Final Pre-Feasibility Report for Phosphatic Fertilizer Project - Part 1.pdf

PRE-FEASIBILITY REPORT FORHINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S INDEX SECTION NO. TITLE PAGE NO. SECTION-1 Introduction ................................................................. SEC 1/1 to 1/2 SECTION-2 Scope of Project ........................................................... SEC 2/1 to 2/2 SECTION-3 Basis of Design ............................................................. SEC 3/1 to 3/5 SECTION-4 Specifications of Raw Material & Utilities ................... SEC 4/1 to 4/7 SECTION-5 Site Selection ............................................................... SEC 5/1 to 5/2 5.1 Zawar Mines 5.2 Maton Mines SECTION-6 Selection of Technology ............................................... SEC 6/1 to 6/41 6.1 Rock Beneficiation Plant .............................................. SEC 6/1 to 6/1 6.2 Phosphoric Acid Plant .................................................. SEC 6/1 to 6/12 6.3 Di-Ammonium Phosphate Plant .................................. SEC 6/13 to 6/41 SECTION-7 Process Description ...................................................... SEC 7/1 to 7/18 7.1 Rock Beneficiation Plant .............................................. SEC 7/1 to 7/4 7.2 Phosphoric Acid Plant .................................................. SEC 7/5 to 7/10 7.3 Di-Ammonium Phosphate Plant .................................. SEC 7/10 to 7/18 SECTION-8 Mass Balance ............................................................... SEC 8/1 to 8/6 8.1 Rock Beneficiation Plant 8.2 Phosphoric Acid Plant 8.3 Di-Ammonium Phosphate Plant SECTION-9 Expected Raw Material & Utilities Requirement ......... SEC 9/1 to 9/3 SECTION-10 Product Quality ............................................................ SEC 10/1 to 10/4 PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION NO. TITLE PAGE NO. SECTION-11 By-Product Quality ...................................................... SEC 11/1 to 11/7 SECTION-12 Environmental Regulations ......................................... SEC 12/1 to 12/10 SECTION-13 Offsite Facilities ........................................................... SEC 13/1 to 13/11 SECTION-14 Scope of Work & Equipment list .................................. SEC 14/1 to 14/19 14.1 Rock Beneficiation Plant 14.2 Phosphoric Acid Plant 14.3 Di-Ammonium Phosphate Plant SECTION-15 General Specifications ................................................. SEC 15/1 to 15/7/6 15.1 Mechanical .................................................................. SEC 15.1/1 to 15.1/20 15.2 Piping ........................................................................... SEC 15.2/1 to 15.2/26 15.3 Electrical ...................................................................... SEC 15.3/1 to 15.3/23 15.4 Instrumentation .......................................................... SEC 15.4/1 to 15.4/6 15.5 Civil .............................................................................. SEC 15.5/1 to 15.5/19 15.6 Painting ....................................................................... SEC 15.6/1 to 15.6/5 15.7 Rubber Lining/Insulation ............................................. SEC 15.7/1 to 15.7/6 SECTION-16 Estimated Manpower Requirement ............................ SEC 16/1 to 16/7 SECTION-17 Estimated Operating Cost ............................................ SEC 17/1 to 17/9 SECTION-18 Drawing List ................................................................. SEC 18/1 to 18/2 SECTION-19 Vendor List ................................................................... SEC 19/1 to 19/27 SECTION-20 List of Spare Parts ........................................................ SEC 20/1 to 20/25 SECTION-21 Project Schedule .......................................................... SEC 21/1 to 21/9 SECTION-22 List of Proprietary Equipment ...................................... SEC 22/1 to 22/2 PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION NO. TITLE PAGE NO. SECTION-23 Budget Estimate ......................................................... SEC 23/1 to 23/6 SECTION-24 Information for 800 MTPD Phosphoric Acid Plant And 1500 MTPD DAP Plant ……………………………………….SEC 24/1 to 24/16 SECTION-25 Exclusions ................................................................... SEC 25/1 to 25/2 HINDUSTAN DORR-OLIVER LIMITED SECTION‐1  INTRODUCTION PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 1 INTRODUCTION Hindustan Zinc Limited (HZL), Udaipur, a Vedanta Group Company is a leader in Zinc, Lead and Silver businesses. HZL is the world’s largest integrated producer of Zinc & Lead. HZL’s business comprises of mining and smelting of zinc & lead along with captive power generation. HZL is India’s largest and second largest integrated zinc/lead producer in the world. HZL has mining, smelting and power operations in multiple locations across India. The principle products are refined zinc metal and refined lead metal. In addition, HZL also has a Rock Phosphate Mine at Maton, Udaipur. Hindustan Zinc Limited is planning to set up a Phosphatic Fertilizer Complex at Udaipur comprising of:  Rock Phosphate Beneficiation Plant having capacity of 5,00,000 MTPA at Maton Mines, Udaipur  Phosphatic Acid Plant having capacity of 1,00,000 MTPA at Zawar Mines, Udaipur  Di-Ammonium Phosphate Plant having capacity of 2,00,000 MTPA at Zawar Mines Udaipur HZL has selected Hindustan Dorr-Oliver Limited (HDO) for preparation of Pre-feasibility Report for the Phosphatic Fertilizer Plant Hindustan Zinc Limited (HZL) own and operate Maton Mines, where Indian Grade Rock Phosphate is available as mined product. HZL intends to beneficiate this Rock Phosphate for production of Merchant Grade Phosphoric Acid. Phosphoric Acid will be used as the major raw material in the Di-Ammonium Phosphate (DAP) Plant for production of 18:46:00 (DAP), 16:20:00 & 20:20:00 grade of fertilizer. -SEC 1/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S HDO team comprising of the following members visited HZL, Udaipur from 15th April 2013 to 19th April 2013 for discussions about the Pre-feasibility Report for the Phosphatic Fertilizer Project. HDO team visited the proposed sites at Maton Mines & Zawar Mines and held discussions with Sr. executives of HZL. HDO collected all the relevant information as required for the pre-feasibility report from HZL executives. 1) Mr. A.K. Gupta 2) J.K. Jani 3) Mr. Zaibu Hudson 4) Mr. Sachin Joshi 5) Mr. Anirudh Prasadh HDO is pleased to present the Pre-feasibility Report for the proposed Phosphatic Fertilizer Complex comprising of Phosphoric Acid Plant and Di-Ammonium Phosphate Plant at Zawar Mines. -SEC 1/2- HINDUSTAN DORR-OLIVER LIMITED SECTION‐2  SCOPE OF PROJECT PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 2 SCOPE OF PROJECT The scope of work for preparing Pre-feasibility Report for Phosphatic Fertilizer Complex will include the following: A] Maton Mines 2.1 Battery Limit 5,00,000 MTPA Rock Phosphate Beneficiation Plant based on Basic Engineering Feed package provided by HZL. 2.2 Beneficiated Rock Phosphate Storage & Handling System at Maton Mines 2.3 Water Storage & Distribution System 2.4 Power Distribution System 2.5 DG Set B] Zawar Mines 2.1 Beneficiated Rock Phosphate Storage & Conveying System 2.2 Sulphuric Acid Storage & Conveying System 2.3 Battery Limit 1,00,000 MTPA Phosphoric Acid Plant 2.4 Phosphoric Acid Storage & Pumping System 2.5 Gypsum Pond 2.6 Aluminium Fluoride Plant 2.7 Solid Raw Material such as filler storage, seed storage 2.8 Ammonia Storage & Handling System at Site 2.9 Battery Limit 2,00,000 MTPA Di-Ammonium Phosphate Plant 2.10 Product Conveying to Bulk Silo & Bagging Plant -SEC 2/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 2.11 Bulk Silo & Screening System for Product 2.12 Bagging Plant & Bagged Product Storage Facility 2.13 Steam Generation & Distribution System 2.14 Fuel Oil Storage & Distribution System 2.15 Water Storage & Distribution System 2.16 Power Distribution System -SEC 2/2- HINDUSTAN DORR-OLIVER LIMITED SECTION‐3  BASIS OF DESIGN PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 3 BASIS OF DESIGN 3.1 Project : Phosphatic Fertilizer Complex. 3.2 Location : 1) Maton Mines – Rock Phosphate Beneficiation 2) Zawar Mines – Phosphoric Acid & DAP Plant 3.3 Plant capacity : 1) Rock Phosphate Beneficiation Plant – 5,00,000 MTPA 2) Phosphoric Acid Plant – 350 MTPD (100% P2O5) 3) DAP Plant – 600 MTPD 3.4 RAW MATERIAL 3.4.1 ROCK PHOSPHATE BENEFICIATION PLANT ROM Rock Phosphate ROM Rock Phosphate required for the Beneficiation Plant will be made available at the Battery Limit at Maton Mines by the OWNER. 3.4.2 PHOSPHORIC ACID PLANT We have assumed that the Beneficiated Rock Phosphate will be suitable for Phosphoric Acid production in the Phosphoric Acid Plant. 3.4.2.1 Beneficiated Rock Phosphate Beneficiated Rock Phosphate required for the Phosphoric Acid Plant will be made available at the Battery Limit of the Fertilizer Complex at Zawar site by the OWNER. HDO has considered Beneficiated Rock Phosphate storage of three days at Zawar site. The capacity of Beneficiated Rock Phosphate storage will be 4000 MT. -SEC 3/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 3.4.2.2 Sulphuric Acid Sulphuric Acid (98%) required for Phosphoric Acid Plant will be provided at the Battery Limit of the Phosphatic Fertilizer Complex at Zawar site by the OWNER. Sulphuric Acid storage of 5000 MT equivalent to three days is considered for storage for the Phosphoric Acid Plant & DAP Plant. The system shall consist of the following: a) Two (2) Tanks of 2,500 MT capacity each b) Three (2 working + 1 installed standby) Sulphuric Acid Unloading Pumps c) Three (2 working + 1 installed standby) Sulphuric Acid Transfer Pumps. 3.4.2.3 Defoamer Defoamer will be made available at the Battery Limit by the OWNER. The Defoamer System will consist of One (1) No Day Tank, and Three (3) Nos (2 working + 1 installed standby) Defoamer Transfer Pumps for transferring to the Phosphoric Acid and the DAP Plant. 3.4.3 DI – AMMONIUM PHOSPHATE PLANT 3.4.3.1 Phosphoric Acid Phosphoric acid required for DAP plant will be made available at the Battery Limit of the plant. HDO has considered ten days storage of Phosphoric Acid. Thus, based on 350 MTPD (100% P2O5) Plant capacity, 7000 MT (52-54 % P2O5) storage is considered for Phos Acid product (54% P2O5). The Phos Acid Storage & Handling System will consist of a) Two (2)Tanks of 3500 MT (52-54% P2O5) capacity b) Three (2 working + 1 Installed Standby) Transfer Pumps. 3.4.3.2 Liquid Ammonia Liquid Ammonia required for DAP plant will be made available at the Battery Limit of the Phosphatic Fertilizer Complex at Zawar by the OWNER. HDO has considered 5000 MT of Ammonia storage facility at Zawar Site. The Ammonia Storage & Handling System will consist of -SEC 3/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S a) Two (2)Tanks of 2500 MT capacity b) Three (2 working + 1 Installed Standby) Supply Pumps. The system shall include Ammonia unloading from road tankers, storage and refrigeration, ammonia distribution via the supply pumps and heating upto 5 °C as required for the DAP plant, 3.4.3.3 Sulphuric Acid Sulphuric Acid (98%) required for Phosphoric Acid Plant will be provided from the common Sulphuric Acid Storage & Handling Facility. The sulphuric acid requirement for the DAP Plant will also be provided from the common Sulphuric Acid Storage & Handling Facility. 3.4.3.4 Defoamer Defoamer will be made available at the Battery Limit by the OWNER. The Defoamer requirement will be provided from the common Defoamer System. 3.4.3.5 Filler Filler will be made available in the Raw Material Storage by the OWNER. Thus, Filler/Seed Material Storage of 500 MT capacity is considered. 3.5 Utilities 3.5.1 Power Electric power will be made available at 132 KVA by HZL. Electrical substation is considered for tapping from grid/power plant for sites at Zawar and Maton mines. 3.5.2 Fuel Oil The Fuel Oil requirement will be provided at the Battery Limit by the OWNER. The Fuel Oil specifications are as follows: Flash point : 73oC Sp. Gravity at 15oC : 0.9474 Kinematic viscosity (50oC) : 77.1 cs. Normal 160 cs. Max. Carbon residue : 6.8% by wt. Total sulphur : 2 to 3% by wt. -SEC 3/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Water content : Traces Sediments : 0.016% by wt. Gross calorific value : 8200 kCal / kg. 3.5.3 Water The water requirement for Zawar and Maton Locations would be met from the existing facilities of HZL and will be made available at the Battery Limit by HZL. The water quality is as follows, Maton Mines Alkalinity Hard. in CL. in Season Month PH in PPM PPM PPM Monsoon Sep – 12 7.7 218.7 375.5 465.4 Post Monsoon Dec – 12 7.6 247.4 381.2 398.7 Winter Mar - 13 7.7 267.5 390.4 459.3 Zawar Mines Alkalinity in Hard. in CL. in Season Month PH PPM PPM PPM Post monsoon Dec – 12 7.6 247.4 381.2 398.7 3.6 Meteorological Data AT ZAWAR (UDAIPUR) Air temperature - Maximum : 44.6 °C - Minimum : 3 °C Rainfall - Average per annum : 650 mm. -SEC 3/4- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Wind Velocity - Average : 100 KMPH - Wind speed range : 2.6 – 11.7 KMPH Relative humidity - Maximum : 82 % - Minimum : 34 % Seismic - Seismic zone III 3.7 Environmental Requirement 3.7.1 The Phosphoric Acid Plant will be designed to meet the following stack gas emission: Particulate matter : 50 mg/NM3 Fluorine : 5 mg/NM3 3.7.2 The DAP Plant will be designed to meet the following stack gas emission: Ammonia : 50 mg/NM3 Particulate matter : 50 mg/NM3 Fluorine : 5 mg/NM3 3.8 Product Quality 3.8.1 The Phosphoric Acid produced from the Phosphoric Acid Plant will be suitable for the production of DAP and other grades (16:20:0, 20:20:0) 3.8.2 The product from the DAP plant will meet the F.C.O. requirement. -SEC 3/5- HINDUSTAN DORR-OLIVER LIMITED SECTION‐4  SPECIFICATIONS OF RAW MATERIAL & UTILITIES  PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 4 SPECIFICATIONS OF RAW MATERIAL & UTILITIES The Rock Phosphate Beneficiation Plant at Maton Mines & the Phosphatic Fertilizer Complex consisting of Phosphoric Acid Plant and Di-Ammonium Phosphate Plant, at Zawar Mines will be designed based on the following Raw Materials & Utilities: 4.1 RAW MATERIALS 4.1.1 ROCK PHOSPHATE BENEFICIATION