add to the soil in order to remove deficiencies
of essential elements required for the plant growth. Fertilizers are added to soil.
 To supplement that has been eaten by the plants.
 To supply additional tonic for better yield and healthy growth.
 To maintain pH of soil at 7-8 for optimum growth & health.

THE CHIEF REQUISITES OF A FERTILIZER:

 The element present in the compound must be easily available to the plant & soluble
in water.
 It should be stable, so that it may be made available to the plant for a long time.
 It should maintain a pH of soil in the vicinity of 7-8.
 It should not be a poison for the plant.

Plant nutrients:
The following 16 elements are necessary for a plant to carry out their metabolic activities
.
 Natural nutrients - C, H, O (Basic elements)
 Primary nutrients - N, P, K (Critical elements)
 Secondary nutrients - Ca, Mg, S
 Micro nutrients - Fe, Zn, Cl, Cu, Mb, B, Mn

Water and air are supplying Natural nutrients. The remaining elements
are supplied by the soil. There are six macro and micronutrients. Macronutrients are
available in large amounts while micronutrients in small amounts i.e. in traces in the soil.

17
.

1. Complex Fertilizer: -

A fertilizer intended to supply more than one nutrient is called complex fertilizer.
Its production involves a chemical reaction.

Example: MAP, DAP etc.

2. Compound Fertilizers: -

These are prepared by mixing appropriate amounts of complex fertilizers like

ammonium salts, super phosphates, Potassium salts etc & in this manner they supply
more than one essential element to the soil.

Example: DAP etc.

3. Mixed Fertilizers: -

A fertilizer with more than one essential element is called mixed fertilizer.

Example: NPK etc.

Plants do not take the oxides of elements. In the analysis of plant ash done by the
earlier chemist’s various elements are expressed as oxides summing up to 100 indicating total
analysis. All elements except nitrogen are expressed in the oxide form.

The most important factor, which is of prime importance in Fertilizer function, lays
movement of water in soil. Application of lime enables free circulation of water by opening
the pores of soil. Other important factor of such type is action of CO 2 on the contents of soil.
CO2 is soluble in water to form carbonic acid having high solvents power, carbonates of
calcium & magnesium and oxides of iron and manganese that are insoluble in soil, other wise
they are hardly available.

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COMPLEX PLANT :

 Neutralization
 Granulation
 Drying
 Screening
 Size reduction
 Cooling & Product Conveying
 Ammonia & Dust recover
 Scrubbing

19
INTRODUCTION

Complex plant was originally designed by WELLMAN LORD Inc USA in 1967 consisting
of two identical trains (A&B). The grades produced were 20.20.0.13s, 28.28.0,24.24.0.8s. Later
some of the grades were suspended due to varied reasons. The capacity of each train is650
tons per day. A third train was proposed to be built in 1998 and was completed in a recordtime
of 20 months. The plant was designed by INCRO of Spain and engineering was done by UHDE.
Latest technologies were adopted using pipe reactor, which is energy efficient. Tail gas
scrubber to absorb fluorine emission.
The total operation is based on Digital Control System (DCS) supplied by Yokogawa
Blue star. The C train was designed for zero liquid effluents and minimum gaseous emissions.
The plant has a capacity to produce 750 –850 MT/day of 20.20.0 and 14.35.14 grades, with
an annual capacity of 2.25 Lakh MT. Present produces around 1500MTPD (max) with pipe
reactor technology.
With the new plant in operation the annual capacity of the three plants has gone up
to 6.0 Lakh MT comprising of three different products Urea Ammonia Phosphate (28.28.0),
NPK and Ammonium Phosphate Sulfate (20.20.0.13s),(24.24.0.8s). The scrubbing system was
supplied by Thermax Limited in technical collaboration with Swimco USA. With the
adaptation of new technologies ammonia loss through stack has reduced from 4MT/day to
0.5 MT/day and a fuel saving from 15 kg/MT to 6 kg/MT.
Introduction:

Complex plant is the main plant in Coromandel & plays a vital role in producing
different grade of fertilizers. It is also known as granulation plant. As the product
manufactured in a granular from.

Complex plants are basically designed to produce mixed fertilizer of different grades
namely .

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  28-28-0 (Urea Ammonium Phosphate)
 20-20-0-13s (Ammonium phosphate Sulphate)
 24-24-0-8s (Ammonium phosphate Sulphate)

For improving the productivity and for producing different grades to meet the needs of the
customers. This plant was divided into 3 trains.

 A- Train - 1000 MTPD

 B- Train - 1000 MTPD
 C- Train - 2000 MTPD

EQUIPMENTS INVOLVED:
The equipment’s that are involved in the production of different variety grades of fertilizes
involves mechanical operations, fluid mechanics operation, heat transfer & mass transfer operations
equipment’s.

OVERALL EQUIPMENTS:

 Air preheater
 Fan
 Filter
 H2SO4 Pumps (Booster pumps)
 Sulfuric Acid tank
 Pipe reactor pumps
 Pipe reactor / PN tank
 Rotary Granulator
 Rotary drier
 Rotary cooler
 Conveyors ( Screw Conveyors belt& pipe conveyors)
 Elevators (Recycle elevator, Drier Elevator, Product elevator)
 Raw material bins
 Weigh feeders
 Vibrators
 Diverters
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
 Chain mills/ flair mills
 Polishing screens
 Process screens
 Main sump (Agitator)
 Pre sump (Agitator)
 Effluent Pit (Agitator)
 Duct scrubber
 Granulator pre scrubber
 R/G scrubber
 Drier Scrubber
 Cooler Scrubber
 Dedusting scrubber
 Dedusting point ( Elevators, Pulverizers, Conveyors)
 R/G scrubber fan
 Drier scrubber fan
 Cooler scrubber fan
 Dedusting scrubber fan
 Drier cyclones
 Cooler cyclones
 Dedusting cyclones
 Tail gas scrubber

Sections of the plant:

Based on the physical state of the materials handled in the equipment’s the total plant is
broadly classified into two sections.

 Solid Sections (solid handling)

 Fluid Sections (fluid handling)

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 Solid Sections:

All the equipment’s handling the solid state materials are placed under this section

Solid Section Equipment’s:

 Granulator
 Rotary Drier
 Electrically Vibrated Screens
 Cooler
 Elevators, Bins & Conveyors
 Weight feeders & Diverters.

Fluid Sections:

All the equipments handling the fluid state materials are placed under this section.

