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DAP Revamp Project at FFBL: Enhancing Capacity and Efficiency

Explore the DAP Revamp Project at FFBL, detailing the purpose, challenges faced in the old plant, major additions and modifications made, and the outcomes post-revamp. Learn how the project improved production capacity and efficiency.

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DAP Revamp Project at FFBL: Enhancing Capacity and Efficiency

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  1. First of all . . . . .

  2. DAP REVAMP PRESENTED BY: MUHAMMAD SHAKEEL APPRENTICE ENGINEER DAP OPERATIONS FAUJI FERTILIZER BIN QASIM LIMITED

  3. OBJECTIVE • An integral part of Apprenticeship at FFBL • Self study for more detailed exposure

  4. CONTENTS • Purpose • Why not a new plant instead of BMR? • Problems faced in old plant. • Major additions made in Revamp • Modifications made in Revamp • From AZF dual pipe reactor to JACOBS’ PN technology • Problems emerging after Revamp • Conclusion

  5. PURPOSE FOLLOWING WERE THE PURPOSES TO BE ACHIEVED BY DAP REVAMP • To utilize the increased NH3 production • To enhance plant capacity by 50% • To uplift the country’s economy by reducing the DAP imports as FFBL is its sole manufacturer in Pakistan

  6. WHY NOT A NEW PLANT INSTEAD OF BMR Following main factor lead FFBL management to go for revamp of existing plant instead of installing new plant. • COST According to JACOBS budgetary estimate the company would have to spend 13.1 Million USD for Revamp while the total installed cost of new plant was ~ 24 Millions USD. CONTINUE…

  7. WHY NOT A NEW PLANT INSTEAD OF BMR • TIME • Time was one of the most important factors. • Revamp project was to be completed in 14 months while new plant completion requires 24 - 26 months minimal. • MANPOWER Additional Manpower was required to run a new plant but after BMR the same no. of persons are operating the plant.

  8. PROBLEM FACED IN OLD PLANT • GRANULATOR • Frequent rubber panels replacement due to short life i.e. approx. 1~2 months only • High frequency of Granulator outlet chute (DM-122) rubber panels damaging. • Damage to grizzly CONTINUE…

  9. PROBLEMS FACED IN OLD PLANT • DRYER • High noise from hammers • Plugging of inlet spiral plates & lifters • Frequent plant shutdowns for impeller washing due to dust deposition on Dryer off-gases fan CONTINUE…

  10. PROBLEMS FACED IN OLD PLANT • HGG Frequent blockage of discharge duct • FRP PIPING Frequent blockages, failures and seepages • DUST GENERATION MAP formation in powdered form in DPR • COATER • High vibration • Frequent failure of Hydraulic Coupling

  11. MAJOR ADDITIONS MADE IN REVAMP • PRE-NEUTRALIZER • A new reactor system to take a significant load of reaction. • AMMONIA VAPORIZER • Removes heat from the circulating tail gas scrubber liquor. • The cooling provided to the scrubbing liquor improves its Fluorine scrubbing efficiency. • AIR CHILLERS • Additional state-of-the-art feature is an air chiller for product cooling & Ammonia Vaporization. CONTINUE…

  12. MAJOR ADDITIONS MADE IN REVAMP • PRE SCRUBBER & RG SCRUBBER • Utilize a “dual mole” ratio Scrubbing system for Pre Neutralizer & Granulator off gases. • Recovers maximum NH3 & Fluorine from off gases • BAG HOUSE A dedust bag House installed in series with cyclones to minimize dust carryover to Hot Gas Generator outlet duct

  13. MODIFICATIONS MADE IN REVAMP • GRANULATOR • Slope increase from 3% to 6.23% • Exit chute replaced • Grizzly has been changed to a stronger design • GPR replaced • NH3 sparger replaced • Barring device added DRYER • Slope increased from 2.5% to 5% • Speed increased from 2.2 to 3.8 RPM • Hammers replaced with balls in tube CONTINUE…

  14. MODIFICATIONS MADE IN REVAMP • MATERIAL HANDLING CAPACITY • Dryer exit belt upgraded from11.5 to 16 kW • Product conveyor power increased from 8 to 11.5kW • Recycle conveyor drive system has been upgraded from 16 to 30 kW • Screen feed elevator & Granulator feed elevator internals changed

  15. AZF DUAL PIPE REACTOR Water fed to Granulator: 6~8% Low recycle ratio Low fuel consumption MAP is formed in powdered form Less residence time PN SLURRY PROCESS Water fed to Granulator 20% High recycle ratio High fuel consumption No MAP is formed More residence time FROM AZF TO JACOBS CONTINU…

  16. Less NH3 fixation More emissions More NH3 fixation Less emissions FROM AZF TO JACOBS

  17. PROBLEMS EMERGING AFTER REVAMP • BAGHOUSE • Dust conveyor safety pin breaking • Dust accumulation on grating • Passage of dust through Bags • Baghouse Inlet Damper passing • VIBRATING FEEDERS • Material spillage • Overflowing of material from one compartment to the other CONTINUE…

  18. PROBLEMS EMERGING AFTER REVAMP • NEW POLISHING SCREEN • Less efficiency to segregate the material • DEDUSTING • Frequent blockage of new dedusting chutes • High dust formation • Limitations of Crushers

  19. CONCLUSION • The plant capacity has been increased by 50%. • Majority of the problems faced prior to Revamp has been overcome. • Enhanced Ammonia production finds its usage to produce more DAP, hence increasing the company profit

  20. QUESTIONS ???

  21. THANKS

  22. NH3 GRANULATOR H DRYER

  23. DRYER SLURRY GRANULATOR GRANULATOR DRYER

  24. PRODUCT RESULTS BEFORE & AFTER REVAMP

  25. POLISHING SCREEN INLET & OUTLET ANALYSIS

  26. BAGHOUSE INLET & OUTLET ANALYSIS

  27. WORLD MONTHLY CS PRICES

  28. FEEDERS OVERFLOWING

  29. OLD & NEW POLISHING SCREENS

  30. BAGHOUSE DUST CONVEYOR

  31. GRANULATOR BARRING MOTOR

  32. BAGHOUSE FILTERS & GRATING

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