PLANT ROM Rock Phosphate ROM Rock phosphate required for the Rock Phosphate Beneficiation plant will be made available at the Battery Limit at Maton Mines by the OWNER. The specifications of the ROM Rock Phosphate are as follows: Grade ROM Rock Phosphate (Maton Rock) Sr No Property Value (%) 1 P2O5 21.76 2 SiO2 32.76 3 Fe2O3 9.22 4 Al2O3 1.64 5 CaO 27.91 6 MgO 0.95 7 Na2O 0.15 8 K2 O 0.07 9 SiO2 0.22 10 BaO 3.51 11 LOI 1.81 Total 100 4.1.2 PHOSPHORIC ACID PLANT a. Beneficiated Rock Phosphate The Beneficiated Rock Phosphate requirement for the Battery Limit Phosphoric Acid Plant will be met from the Rock Phosphate Beneficiation Plant at Maton Mines. The specification of the Beneficiated Rock Phosphate will be as follows: -SEC 4/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Grade Beneficiated Rock Phosphate (Maton Rock) Sr No Property Value (%) 1 P2O5 35.8 2 SiO2 9.0 3 Fe2O3 0.79 4 Al2O3 0.22 5 CaO 45.8 6 MgO < 0.1 7 Na2O 0.1 8 K2 O < 0.1 Particle Size: The beneficiated rock phosphate should be screened at 5 mm size. The typical sieve analysis for Beneficiated Rock Phosphate to be used as Phosphoric Acid Plant Raw Material should be as follows, Sieve Analysis Sr No Sieve %w 1 4 0-5 2 2 0-5 3 24 20 - 25 4 30 30 - 35 5 25 0-5 6 15 20 - 25 7 100 15 - 25 8 -200 5 - 10 b. Sulphuric Acid The Sulphuric Acid required for the Phosphoric Acid Plant would be transported via road tanker from HZL at Chandelia. The specifications of Sulphuric Acid are as follows: -SEC 4/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CHARACTERISTICS RESULTS Specific Gravity 1.83 % H2O4 98.00 Fluoride (ppm) N.T. % Cl as HCl 0.043 % NO3 as HNO3 0.003 c. Active Silica PARAMETERS Value (%) Moisture 32.45 Purity as SiO2 73.8 Fe2O3 0.006 Al2O3 10.25 CaO 0.08 MgO BDL Na2O 0.12 K2O 0.01 Fluorine 5.61 As BDL BDL – Below Detectable Level 4.1.3 DI – AMMONIUM PHOSPHATE PLANT a. Phosphoric Acid Phosphoric Acid requirement for the Battery Limit Di-Ammonium Phosphate Plant would be met from the Phosphoric Acid Plant. The specifications of Phosphoric Acid are as follows: -SEC 4/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Sr No. PARAMETERS Value 1 P2O5 53.48%. 2 Fe2O3 0.72% 3 Al2O3 0.4% 4 MgO 0.37% 5 Fluorides as F 0.36% 6 SO4 2.02% 7 CaO 0.1% 8 Chlorides 0.0275% 9 Specific Gravity 1.6209 b. Liquid Ammonia The Ammonia requirement for the DAP Plant would be met through imports. The Ammonia would be unloaded at the port and transported to the site via tankers by Owner. The specifications are as follows: NH3 : 99.5 % minimum Oil : 5 ppm maximum Temperature at battery limit : -1 to +2 °C Pressure at Battery Limit : 9 to 11 kg/cm2 (g) c. Sulphuric Acid The Sulphuric Acid required for the Phosphoric Acid Plant would be transported via road tanker from HZL at Chandelia. The specifications of Sulphuric Acid are as follows: CHARACTERISTICS RESULTS Specific Gravity 1.83 % H2O4 98.00 Fluoride (ppm) N.T. % Cl as HCl 0.043 % NO3 as HNO3 0.003 -SEC 4/4- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S d. Defoamer The Defoamer will be sourced locally. The specifications are as follows: Product Type Defoamer / Anti-foaming Agent (Oil Based) Product Description XG 329 is a specially designed defoamer to provide optimum foam control in process that involves neutralizing and/or exothermic reactions. There are several other applications that can benefit from XG 329. Typical Properties Appearance Clear dark amber liquid Odor Mild Boiling Point > 101oC pH 7.0 + - 1 Activity 100% Nature Modified linear organic esters Specific gravity @ 0.92 +- 0.01 25oC Pump Ability Due to non-gelling/non thickening behavior, does not pose any problem in pumping or choking of pipe lines Typical Applications Typical applications for XG 329 include: 1. Phosphoric acid production 2. Phosphate fertilizer production (MAP, DAP, etc) 3. Acid – base neutralizing reaction process Incorporation Add XG 329 constantly right before foaming condition occurs (agitation / reaction). Storage & Handling Keep containers close when not in use. Wash thoroughly after handling. Mix before use. -SEC 4/5- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S e. Filler This requirement of Filler for Di-Ammonium Phosphate Plant would be met locally using the Bottom (Pond) Ash available at Zawar Mines. The specifications are as follows: Color : Gray Specific Gravity : 1.71 Particle Size Analysis Coarse (1.18 mm – 600 µm) : 1.58 % Medium (600 µm - 150 µm) : 17.96 % Fines (150 µm - 20 µm) : 66.66 % Very Fine (< 20 µm) : 13.80 % Water Absorption : 18.70 % The suitability of bottom ash as a filler will be confirmed by the Process Licensor during the execution of the project. Alternatively, Bentonite is usually used as the Filler Material in NP/DAP Plants. The specifications of Bentonite area as follows, Size : 0.17 mm to 1 mm 90% min Bulk density : 720 kg/m3 Conditions : Free flow and without lump Temperature : Ambient 4.2 UTILITIES The Rock Phosphate Beneficiation Plant at Maton Mines and the Phosphatic Fertilizer Complex Battery Limit at Zawar Mines will be designed based on the following utilities: 4.2.1 Plant Air Temperature : Ambient Pressure : 5.5 kg/cm2 (g) min. -SEC 4/6- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 4.2.2 Instrument Air Specification : Dry, oil free air Dew point : -20 °C Pressure : 5.5 kg/cm2 (g) min. 4.2.3 Service Water Water temperature : 38 °C max. Pressure : 5.0 kg/cm2 (g) min. 4.2.4 Potable Water Specification : Standard Temperature : 38 °C Pressure : 5.0 kg/cm2 (g) min. 4.2.5 Fuel Oil Flash Point : 73 °C Density at 15 °C : 0.9474 Kinematic Viscosity at 50 °C : 77.1 cSt Normal 160 cSt Maximum Carbon residue : 6.8 % by Wt. Total Sulphur : 2 to 3% by Wt. Water Content : Traces Sediments : 0.016 % by Wt. Gross Calorific Value : 8200 kCal/Kg 4.2.6 Steam Specification : Saturated steam Pressure : 10 kg/cm2 (g) 4.2.7 Fire Water Specification : Clear water Temperature : Ambient Pressure : 10 kg/cm2 (g) -SEC 4/7- HINDUSTAN DORR-OLIVER LIMITED SECTION‐5  SITE SELECTION PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION ‐ 5    SITE SELECTION    HDO  Executives  visited  Zawar  and  Maton  Mines,  HZL,  Udaipur,  from  15th  March  to  18th  March 2013.  Based on the same the findings of our study are as follows,  A] Zawar Mines  The location considered for the Phosphatic Fertilizer Plant at Zawar Mines was observed to  be totally hilly and therefore, terracing is required for each unit. It was also observed that  all  old  buildings  and  electric  overhead  cables  are  to  be  dismantled  and  rerouted  prior  to  any construction work, respectively. The cost for the same is not considered in this report.  HDO noted that due to the hilly area, storm water drain has to be considered thoroughly to  avoid water logging during monsoon. The collected water will be passed to Tidi River. HDO  has considered separate effluent system and it is to be ensured that the storm water does  not in anyway mix with the effluent stream.  Considering  all  products  and  raw  materials  will  be  dispatched  through  road,  the  bagging  plant  was  considered  at  South  west  side,  crossing  Todi  River  and  the  Railway  Line.  The  existing  road  has  to  be  widened  and  bridge  at  Todi  River  has  to  be  strengthened.  Additionally, a Material Gate shall be considered on the Road as marked.  As  the  wind  direction  is  normally  towards  South  West  HDO  has  considered  Two  Nos.  of  Ammonia Storage Tanks and Unloading Facility near Material Gate in order to avoid any air  contamination possibilities.   The Truck parking Area is considered towards  West at El. 365.00 M. The Bagging Plant is  further  towards  East  of  Truck  Parking  Area  and  since  we  cannot  store  about  15  days  production  in  Platform  we  have  considered  unique  feature  of  Bagging  Plant,  having  two  stories Storage Area of Bagged Product.  The approximate Ground Floor Elevation is 362.00  M.  Moreover,  necessary  slope  for  Truck  movement  and  storm  water  drainage  has  been  included. The Sulphuric Acid Storage and Fuel Oil Storage have been also considered with  Truck Unloading Facilities.   The DAP Plant and Filler Storage Area is located towards the South direction. Filler will be  received  by  dumpers  and  unloaded  manually  and  through  pay  loader.  From  DAP  Plant  product will be transferred to Bulk Silo.   ‐SEC 5/1‐  PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S We have considered Scrapper Reclaimer for reclaiming the product. A Main Receiving Sub  Station is towards the East of Plant since power will be received from CPP we have located  in East Sid. The Rock Phosphate Storage is considered at East of PAP and will receive Rock  Phosphate by trucks.  The  Gypsum  Pond  will  be  receiving  gypsum  with  app.  25  %  moisture  through  conveyors  from  PAP.  HDO  has  considered  size  of  Gypsum  pond  as  approximately  51,450  SQM.  Gypsum  will  be  collected  by  Cement  Manufacturers  and  will  be  dispatch  through  trucks.  Bund of 5 M with all around is provided. The Rock Garden area due its natural depth from  considered ground level will be an ideal place for consideration of the Gypsum Pond.  All  major  buildings  are  in  RCC  with  ACC  Roofing.  Conveyor  Gallery  will  be  also  of  in  RCC  construction for longer life. Pipe Racks are in Structure Steel construction and cable will be  routed with pipe racks (multi tire pipe rack) or through underground cable trench.  Administration  Building,  Time  Office  and  Canteen  is  considered  North  of  Rajasthan  State  Electricity  Substation  so  that  the  area  available  can  be  utilized  for  any  future  plants,  like  potash storage for NPK Plant etc. Additionally, the location of Bagging Pant is considered  such that future Rail connectivity is possible.  i) The  total  area  requirement  for  350  MTPD  Phosphoric  Acid  plant  and  600  MTPD  Di‐ Ammonium Phosphate plant along with the associated offsite facilities is 31.3 Hectares.  Future  provision  for  100%  expansion  is  considered  within  the  same  boundary  consideration as shown in drawing no.   The Area requirement of major individual sections at Zawar Mines is given as follows:   1) Phos Acid Plant + Cooling Tower      200 m x 100 m   2) DAP Plant            80 m x 50 m  3) DAP Bagging Plant          140 m x 60 m        4) Bulk Silo            70 m x 40 m  5) Filler Storage            25 m x 12 m    6) Ammonia Storage & Handling      100 m x 60 m  7) Rock Phosphate Storage        50 m x 20 m  8) Sulphuric Acid Tanks          50 m x 40 m  9) Phosphoric Acid Tanks        35 m x 20 m  10) Boiler House            25 m x 25 m  ‐SEC 5/2‐  PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 11) Fuel Oil Storage          40 m x 30 m  12) Aluminum Fluoride Plant        100 m x 50 m    ii) The  total  area  requirement  for  800  MTPD  Phosphoric  Acid  plant  and  1500  MTPD  Di‐ Ammonium Phosphate plant along with the associated offsite facilities is 31.3 Hectares.  However,  in  this  case  no  provision  has  been  considered  for  future  expansion  due  to  area availability.   The Area requirement of major individual sections at Zawar Mines is given as follows:   1) Phos Acid Plant + Cooling Tower      200 m x 208 m   2) DAP Plant            100 m x 80 m  3) DAP Bagging Plant          140 m x 60 m        4) Bulk Silo            70 m x 40 m  5) Filler Storage            40 m x 20 m    6) Ammonia Storage & Handling      50 m x 130 m  7) Rock Phosphate Storage        80 m x 36 m  8) Sulphuric Acid Tanks          50 m x 75 m  9) Phosphoric Acid Tanks        90 m x 50 m  10) Boiler House            25 m x 25 m  11) Fuel Oil Storage          40 m x 30 m  12) Aluminum Fluoride Plant        200 m x 50 m  B]   Maton Mines  HZL  has  identified  the  Rock  Phosphate  Beneficiation  Plant  to  be  located  at  Maton  Mines.  HZL  has  provided  the  basic  engineering  of  the  Rock  Phosphate  Beneficiation  Plant. The Area requirement of the Rock Phosphate Beneficiation Plant will be as given  in the Plot Plant Drawing No.    ‐SEC 5/3‐  HINDUSTAN DORR-OLIVER LIMITED SECTION‐6  SELECTION OF TECHNOLOGY  PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 6 SELECTION OF TECHNOLOGY 6.1 ROCK PHOSPHATE BENEFICIATION PLANT: The Owner has carried out Pilot Plant Test for developing the FEED Package for the Rock Phosphate Beneficiation Plant. The Owner has given the FEED Package and we have used the process technology given by the Owner for the Rock Phosphate Beneficiation Plant. 