Fluid Sections Equipments:

 Main Reactor (Pre-Neutralizers)

 Pumps
 Pipe reactor
 Cyclones
 Fans
 Scrubbers
 Main & pre sumps & effluent pit sump

Raw material specifications:

Conc .Phos Acid: Diluted Phos acid

P2O5 - 46% Min 26% Min
Solids - 7% Max 30% Max
SO4 - 2.5% Max 1.9% Max
F - 1.7% Max 2.1% Max
Al2O3 - 0.8% Max 0.5% Max
Fe2O3 - 1.0% Max 0.4% Max

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MgO - 0.53% Max 0.35% Max
SiO2 - 0.35% Max 0.7% Max
H2O - 25% Max 57% Max
SP. Gravity - 1.656 Approx. 1.305 Approx.
Temp - 600C 600C Max
Pressure - 2.5 Kg/ Cm2 4.5 Kg/ Cm2

Sulfuric Acid: Ammonia

Conc - 93% H2SO4 State - Liquid
Sp. Gr - 1.820 Temp - 100C
Temp - 600C Pressure - 22/10 Kg/Cm2 (g)
Pressure - 3 Kg/ Cm2 (g) NH3 - 99.5% Min
Water - 0.5% Max
Urea:

Total N - 46% Min

Moisture - 2% Max
Biuret - 1% Max
State - Prills
Bulk Density - 750-800 Kg/ Cm2 (Approx.)
Temp - Ambient

Raw Materials used:

 Phosphoric Acid (48% & 30% Conc)

 Sulfuric Acid (98.5% Conc)
 NH3 (99.5% Min)
 Urea ( %N2-46, Dry basis)
 Air
 Steam
 Water
 Fines
 Muriate of potash
24
The Main Steps involved are:

 Neutralization
 Granulation
 Drying
 Screening
 Size reduction
 Cooling
 Product conveyors
 Ammonia & dust recovery

Overall process (c- train):

Description:

 From pipe reactor vessel phosphoric acid of 48% Conc is pumped in to pipe reactor by
PR pumps of temp 680C and pressure 3 Kg/ Cm2
 From H2SO4 tank H2SO4 of 98% or 94% conc is pumped into the pipe reactor by H2SO4
pumps of pressure 3 Kg/ Cm2 & Temp 600C.
 Liquid NH3 of 5-9 Kg/Cm2 pressure & 5-100C temp is pumped in the pipe reactor
 The ammonium Phosphate & ammonium Sulphate slurries are formed depending
upon the grade

The following reaction takes places:

 With Sulfuric Acid

a. 2 NH3 (Gas) +H2SO4  (NH4)2SO4+ 1800 KCal/KG of NH3 Gas

b. 2 NH3 (liq) +H2SO4  (NH4)2SO4+ 1500 K Cal/KG of NH3 Liquid

 With Phosphoric Acid

a. NH3 (liq) +H3PO4  NH4H2PO4+ 1500 Kcal/ Kg NH3 Liquid

b. NH3 (liq) +NH4H2PO4  (NH4)2HPO4+ 1300 Kcal/ Kg NH3 Liquid
c. NH3 (gas) + NH4H2PO4  (NH4)2HPO4+ 1000 Kcal/ Kg NH3 Gas

25
 The formed slurries are at a temp of 1300C-1700C & 85% of the reaction takes place
in the pipe reactor.
 The formed slurry is fed to the granulator where urea refilled fines (Crushed over sizes
& fines) are feds where the required product forms.
 The granules are formed in the granulator are with a temp of 114-1200C with 2-3%
moisture content.
 The granules are sent to drier through the drier chute.
 In the drier, the granules are dried by the preheated air of temp 220-2400C
co-currently for quick & efficient removed of moisture.
 The temperature of granules drops from 112-1200C to 850C in drier.
 Air is pre heated by a preheater to a temp of 220-2400C and pressure 3-4 Kg / Cm2
 Generally, the fresh air is filtered in the fitters sucked by air blower.
 In air preheater, HP Steam of Temp 3160C ^ 16-32 Kg/ Cm2 pressure passes through
the tubes of the air preheater & filtered air passes through the shell side.
 Heat transfer takes place where the HP Steam losses it latent heat of vaporization
resulting in the formation of condensate to a temperature of 780C.
 Air at a temperature of 2400C is sent to drier where the dried product is dried to a
temp of 85-900C from 112-1200C with a moisture of below 1% .
 The dried product is sent to process screens where there is a size separation of the
dried product as over size (above 4mm) under size (below 2mm) & the on size product
( 1 to 4mm) size.
 The over size is crushed in a chain / flail mills & recycled back to granular via recycle
elevator & recycle belt conveyor
 The under size of below 4mm is sent back to conveyor via recycle elevator & recycle
conveyor
 The on-size product (850C) is sent to rotary cooler where the heat present in the
granules are sucked by fan, where the temp of cooled product is about 60-450C
 The cooled product is sent to polishing screens for further screening which were
rejected by the process screens
 The cooled product falls into product discharge pipe conveyor provided .
 From the product discharge belt conveyor the product is sent for bagging

26
 The off gases evolved from the reactor / granulator is sent to the duct scrubber where
the scrubbing liquid ( Phos Acid + Some dust) from the pre sump is used as scrubbing
liquid to recover the NH3 & dust from the evolved gases.
 The scrubbed liquid is sent back again to the pre sump where again it is recycled to
the system back.
 The gasses leaving the duct scrubber are sent to pre-scrubber where (Weak phos Acid of
28% conc with a little amount of NH3 & dust in it) used as a scrubbing liquid.
 The scrubbed liquid is back to pre-sump & recycled.
 The off gases leaving the R/G pre scrubber are fed to the R/G main scrubber
 In R/G the gases are scrubbed with the scrubbing liquid where the gases are scrubbed
in two parts of the scrubber, venturi & Separator.
 The scrubbed liquid is sent to main sump & recycled.
 The off gases leaving R/G scrubber are sucked by R/G scrubber fan to TGS common
duct. Where they are scrubbed in the final tail gas scrubber.
 The gases leaving the drier are at a temp of 850C are fed to the cyclone separator ( 4
battery) where all the heavy particulars (duct) are collected at the conical bottom.
 The collected dust particles are fed into the granulator along with the raw materials
feeds.
 The off gases from the cyclones are fed to the drier scrubber by means of a drier
scrubber fan
 Before the gases are scrubbed in the venturi scrubber in increase the time of contact
for effective scrubbing

27
28
 The unscrubbed gases are sent to final scrubbing system i.e tail gas scrubber
 The off gases sucked by the cooler fans are cycloned in the respective cooler cyclones
 Air is cycloned in a battery of 4 cyclones in orders to separate the main part of carried
dust.
 The collected carried away dust is fed as recycled feed to the granulator via recycle
belt conveyor.
 After cycloning gas will be sucked to the cooler & dedusting scrubbers
 In the cooler & dedusting scrubber, the air leaving the cyclones are scrubbed with
scrubbing liquid.
 Screens, pulverizes, conveyors & elevators are equipped with dedusting points as
more amount of dust evolved at these equipments
 The dedusting point sucks the dust evolved by cooler & dedusting fan to cyclones
where the dust is cycloned in a battery of 4 cyclones.
 The collected dust is fed to granulator
 After cycloning gas will be sucked to the dedusting scrubber where it is scrubbed by
scrubbing liquid
 The stream gases from all the scrubbers are washed in tail gas scrubber for
effective scrubbing & for the recovery of fertilizers dust, NH3, water vapor, steam &
Flourine.
 In the 1st step, phos acid or H2SO4 are spend depending upon the PH of the scrubbing
liquid in the main sump
 In the 2nd step, process water is added for washing the demister pad & to remain the
SP gravity & PH
 The gases leaving the TGS are vented out into the atmosphere through stack.

