In the name of Allah, The most Merciful & Beneficent.

1. In the name of Allah, The most Merciful & Beneficent.

2. FAUJI FERTIZER BIN QASIM LTD. COMPARISON OFAZF DPR AND JACOBS SLURRY TECHNOLOGY FOR DAP MANUFACTURING BY: MUHAMMAD WASEEM APP. ENGINEER DAP OPERATIONS

3. DAP formation & plant description. Various methods for DAP manufacturing. Description of AZF double pipe reactor process. Description of Jacobs slurry process. Difference between AZF & Jacobs technology. Advantages of AZF DPR & Jacobs slurry technology. OUT LINES

4. HOW DAP IS FORMED The main principle of DAP formation is to neutralize phosphoric acid with ammonia and afterwards to granulate the neutralization products. 2NH3 + H3PO4 (NH4)2HPO4 + Q • Raw materials • Phosphoric acid • Ammonia • Filler • Sulfuric acid • River sand • Utilities • Natural gas • Antifoam • Coating agent • Industrial water

5. DAP plant consists of Reactors Granulation loop Granulator Dryer Screening & crushing equipment Handling & recycling equipment Product treatment (conditioning) section Cooling Coating Scrubbing section De dusting network DESCRIPTION OF DAP PLANT

6. Feeds To stack Gases Reaction Scrubbing De dusting Gases Gases Granulation & Drying Product Recycle Cooling Elevators & conveyors Screening Coating Under size & grinded over size Grinding Storage GRANULATION LOOP CONDITIONING SECTION DESCRIPTION OF DAP PLANT

7. Conventional pre neutralizer process. Single pipe reactor process. Double pipe reactor process. Pre neutralizer with pipe reactor process. PROCESSES FOR DAP MANUFACTURING

8. In AZF process two pipe reactors (tubular reactors) are used for neutralization of phosphoric acid with ammonia. Each operates individually, forming slurry & dust. H2SO4 H3PO4 LIQ. AMMONIA GRANULATOR LIQ. AMMONIA GPR SCRUBBING LIQUOR AMMONIA SPARGER H3PO4 DPR DRYER LIQ. AMMONIA HOT AIR SCRUBBING LIQUOR DESCRIPTION OF AZF DPR PROCESS

9. This is the pre neutralizer with pipe reactor kind process. Most of the reaction takes place in pre neutralizer forming slurry. This slurry is sprayed in granulator through pipe reactor where more ammonia and phosphoric acid is reacted for capacity increase. SCRUBBING LIQUOR H3PO4 H2SO4 H3PO4 GASEOUS AMMONIA GRANULATOR GPR AMMONIA SPARGER PN LIQ. AMMONIA SLURRY DRYER GASEOUS AMMONIA HOT AIR DESCRIPTION OF JACOBS SLURRY PROCESS

10. Process Reactors Raw material feeding system Recycle ratio Scrubbing system Bag house Ammonia vaporization Environmental impact DIFFERENCES B/W JACOBS & AZF TECHNOLOGY

11. ADVANTAGES

12. Two reactors operates in parallel, one in granulator (granulator pipe reactor) and one in dryer (dryer pipe reactor). Dryer pipe reactor operates at a mole ratio of 1-1.05 producing MAP (dust), while granulator pipe reactor operates at mole ratio of 1.4 - 1.45 producing slurry. Slurry moisture content low. Low residence time for reaction. PROCESS AZF double pipe Reactor Process:

13. Jacobs slurry Process : Two reactors operates in series, one is a pre neutralizer (CSTR) and other a pipe reactor which operates in granulator. Pre neutralizer operates at a mole ratio of 1.45 producing slurry. This slurry is sprayed in granulator through granulator pipe reactor where more ammonia & phosphoric acid is reacted for capacity increase. Slurry moisture content high. High residence time for reaction. PROCESS

14. Gases to scrubber Scrubbing liq. Solids recycle Sulfuric acid Granulator Liq. Ammonia Granulator pipe reactor Liq. Ammonia Ammonia sparger Gases to scrubber Phosphoric acid Phosphoric acid Solids to dryer Dryer pipe reactor Dryer Liq. Ammonia Scrubbing liq. Hot air Solids to screening AZF REACTORS

15. Gases to scrubber Solids recycle Phosphoric acid Granulator pipe reactor Gas. Ammonia Granulator Liq. Ammonia Scrubbing liq. Ammonia sparger Sulfuric acid Solids to dryer Slurry Pre neutralizer JACOBS REACTORS

16. RAW MATERIAL FEEDS SYSTEM

17. AZF DPR process: Low recycle ratio. Low fuel consumption. Low power consumption. Jacobs slurry process: High recycle ratio. High fuel consumption. High power consumption. RECYCLE RATIO

18. AZF SCRUBBING SYSTEM In AZF process scrubbing consists of two stages. One scrubs the gases of granulator and the other gases from the dryer. A tail gas scrubbing column finally scrubs the gases. High mole ratio & high sp. gravity operation.

19. In Jacobs slurry process scrubbing system is designed consisting of “dual mole” scrubbing and a tail gas scrubber. Thus reduces the ammonia emissions to atmosphere. Also scrubbing liquor operates at low mole ratio & low sp. gravity. JACOBS SCRUBBING SYSTEM

20. BAG HOUSE For energy conservation both AZF & Jacobs process used hot de dusting gases as dilution air in hot gas generator flue gases.

21. As compared to AZF process where liquid ammonia is used, Jacobs process designed both the reactors (pre neutralizer and pipe reactor) to operate with gaseous ammonia. AMMONIA VAPORIZATION Also the cooling provided to the scrubber liquor improves fluorine scrubbing efficiency in the tail gas scrubber.

22. ENVIRONMENTAL IMPACT AZF PROCESS JACOBS PROCESS Higher ammonia losses from reactor and granulator Low ammonia losses from reactor and granulator Higher dust Low dust Stack analysis: NH3: 250 mg/nmc P2O5: 33 mg/nmc F : <1 mg/nmc Particulates : 34 mg/nmc Stack analysis: NH3: 113 mg/nmc P2O5: <10 mg/nmc F : <1 mg/nmc Particulates : <10 mg/nmc

23. THANK YOU Questions????