6.2 PHOSPHORIC ACID PLANT: The production of Merchant Grade Phosphoric Acid is a well proven process worldwide. The major raw materials required for production of Phosphoric Acid are 30-32% P2O5 Rock Phosphate and 98% Sulphuric Acid. Phosphoric Acid is manufactured using the following processes:  Dihydrate Process (DH)  Hemi-Hydrate Process (HH)  Hemi Dihydrate Process (HDH) (A) Dihydrate Technology Most of the Phosphoric Acid Plants in the world are designed using the Dihydrate (DH) Process. The DH Process is offered by the following process licensors:  Prayon, Belgium  Jacobs Dorrco, U.S.A  RhÖne-Poulenc, France  Yara International, Belgium -SEC 6/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The DH process consists of the following major sections: Rock Phosphate preparation and grinding Rock Phosphate is ground from the received size to a fineness of less than 75 microns (90 % passing through 200 Tyler Mesh) and metered in to the reaction system together with recycle acid and sulphuric acid. Normally for such fine grinding an attrition mill such as a ball mill or vertical roller mill is preferred. Rock phosphate stored in close storage is fed to the mill system and ground rock phosphate transferred to the hopper over the reactor. The hopper is rated for an hour’s storage. Reactor System The main function of the reactor and filter are to prepare chemical and mechanical conditions for digestion of the rock phosphate with the mixture of sulphuric acid and recycle acid (obtained from washing of gypsum from filtration section) for the formation of good crystals of dihydrate calcium sulphate crystals that can be filtered off and washed. The reactor specific volume is adequately sized for good growth of crystal for ease of filtration. The ground rock from the mills is fed to reactor through a metering device from a bin of adequate size, and concentrated sulphuric acid is fed through another flow measuring device. The rock is mixed and decomposed with recycle acid and sulphuric acid. The products of digestion are basically phosphoric acid and gypsum in the form of a large percentage of CaSO4.2H2O and a fraction in other from-CaSO4·1/2H2O. The reactor temperature is controlled at 75-80°C maximum for maintaining proper slurry conditions. The recycle acid of 18-20% concentration is mixed preferably in a mixing tee of graphite to be fed to the reactor to avoid super saturation of the slurry at the impingement with high sulphates. Very high localized sulphate concentration could result in formation of hemi hydrate on rock particles thereby impeding reaction rate. -SEC 6/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Filtration The slurry of phosphoric acid and gypsum is separated on a vacuum belt filter. The specific filtration area has been provided liberally for taking care of change in phosphate rock. The belt filter is of counter current wash system with appropriately designed filtration areas for mother liquor filtration and washes solutions. Wash Solutions Wash solutions and Extracted mother liquor are managed in such a way that a constant volume and concentration is maintained in recycle acid fed to the reactor to achieve steady state conditions in continuous operation. Product acid: The product acid is stored in a tank that can hold a day’s production and clarified acid is transferred to another tank. Concentration The product acid (27-30% P2O5) will then pass through evaporation units for concentration in order to obtain 52-54 % P2O5 Merchant Grade Phosphoric Acid to be used as raw material in the DAP plant. Gypsum The gypsum in dihydrate form is recovered from filter with moisture of 22- 25% and eventually is carted out to an appropriate storage area. Local regulations for storing gypsum have to be followed for storing and eventual disposal to cement or other industries (extra washing stage required). The gypsum can also be used for agricultural application. The Partial List of Plants (worldwide) using DH technology is given below: -SEC 6/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT Fertilizantes de lberia SA Huelva Spain 70,000 MTPA P2O5 Somerset west South Triomf Fertilizers (Pty) ltd 27,000 MTPA P2O5 Africa Quimica Industrial Brasileira Jacupiranga Brazil 65,000 MTPA P2O5 SA Titovica Mitrovica RMHK Trepca 65,000 MTPA P2O5 Serbia Rustenburg Sout Omnia Phosphate (Pty) Ltd. 25,000 MTPA P2O5 Africa Titosv veles Hemijska Industrija veles 50,000 MTPA P2O5 Macedonia Hemijska Industrija Zorca Sabac Serbia 75,000 MTPA P2O5 Sabac Abu Zaabal Fertilizer and Abu Zaabal Egypt 65,000 MTPA P2O5 Chemical Company Industrijia nafta Kutina Croatia 160,000 MTPA P2O5 Tovarna Kemicinih lzdelkov Hrastnik Slovenia 10,800 MTPA P2O5 Wengfu China 1000 MTPD P2O5 Imacid Morocco 1050 MTPD P2O5 OCP Morocco 720 MTPD P2O5 Omnia South Africa 300 MTPD P2O5 Nu West USA 1200 MTPD P2O5 IOF-Foskor South Africa 1100 MTPD P2O5 Arya Iran 400 MTPD P2O5 Imacid Morocco 100 MTPD P2O5 Bunge Maroc Phosphore Morocco 120 MTPD P2O5 Vinachem Vietnam 576 MTPD P2O5 AZFC Egypt 220 MTPD P2O5 Coromandel India 600 MTPD P2O5 Fosfertil Brazil 900 MTPD P2O5 -SEC 6/4- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The disadvantages of the DH Process are as follows: a) High energy requirement due to Rock Grinding Section b) Higher operating cost c) High steam consumption d) Low P2O5 recovery e) Higher Concentration System is required to concentrate from 27-54% P2O5 f) Higher cooling water required g) Gypsum not suitable for cement plant The advantages of the DH Process are as follows: a) Well proven technology b) Well proven for all types of rock phosphate c) High reliability of the operation d) High on-stream factor e) Ease of operation f) Plants can be designed upto single train having capacity of 2650 MTPD (100% P2O5). (B) Hemihydrate Technology The HH Process is offered by the following process licensors:  Yara International  P. Smith & Associates (PSA) / MBR Engenharia Ltda (MBR) The HH process consists of the following major sections: a) HH Reaction Section b) Filtration Section c) Clarifier& Storage Section In the HH process, normally grinding of the rock phosphate is not required. Rock Phosphate and Sulphuric Acid is reacted into series of reactors. The slurry produced in the HH Reactor having acid concentration of 40-43% and temperature maintained around 110-115oC. The slurry is cooled in the Low -SEC 6/5- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Level Flash Cooler. The Low Level Flash Cooler is operated under vacuum and the vacuum is maintained by either Steam Ejector System or Vacuum Pump. The reactor slurry is fed to the HH Filtration System. Normally, HH Filtration is Horizontal Belt Filter. The Filter is provided with 2-3 stage counter washing to have gypsum of suitable quality. The gypsum is discharged from the HH Filter by series of conveyors to the Gypsum Pond. The acid produced from the HH Filter having acid concentration of 40-43% P2O5 will be sent to the Clarifier. The acid from the Clarifier will be concentrated into Single Stage Forced Circulation System to concentrate from 43-54% P2O5. The Evaporation System will be provided with Fluorine Recovery System. The acid produced from the Acid Concentration System will be sent to the Clarifier System to have clarification of the final product acid less than 1% by wt. The disadvantages of the HH Process are as follows: a) The plant capacity is limited to 1500 MTPD (100% P2O5) b) Adaptability with limited types of Rock Phosphate c) Very poor quality of Gypsum d) High P2O5 losses e) High erosion and corrosion f) Low on-stream factor g) Low reliability of the plant The advantages of the HH Process are as follows: a) No Grinding System is required b) Low power consumption c) Low steam required d) Single stage Filtration System e) Eliminates 26-42% evaporation system f) Low cooling water required -SEC 6/6- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The Partial List of Plants using HH technology is given below: CLIENT LOCATION PLANT Windmill** Holland HH – 200 MTPD P2O5 HCl Cyprus HH – 130 MTPD P2O5 CCF Industries Vassiliko Cyprus HH – 40,000 MTPA P2O5 Windmill** Holland HH – 330 MTPD P2O5 Hydro Agri Alaardingen HH – 80,000 MTPA P2O5 Rotterdam The Netherlands Royster Florida, USA HH – 650 MTPD P2O5 Belledune Canada HH – 600 MTPD P2O5 Arcadian (PCS)* Louisiana, USA HH – 800 MTPD P2O5 Saranya* Brazil HH – 580 MTPD P2O5 Indo-Jordan* Jordan HH – 870 MTPD P2O5 Western Mining* Australia HH – 1650 MTPD P2O5 Ma’aden Saudi Arabia HH – 1460 MTPD P2O5 Ma’aden Saudi Arabia HH – 1370000 MTPA P2O5 * Operating ** Two Windmill Plants were converter into one Hemi-Di Plant in 1991. Royster, Belledune, and Arcadian were converted from Prayon Dihydrate Process (C) Hemi Di-Hydrate Technology The HDH Process is offered by the following process licensors:  Yara International  P. Smith & Associates (PSA) / MBR Engenharia Ltda (MBR) -SEC 6/7- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The HDH process consists of the following major sections: a) Reaction Section This section is usually comprised of series of reactors in order to enable smooth mixing and production of phosphoric acid product. Sulphuric Acid is mixed with return phosphoric acid in the high sulphate zone. Rock phosphate is fed in to the low sulphate zone and slurry pumps are provided to recirculate the slurry in the reactors. Launders enable flow of overflow slurry in to the adjacent reactor. The high sulphate zone slurry is cooled in a low level vacuum flash cooler before filtration stage. b) Flash Cooler Vacuum and HH Off-Gas Scrubbing System The off-gases from the reactors and the flash cooler are passed through wet scrubbing system including droplet separators in order to recover the Phosphoric Acid. The gas then scrubbed in venturi scrubbers in order to reduce the quantity of Fluorine in the gas stream before it exits from the stack. c) HH Filtration, Hydration and DH Filtration Sections. This section consists of a HH horizontal belt filter, where most of the P2O5 in the gypsum cake is recovered. The cake is then sent to the transformation tanks where it is re-slurried using sulphuric acid. This section is known as the Hydration Section. The slurry is then pumped to the DH filtration section where a DH horizontal belt filter separated the P2O5 from the gypsum cake. The dry gypsum obtained as by- product from the belt filter contain around 20-25 % moisture. d) Filtration Off-Gas Scrubbing System The off-gases from the HH filter and the Hydration section passes through multi stage scrubbers to recover any P2O5 and fluorine. The gases eventually meet the HH off gas scrubbing exit stream in to the tail gas scrubber and exit from the stack. The disadvantages of the HDH Process are as follows: a) Adaptability with limited types of rock phosphate -SEC 6/8- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S b) High erosion and corrosion c) Low on-stream factor d) Higher material of construction required for various equipment The advantages of the HDH Process are as follows: a) Acid produced of higher concentration 40-45% P2O5 b) Higher P2O5 recovery efficiency (98-99%) depending upon the type of rock c) Good quality of gypsum suitable for cement industry d) Low power consumption e) Low steam consumption f) Low sulphuric acid requirement g) Low cooling water required h) Eliminates 26-43% P2O5 evaporation system i) Eliminates Rock Grinding The Partial List of Plants using HHH technology is given below: CLIENT LOCATION PLANT RMKH Trepka Yugoslavia 160 MTPD P2O5 Albright & Wilson England 500 MTPD P2O5 CSBP Australia 500 MTPD P2O5 Pivot Australia 100 MTPD P2O5 Phosphate Co-operative Geelong Victoria, 33000 MTPA P2O5 of Australia Ltd. Australia Supra*** Sweden 360 MTPD P2O5 Chinhae South Korea 250 MTPD P2O5 -SEC 6/9- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT Hydro-Agri** Holland 620 MTPD P2O5 Hong He Zhou* China 210 MTPD P2O5 NFC* Thailand 700 MTPD P2O5 Sterlite* *** India 335 MTPD P2O5 Greenstar Fertilizers India 500 MTPD P2O5 (Revamp) * Operating ** Two Windmill Hemi Plants were converter into one Hemi-Di Plant in 1991 *** Much of the Supra plant equipment was relocated to Sterlite in India. 6.2.1 Selection & Recommendation of Technology Based on the above, we propose HDH Technology to be adopted for the Phosphoric Acid Plant for Hindustan Zinc Ltd., Zawar. HDO has built 335 MTPD Phos Acid Plant using Yara technology for Sterlite Industries (I) Ltd. (SIIL), Tuticorin in 2000. The plant is based on HDH technology using various imported rock including Jordan, Morocco, Egypt, Togo, and Israel. The plant was subsequently upgraded from 335 to 500MTPD by P. Smith & Associates and in the second phase Paul Smith & Associates had subsequently upgraded to 800 MTPD. The plant is working satisfactorily since 2000. SIIL was planning to set up a Brown Field Plant in the existing complex of SIIL- Tuticorin having capacity of 800 MTPD in 2010. The License, Know-How and Basic Engineering was provided by P. Smith & Associates for this Brown Field project. The project is under hold. HDO is currently converting the existing 350 MTPD Phos Acid Plant for Greenstar Fertilisers at Tuticorin to HDH. The existing plant is using NISSAN Process which will be converted to HDH based on technology provided by P. Smith & Associates. The capacity will be upgraded to 500 MTPD. The plant is designed to use Jordan and mixture of Jordan, Morocco and Egyptian rock. -SEC 6/10- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The advantages of the HDH Process are as follows: a) Acid produced of higher concentration 40-45% P2O5 b) Higher P2O5 recovery efficiency (98-99%) depending upon the type of rock c) Good quality of gypsum suitable for cement industry d) Low power consumption e) Low steam consumption f) Low sulphuric acid requirement g) Low cooling water required h) Eliminates 26-43% P2O5 evaporation system i) Eliminates Rock Grinding Based on the above, we recommend that HZL should use HDH Technology which is working satisfactorily. 