PN-REACTOR (PRE-NEUTRALIZER):
Construction:
 Reactor is a long cylindrical vessel multi – layered of carbon sheet with “Polytetra
Fluoro Ethylene” lining on the acid proof bricks lining
 It consists of four tangential openings
 Each opening is provided with NH3 spargers.
 NH3 sparger is long tube extending into the reactor through tangential opening
 It is also provided with the inlet for HP steam injection
29
  The periphery of the tube in the reactor is provided with small opening facing bottom
of the reactor.
 Suction end of a centrifugal pump is connected to reactor to remove the over flow
 Four baffles are provided in the reactor.

Inlets to Reactor:

 Liquid Ammonia
 Vapor Ammonia
 Phosphoric acid (Weak acid (30%) & strong acid (48%)
 HP stream

PROCESS:

 75-85% of the reaction takes place in the reactor

 Phosphoric acid (30% & 48%) depending upon the grade & scrub liquid from the main
sump are injected from the top of the reactor
 Vapor NH3 (Sometimes form the pre cooling line is fed) & liquid. NH3 from the
ammonia spargers is fed into the reactor
 Phosphoric acid form PR vessel is also fed to the reactor
 H3PO4 reacts with the NH3 8 partially neutralized to an more ratio of their respective
grades depending upon the grade
 The ammonium phosphate slurry so formed from the reactors is fed to the rotary
drum granulator
 HP steam is fed to the reactor to avoid the plugging of slurry in the slurry distribution
pipe.
 The reactor level should be maintained to 40-50%. If the level in the reactor increases,
them there will be a spillage of slurry out from it.
 The slurry SP. Gravity should be maintained depending upon the grade
 If the SP. Gravity is high, weak acid or process water is added to attain the desired SP.
Gravity.
 It if the SP. Gravity is low, 48% acid is added to attain the desired SP. Gravity
 The slurry is transferred to the granulator at temp 114-1200C, of 20% moisture content
depending upon the grade is pumped by the slurry pump through the slurry
distribution pipe.
30
Reactor Specifications:
Width - 3.66 M
Height - 7.10 M
Operation pressure - 4 Kg/ Cm2
Operation temp - 114-1200C
NH3 spargers - 4 Nos
Baffles - 4 Nos
Residence time - 15-20 Min

Conditions 14-35-14 10-26-26 20-20-13 28-28-0

Temp 114-1180C 114-1180C 115-1160C 120-1240C
Conc of P2O5 used 48% 48% 30% 45-48%
Mole ratio 1.52-1.53 1.52-1.525 1.3-1.35 1.30-1.41
SP. Gravity 1550 1550 1500-1520 1450-1500
Moisture content 18% 18% 20% 20%

PIPE REACTOR:

Installed in A & C trains.

Construction:

 The pipe reactor is a tubular reactor of small dimensions consisting of a mixer & a
reaction head to which the slurry distribution pipe is fitted.
 This reactor resembles a venture tube
 This reactor is provided with 3 inlets.
 From the top, a provision is provided for feeding of NH3, from the middle there is a
provision for H2SO4 feeding (depending upon the grade required) & from its bottom
H3PO4 is fed.
 For cleaning the pipe reactor. HP steam is fed from the bottom end of the H 3PO4 inlet
by stopping all the inlets.
 The venture throat is a mixing chamber with a slurry for homogenous mixing of the
feeds fed into it.
 The other end of the pipe reactor opens into granulator.

31
Feeds to pipe Reactor:

Liquid Ammonia : 94% Sulfuric Acid:

Temp - 5-100C Temp - 60-750C

Inlet pressure - 10 Kg/Cm2 Pressure - 3-4 Kg/ Cm2
Pressure drop - 2 Kg/ Cm2 Pr. Drop - 2 Kg/ Cm2
SP. Gravity - 0.64 Sp. Gravity - 1.83

48% Phos Acid:

Temp - 60-750C
Pressure - 2-4 Kg/ Cm2
Pressure Drop - 2 Kg/ Cm2
Sp. Gravity - 1.57-1.63

Chemistry of Process:

 During the manufacture of the different grades of NP and NPK, the main reaction will
take place between the NH3 & the acids according to the following equation.

a. With Sulfuric Acid:

2NH3 (Gas) + H2SO4  (NH4)2SO4+1800 Kcal/ Kg NH3 Gas
2NH3 (Liq) + H2SO4  (NH4)2SO4+1500 Kcal/ Kg NH3 Liquid

b. With Phos-Acid:
NH3 (Gas) + H3PO4  (NH4)H2PO4+1500 Kcal/ Kg NH3 Gas
NH3 (Gas) + NH4H2PO4  (NH4)2PO4+1300 Kcal/ Kg NH3 Gas
NH3 (Liq) + NH4H2PO4  (NH4)2PO4+1000 Kcal/ Kg NH3 Liquid

Other reactions can take places at the same time along with the main reactor or during
the residential time in other equipments

32
  Some NH3 will react with the impurities contained in the crude phosphoric acid coming
from the phosphate rock such as iron, aluminum, magnesium, calcium, fluorine etc-
producing a series of phosphate complex compounds such as.
 FeNH4 ( HPO4)2
 Fe NH4PO4 NH2O
 Mg NH4PO4. H2O
 Ca ( NH4)2 (HPO4)2 H2O
 Al. NH4PO4. FH2O

The impurities present in the phosphoric acid helps the following granules formation like
FE2O3 strengthen the granules formation.

Impurities like Al2O3 & MGO etc – deteriorates the granules formation like.

MGO - If more MGO present in H3PO4 results in more dust concentration &
which turn lead to scales formation.
Al2O3 - Lower content of Al2O3 leads to formation of poor granules.