6.2.2 Contact Details of the Process Licensors Prayon, Belgium Prayon S.A. Rue J. Wauters 144 B-4480 Engis BELGIQUE Jacobs Engineering Group Inc, U.S.A. 1111, South Arroyo Parkwa P.O. Box 7084 Pasadena CA 91109-7084 U.S.A. Email : [email protected] Rhone Poulence Technip 89 Avenue de la Grande Armee 75773 Paris Cedex 16, France Phone: 33(01) 147782400 -SEC 6/11- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S P. Smith & Associates Ltda. Rua Capitão Izidro 321, Sala3 Araxá (Centro), Minas Gerais, Brasil – CEP: 38183-190 Tel: +55-34-9126-3768 YARA Belgium SA NV Corporate Village-Aramis Building Da Vincilaan 1 B1935 Zaventem (Belgium) Tel.: 32-2-7735-220 Fax: 32-2-7735-635 -SEC 6/12- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 6.3 DI-AMMONIUM PHOSPHATE (DAP) PLANT : The production of DAP grades of fertilizer is a well proven process worldwide. The major raw material required for production of DAP grades of fertilizer are phosphoric acid, ammonia, filler and defoamer. DAP is manufactured using the following process:  Conventional Slurry Process  Pressure Reactor Technology  Pipe Reactor Technology (A) Conventional Slurry Process Most of the DAP plants were designed based on Conventional Slurry Process. The Flow Diagram of the Conventional Slurry Process is given in Drg. No. A4 - 120013S – F - 001. The Conventional Slurry Process is offered by the following Process Licensors: a) HDO, Mumbai b) Jacobs H&G, U.S.A. In a conventional slurry granulation process, phosphoric acid and ammonia are reacted in a preneutraliser tank at atmospheric pressure to produce ammonium phosphate slurry. The reactions involved in the process are: H3PO4 + NH3 NH4H2PO4 Phosphoric Acid + Ammonia Mono Ammonium Phosphate H3PO4 + 2NH3 (NH4)2HPO4 Phosphoric Acid + Ammonia Di-Ammonium Phosphate The slurry which has a mole ratio of 1.4 to 1.45 is pumped to the Rotary Granulator where it mixes with recycle solids and solid raw material feed such as urea and filler and forms into granules due to the rolling action inside the Granulator. The granules inside the Granulator are further ammoniated to mole ratio of 1.8 to 1.85 to produce DAP as the final product. The granules leaving the Granulator contains 1.8-2.25% moisture and is hence dried in a co-current Rotary Drum Dryer using hot air generated by burning fuel oil in a -SEC 6/13- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S combustion chamber. The dried granules are then screened (double / single deck) to separate the product size material from oversize and undersize, and cooled in a Rotary Cooler before being conveyed to storage as the final product. The oversize from the screen is pulverized in chain mills and returned to the Granulator, along with the undersize, recovered dust from gas streams, and fresh raw material feed, as the recycle solids. The fumes leaving the pre-neutralizer and the granulator contain ammonia which is recovered by scrubbing the fumes with phosphoric acid. Gases leaving the dryer, screens, cooler and other material handling equipment is first passed through cyclones to recover the heavy dust particles and then scrubbed with scrubber liquor to recover the dust. Thus the in-plant losses are kept at a minimum. The quantity of recycle solids required to produce the optimum amount of liquid phase that is required for good granulation, depends on the water balance inside the granulator. The major factor affecting the water balance inside the granulator is the water content in the ammonium phosphate slurry. The conventional process plants produce ammonium phosphate slurry containing 15 to 20% water below which the slurry is not easily pumpable resulting in scaling and blockage of pipelines and equipment. The recycle material required to maintain the moisture content of about 2% for good granulation when producing DAP, is about 6.0 times the production rate. This results in material handling equipment of substantial size and limits the plant capacity. The proportion of the product to recycle solids is called the recycle ratio and is about 1:6 for DAP production by the conventional process. The List of Plants in India using Conventional Slurry Process is as follows: 1. Madras Fertilizers Ltd., A-Train Dorrco Conventional Slurry Chennai Process C-Train Dorrco Conventional Slurry Process 2. Indian Farmers Fertiliser A-Train Dorrco Conventional Slurry Cooperative Limited, Kandla Process B-Train Dorrco Conventional Slurry Process C-Train Dorrco Conventional Slurry Process D-Train Dorrco Conventional Slurry Process -SEC 6/14- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 3. Paradeep Phosphates Ltd. A-Train Dorrco Conventional Slurry Orissa Process B-Train Dorrco Conventional Slurry Process C-Train Dorrco Conventional Slurry Process D-Train Dorrco Conventional Slurry Process 4. Indian Farmers Fertiliser A-Train Jacobs Conventional Slurry Cooperative Limited, Paradeep Process B-Train Jacobs Conventional Slurry Process C-Train Jacobs Conventional Slurry Process 5. Fertilizer & Chemicals Travancore Conventional Slurry Process Ltd., Ambalamedu 6. Gujarat State Fertilizers & Conventional Slurry Process Chemicals Limited, Vadodara 7. Gujarat State Fertilizers & A&B Train Dorrco Conventional Slurry Chemicals Limited, Sikka Process The disadvantages of the Conventional Slurry Process are as follows: a) High recycle ratio b) High capital investment c) High operating cost d) High maintenance cost e) High energy consumption (B) Pressure Reactor Technology The Pressure Reactor Technology operates the Reactor under pressure of approx. 1 kg/cm2. The Reactor is located at a higher elevation whereby the slurry is fed to the Granulator Slurry Sprayer under pressure. -SEC 6/15- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The Reactor is provided without any agitator. The slurry temperature is maintained at 120-130°C with 85-90% solids. The technology is supplied by FISION, U.K. They have provided this technology to Tata Chemicals, Haldia (earlier Hindustan Lever Ltd.). However, due to operating problems, Tata Chemicals has revamped the Pressure Reactor Technology with Pipe Reactor. The disadvantages of the Pressure Reactor Technology are as follows: a) The Reactor is located at a higher elevation within the plant which causes maintenance problems. b) The Reactor is not provided with agitator and hence the mixing problem and keeping the slurry in suspension. c) The flow rate variation of slurry due to fluctuation in the Reactor level d) The slurry spray is not good as the pressure of the slurry is not constant. (C) Pipe Reactor Technology The Pipe Reactor Technology is well proven worldwide for the production of DAP grades of fertilizer. Considerable improvement in the Pipe Reactor Technology has taken place mainly in Europe, Australia and other parts of the world. The Pipe Reactor Technology has the following major process licensors worldwide: a) Incro S.A., Spain b) GPN, France c) ESPINDESA, Spain 6.3.1 INCRO PROCESS INCRO-Spain also offers Pipe Reactor Technology based on Granulator Pipe Reactor. Incro has also supplied various Pipe Reactor Systems worldwide. The List of Incro Technology for DAP/NPK Plants is given in Table-I. Incro normally proposes GPR technology as well as mixed technology (GPR & Preneutralizer System). For production of various grades of DAP fertilizer, INCRO either proposes single Pipe Reactor into Granulator or two Pipe Reactors into Granulator depending on the plant capacity and grade to be produced. -SEC 6/16- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Incro also proposes mixed technology (GPR along with Preneutraliser) depending on the plant capacity and grade to be produced. The following plants are using Incro Pipe Reactor Technology in India: 1 Birla Copper, Dahej Production of DAP & NPK grades of Fertilizer 2 Revamp of A&B Train DAP Coromandel International Ltd. Kakinada Plant 3 C Train New Plant Coromandel International Ltd. Vizag 4 Gujarat State Fertilizers & Chemicals Limited, C Train New Plant Sikka Revamp of DAP / NPK 5 Mangalore Chemicals & Fertilisers Ltd. Plant 6 Tata Chemicals Ltd. Haldia Revamp of DAP Plant Revamp of NPK Plant -SEC 6/17- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S TABLE-I CLIENT LOCATION PLANT SERVICES GSSP/TST/DAP/NPK BASIC ENGINEERING S.A. CROS SPAIN LINE 1 START-UP ASSISTANCE GSSP/TST/DAP/NPK BASIC ENGINEERING S.A. CROS SPAIN LINE 2 START-UP ASSISTANCE QUIMBRASIL BRASIL DAP/NPK FEASIBILITY STUDY FEASIBILITY STUDY COPEBRAS BRASIL DAP/NPK BASIC ENGINEERING (TEST) BASIC ENGINEERING AGRICO USA DAP/NPK REVAMPING START-UP ASSISTANCE (TEST) INDUS PERU DAP/NPK FEASIBILITY STUDY FERTIA EL SALVADOR DAP/NPK FEASIBILITY STUDY ABOCOL COLOMBIA DAP/NPK FEASIBILITY STUDY FEASIBILITY STUDY DAP/NPK BASIC ENGINEERING COPAS BRAZIL LINE 1 REVAMPING GSSP/TSP START-UP ASSISTANCE TRAINING FEASIBILITY STUDY DAP/NPK BASIC ENGINEERING COPAS BRAZIL LINE 2 REVAMPING GSSP/TSP START-UP ASSISTANCE TRAINING FEASIBILITY STUDY BASIC ENGINEERING SAPEC PORTUGAL DAP/NPK REVAMPING DETAILED ENG. SUPERVISION START-UP ASSISTANCE START-UP ASSISTANCE PEQUIVEN VENEZUELA DAP/NPK TRAINING FERT. UNIAO BRAZIL DAP/NPK FEASIBILITY STUDY DAP/NPK BASIC ENGINEERING PHILPHOS PHILIPPINES LINE 1 DETAILED ENG.SUPERVISION -SEC 6/18- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES PROCUREMENT SUPERVISION START-UP ASSISTANCE TRAINING BASIC ENGINEERING DETAILED ENG.SUPERVISION DAP/NPK PHILPHOS PHILIPPINES PROCUREMENT SUPERVISION LINE 2 START-UP ASSISTANCE TRAINING FEASIBILITY STUDY BASIC ENGINEERING NITTO JAPAN DAP/NPK REVAMPING CHEMICALS START-UP ASSISTANCE TRAINING FERTIPLAN BRAZIL DAP/NPK FEASIBILITY STUDY UBE CHEMICALS JAPAN DAP/NPK FEASIBILITY STUDY DAP/NPK REVAMPING CINSA SPAIN GSSP START-UP ASSISTANCE FEASIBILITY STUDY PEQUIVEN VENEZUELA DAP/NPK START-UP ASSISTANCE TRAINING BASIC ENGINEERING DETAILED ENG.SUPERVISION ENGRAIS DE TUNISIA DAP/NPK PROCUREMENT SUPERVISION GABES START-UP ASSISTANCE TRAINING GOHDO JAPAN DAP/NPK FEASIBILITY STUDY HIRYO K.K BASIC ENGINEERING DETAILED ENG. SUPERVISION EGE GUBRE TURKEY DAP/NPK REVAMPING SANAYII START-UP SUPERVISION PROCUREMENT SUPERVISION BASIC ENGINEERING I.Q.Z SPAIN NPK DETAILED ENG. SUPERVISION START-UP ASSISTANCE -SEC 6/19- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES BASIC ENGINEERING DAP/NPK DETAILED ENG. SUPERVISION ELEKEIROZ BRASIL AMMONIUM SULPHATE REVAMPING LINE 1 GSSP/TSP START-UP ASSISTANCE DAP/NPK BASIC ENGINEERING AMMONIUM SULPHATE DETAILED ENG. SUPERVISION ELEKEIROZ BRASIL LINE 2 REVAMPING GSSP/TSP START-UP ASSISTANCE BASIC ENGINEERING GUBRE DAP/NPK DETAILED ENG. SUPERVISION TURKEY FABRIKALARI GSSP REVAMPING START-UP ASSISTANCE FEASIBILITY STUDY DETAILED ENG. SUPERVISION GALVANI MAP/NPK BRAZIL REVAMPING FERT.LTDA. GTSP START-UP ASSISTANCE FEASIBILITY STUDY BASIC ENGINEERING S.A. CROS SPAIN SUSP.NPK DETAILED ENG. SUPERVISION START-UP ASSISTANCE PROCUREMENT ASSISTANCE FEASIBILITY STUDY BASIC ENGINEERING S.A. CROS SPAIN SUSP.8-24-0 DETAILED ENG. SUPERVISION START-UP ASSISTANCE PROCUREMENT ASSISTANCE BASIC ENGINEERING DETAILED ENG. SUPERVISION REVAMPING TUGSAS TURKEY TSP/NPK TRAINING START-UP ASSISTANCE PROCUREMENT SUPERVISION DAP-GTSP BASIC ENGINEERING SABIC SAUDI ARABIA LINE 1 DETAILED ENG. SUPERVISION -SEC 6/20- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES TRAINING START-UP ASSISTANCE PROCUREMENT SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION DAP/NP/NPK SABIC SAUDI ARABIA TRAINING LINE 2 START-UP ASSISTANCE PROCUREMENT SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION NPK COPAS BRAZIL REVAMPING GSSP START-UP ASSISTANCE PROCUREMENT SUPERVISION ADUBS TREVO BRAZIL NPK FEASIBILITY STUDY UNITED FEASIBILITY STUDY ETC NPK KINGDOM REVAMPING BASIC ENGINEERING TAIWAN DETAILED ENG. SUPERVISION NPK FERTILIZER TAIWAN PROCUREMENT SUPERVISION GSSP/TSP CO. START-UP ASSISTANCE TRAINING BASIC ENGINEERING DETAILED ENGINEERING FESA/ REVAMPING SPAIN DAP ENFERSA TRAINING START-UP ASSISTANCE PROCUREMENT REVAMPING BASIC ENGINEERING DETAILED ENGINEERING PEQUIVEN VENEZUELA DAP/NPK PROCUREMENT START-UP ASSISTANCE TRAINING REVAMPING DAP/NPK PHILPHOS PHILIPPINES BASIC ENGINEERING LINE 1 DETAILED ENGINEERING -SEC 6/21- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES PROCUREMENT START-UP ASSISTANCE TRAINING REVAMPING BASIC ENGINEERING DAP/NPK DETAILED ENGINEERING PHILPHOS PHILIPPINES LINE 2 PROCUREMENT START-UP ASSISTANCE TRAINING DEFER BRAZIL NPK FEASIBILITY STUDY NCFC SAUDI ARABIA NPK TECHNICAL ASSISTANCE MECHANICAL & MAINTENANCE PEQUIVEN VENEZUELA NPK OPTIMIZATION REVAMPING BASIC ENGINEERING SUPERV. FERTIBERIA SPAIN DAP DETAILED ENGINEERING SUPERV. PROCUREMENT REVAMPING DETAILED ENGINEERING SUPERV FERTIBERIA SPAIN NPK PROCUREMENT SUPERVISION START-UP ASSISTANCE BASIC ENGINEERING DETAILED ENGINEERING SUPERV. AL-NOOR PAKISTAN DAP TRAINING START-UP ASSISTANCE PROJECT COMPLETION ON HOLD NPK BASED IN BASIC ENGINEERING FERTIBERIA SPAIN AMMONIUM NITRATE DETAILED ENGINEERING (ASUR) SSP START-UP ASSISTANCE FEASIBILITY STUDY HINDUSTAN INDIA DAP Revamp. LEVER LTD. HINDUSTAN LEVER LTD. INDIA NPK Revamp. FEASIBILITY STUDY -SEC 6/22- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES BASIC ENGINEERING DETAILED ENGINEERING SUPERV. DAP/NPK Rev. PROCURE. OF CRITICAL EQUIP. NAMHAE KOREA LINE 1 SUPERV. OF LOCAL PROCURE. TRAINING START-UP ASSISTANCE BASIC ENGINEERING DETAILED ENGINEERING SUPERV. DAP/NPK Rev. PROCURE. OF CRITICAL EQUIP. NAMHAE KOREA LINE 2 SUPERV. OF LOCAL PROCURE. TRAINING START-UP ASSISTANCE BASIC ENGINEERING DETAILED ENGINEERING SUPERV. PROCURE. OF CRITICAL EQUIP. FACT INDIA DAP/NPK Rev. SUPERV. OF LOCAL PROCURE. TRAINING START-UP ASSISTANCE PROJECT COMPLETION ON HOLD BASIC ENGINEERING DETAILED ENGINEERING SUPERV PROCURE. OF CRITICAL EQUIP. DONGBU KOREA DAP/NPK SUPERV. OF LOCAL PROCURE. TRAINING START-UP ASSISTANCE BASIC ENGINEERING CONSTRUCTION DRAWINGS DETAILED ENG. SUPERVISION NPK/CAN 50 T/h ABOCOL COLOMBIA PROCURE. OF CRITICAL EQUIP. LINE II SUPERV. OF LOCAL PROCURE. TRAINING START-UP SUPERVISION BASIC ENGINEERING DETAILED ENGINEERING SUPERV GRESIK INDONESIA NPK 50 t/h PROCURE OF CRITICAL EQUIP. SUPERV. OF LOCAL PROCURE. -SEC 6/23- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES TRAINING START-UP ASSISTANCE NPK Rev. BASIC ENGINEERING CHOBI CO. KOREA LINE I DETAILED SUPERVISIONS NPK Rev. BASIC ENGINEERING CHOBI CO. KOREA LINE II DETAILED SUPERVISIONS BASIC ENGINEERING DETAILED ENGINEERING SUPERV. PROCURE. OF CRITICAL EQUIP. HINDUSTAN INDIA DAP/NPK Rev. 50 t/h SUPERV. OF LOCAL PROCURE. TRAINING START-UP ASSISTANCE BASIC ENGINEERING DAP/NPK/CAN CONSTRUCTION DRAWINGS 50 t/h DETAILED ENG. SUPERVISION ABOCOL COLOMBIA using Phosphoric Ac.