PROCESS:

 From the pipe vessel. Phos acid is pumped into the pipe reactor by pipe reactor pumps
 From the sulfuric acid tank, H2SO4 is pumped into the pipe reactor by H2SO4 booster
pumps
 Liquid NH3 is fed into PR by the NH3 transfer pumps
 The phos acid fed is partially ammoniated phos liquid from the scrubbing system,
although sometimes it can be mixed with fresh concentrated or dilute phos acid.
 The phos acid, NH3 & H2SO4 are closed mixed reacting producing ammonium
phosphate/sulphate slurry with the vaporization of water due to the excess heat
evolution.
 The reaction in the system along the distribution tube the pressure in the system
propels the formed slurry into the granulator.
 85% of the reaction take place in the pipe reactor.
 The slurry distribution pipe has 3 screwed sprays through which the emerging slurry
will be distributed

33
  It has the possibility to close any one of these sprays depending on the operative
capacity required in the reactor on the solid bed area on to which the slurry is to be
poured out.
 The phos acid feed line is connected to steam purging where we use HP steam for
cleaning the PR in case of any occasional blockage that being detected.
 During the cleaning operation, steam is fed from phos acid feed line, where all the
feed inlets are stopped.
 After cleaning the PR with steam, air has to be purged immediately to drive the
condensate if so present inside the injection pipes.
 PIPE REACTOR:-
Operating conditions:-
Pressure (Normal) - 2-5KG /Cm2 (G)
(Max) - 6 kg/cm2 (g)

Temperature (Normal) - 1300

Max - 1700

Problems in pipe reactor:-

Effects of temperature:

 High temperature in the pipe reactor (S) leads to the destruction of granules.
 Low temperature in the pipe reactor (S) leads to the formation of Mono
ammonium phosphate & diammonium phosphate.
 If PR is working only with NH3 & H3PO4, If the temperature is under 110o, It will be
an indicative of too dilute phos acid feed or not enough NH3 feed.
 It PR IS Working with H2SO4 besides NH3 & H3PO4 , It the temperature is over 175-
1800, the phos acid in the PR vessel must be diluted to avoid excessive reaction
temperature which can produce corrosion & high NH3 loses.

34
Effect of improper mole ratio:

 Proper mole ratio has to be maintained depending upon the grades in pipe reactor
to avoid crystallization problems in the pipe reactor i.e. plugging in the distribution
tube.

Effect of pressure:
 The pressure of NH3 and acids should be equally maintained when its turns a back
pressure and makes the inlet fluid to move backward against to their respective
vessel.
Effect of scaling:

If the slurry in the PR makes a characteristic noise then there is a need to purge the pipe
reactor with medium pressure steam.
Helium pressure steam

Temp - 1758
Pressure - 8-10kg/cm2

Advantages of pipe reactor:-

 With low additional cost, the plant capacity can be almost doubled, this the cost
of production can be reduced.
 PR can be extremely flexible & precise control of reactants is possible due to short
residence time in the PR.
 The plant can be started at full rate start & short down can be accomplished with
less effort and thus some losses can be avoided.
 Requires less time for slurry formation.
 The product grade can be changed with less down time & the effort
 The power consumption can be reduced due to its lower recycle ratio.
 Consumption norms can be reduced due to its higher rate of production.
 Vapor NH3 is used in the pipe reactor so that the heat of reaction evolved during
the reaction is used to absorb. The moisture content in the slurry.
 Then the use of dilute H3PO4 is maximized than the conc. one.

35
GRANULATOR:-

 This is a horizontal cylindrical rotary type granulator.

 Granulator is lined with rubber panel internally to avoid the built-up of granules to the
walls of it.
 It is provided with 4 inlets for feeding the crushed oversize fines, filler if required, raw
materials, slurry & for steam injection.
 At the lower portion of the granulator, NH3 plough type Spargers are provided for
NH3feeding.
 4 spargers contains fine holes facing in to the bottom of the granulator.
 The four ammonia pipes are fed through a common header to which a steam & air line
connects for the eventual cleaning of the injection pipes if any blockages is detected
in them.
 All pipes entering the granulator i.e. the pipe from the pipe reactor, the four NH3 pipes
and water pipes are supported by a main beam that crosses the drum from one end
to other.
 Gases, vapors and dust coming from the solid fed & the pipe reactor, are sucked
towards the granulator pre-scrubber by a suction duct located on the product exit
side.
 Both of the granulator inlet have some fixed chute boxes from which the gas suction
duct and the drier have inlet chute on the product exit side.
 On the product entrance side, there are drops for the observation of the drum. (Solid
bed, slurry distribution etc…) and register doors that allow the entrance of air, in a
bigger or lesser degree, which could enhance the solids bed cooling or by producing
an extra. Vaporization of the solid bed water with subsequent additional cooling that
this would product.
 Granulator is the main equipment for production, like heart of the complex plant.
That’s why the complex plant also known as “granulation plant”.

Process:-

 The second important point is where the reaction occurs in the granulator drum.
 About 15% of the reaction takes place in the granulator.

36
 Solid raw materials are fed in to the granulator through an recycle elevator, which
contain recycle solids.
 The main purpose of recycle feeding into granulator is to maintain heat & water
balance.
 The ammonium phosphate/ammonium sulphate slurries are at a temp of 45 cc -1200c
coming from the pipe reactor are distributed inside the granulator drum over the solid
bed.
 These slurries are ammoniated with the NH3 fed through the ammonization plough
spargers deeply in to the solid bed.
 The formed product is at a temp of 1100c and 2-3% of moisture content maximum.
 The adjusting of granulometry is done by the addition of water from scrubber directly.
 Retention ring is provided in the granulator to increase the retention time of the solids
in the granulator as well as time for granulation.
 Then, the product leaving the drum, bouncing over the retention ring, will usually pass
between the grizzly towards the drier feeding.
 The lumps retained on the grizzly are crushed into small bits to prevent blocking of the
feeding chute.
 The purpose of the flexible rubber panel in order to avoid the buildup of the granules
as lump obstruction the effective formation of granules and blocking of the granules
outlet chute.
 NH3 liquid spargers are provided to control the temp & to avoid the blocking of nozzle.
 These nozzles are flushed with steam periodically to avoid the closing of the solids &
after steam purging air is purged to remove any condensate if so present in the
injection pipes.
 It is necessary to keep the mechanical component will lubricated at all times, specially
the attacking ring gear & pinion, otherwise they will rapidly wear down producing
distortion and noise when the drum rotates.
 The perfect formation of the granules also depends upon the rotation direction which
decides upon the type of granulation (cascade or kiln).
 In case cascade type the required size of granulation is achieved.
 The kiln type the granules formed area of fine type hence cascade type.

37
Overall specifications:-

Type : Rotary Cascade.

Axis : Horizontal
Length : 2011 (6050 mm)
Outer dia : 1011 (3028 mm)
Rotation speed : 9.5 rpm
Slope : 3.580
Retention time : 1.5min
Capacity : 182 TPH

Operating conditions:-

Slurry inlet temp : 114-1200c

Moisture content : 5-6% max
Granules temp : 90-1140c
Granules fumes temp : 850C.
Gases generated in the granulator are sucked towards the granulator fumes to recover
most of the evolved dust & NH3.
Granulator fumes generally contain fertilizer dust, NH3, fluorine, steam & water vapor.

Granulator fumes stream: -

The formed fertilizer granules are fed to the drier through the drier chute.

Process Control:-

Excess fluidity - Over size granules formation.

Insufficient fluidity - under size granules formation.
Conditions in granulator - corrections to be applied in listed order.
Too wet - increase granulator H/R, it possible by
increasingNH3 feed to granulator.
Reduce reactor slurry water content by reducing
process water to scrubbers, if possible.
Increase NH3 feed/% of acid feed to PR

38
 Increase fines recycle rate/reduce raw materials
rates
Too big (but not too wet) - increase reactor H/R, if possible by increasing
NH3 feed to reactor, Reduce gap between
pulverizes hammer & drum rotors.
AIR PRE-HEATER:

Construction:

 It is a cylindrical structure placed in vertical position.