& PROCURE. OF CRITICAL EQUIP. Ammonia + Nitric Acid + SUPERV. OF LOCAL PROCURE. Phosphate Rock New Plant TRAINING START-UP SUPERVISION BASIC ENGINEERING CONSTRUCTION DRAWINGS DAP/NPK Rev. DETAILED ENG. SUPERVISION using Pipe Reactor for PROCURE. OF CRITICAL EQUIP. PHILPHOS PHILIPPINES Ammonia+Sulphuric Acid SUPERV. OF LOCAL PROCURE. + diluted Phosphoric Acid TRAINING START-UP SUPERVISION BASIC ENGINEERING CONSTRUCTION DRAWINGS DETAILED ENG. SUPERVISION NP/NPK COROMANDEL INDIA PROCURE. OF CRITICAL EQUIP. New Plant SUPERV. OF LOCALPROCURE. TRAINING START-UP SUPERVISION DAP/NPK BASIC ENGINEERING HONGHE CHINA Revamp CONSTRUCTION DRAWINGS -SEC 6/24- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES DETAILED ENGINEERING SUPERV. PROCURE. OF CRITICAL EQUIP. SUPERV. OF LOCAL PROCURE. TRAINING START-UP SUPERVISION BASIC ENGINEERING CONSTRUCTION DRAWINGS DETAILED ENGINEERING SUPERV INDO GULF INDIA DAP/NP/NPK PROCURE. OF CRITICAL EQUIP. SUPERV. OF LOCAL PROCURE. TRAINING START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION GUJARAT STATE PROCURE. OF CRITICAL EQUIP. INDIA DAP FERTILIZER CO. SUPERV. OF LOCAL PROCURE. TRAINING START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION GODAVARI DAP/NPK PROCURE OF CRITICAL EQUIP. FERTILISERS INDIA Revamp. SUPERV OF LOCAL PROCURE. & CHEMICALS Line I & II TRAINING START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION PROCURE OF CRITICAL EQUIP. NAFAS MALAYSIA NPK SUPERV OF LOCAL PROCURE. TRAINING START-UP SUPERVISION BASIC ENGINEERING DAP/NPK DETAILED ENG. SUPERVISION REVAMPING OCP MAROCO SUPPLY OF EQUIPMENT PRODUCT ERECTION SUPERVISION CONDITIONING START UP SUPERVISION -SEC 6/25- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES BASIC ENGINEERING TSP/DAP/NPK DETAILED ENG. SUPERVISION OCP MAROCO GRANULATION AND SUPPLY OF EQUIPMENT DRYING REVAMP ERECTION SUPERVISION START UP SUPERVISION BASIC ENGINEERING SUPERVISION OF DETAILED ENG. MCF INDIA DAP/NP REVAMPING SUPPLY OF CRITICAL EQUIPMENT ERECTION SUPERVISION START UP SUPERVISION BASIC ENGINEERING CONSTRUCTION DRAWINGS DETAILED ENGINEERING SUPERV GRESIK INDONESIA NPK/DAP Revamp PROCURE. OF CRITICAL EQUIP. SUPERV. OF LOCAL PROCURE. START-UP SUPERVISION BASIC ENGINEERING CONSTRUCTION DRAWINGS DETAILED ENG. SUPERVISION GRESIK INDONESIA TSP/DAP/NPK Revamp PROCURE OF CRITICAL EQUIP. SUPERV OF LOCAL PROCURE. TRAINING START-UP SUPERVISION BASIC ENGINEERING DAP Train # 4 DETAILED ENG. SUPERVISION Granulation plant CARGILL USA SUPPLY OF EQUIPMENT Process Revamping 1,815,000 TPY ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DAP Train # 6 DETAILED ENG. SUPERVISION Granulation plant CARGILL USA SUPPLY OF EQUIPMENT Process Revamping 1,050,000 TPY ERECTION SUPERVISION START-UP SUPERVISION DAP Train # 5 BASIC ENGINEERING CARGILL USA Granulation plant DETAILED ENG. SUPERVISION Process Revamping SUPPLY OF EQUIPMENT -SEC 6/26- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES 990,000 TPY ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DAP Train # 3 DETAILED ENG. SUPERVISION Granulation plant CARGILL USA SUPPLY OF EQUIPMENT Process Revamping 825,000 TPY ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING NPK DETAILED ENG. SUPERVISION CNPC Granulation plant SUPPLY OF EQUIPMENT CHINA URUMQI New Plant ERECTION SUPERVISION 300,000 TPY TRAINING START-UP SUPERVISION MAP BASIC ENGINEERING Granulation Plant DETAILED ENG. SUPERVISION FOSFERTIL BRASIL New Plant SUPPLY OF EQUIPMENT 350,000 TPY ERECTION SUPERVISION START-UP SUPERVISION NPK – TSP OCP MAROCCO SUPPLY OF CRITICAL PARTS Granulation Plant BASIC ENGINEERING NPK DETAILED ENG. SUPERVISION Granulation Plant SENTANA INDONESIA SUPPLY OF EQUIPMENT New Plant 350,000 TPY ERECTION SUPERVISION START-UP SUPERVISION NPK SUPPLY OF CRITICAL PARTS ABOCOL COLOMBIA Granulation Plant NPK SUPPLY OF CRITICAL PARTS PDVSA VENEZUELA Granulation Plant BASIC ENGINEERING DAP/MAP DETAILED ENG. SUPERVISION YTCC CHINA Two New Granul. Plants SUPPLY CRITICAL EQUIPMENT 600,000 TPY, each ERECTION SUPERVISION START-UP SUPERVISION -SEC 6/27- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES BASIC ENGINEERING DETAILED ENG. SUPERVISION DAP SUPPLY CRITICAL EQUIPMENT Granulation Plant MA’ADEN SAUDI ARABIA ERECTION SUPERVISION 2,920,000 TPY 4 DAP Units START-UP SUPERVISION PLANT OPERATION MANAGEMENT TRAINING BASIC ENGINEERING DETAILED ENG. SUPERVISION NPK SUPPLY CRITICAL EQUIPMENT IGSAS TURKEY Granulation Plant ERECTION SUPERVISION CONSTRUCTION DRAWINGS START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION DAP VINACHEM VIETNAM SUPPLY OF EQUIPMENT Granulation Plant ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION SOUTH NPK / MAP / LAN SASOL NITRO SUPPLY OF EQUIPMENT AFRICA Revamping Plant ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION NPK IGSAS TURKEY SUPPLY OF EQUIPMENT Revamping to DAP ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DAP / NPK DETAILED ENG. SUPERVISION BAGFAS TURKEY Revamping SUPPLY OF EQUIPMENT Line I & II ERECTION SUPERVISION START-UP SUPERVISION MAP / DAP BASIC ENGINEERING FOSFERTIL BRASIL New Plant DETAILED ENG. SUPERVISION 90 mtph SUPPLY OF CRITICAL EQUIPMENT -SEC 6/28- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION DAP / NPK NCIC EGYPT SUPPLY OF CRITICAL EQUIPMENT New Plant ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION DONGBU KOREA NPK Revamping SUPPLY OF CRITICAL EQUIPMENT ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION DAP / NPK ZUARI INDIA SUPPLY OF CRITICAL EQUIPMENT Revamping ERECTION SUPERVISION START-UP SUPERVISION FEASIBILITY STUDY IFFCO INDIA Revamping Study BASIC ENGINEERING FEASIBILITY STUDY MAXAM UZBEKISTAN Revamping Study BASIC ENGINEERING BASIC ENGINEERING DETAILED ENG. SUPERVISION JINKAI CHINA NPK Plant SUPPLY OF CRITICAL EQUIPMENT ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DETAILED ENG. SUPERVISION COROMANDEL INDIA NPK Plant SUPPLY OF CRITICAL EQUIPMENT ERECTION SUPERVISION START-UP SUPERVISION BASIC ENGINEERING DAP DETAILED ENG. SUPERVISION VINACHEM VIETNAM New Plant SUPPLY OF CRITICAL EQUIPMENT ERECTION SUPERVISION -SEC 6/29- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT LOCATION PLANT SERVICES START-UP SUPERVISION PLANT OPERATION MANAGEMENT TRAINING CRITICAL EQUIPMENT PROCUREMENT BASIC ENGINEERING DETAILED ENG. SUPERVISION DAP / NPK SUPPLY OF CRITICAL EQUIPMENT SAUDI 3 Units DAP ERECTION, START-UP SUPERVISION MA’ADEN ARABIA 1 Unit NPK PLANT OPERATION MANAGEMENT New Plants TRAINING CRITICAL EQUIPMENT PROCUREMENT BASIC ENGINEERING DETAILED ENG. SUPERVISION SUPPLY OF CRITICAL EQUIPMENT DAP / NPK GUBRETAS TURKEY ERECTION SUPERVISION 2 New Plants START-UP SUPERVISION CRITICAL EQUIPMENT PROCUREMENT BASIC ENGINEERING DETAILED ENG. SUPERVISION SUPPLY OF CRITICAL EQUIPMENT NP / NPK TOROS TURKEY ERECTION SUPERVISION Revamping START-UP SUPERVISION CRITICAL EQUIPMENT PROCUREMENT 6.3.2 ERT-ESPINDESA PROCESS ESPINDESA-Spain is a 100% subsidiary of Tecnicas Reunidas (TR). ESPINDESA has supplied only few Pipe Reactor Systems for production of DAP grades of fertilizer. The List of DAP/NPK Plants based on ESPINDESA Technology is given in Table-II. A unique special feature of ESPINDESA Pipe Reactor Technology is that while producing DAP (depending on the phosphoric acid quality), total ammoniation is possible in the GPR. The mole ratio at the discharge of the GPR is maintained at 1.8 -SEC 6/30- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S – 1.9 for production of DAP and hence no future ammonization is required in the Granulator Sparger. Another feature of ESPINDESA Pipe Reactor Technology is that the GPR uses vapor ammonia instead of liquid ammonia normally used in other Pipe Reactor Technologies. -SEC 6/31- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S TABLE-II CLIENT LOCATION PLANT GSFC India NPK/DAP Plant – 1800 MTPD JPMC/ SNC Lavalin Aqaba (Jordan) DAP Plant– 2 x 1600 TPD NPK/MAP Plant SASOL Secunda (South Africa) NPK – 1200 TPD MAP – 800 TPD Chittagong CUFL/TEC DAP Plant (Bangladesh) CMC Jingzhou (P. R. China) NPK Fertilisers Plant SHANDONG Luxi (P.R. China) NPK Fertilisers Plant Revamping LIAOCHENG Co GUIXI Guixi (P.R. China) DAP Plant Expansion FERTILIZERS CNTIC Luzhai (P.R. China) DAP Plant Fertiliser Granulation Plants MINISTRY OF (NPK, DAP, MAP, TSP). Project Al-Kaim (Iraq) INDUSTRY cancelled due to UNO embargo against Iraq DAP/NP Unit TOROS GUBRE Ceyhan (Turkey) NP Unit INSTITUTO VENEZOLANO DE Morón (Venezuela) Diammonium Phosphate Plant PETROQUÍMICA INSTITUTO VENEZOLANO DE Morón (Venezuela) NPK Fertilisers Plant PETROQUÍMICA NITRATOS DE Valladolid (Spain) NPK Fertilisers Plant CASTILLA Nitric Acid ASUR Cartagena (Spain) NPK Off-sites -SEC 6/32- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 6.3.3 GRANDE PAROISSE PROCESS (GPN) GPN-France earlier Grande Paroisse AZF Technology is one of the leading Pipe Reactor Technology supplier and has supplied more than 77 Pipe Reactor Systems worldwide for production of DAP fertilizer. The List of DAP/NPK Plants based on GPN Technology is given in Table-III. GPN can propose various Pipe Reactor Technologies depending on the type of fertilizer to be produced as well as clients’ requirement. GPN normally proposes the following three alternatives for the Pipe Reactor System. a) Dual Pipe Reactor (Dryer Pipe Reactor + Granulator Pipe Reactor) b) Granulator Pipe Reactor (GPR) c) Dryer Pipe Reactor (DPR) with Preneutraliser System GPN is having patent for providing Dryer Pipe Reactor. The Dryer Pipe Reactor can be offered only by GPN. GPN has supplied Pipe Reactor Technology in India. The details are as follows: 1. SPIC-Tuticorin A-Train Dual Pipe Reactor (DPR + GPR) 18-46-0 2. Coromandel International Ltd. GPR 16-20-0 (earlier E.I.D. Parry, Ennore) 20-20-0 3. Madras Fertilisers Ltd. B-Train 17-17-17 Chennai 18-46-0 14-34-14 4. Zuari Industries Ltd., Goa DAP Plant DPR + P/N 20-20-0 5. Indian Farmers Fertiliser E&F Train GPR + DPR Cooperative Limited, Kandla 10-26-26 12-32-16 18-46-0 -SEC 6/33- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The advantages of GPN Pipe Reactor Technology are as follows: a) Maximum number of Pipe Reactor System supplied worldwide b) Production of various grades of fertilizer. c) GPN can suggest various Pipe Reactor Schemes based on the client requirement i.e. GPR + DPR, GPR, DPR + P/N. d) GPR + DPR offers low recycle ratio as compared to only GPR. e) Low capital investment f) Low energy consumption g) Pipe Reactor can be operated on auto-thermal depending on the quality of phosphoric acid and site condition. h) GPN is having wide experience for production of high sulphuric acid grade from GPR (i.e. 16-20-0, 20-20-0). i) The Scrubbing System can be operated with Dual Mole Ratio (high & low mole ratio). j) DPR is patent technology of GPN -SEC 6/34- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S TABLE-III CLIENT / OWNER LOCATION PLANT ROUEN B, NPK – 45 MTPH Plant GPN FRANCE Loop Capacity : 180 MTPH SAS VAN GENT NPK – 50 MTPH Plant ZUID CHEMIE NETHERLANDS Loop Capacity : 200 MTPH NPK – 40 MTPH Plant GPN BORDEAUX, FRANCE Loop Capacity : 180 MTPH L’OSERAIE, NPK – 50 MTPH Plant DAP SUD FERTILIS FRANCE Loop Capacity : 200 MTPH ROUEN A NPK – 55 MTPH Plant GPN EG IV, FRANCE Loop Capacity : 220 MTPH ROUEN A NPK – 100 MTPH Plant GPN EG IV, FRANCE Loop Capacity : 400 MTPH TOULOUSE NPK – 30 MTPH Plant DAP GPN FRANCE Loop Capacity : 120 MTPH MONTOIR de BRETAGNE NPK – 65 MTPH Plant GARDILOIRE FRANCE Loop Capacity : 300 MTPH THESSALONIQUE NPK – 90 MTPH Plant ASP SICNG GREECE Loop Capacity : 300 MTPH NPK – 50 MTPH Plant SOCADOUR BAYONNE FRANCE Loop Capacity : 250 MTPH GABES DAP – 83 MTPH Plant S.A.E.P.A. TUNISIE Loop Capacity : 300 MTPH NPK – 50 MTPH Plant GPN MAZINGARBE FRANCE NPK – 130 MTPH Plant MELEUS Loop Capacity : 700 MTPH TECHMA SHIMPORT (USSR) DAP – 100 MTPH Plant Loop Capacity : 420 MTPH NPK – 130 MTPH Plant TECHMA SHIMPORT BIELORECHENSK (USSR) Loop Capacity : 700 MTPH -SEC 6/35- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT / OWNER LOCATION PLANT DAP / NPK – 31 MTPH PRAHOVO RTB-BOR-IHP Plant YUGOSLAVIA Loop Capacity : 160 MTPH NPK – 30 MTPH Plant DONAU CHEMIE PISCHELSDORF AUSTRIA Loop Capacity : Retrofitting 120 MTPH SUD NPK – 30 MTPH Plant BALARUC FRANCE FERTILIS Loop Capacity : 100 MTPH ROZDOL NPK – 130 MTPH Plant TECHMA SHIMPORT (USSR) Loop Capacity : 700 MTPH NPK – 35 MTPH Plant SECO RIBECOURT FRANCE Loop Capacity : 130 MTPH DAP - 4 X 60 MTPH Plant MAROC PHOSPHORE JORF LASFAR MOROCCO ASP Loop Capacity : 320 MTPH NPK – 52 MTPH Plant LEITH EDINBURGH SAI Loop Capacity : SCOTLAND Retrofitting ..... MTPH DAP – 42 MTPH Plant AZOT SANAYII SAMSUN TURNKEY Loop Capacity : 200 MTPH DAP – 45 MTPH Plant SPIC TUTICORIN INDIA Loop Capacity : Retrofitting 200 MTPH NPK – 45 MTPH Plant G.F.T. YARIMCA TURKEY Loop Capacity : 140 MTPH THESSALONIQUE NPK – 35 MTPH Plant SICNG GREECE Loop Capacity : 100 MTPH ASP – 30 MTPH Plant ROSIER MOUSTIERS BELGIUM Loop Capacity : 100 MTPH DAP – 67 MTPH Plant SINO ARAB QIN HUANG DAO CHINE NPK – 83 MTPH Plant SACF Loop Capacity : 300 MTPH -SEC 6/36- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT / OWNER LOCATION PLANT DAP – 42 MTPH Plant ICS MBAO NPK – 42 MTPH Plant SENEGAL SENEGAL Loop Capacity : Retrofitting 210 MTPH MAP – 5 MTPH Plant SHENXIAN HEBEI PROVINCE CHINA Loop Capacity : 30 MTPH 17-17-17 – 55 MTPH Plant DAP – 35 MTPH Plant M.F.L. MADRAS MANALI INDIA Loop Capacity : Retrofitting 220 MTPH DAP – 42 MTPH Plant NIPPON JORDAN FERT. AQABA JORDAN NPK – 45 MTPH Plant CO. Loop Capacity : 200 MTPH NP – 34 MTPH Plant EID PARRY MADRAS ENNORE INDIA Loop Capacity : Retrofitting 145 MTPH NPK – 35 MTPH Plant ATLAS FERTILIZER TOLEDO PHILIPPINES Loop Capacity : 100 MTPH DAP – 50 MTPH Plant GOA ZUARI NP – 40 MTPH Plant INDIA Loop Capacity : 240 MTPH GANSU PROVINCE DAP – 20 MTPH Plant JINCHANG CHINA Loop Capacity : 80 MTPH DAP – 18 MTPH Plant SELAATA CHEMICAL NPK – 22 MTPH Plant SELAATA LEBANON COMPANY Loop Capacity : Retrofitting 90 MTPH FAUJI JORDAN DAP – 62 MTPH Plant BIN QASIM PAKISTAN FERTIL.CO Loop Capacity : 280 MTPH GOA NPK – 50 MTPH Plant ZUARI INDIA Loop Capacity : 240 MTPH KANDLA DAP – 60 MTPH Plant IFFCO INDIA NPK – 75 MTPH Plant -SEC 6/37- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S CLIENT / OWNER LOCATION PLANT Loop Capacity : 335 MTPH DAP – 50 MTPH Plant SASOLBURG SOUTH OMNIA NPK – 50 MTPH Plant AFRICA Loop Capacity : 220 MTPH QUIN HUANG DAO, NPK – 84 MTPH Plant SACF CHINA Loop Capacity : 340 MTPH CHITTAGONG DAP – 36 MTPH Plant BCIC BANGLADESH Loop Capacity : 200 MTPH DPR – Dryer Pipe Reactor GPR – Granulator Pipe Reactor 6.3.4 SELECTION & RECOMMENDATIN OF THE TECHNOLOGY Based on the above, we propose Pipe Reactor Technology to be adopted for HZL for production of DAP grades of fertilizer. As mentioned above, Pipe Reactor Technology is offered by GPN-France, INCRO- Spain and ESPINDESA-Spain. Based on the above, we propose Owner should use INCRO Pipe Reactor Technology for the DAP Plant at Zawar Mines. The advantages of Incro Pipe Reactor Technology is as follows, a) Saving on maintenance cost INCRO’s Pipe Reactor velocities of reactant are very high and as a consequence self-cleaning capability is remarkable. Low recycle ratio also reduces the general maintenance cost. -SEC 6/38- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S b) Simplicity of equipment and operation Normal operation of the PR is quite simple and does not suppose any big change on operation from a traditional granulation plant, being process routing quite soon familiar to the operators. In case of an eventual PR plugging, which is very seldom on our PR due to its special design, a special automatic cleaning sequence is foreseen. INCRO's PR reacting head has some internals that provide a more intimate contact between phosphoric acid and ammonia than other empty P.Rs, achieving a higher efficiency and reducing ammonia losses to the scrubbing system. This head can be completely and easily disassembled. Pipe reactors are manufactured with materials that will withstand the corrosion that might be caused by the products in its contact. For the ammoniation of the bed INCRO S.A has developed a high efficient device, of a ploughshare type, feeding ammonia very close to the granulator's shell and parallel to it. Its special design avoids product accumulation on it, as well as breakdown problems during start-up. c) Improved ammonia yields As it is well known, ammonia loss to the scrubbing system increases exponentially with the N/P ratio, quite rapidly after N/P 1.7. Based on that fact INCRO decided it is preferable to ammoniate in the Pipe Reactor up to a certain extent (1.4 - 1.5) and complete the ammoniation in the granulator. This solution relies on the fact the ammonia which is fed deep into the solids granulator’s bed, through our specially designed ammoniation system, is not lost so easily as in the Pipe Reactor exit, where ammonia and steam flash freely occurs. Ammonia feeding to the granulator’s bed it is also advisable since the ammonia reaction on the granules surface favourizes an extra-evaporation of water and makes final granule drier and harder. -SEC 6/39- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S d) Low pollution After considering the efficiency of both our PR and ammoniation system, as well as the suitable distribution of the ammonia, it is easy to understand why there is low pollution problem related with our PR process. The small emissions of ammonia, dust and fluorine will be recovered in a high efficiency scrubbing system, specially designed by INCRO both to recover the pollutants, as well as to match the requirement of the reaction section, being fully integrated into the process. e) Flexibility of the settings INCRO’s Pipe Reactor has no any constraint about slurry water content, slurry solubility and operating molar ratio N/P, although we normally recommend operating it from 1.0 to 1.7, depending on the manufactured grade and the granulator conditions. INCRO’s Pipe reactor is adjustable to production rate, which gives the system great adaptation flexibility, achieving a continuous and stable reactor operation. Both items combined, pipe reactor plus ammoniating system, allow a high flexibility for adjusting moisture and temperature of the granulator bed to the optimum for each formulation. This makes possible to work with low recycle ratio, high granulation yields, high production rates and more steady plant operation f) Versatility of the installation Due to the above mentioned considerations all our plants have a very high flexibility in operation, not only for the chosen product grade (using different raw materials according their availability and price...) but also for the future eventual manufacture of other grades. In fact most of our plants are designed from the very early beginning to produce DAP / NPK / MAP, using the same equipment. Whenever only one product is envisaged, provisions for a future simple upgrading are considered. -SEC 6/40- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 6.3.5 CONTACT DETAILS OF PROCESS LICENSOR A) INCRO INCRO, S.A. C/ Serrano 27 28001 Madrid (Spain) Phone: +34 91 435 0820 Telefax: +34 91 435 7921 B) ESPINDESA C/ Arapiles 13, 28015 Madrid Spain Tel. +34 91 5924884 Fax +34 91 4480456 C) GPN GPN 30 rue de l'industrie 76121 GRAND QUEVILLY Tel (33) (0)235674008 -SEC 6/41- HINDUSTAN DORR-OLIVER LIMITED SECTION‐7  PROCESS DESCRIPTION PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION – 7 PROCESS DESCRIPTION 7.1 ROCK PHOSPHATE BENEFICIATION PLANT Based on the design basis criteria, the primary & secondary crushing plant shall be of capacity 120 TPH (design capacity) while the HPGR, grinding, flotation, thickening & filtration of capacity 70 TPH (Design capacity).The Process Flow Diagram for Rock Phosphate Beneficiation plant is 1-M026-DS00-2-0001. The proposed plant shall consist of following sections: 7.1.1 ROM Ore Receiving & Primary Crushing Section: Run-of-mine ore shall be dumped into a hopper with a fixed grizzly at the top. A rock breaker shall be provided so as to break any occasional lumps above 600mm. The ore shall be reclaimed from the hopper by an Apron Feeder. The primary crushing unit comprises an apron feeder, jaw crusher & a conveyor belt. The apron feeder shall feed a primary jaw crusher which shall reduce the material to approximately 100% passing (-) 125 mm size. The jaw crusher product shall be discharged onto the conveyor BC-1. 7.1.2 Secondary Crushing Section: The primary crushed product shall be transported by conveyor BC-1 to a single deck vibrating screen (aperture: 40mm) ahead of a secondary crusher. Oversize (+ 40mm) of this screen shall be fed to a secondary cone crusher feed bin from where it shall then be fed to the secondary cone crusher through a rod gate followed by a vibrating feeder. The screen undersize along with the secondary cone crusher product (i.e. - 40mm) shall be transported to crushed ore stockpile (COSP) via a belt conveyor and a tripper conveyor BC-2. 7.1.3 HPGR & Grinding Section: The crushed ore from COSP (- 40mm) shall be reclaimed by reciprocating feeders with variable speed drives and fed to a HPGR through a HPGR feed bin by a belt conveyor BC-3. HPGR shall be in closed circuit with a single deck vibrating screen with aperture size of 6 mm. Screen oversize (+ 6 mm) shall be recycled back to -SEC 7/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S HPGR by conveyors BC-5 & BC-6 and the screen undersize (- 6 mm) shall discharge on a belt conveyor BC-4 with a fixed tripper which shall convey to the two fine ore bins. Ore shall be reclaimed from FOB through weigh feeder to discharge into a mill feed conveyor BC-4A which shall feed the primary ball mill. Grinding circuit shall consist of a primary ball mill in closed circuit with a classification cyclone. The primary ball mill product shall be discharged into the cyclone feed sump from where it shall be pumped to the hydro cyclone. Overflow of the cyclone shall be transferred to rougher conditioner tank 1 of flotation circuit while the underflow returns back to the primary ball mill as recirculation load. The primary ball mill feed pump shall be provided with VFD. 7.1.4 Flotation Section: The feed size of the material to the flotation circuit shall be 80% passing 58µ. Flotation section shall consist of rougher conditioning tanks, rougher cells followed by three stages of cleaning circuits. The hydro cyclone overflow from the grinding circuit shall be conditioned with reagents in two stage conditioner tanks and subjected to flotation in rougher bank. The rougher 1 tails shall gravitate into the rougher 2 cells. The tails of rougher 2 cells constitute the rejects of the flotation circuit. The rougher concentrate shall be cleaned in 3 stages of cleaners. The rougher concentrate from both the cells shall be pumped to the cleaner 1 cells. The concentrate from the cleaner 1 cells shall be pumped to the cleaner 2 cells and the concentrate from the cleaner 2 cells shall be pumped to the cleaner 3 cells. The cleaner 3 concentrate shall be the final concentrate which shall be pumped to the WHIMS. The tailings from the cleaner 3 cells shall gravitate to the cleaner 2 cells & that from the cleaner 2 cells shall gravitate into the cleaner 1 cells. The tailings from cleaner 1 shall report to cleaner tails sump from where it shall be pumped to rougher 1 cells. Process water of suitable quantity shall be added on the concentrate launder of all the flotation cells. 7.1.5 Magnetic Separation: The final conc. from cleaner 3 cells shall be pumped to WHIMS for minimizing the iron content in the final concentrate. The WHIMS non mag portion shall gravitate into the acid grade concentrate transfer sump from where it shall be pumped to the acid grade concentrate thickener & the WHIMS mag portion shall gravitate into the WHIMS tailing transfer sump from where it shall be pumped to the tailings thickener. -SEC 7/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 7.1.6 Acid Grade Concentrate Thickening & Filtration: There shall be a thickener for acid grade concentrate thickening & filtration. Thickener u/f shall be pumped to a filter feed tank. From filter feed tank, slurry shall be pumped to the pressure filter. The filtered cake shall be carried away by the belt conveyor BC-7 with a fixed tripper and shall be stored in the stock pile with 2 heaps each of capacity 2100MT. The overflow of the thickener shall be stored in the process water tank. 7.1.7 Tailing Dewatering System: The tailings from the rougher 2 cells & WHIMS tails transfer sump of flotation area constitute the final plant tailings. The plant tailing shall be pumped to the tailing thickener. The thickener u/f shall be pumped to tailing thickener underflow tank and the overflow shall be fed to the common process water tank. There shall be two tailing disposal lines each capable of handling the tailing generated from 0.5 MTPA plant capacity. One of the lines shall be in operation while the other one shall be in standby mode. Water shall be reclaimed from tailing pond and shall be pumped back to process water tank (i.e. tailing thickener o/f tank). 7.1.8 Magnetic Tailings Thickening & Filtration: (Optional) There shall be a thickener for magnetic tailings thickening & filtration. Thickener u/f shall be pumped to the drum filter. The filtered cake shall be carried away by the belt conveyor BC-8 and shall be stored in the stock pile. The overflow of the thickener shall be stored in the process water tank. The thickener feed pump & the thickener underflow pump shall be provided with VFD. -SEC 7/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 7.1.9 Utility Section (Water /Air): Water Systems: Fresh water shall be supplied by the client at the fresh water tank. The distribution of this fresh water inside plant at different points shall be in scope of EPC contractor. Process water sources will be from the tailing thickener overflow, magnetic tailing thickener overflow & concentrate thickeners overflow. This will be pumped to the milling and flotation sections. Potable water shall be provided by the client at potable water tank. The distribution of the potable water to safety shower and eye wash and potable overhead tank in shall be in the scope of EPC contractor Reclaim water shall be pumped from the tailing dam area to process water tank. Seal Water Tanks with pumps are envisaged for the seal water requirement for different pumps. Cooling Tower shall be provided for cooling the recirculating water to mill bearing cooling etc. Air Systems: For plant and instrument air, there shall be 2 nos. oil flooded screw compressors (1 operating + 1 standby) and one air receiver of 1.5 m3 capacity. For instrument air, there shall be refrigerant air dryer (1 operating + 1 standby) and 1 no. air receiver of 1.0 m3 capacity. Dedicated oil flooded screw compressors (1 operating + 1 standby) and one air receiver shall be provided for air pressing of pressure filter. There shall be 2 nos. (1 operating + 1 standby) air blowers for low pressure air requirements in flotation cells. -SEC 7/4- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 7.2 PHOSPHORIC ACID PLANT We propose new Phosphoric Acid Plant for the capacity of 350 MTPD P2O5 (100 % P2O5) according to the HDH Process. The proposed Phosphoric Acid Plant will be designed according to the latest technology available in the world. The design will be tailored to have a low investment cost and a high operational factor. The design will also take into account safety in the workplace have a low energy consumption and will also be environmentally friendly with a zero liquid effluent discharge during normal operation. Please refer Drg. No. A2 - 120013S - F – 008 to A2 - 120013S - F – 009 7.2.1 HH Reaction Section The design uses three reactors in series with low-sulphate zone and high-sulphate zone. These reactors, of almost identical operating volume, are fitted with modern agitators fabricated in duplex material resistant to corrosion and erosion in the HH slurry. All the agitators of the HH reaction section will be fitted with foam-breaking blades to reduce defoamer consumption. The design of the launders and the differential heights between each of the tanks will be considered so as to enable the foam produced to be tolerated more easily and reduce the defoamer consumption. Phosphate rock, from storage, is fed to the first reactor along with a controlled slurry recycle flow from the high–sulphate reactor. Based on experience there will be two horizontal centrifugal pumps, one spare, operating with variable speed control providing the slurry recycle. The slurry from the first reactor overflows to the second reactor which complements the low-sulphate volume. This reactor is also fitted with a similar agitator to the first reactor. There are no feeds to the second reactor. The third reactor receives the sulphuric acid premixed with the return acid from the HH filter in a special Zone and as such forms the high-sulphate zone of the HH reaction section. The heat of reaction is removed by a low-level flash cooler which re-circulates around this tank. The HH belt filter is also fed from this reactor by the HH feed pumps. The gases from the flash cooler go to the vacuum fluorine recovery section. The dip- pipe of the flash-cooler return is situated in an external chamber to prevent interference with the agitator of the third reactor. -SEC 7/5- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 7.2.2 Flash-Cooler Vacuum Section Fluorine recovery from the off-gases of the hemihydrate reaction section has two advantages; it provides additional revenue from the sale of Fluosilicic acid and protects the environment as it reduces the fluorine level in the recycled cooling water. This section is a vacuum scrubber design having a droplet separation tower to remove entrained acid carry-over but has a single stage scrubbing tower operating batch-wise in an automatic programme improving the fluorine recover efficiency. The FSA seal tank is initially filled with water to the controlled level and the recirculation pump started. Water is bled into the system to maintain the level which decreases due to de-supersaturation of the vapors. As time goes by the absorption of fluorine compounds increases the strength of the FSA. When the desired product strength, 20 – 22 % FSA, is reached the water valve is closed and the export valve opened. This valve remains