 It consists of no of vertical tubes in a chamber.
 Baffles plates are provided in the shell side to increase the turbulence of air for greater
heat transfer rates.
 Side of the preheater is provided with an condensate tank.
 50% of condensate is maintained in the condensate tank for effective heat exchanging.
 It is provided with 2 inlet and 2 outlets.
 Air inlet is provided at the bottom and its outlet is provided at the top of drier.
 HP stream inlet is provided from the top of the tube side.
 The condensate is drawn from the bottom of the air preheater.

Process:

 Fresh air is sucked by the blower and the air is filtered in the filter,
 Filtered air is heated in air pre heater.
 Air at a ambient temperature enters through the shell side and up steam of temp
3160C & 16-32 Kg./Cm2 pressure passes through the tubes
 Air gets heated up to a temp of 2200C by gaining the heat from high pressure steam
 The pre heated air of temp 2200C & 3-4 Kg/ Cm2 (g) Pressure enters into the drier
 The condensate of temp 780C is drawn from the bottom of APH
 he collected condensate is sent back to utility plant.
Specifications:
Shell side : air
Tube side : HP steam
Air inlet temp : Ambient

39
 Air outlet temp : 2200 c
Air inlet pressure : Atm
Air outlet pressure : 3-4 kg/cm2
HP steam temp (inlet) : 3160c
HP steam pressure : 16 kg/cm2
Condensate tank level : 780c
HP steam consumption : 2 tons/hr
Air flow rate to APH : 10,600 Nm3/hr
Retention time in APH : 15min

Causes:
The condensate in the condensate tank should be maintained 50% level.
If the condensate level is not maintained properly leads to the lower heat transfer area.

DRIER:
Construction:
 It is a rotary drum type drier placed at an inclination of 2.390c to the horizontal.
 It is 85 feet (25.91m) in length and 12-61 (3.8m) in diameter
 A ring gear box is mounted on drier, which is driven at a speed of 3 RPM using hp
motor through speed reducing gearbox & pinion.
 Two tyres are placed on either side of ring gear support on trunnions.
 It is provided with knocker balls housing each containing a solid fall of 50kg near
the feed of the drier.
 It is also provided with guide plates & with helical flights of different kinds.
 1/3rd portion of the drier is provided with lifters & the remaining 1/3rd portion of
the drier is provided with distribution flights.
 They are,
 Distribution flights
 Lifting flights

40
Lifting flights:
Lifting flights are maintained at an angle of 900c. The main purpose of these flights in
to lift the granules to the top of drier & drop them. The materials start to drop drown after
it crosses the top center.

Distribution flights:
Distribution flights are maintained at an angle of 1100c. The main purpose of these
flights to raise the granules to a height and distribute them before reaching the top of the
drier.

Placements of flights:
 Flights are provided up to 40ft of the drum length, the no. of flights are 16
comprising both distribution & lifting flights arranged in circular ring.
 Among these, 8 are distribution flights and 8 are lifting flights.
 They are arranged one after the other along the drum circumferences.
 For the next 40ft of drier both distribution & lifting flights are arranged in same
order but the no of flights increase to 32. Every ring of flights contains 16
distribution rings and rest lifting flights.
 The reason for increase of flights at the discharge & is to increase the time of
contact of prills with hot air this is because at this part, the evaporation of water
is to be down from inner core of prills.
 At the entrance of drier, iron plates called scrolls are provided which are in curved
shape.
 These scrolls act as guiding vanes for the granulator outlet in to the drier flights.
 Outlet of drier is collected in the drier elevator through drier conveyor.

Process:
 The product leaving the granulator has a free humidity of between 2-3% and that
should be reduced to achieve the final product specifications (1% below
maximum)
 The drying process takes places inside the rotating drum drier.
 The wet granule from the granulator enters by gravity through the feeding chute.

41
  The product stays for 6min at the entrance as during the initial stages, granules
contain higher moisture content.
 During this, some of the product gets adherent to the walls of the dries & which in
turn leads to the formation of scales on the inner surface near the entrance.
 To avoid this, knocker balls helps to remove the product stuck to the wall of drier.
 Hot air from air preheater is at a temp of 2200c gets connected with the granules
of temp 114-1200c.
 Direct co current drying is employed for higher heat transfer rates & quick drying.
 As the granules are lifted by the flights and expose them to the hot air for effective
drying.
 Hence evaporation of moisture from the granules takes place.
 Thus, the product is dried to the required value to below 1% moisture content &
with a temp 850c is fed to the process screens.
 The gas flow at the drier exit pass through the cyclone battery sucked by the drier
exhaust fan.
 This gas flow is directed to the scrubbing system before being released to
atmosphere.
Drier gas stream:
Specifications:
Capacity : 150TPH
IO : 121-611 (3.8m)
Length : 851-011 (25.91m)
Rotation speed : 3 RPM
Type : rotary
Slope : 2.390
Axis : horizontal
Retention time : 15min
End opening : feed - 71-611(ID)
Discharge : 121-611

Internals:
Knocker balls : 12No
Scrolls : 12No
42
 Lifting flights : 24No
Distribution : 24No
Operating conditions:
Moisture contents of wet granules : 2-3% max
Moisture contents of dry granules : <1%
Air inlet temp pressure : 2200c, 3-4kg/cm2(g)
Air flow rate to drier : 10,600m3/hr
Flue gas outlet temp : 850c
Temp of dried granules : 850c
Causes & effects:
 At high temp, the material in the drier becomes sticky and may result in drier build
up
 High area content products, have to be dried at lower temperature to avoid
excessive granule softening will build up in the drier.
 The drier should be rotated occasionally if possible to prevent the material
overheating or resetting.
PROCESS SCREENS:
 It is a double deck screens (vibrating screens) placed one mesh over the other
mesh.
 Screens are provided with motor vibrators.Top mesh is of size 4.2mm & the
bottom mesh is of size of 1.8mm.
 Diverter is normally used for diverting product equally to both screens where total
solids flow is roughly divided 50% to each screen.
 This provision helps to temporarily bypass a screen for its maintenance & still
continue to operate the plant.
 Process screen feeders is to optimize the distribution of the product along the
screen width.
Process:

 Dried product is fed to the drier conveyor (exit) and from there to the drier
exit elevator.

43
  The product is conveyed to the process screens through screen feeders & the screen
diverters.
 The product is equally distributed to all over the screen through the diverters.
 The used screen is a double deck type, the over sizes retains on the top mesh,
where,the oversize are distributed through the chute to the pulverizes.
 The on-size product retains on the bottom mesh where it is sent to the cooler.
 The fines are sent to the recycle belt conveyor via recycle elevator.
 The fines are fed to granulator as recycle.