open until the level reaches the low level alarm which closes the export valve and once again allows the water inlet valve to control the level in the tank. Now the strength of the circulating liquid is about 5% and the strength progressively increases once again until the desired product strength is reached when the cycle repeats itself. After the fluorine recovery section there is a pre-condenser to provide hot water for filter washing without requiring the use of steam and this is followed by the main condenser prior to the vacuum pump. 7.2.3 HH Off-Gas Scrubbing Section The off-gas from the hemihydrate reactors even though having a relative small volumetric flow contains relatively high fluorine content and the fluorine must be removed before being directed to the stack to protect the environment. This section consists of a first stage to remove entrained acid droplets that could contaminate the fluosilicic acid (FSA). This first stage has a droplet separator and a wet scrubber that operates with liquor saturated in FSA and the recovered droplets with the FSA are returned to the HH reaction system. After the removal of the acid droplets, the gases pass to two stages of venturi scrubbers. A variable speed fan draws from the final void tower and the gases are combined with those from the filtration off-gas section before passing through the main exhaust fan to the stack. -SEC 7/6- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 7.2.4 Hemihydrate Filtration Section This section consists of single horizontal belt filter having two counter-current washes with the final wash being filtrate from the Dihydrate filter. This filter discharges directly into a re-pulp tank the cake being re-slurried by filtrate from the Dihydrate filter. Off-gas from the filter hood goes to the Filtration Off-gas Scrubbing Section and fan. The gas joins the other streams from the filters and the DH Off-gas scrubbers and proceeds to the tail- gas scrubber and stack via the main exhaust fan. Operating at the present speed of 14 mpm the filter would have a cycle time of 90 seconds. Thus each filter would be capable of producing 350 TPD P2O5. Self-draining double outlet slurry feed boxes will be provided for the filter and the wash box shall be of self-draining type with no pockets with integral dams up- stream to prevent mixing of washes. Downstream separately movable dams will be provided for each box. Vacuum box divisions shall be liquid tight and with variable positions, provision shall be made for the future addition of a separator block in the vacuum box touching the belt to allow operation of the vacuum box at two different vacuums. If implemented, this will enable a final cake drying zone to be provided. The vacuum box shall be jacketed for hot water heating if required. Phosphoric acid from 10 filtrate will be sent to storage/clarifier for 42% phosphoric acid. 7.2.5 Hydration Section This section consists of the two hydration tanks preceded by a re-pulp tank with intensive agitation so as to fully disperse the HH cake in the re-pulping liquor. This re-pulp tank also has an inlet for sulphuric acid either premixed with hydration slurry or re-pulping liquor. Seed crystals from the second hydration tank are recycled to the first hydration tank by a DH slurry recycle pump. The first tank will be maintained in depression by the off-gas fan which creates a air-flow to be able to maintain the temperature of the hydrating slurry below 65°C. Two new DH filter feed pumps feed the DH filter with two washes and a final dedicated cake drying section. Off-gas goes to the DH Off-gas Scrubber. 7.2.6 Dihydrate Filtration Section This section consists of a single belt filter, fitted with two counter-current washes and a polishing wash. Hot water from the precondenser is used for the cloth wash -SEC 7/7- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S and subsequently for final cake wash. The filtrates are returned to the hemihydrate filtration section as wash-water and also for sluicing the discharged hemihydrate cake in the repulp tank. Off-gas from the filter hood goes to the DH Off-gas Scrubber. A split vacuum box enabling the final cake drying section to be independent will be used which uses two separate vacuum systems on the filter ensuring minimum moisture in the discharged dihydrate cake. 7.2.7 Filtration Off-Gas Scrubbing Section This section consists of a multi-stage venturi scrubber system with intermediate void cyclonic towers these gases combine with those of the HH Off-gas Scrubbing system and the HH filter prior to being routed to the stack via the main exhaust fan. 7.2.8 Evaporation Units and Fluorine Recovery The evaporation section of the Phosphoric Acid Plant, considering two single-stage vacuum evaporators, with carbon tube heat exchangers, operating in parallel is designed to raise the concentration from 43 % P2O5 to 52-54 % P2O5. The design consists of two single-stage vacuum evaporators in parallel with forced circulation using a graphite tube heat exchanger, an axial-flow pump and a flash chamber. The recirculation loop is connected to the base of the flash chamber which is fitted with a vortex breaker to prevent cavitation of the axial-flow pump. The Heat Exchanger is mounted in a vertical position at an elevation with a liquid head on it to prevent boiling in the tubes. Low pressure steam is received from the Battery Limits and the evaporative capacity of the unit is defined by the flow controller on the steam feed. A desuperheater after the flow control valve ensures that saturated steam is fed to the Heat Exchanger. The heat exchanger is fitted with a distribution bustle to prevent erosion of the tubes. The velocity of acid in the tubes is selected to minimise scaling and maximise the heat transfer coefficient whilst preventing erosion of the graphite tubes. The level in the flash chamber is controlled by an overflow at such a height that the boiling of the heated acid prior to entering the flash chamber is prevented. Weak acid is received from storage/clarifier 42% phosphoric acid and fed into the acid flow leaving the heat exchanger. The concentrated acid drains via the standpipe overflow to the agitated product acid seal tank and is pumped to storage/clarifier 52% phosphoric acid by the concentrated acid pump. -SEC 7/8- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Fluosilicic acid (FSA) is produced in the fluorine recovery section which is a co- current absorption tower operating batch wise to improve recovery. The flashed vapours containing mainly water and fluorine compounds pass through a high- efficiency droplet separator prior to entering the fluorine recovery section. The acid droplets will report back to the flash chamber. Product is drawn off by a self regulating variable speed pump and delivered to the storage area. The residual water vapour, almost free of fluorine compounds, passes through a direct contact condenser fed with cooling water. The condenser water is collected in a barometric seal tank which overflows to the return trench and returned by gravity to the cooling tower. 7.2.9 Auxiliaries The auxiliaries section includes the following activities, the wash circuit, the defoamer system and the silica system. A] Wash Tank The wash tank receives wash liquors from various sections of the plant and provides wash liquor for two distinct duties. The first is the cloth wash of the HH filters. The second is a wash pump that is used to wash parts of the plant during periodic shutdowns. The level in this tank is maintained by water fed from the hot water tank which is pre-heated in the flash-cooler pre- condenser. B] Defoamer Defoamer is received in drums and poured into the defoamer storage tank. The ambient conditions at the site and the defoamer used mean that heating is not required in the defoamer tank. Three multi-head dosing pumps fed the three sections of the plant requiring defoamer and each head can be adjusted independently to enable different flows to be fed to each point of application. The first pump feeds the Reactor 1 (where the phosphates are added) and Reactor 2 where the mixed acids are fed. The third addition point is the inlet to the flash-cooler. -SEC 7/9- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The second pump feeds the two return acid tanks of the HH filters and also the two transformation tanks. The third pump will not normally be used as it feeds the three evaporators but it is a fall-back and will only be used if the FSA is contaminated with P2O5 above the design value of 100 ppm. C] Silica Filtration The unfiltered FSA is stored in two dedicated tanks and the content of each tank are fed to the silica filter section under flow control varying the speed of the FSA pumps. Silica cake discharged from the filter section falls directly into the silica slurry tank where it is complemented, if necessary, with silica powder. The solids content is adjusted by addition of water or silica. Two centrifugal pumps feed the two first transformation tanks by individual lines and flowmeters controlling the pump speed. 7.3 DI-AMMONIUM PHOSPHATE We propose Pipe Reactor Technology for the DAP Plant. The Process Description of Incro’s Pipe Reactor Technology is given below. Please refer Drg No. A2 - 120013S - F – 010 to A2 - 120013S - F – 011. The Pipe Reactor is the patent technology of Incro and is working satisfactorily worldwide. Phosphoric acid at 50-54 % P2O5 strength is pumped from its storage day tanks to the various destinations in the plant, namely the Pipe Reactor Tank, the Granulator Pre-scrubber Tank, the Scrubber tank depending on the grade of DAP/NP fertilizer production. Liquid ammonia is pumped from storage to the Pipe Reactor, to the Granulator Ammonia System and to Ammonia vaporizer. Sulphuric acid is used for grade and scrubber N/P molar ratio control. Solid raw materials Filler and spillages (or off‐spec product) are fed from their storage building to the plant building by a common conveyor. Once in the plant there is a common raw material diverter to feed the different solid raw material to their correspondent bins. Each bin is equipped with a vibrating bin activator, dedusting air suction with valve interlocked with the position of Raw Materials Rotary Diverter, air knockers to prevent arching inside the bins and an isolating gate. -SEC 7/10- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 7.3.1 Slurry Preparation and Granulation Slurry preparation and Granulation DAP (18‐46‐0) and other NP Grades will be produced via the Pipe Reactor process. For DAP production, in Pipe Reactor a molar ratio N/P = 1.4-1.5 is reached at 135- 1450C, by reaction of resulting phosphoric acid of about 42-45% P2O5 (including some sulphuric acid) and liquid ammonia. Two pumps with independent piping systems are provided to constantly deliver the required quantity of liquid ammonia to the Granulator. Pipe Reactor The neutralization reaction takes place in the Pipe Reactor. The discharge or distribution pipe of PR is installed inside the granulator in such a way that the slurry of ammonium phosphate is poured directly onto the solids bed of the Granulator in several distribution points. These PR slurries have temperatures ranging from 130 to 145°C and moistures content between 3% and 5%. Some steam is released from the PR discharge. A good air draft from Granulator is required to remove the mentioned steam. The Pipe Reactor has phosphoric liquor and ammonia flow controls. Phos acid liquor will be fed from Pipe Reactor (PR) Tank, by means of the Pipe Reactor Pumps. Phosphoric acid fed to Pipe Reactor is made by the acid coming from the scrubbing system, complemented by the concentrated acid fed to PR Tank (not previously used into the scrubbing) plus, occasionally, some process water. Medium pressure steam is provided for cleaning Pipe Reactor. There will be an interlocked three positions switch that will automatically shut-off feedings of acid and ammonia when steam is fed. To complete the phosphoric acid neutralization to the final required N/P ratio, a new Ammoniation System, designed by INCRO S.A., is provided. The sparger is flexible type offering a minimum resistance to the bed, through which liquid ammonia is fed deeply into the bed and distributed lengthwise and parallel to the Granulator shell, so that losses of ammonia to the scrubber are minimized. -SEC 7/11- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Both items combined, PR and Ammoniation System provide a great flexibility on adjusting operation parameters in order to achieve high granulation efficiency. The use of ammonia in liquid state will also favour the control of temperature into the bed, which is very important for a good granulation. No further reaction is necessary into the Dryer using the INCRO, S.A. process. All the reactions take place into the Granulator and the product leaving this equipment has already the requested levels of N and P2O5 for the final product. Gases developed into the Granulator are sucked up towards the Granulator Pre- Scrubber, to recover most of the evolved dust and ammonia losses. Granulation The function of the granulation system is to transform the slurry and solid raw materials into a granular fertilizer product with the required composition and size. Granulation occurs in the drum Granulator, where phosphate slurries are sprayed onto a bed of dry material, composed by the added solid raw materials (Filler, Off- spec/Seed) plus the fines, crushed oversizes and part of the commercial product returned to granulator. Slurries are directly sprayed from the Pipe Reactor distribution Pipe. The rolling action within the Granulator distributes the slurry evenly on the surface of the granules, and produces a very uniform, hard, well‐rounded, layered granule. The resultant thin film of slurry is easily dried after rolling and reaction with liquid ammonia. The Granulator is inclined towards the discharge end to facilitate transfer of the large recycle load. There are several emptying doors, at the granulator’s exit ring, to adjust bed depth to the optimum value, as well as to allow emptying granulator for maintenance / cleaning purposes. To complete the acid neutralization of the slurries to the required N/P ratio for DAP and NP grades, an Ammonia System