Specifications:
Type : double deck-vibrating screens
Capacity : 44.25 TPH
Slope : 36
Mesh aperture : 4.2mm (top mesh)
: 1.8mm (bottom mesh)
Types of decks : rectangular type
Material of construction : SS spring steel
Efficiency : 90% min

Operating conditions:
 Granulometry : granules
 > 4 mm : 5-25%
 1-4 mm : 35-75
 < 1 mm : 15-30
 Bulk density : 950-1000kg/m3
 Temperature : 850c
 Moisture : 1%
Process control:
Screens are usually cleaned for every 2hrs it any materials are plugged.

44
 Product specifications:
+4mm : 5% max
-4+1mm : 90% max
-1mm : 5% max

CHAIN MILLS:
 Chain mills are used in c-train, for size reduction of oversize in c-train. It consists of 2
rotating pulverizers
 It consists of chains over them.
 These pulverizers rotating in opposite direction in turn crushes material feed from
top discharges to the bottom & they are sent to fines conveyor.
 Rotating speed of pulverizes – 1440 RPM.

FLAIL MILL:
 It consists of one pulverizes crushes material due to attrition.
 It contain chain like hard material with an interlock each other on rotating
Pulverizes.

Process:
 The oversize from the screens fall by
gravity to the oversize pulverizers.
 The over sizes are crushed to a size of
4mm mesh
 The crushed product is fed to the recycle
belt elevator & through it is fed to
granulator through recycle belt conveyor.
 Chain mills are used in c-train & flail mill are used in A & B trains.

Chain mill flail mill

 Type – chain crusher - Type-flail crusher
 Cap-125 HTPH - Cap-100 tons/hr
45
 Operating conditions:-
 Temp (feed) - 850c
 Moisture - 1-2%
 Bulk density - 950 (1100 max)
Product size Feed discharge

>4 mm 90% 5-10% max

1-4 mm 10% 25-40% max
<1 mm 0 60-70% max

Causes & effects:

Check the ammeter readings & if there the power consumption is high it is a sign that
there is a solid build up inside the pulverizer.

COOLER:-
Construction:
 It is a rotary drum type cooler placed at an inclination of 1.79 to the horizontal.
 It is 25.91m in length and 3.8m in diameter.
 A ring gear in mounted on cooler, which is driven at a speed of 6 RPM using
100hp motor through speed reducing gear box & pinion.
 Two types are placed on either side of ring gear supported on trunnions.
 Internally it is provided with helical flights of two different kinds they are.
 Distribution flights.
 Lifting flights.
Process:
 On size product from the screens are fed to the rotary cooler.
 Counter current cooling is adopted for cooling of the granules.
 The hotness that is acclimated in the product is sucked by the fan provided opposite
to the cooler on the other end.
 The granules are cooled to 45-600c from 850c with a moisture content of 1%.
 The cooled product is lifted by the flights present in it.
 The cooled product is discharged from the other end of the cooler drum into product
conveyor.
46
  Dust coming out with the air leaving the cooler is recovered in a battery ofcyclones
and collected in these respective hoppers, from where it is fed back to the recycle
belt conveyor.
 After cycloning, gas will be sucked to the coder and deducting scrubber.
 Cooler & dedusting exhaust fan is located downstream of that scrubber.
 It is also equipped with an inlet damper to regulates the amount of air.
 Cooled product is fed by gravity to the final product elevator via. Product conveyor
which sends it to polishing screens through diverter & feeder.

Overall dimensions:
 Capacity : 33TPH
 Outer dia : 81-011 (2420mm)
 Length : 501-011
 Rotation speed : 6 RPM
 Axis : horizontal
 Slope : 1.79
 Retention time : 16.6min.
Operating conditions:
 Flow direction - counter current flow
 Temp of granules fed - 85-900c
 Temp of granules discharge - 45-600c
 Bulk density - 950-1110kg/m3
 Outlet gas temperature - 55-600c

POLISHING SCREENS:
It is a single deck screens which has only one single mesh.
Screens are provided with motor vibrators & with self-cleaning system.
Polishing screens are used in c-train only.

47
Process:
 The cooled product from the cooler is fed by gravity to the final product elevator,
which sends it to the polishing screens through diverters & feeders.
 The remaining fines or the possible fines generated in the rotary cooler are
separated.
 The separated fines are sent back to the recycle by the fines belt conveyor.
 This diverter helps to bypass polishing screens in case of its maintenance.
 Commercial product leaving the polishing screen is fed to the final product
beltconveyor to be finally sent to its corresponding storage.

Specifications:
 Process capacity : 35-45 tons/hr
 Type : vibrating screens
 Type of decks : rectangular
 No. of decks : 1
 Angle of repose : 32-36

Operating conditions:
 Temp of feed : 34-360c
 Moisture : 1%
 Granulometry : granules
 >4mm : 2-5
 1-4mm : 85-93
 <1mm : 5-10
Process control:
To avoid plugging of solids, screens are cleaned for every 2hr.
Conveying:
For conveying of materials from one place to another place without spillages.
Conveyors used in complex plant are.
Belt conveyor
Bucketelevators
Feeder

48
 Screw conveyors
Pipe conveyors

Recycle belt conveyor (belt conveyor):

 It plays a vital role in complex plant in carrying all the fines, crushed oversize’s,
raw material feeds.
 Besides, solid raw materials, the recycle conveyor will collect.
 The dust coming from all cyclone units.
 The crushed product from the
pulverizer Fines coming from
process screens & polishing
screens.
 P205 of the commercial product
which is in excess to required
production.
 Spillages recovery & solid raw
materials.
 The recycle conveyor discharges
into the granulator elevator, which
provides all the necessary recycle,
as well as the required solid raw
materials to the granulation.
 Special care is devoted to the
design of the recycle belt
conveyor. It will operate at a
rather low speed to avoid spillages & it cover will have a special proven design to
avoid excessive dust emission.

Dust collection & its recovery by cyclones:

Cyclones: with this, most of the useful dust product generated in the process Will be
recovered efficiently, increasing the plant yield and releasing to the atmosphere gas flows
with a minimum of polluting compounds.

49
Construction of cyclones:
 It consists of a tapering cylindrical vessel, i.e. cylindrical vessel consisting of a top
vertical section and lower conical/tapering section terminating to an apex
opening a short vertical section which is closed by a flat plate on top & by a
conical bottom.
 It is provided with a tangential fed inlet nozzle in the cylindrical section near
the to & an outlet for the gas, centrally on the top.
 The outlet is provided with a downward extending pipe.
 Each cyclone has an oscillating inner chain to avoid the product tending
toaccumulate on its walls.
 Cyclones are insulated to avoid condensations and for personal protection
reasons due to their high temperature.
 Between the battery entrance and exit, there is one pressure gauge for
the checking of the pressure drop through them.
 Under ordinary operation, the estimated pressure drop of the clean cyclone will
be a maximum of 100-120mmwc.

Process:
 They are three different cyclone batteries
 Drier cyclones
 Dedusting cyclones
 Cooler cyclones
 For the recovery of most dust (or very fine product) carried in air or gas flows coming
from different plant equipments.
Dryer cyclone:
It is composed identical cyclones. It will separate a great deal of dust carried
in the main drier flow then they are taken to the scrubbing tower where the
remaining very fine product, not separate earlier in cyclone & the small
amount of NH3 that might come from the drier are retained by the
corresponding scrubbing liquids which are then usually recycled to the
process.

50
Operating conditions:
Actual flow - 85,000 m3/hr
Max allowable - 125mmwc.
Dedusting cyclones:
It is composed of 3 cyclones, that will separate the dust product coming from
dedusting system, that collects dust from various plant equipment mainly elevators
screens, crushers & conveyors belts this air is aspirated by the cooler & dedusting
exhaust fan being them sent to the scrubbing system where the very fine dust
product not retained in the cyclone will be retained.

Operating conditions:
It is composed of 4 identical cyclones, that will separate fine particles of dust coming
from the rotary cooler this gas, blown to the cooler by the cooler fan is aspired by the cooler
& dedusting exhaust fan being then also sent to scrubbing system where the very fine dust
product not retained in cyclone will be recovered.
Operating conditions:
Actual gas flow : 59750m3/hr

Specifications Drier cyclones Cooler Dedusting

& operating cyclones cyclones
conditions
Actual flow 85, 000 M3/Hr 59,750 M3/ Hr 62, 600 M3/Hr
Max. Allowable -125 MM WC -100 to -150 -100 to -150
mmwc mmwc
Temperature 75-800C 50-600C 40-500C
Dust 50 Gm./ Am3 30Gm./ Am3 65Gm./ Am3
concentration
Material Hygroscopic Hygroscopic Hygroscopic
Overall efficiency 98.5% 95% 95%
No of cyclones 4 4 4
Size analysis >500 Microns : >350 Microns : >350 Macrons
20% 60% : 60%

51
 100- 500 100 Microns : 100 Microns :
Microns: 60% 80% 80%
50-100 20 Microns : 20 Microns :
Microns : 5% 92% 92%
20-50 Microns 75 Microns : 75 Microns :
: 9% 95% 95%
10-20 Microns
: 4-5%
Material Of Carbon Steel Carbon Steel Carbon Steel
construction
Max-allowable : -100 to 150mmwc

CYCLONES SPECIFICATIONS

DEDUSTING POINTS:
Dust laden air extracted from various dust extraction points like drier discharge
elevator, vibrating screens (process screens & polishing screens), pulverizes, product
feeders, product conveyor & elevators, RM bins & recycle conveyors & elevators are
drawn through dedusting cyclones & dedusting scrubbers by the dedusting fan.

Hot Air to Dedusting Points:

As the cyclones and entrance ducts gets loaded with product, the pressure drop will
increase, when its reaches to 150-180mmwc, the section should be stopped and the
cyclones are cleaned.

MAIN & PRE SUMP:

 The liquid in the main & pre sump constitutes of weak phosphoric. acid & process
water with a very minute amount of dissolved of NH3 & dust init.
 To achieve the best mixing of the stream, those vessels are equipped with an
agitator.
 The overflow from the PR vessel is sent to the main sump & to the pre sump.
From the mainsump, liquid is pumped to the required systems by sump pumps.
 Pipe reactor
 R/G scrubber
52
  Drier scrubber
 Cooler & dedusting scrubber
 Tail gas scrubber
 From the pre-sump , the liquid is sent to the duct scrubber & pre scrubber.
 The scrubbing liquid collected is again recycled back to their respective system.

 Conditions to be followed in main & pre sump:

% P 20 5 : 21-26%
Sp. Gravity : 1300-1500
Mole ratio : 1.3-1.4

Process control:
 If the specific gravity is high i.e. above the max limit, process water or weak acid are
added to attain the desired sp. Gravity.
 It the sp. Gravity is low 48% phosphoric acid is added to attain the desired sp.
gravity.

Gas scrubbing:
The gas scrubbing system & the several dedusting equipments are provided with the
aim of cleaning effluent gases as well as to recover nutrient element from side stream
four scrubbers are provided to recover NH3, dust from the effluent gases obtained from
R/G main scrubbers, drier cyclones, cooler & dedusting cyclones are fed to the
respective scrubbers.
 R/G pre scrubber
 R/G main scrubber
 Drier scrubber
 Cooler & dedusting scrubber
 Tail gas scrubber (for final effective scrubbing)

53
Construction of scrubbers:
 Pre scrubber, R/G main scrubber, drier scrubber, cooler scrubber & dedusting
scrubber & tail gas scrubber.
 A scrubbing tower is low pressure drop venture/cyclonic type will be used for
washing granulator/drier/cooler & dedusting scrubber to recover the incoming NH3,
fertilizer dust contained in those gases.
 It is a hollow cylindrical structure with dished ends eight nozzles are provided on its
periphery for spraying pre sump acid.
 Gas inlet connection to scrubber will be flanged & vertically located on the
upper part of vertical washing section.
 From the upper & R/G pre scrubber acid
from presume is fed & for all the
drier/main/cooler/dedusting scrubber acid
from the main sump are fed.
 The vapors from all the R/G drier, cooler,
dedusting scrubber are fed from the bottom
of the scrubber.
 Gas cutlet connection will be also flanged.
 Drain of vertical section will be designed to
eliminate the total amount of washing liquid
fed to that area.
 Also cyclonic part will have a drain centrally
located designed to eliminate the total amount of washing liquid fed to scrubber.
 Both drains will discharge to the suction of the recirculation temp.
 Scrubber washing section will be made of AISI 904l to face the high corrosive/erosion
on that area.
 This scrubbing will be equipped with the quick opening hinged manhole needed
toensure a proper inspection/cleaning in both upper & lower part.

Process:
 Vapors from the R/G/drier/cooler/dedusting cyclones are fed from the bottom of
the venture scrubber.

54
  Scrubbing liquid from main sump is fed from the top part of the scrubber.
 The unscrubbed gases from all the respective scrubber are fed to the TGS duct
scrubber by the respective fans.
 The scrubbed liquid is fed back to the main sump, Acid conditions to be maintained in the
scrubber.
% P 20 5 : 21-26%
SP. Gravity : 1300-1500
Mole ratio : 1.5-1.6

R/G DUCT & PRE SCRUBBER:

The combined gases from the reactor/granulator which contain significant quantities
of NH3 are scrubbed in the duct. Scrubber & R/G are pre scrubber with liquor from the
circulating pumps to remove most around 80% of the NH3 from the gas stream.

R/G MAIN SCRUBBER:

From the R/G pre scrubber, the gases are drown through the R/G scrubber by the
R/G scrubber fan where nearly all the remaining NH3 is removed by scrubbing with re
circulated leaver from the main scrubber pump finally the gases are discharged to TGS
scrubber where fluorine is removed by scrubbing with re circulated water where H2SO4
is added for PH control from the circulating pumps. The gases are discharged through
stack.

DIRER SCRUBBER:
Gases from the drier, which contain some dust & NH3 are drawn by the drier
scrubber fan through the drier cyclone. Where most of the dust is removed and
returned to the recycle belt conveyor. They are then drawn through the drier scrubber
where they are scrubbed with liquor from the main sump to remove at least 90% of NH 3.
the gases are then discharged to stack.

COOLER & DEDUSTING SCRUBBER:

Gases from the cooler are drawn through the cooler & dedusting cyclones & cooler
scrubber by the cooler scrubber fan. They are scrubbed by the circulating scrubber liquor
from the main sump remove traces of dust & NH3 before discharging to the stack through
tail gas scrubber.

55
VENTURI SCRUBBER:
 The venture portion has rectangular cross section. It has a peripheral weir at the
top portion of converging cone into weak acid is pumped from sump.
 The liquid from the overflow weir cascade down the sides of the
conveyingsection and the contacting the accelerating gas stream at the
throat.
 Here at the high velocity the gas atomizes the liquid into the droplets
small enough to impact upon the vapors so on to absorb them.
 The mixed gas and liquid then pass through the diffusing section where the
forces of diffusion and agglomeration act to increase the size of droplets and
wetted particles to a point, where they may be separated from the moving gas in
the separator.
 For this, mixed stream is injected tangentially to the separator where they get
separated by centrifugal action.
 The acid after scrubbing gets collected at the bottom of the separator
and gravitates to the main sump from where it recycles to the scrubber
using centrifugal pump each train has a common weak sump.
 A part of pressure acid is continuously injected into the reactor thereby
economizing the process.
 The gases from the separators are directed to the exhaust fan section. Each train
has 3 stack fans. These stack fan discharge the unabsorbed gases into a common
duct and given to the stack.
 Packing is not provided because the gases and as well as sump acid contains dust
particles which causes plugging, due to contact of weak H3PO4 with NH3 also
forms MAP&DAP & which is also responsible for plugging.
 For drier & cooler & for dedusting points with scrubber named as drier scrubber,
cooler & dedusting scrubber. They have same procedure like venture scrubber &
separator. They are for removing the dust particles polluting gases (NH3,
fluorine).

56
TAIL GAS SCRUBBER:
 The gases leaving from all the 4 scrubbers are fed to the tail gas scrubber the
gases are scrubbed twice. They are first at the entrance scrubbed with dil H2SO4
& again scrubbed with DM water. The unwanted gases are let out through the
stack.
 Packing is not provided because the gases and as well as sump acid contains
dust, particles which causes plugging. Due to contact of weak H3PO4 with NH3
also form MAP & DAP. Which is also responsible for plugging (in a train& b-train).
 But in c-train TGS packing are provided with special raisers for reducing emission
of effluent gases & for reducing how high rates of these gases.
 Discharge is sent to main sump deformer is added to avoid foaming. In TGS the
washing of these gases occurs in 2steps.
 The water & oil H2SO4 are sent to the top portion of scrubber through the
centrifugal pump & sprayed. This liquid mixture is sprayed at the top using spray
nozzles.
 Thus, TGS is to recover evolved dust, besides removal of the remaining NH3, with
the minimum fluorine emission.

Tail Gas scrubber Inlet flow Out let flow

Max. Gas flow ( 290,000 287,000
Am3/ Hr)
Op. Gas flow ( Am3/ 275000-288,000 272,000-
285,000
Hr)
Temperature 55-600C / 750C 50-570C / 600O
Max Max
Density 1-1.1 1-1.1
Relative pressure 200/ 250 150/190
Nor. Max fluorine 150-250/300 22,5/ 38
Mg/ Am3
Nor. Max NH3 Mg/ 85-300/1000 25-90
Am3
Dust Particles 250-350/1000 95-105/300
57
 Scrubber liquor : Acidulated water
 Solid % - 1% max
 Density - 1-1.07
 %P2O5 - 0.1-0.3%

Gas sears effluents through the stack according to fertilizer control

organization:-
 Gas flow - 284,000Am3/hr max
 Temp - 600c
 NH3 - <50PPM
 Dust - <50PPM
 Fluorine - <10PPM
Liquid effluents: No liquids will be entrained in the gaseous effluents.

Main fans: The complex plant has 3 different groups of fan.

Granulator exhaust fan: It sucks gas coming from the granulator (including pipe reactor
gases). The aspirated gases pass through granulator fumes pre scrubber and R/G granulator
scrubber being propelled to the tail gas scrubber, before being released to the atmosphere.
Drier exhaust fan:
This fan is for the aspiration of all drier gases which passes through the cyclones
batteries and the drier scrubber are propelled to the tail gas scrubber before
being released to atmosphere.

Cooler & dedusting exhaust fan:-

This fan aspirates gases from the rotary cooler after passing through the cyclones
battery and from the dedusting points after passing through the dedusting cyclones to
the tail gas scrubber and to atmosphere.

58
 SCRUBBER FAN

Cooler &
Operating R/G scrubber Drier
conditions & Dedusting
Fan scrubber Fan
specifications Fan
Centrifugal Centrifugal Centrifugal
Type
Fan fan fan
Open impeller Open impeller Open impeller
Model with straight with straight with straight
radial blades radial blades radial blades
69200 M3/Hr 1100000 60,000 M3/Hr
Flow
M3/Hr
Operating Temp 900C 600C 600C
0.85-0.90 Kg/ 1.07 Kg/ Am3 1.0-1.5 Kg/
Gas Density
Am3 Am3
500 Mg/ NM3 Ammonia & 500 Mg/ Nm3
Dust load
Dust with air
Fan Speed 1184 RPM 992RPM 1086 RPM

Difference between complex A, B & C train

A- Train C- Train
1. It has a PN tank ( B- Train) & 1. C- Train is completely run
a pipe reactor (B- Train) which with pipe reactor
operated simultaneously, where
as the A- Train is completely run
with PN reactor
2. It has a capacity of producing 2. It has a capacity of producing
1000 MTPD 2000 MTPD

59
3. Flail mill are used for carrying 3. Chain mills are used to
the over size particles carrying out the fines
4. No packing are provided in 4. Packing are provided is the
the tail gas scrubber TGS for effective scrubbing it is
handling more tons of Product

5. More HP steam is used in the 5. HP Steam consumption is less

A & B train than A & b trains
6. It is equipped with the 6. It is equipped with a single
individual scrubbers to scrub scrubber to scrub the gases from
the gases form the cooler & the cooler & dedusting points
dedusting points
7. Polishing screens are not 7. Polishing screens are provided
Provided

60
 BLOCK DIAGRAM OF COMPLEX
Liquid NH3

PhosAcid 48% acid

acid from sump

Sulfuric acid

NH3

Urea/ Potash

Recycle Belt Conveyor

Stack

***
61
62