is installed, to inject liquid ammonia deep into the solids bed, promoting granules water evaporation. The Ammoniation System consists of independent rubber hoses supported from the granulator’s main beam. This system avoids the formation of lumps, provides a homogeneous distribution of ammonia and reduces granulator power -SEC 7/12- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S consumption, thanks to the almost absence of frictions caused by product solid bed while turning. The granulator is a carbon steel drum lined with rubber panels and equipped with an apex scrapper, to minimize product build‐up on the supporting beam and the rubber panels. It will be also equipped with a lumps kicker to prevent any lump from remaining inside the drum, disturbing the flow of solids and promoting other lumps formation. Lumps kicker will make the lumps to jump to an attached grizzly, which will disintegrate them by the rotating action. Rest of product will leave the granulator by passing through the grizzly bars. Special care should be devoted to the design of chute between granulator and dryer to avoid build‐up on the walls and the potential adverse effects due to product contact with the hot gases from combustion chamber. Gases developed into the granulator are sucked up towards the Fumes Pre‐Scrubber to recover most of the evolved dust and ammonia losses. In any case, all the reactions take place into the granulator and product leaving it has already the requested levels of N and P2O5 for the product. Consequently no further reaction is necessary into dryer using INCRO S.A. process. Drying In the rotary drum type Dryer, the solids are lifted and cascaded through a concurrent flow of hot air from the Combustion Chamber. The dryer is designed for maximum efficiency and minimization of material build‐up. The Combustion Chamber will be fuel oil fired. Air for combustion is supplied by the Combustion Air Fan. The Quench Air propelled by Fan is used to reduce the temperature of the combustion gases up to a temperature adequate for the combustion chamber. Excessive temperatures must be avoided to prevent decomposition, ammonia evolution and fumes formation. Control of the firing rate can be done based on the dryer outlet gas temperature depending on the grade, product moisture content and the granulation temperature. -SEC 7/13- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The product at dryer discharge flows through the grizzly, consisting on a bar grizzly equipped with three lumps lifter located on it. The broken lumps and small product will flow through the grizzly bars, whereas harder lumps will be elevated and eventually fed by the elevator to the Lump Crusher, feeding chute. Oversize crushed lumps will then join the rest of product in dryer exit belt conveyor, which feeds Exit Dryer Elevator. Dryer exit gas contains some dust that is removed in the dryer cyclones, collected in the cyclones hoppers and returned to the recycle. Cyclones are equipped with cleaning chains, flap type discharge valves and with small air knockers. Dryer exit conveyor is equipped with a throughput weigher and a magnetic separator, installed to remove any metallic part that may damage oversize mills. From that belt conveyor, solids fall by gravity to the Exit Dryer Elevator. Screening and Crushing The plant will utilize double deck vibrating screens. All recycle material is passed over these screens. The Dryer Elevator feeds the Screens Splitter, which splits the recycle material among the screens. To improve screen efficiency each screen has a dedicated vibrating feeder to evenly distribute the feed across its entire width. There are also two throughput diverters and one seed room diverter, to send the recycle material to the seed room, or to by‐pass the screening section, sending back the entire product to the recycle conveyor. The screen will separate the oversize, fines and product. Feeding is accomplished by independent chutes from each screen. The suggested mill type is a chain mill crusher, which provides and efficient crushing with small size dispersion on ground product and reduces the formation of dust. These mills directly discharge onto the Recycle Conveyor, through oversized chutes. The on‐size product from all three screens is collected in the screens collector conveyor that feeds the recycle regulator conveyor. This variable speed belt conveyor is equipped with a weigher, whose set point can be fixed to maintain a constant rate of product towards the final product section, or to keep a constant recycle rate. -SEC 7/14- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S In the first alternative the operator should fix a rate on the weigher to extract from the granulation loop only the required quantity of product to match the production rate. Any excess of on‐size product will not be extracted at that belt speed and will automatically overflow from the belt hopper to the recycle conveyor. In the second alternative, the product take‐off rate is variable and adjusted according the quantity of recycle in the system, measured by the motor current on the Recycle Elevator. The recycle conveyor will receive: - Dust from all cyclones - Fines from all screens - Overflow from recycle regulator conveyor - Filler and spillages from their respective feeders Special care should be devoted to the design of the Recycle Conveyor. It should operate at rather low speed, to avoid mechanical problems, and its cover should be tight enough, to avoid dust emission. The recycle conveyor discharges onto the Recycle Elevator that feeds all the recycle and filler / spillages to the granulator drum. Final Product Treatment Product size material from the Recycle Regulator Conveyor is fed to the Rotary Cooler, which will cool down final product temperature using ambient treated air. To prevent absorption of moisture by final product during the cooling process, mainly when ambient air is too wet, an air chilling system is provided as DAP and NP Grades (via sulphuric) have a critical relative humidity and they could retain moisture if ambient air condition has higher relative moisture. From rotary cooler the Cooler outlet conveyor will feed cooled product to existing Product elevator. Cooler Feed Conveyor will control the feeding of on size product to cooler; constant production output results in better cooling and improved recycle control, which at the end turns into increased granulation yield. -SEC 7/15- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Product cooling will be done using ambient air in counter current with product. From rotary cooler air will be suck towards cooler cyclone and then to the Dust and Cooler Scrubber Dust and Fumes Collection All process equipment in the plant operates under a small negative pressure in order to prevent the escape of unreacted ammonia, other gases and dust from the process. Air containing ammonia, water vapour and dust form the Granulator is vented to the Granulator PreScrubber, where ammonia and a major portion of the dust are removed by reacting with the phosphoric acid contained in the circulating scrubber solution. From the Pre‐Scrubber the gas flows to the Granulator and Dedusting scrubber, where most of the remaining ammonia and dust are removed. Air leaving this Scrubber is sucked by the Granulator and Dedusting exhaust fan and feeds the double step Tail Gas Scrubber, to recover fluorine evolved during phos acid washing and to complete ammonia and dust recovery. Gas containing ammonia and dust from the dryer, flows to the Dryer Cyclones, to remove a major portion of the dust, which is returned to the Recycle conveyor. Gases from the cyclones flow to the Dryer Scrubber, sucked by the Dryer exhaust fan located downstream the scrubber, and from there to the Final Tail Gas Scrubber for further ammonia and dust removal. Air containing dust from the solids handling equipment (conveyors, elevators, screens, etc.) is vented into the Dedusting Cyclones, where most of the dust is removed. The air from the cyclones flows to the Granulator & Dedusting scrubber to be jointly washed with the gases coming from granulator Pre‐Scrubber. The common Granulator and dedusting exhaust fan provides the required suction from previous scrubber, as well as the impulsion to the Final Tail Gas scrubber. Scrubbing The scrubbing system for this plant consists of the following: First scrubbing step: Granulator Pre‐Scrubber— Duct Cyclonic -SEC 7/16- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Second scrubbing step: It is composed of: Granulator & Dedusting Scrubber — Venturi Cyclonic Dryer Scrubber — Venturi Cyclonic Third scrubbing step: Final Tail Gas Scrubber — Packed Tower The plant utilizes a dual‐mole ratio scrubbing system for the Pipe Reactor / Granulator gases, a single mole scrubbing system for the Dryer and equipment dedusting gases, and water scrubbing as a final step for all gases. First Scrubbing Step The “dual‐mole” scrubbing system gives maximum ammonia and fluorine removal from the gases. The gases from the Pipe Reactor / Granulator (most heavily laden with ammonia) are first scrubbed in the Granulator Pre-Scrubber, which is irrigated by a solution of Phos acid slightly ammoniated Ammonium phosphates are formed by the reaction of ammonia (escaping the Pipe Reactor / Granulator) with phosphoric acid. The latter is fed to the Pre‐Scrubber and recirculated by a one of the Pre Scrubber Pumps. About 80% to 90% of the NH3 and dust in the gases are removed in the Pre‐Scrubber. Second Scrubbing Step This second step includes two identical venturi scrubbers, the Granulator & Dedusting Scrubber and the Dryer Scrubber. The exhaust gases from the Pre Scrubber are mixed with the gases coming from dedusting system cyclones, and are jointly scrubbed in the Granulator and Dedusting Scrubber. Dryer gases, after cycloning, are washed in the venturi scrubber. Both scrubbers share a common scrubber tank and use a more diluted solution of phosphoric acid than in the first washing step, Circulation is provided by the pumps. This two‐stages scrubbing system is known as the “dual mode” system, since the Pre-Scrubber operates at low ammonia to phosphoric acid mole ratio, while the second operates at higher mole ratios. -SEC 7/17- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The advantage of this system is that ammonia is easily recovered at low pH in the first step; whereas once most of the ammonia has been recovered in the first step, second step may use a more diluted solution, at higher pH values, thus reducing fluorine losses and reducing the risks of handling a highly concentrated liquid with a high solids content. Third Washing Step Gases from the Granulator & Dedusting scrubber, Dryer Scrubber and from the Cooler cyclones are finally washed in the Tail Gas Scrubber to remove the fluorine evolved during the Phos acid washing and to complete the ammonia and dust recovery. To fit the stringent legislation, this scrubber has two independent washing steps. The first washing stage consists on several successive washing sections, equipped with spray nozzles, all of them on the almost horizontal duct located before the tangential inlet to the scrubbing tower. Gases, after washing, enter into the cyclonic tower, to disengage the entrained liquid and to proceed to the second washing stage, which consists on an irrigated packing, located on the middle‐upper part of the scrubber tower. The pump sucks from an elevated pit and provides the required packing irrigation, through a sprays distributor. The second stage washing liquid, before feeding the liquid distributor, is passed through an ammonia evaporator. The scrubbing liquid, flowing through the tubes, will cool down, at the same time that will evaporate the liquid ammonia, fed from ammonia separator, which is flowing through the shell. Evaporated ammonia will feed the ammonia separator, joining with the evaporated ammonia coming from the Cooler. The reduction on washing liquid temperature will improve pollutants recovery, mainly fluorine, at the same time that will reduce fresh water consumption, thanks to the water condensation from the effluent gas. -SEC 7/18- HINDUSTAN DORR-OLIVER LIMITED SECTION‐8  MASS BALANCE PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 8 MASS BALANCE 8.1 ROCK PHOSPHATE BENEFICIATION PLANT The Mass Balance of the Rock Phosphate Beneficiation Plant is given in Drg.No.1- M026-DS00-2-0001 SHE 1 of 1 R2 (PFD & MASS BALANCE). 8.2 PHOSPHORIC ACID PLANT The Mass Balance is worked out based on the following assumptions, (a) The plant will be designed for 15.9 MTPH production of Phosphoric Acid (100 % P2O5) (b) The plant will use Hemi-Dihydrate (HDH) Technology (c) The product acid concentration will be 50-54% P2O5. (d) The stack emission will be as follows: Ammonia : 50 mg/NM3 Fluorine : 5 mg/NM3 (e) The raw material feed rate will vary according to the quality of beneficiated rock phosphate feed and process conditions. (f) The overall expected Mass Balance for Battery Limit Phosphoric Acid Plant is as follows: -SEC 8/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Sulphuric Acid (98% H2SO4) 47.064 MTPH Process Water 45.026 MTPH PHOSPHORIC ACID PLANT (100% P2O5) Rock Phosphate CAPACITY : 350 MTPD (15.9 MTPH) Fluosilicic Acid (H2SiF6) 50.8 MTPH 0.45 MTPH Phosphoric Acid Gypsum Product (54% - P2O5) 113 MTPH 29.44 MTPH -SEC 8/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 8.3 DI-AMMONIUM PHOSPHATE PLANT The Mass Balance is worked out based on the following assumptions, (a) The plant capacity for production of DAP & NP grade of fertilizer plant will be as will be as follows: DAP (18:46:0) 30 MTPH 16:20:0 30 MTPH 20:20:0 30 MTPH (b) The plant will use Pipe Reactor Technology GPR = Granulator Pipe Reactor (c) The product quality will be as per F.C.O. requirement. (d) The stack emission will be as follows : Ammonia : 50 mg/NM3 Particulate matter : 50 mg/NM3 Fluorine : 5 mg/NM3 (e) The raw material feed rate will vary according to the quality of raw material and process conditions. (f) The overall Mass Balance for Battery Limit DAP Plant for production of DAP and other NP grades of fertilizer are as follows: -SEC 8/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 18-46-0 IN, MTPH OUT, MTPH Total N P2O5 K2 O Total N P2O5 K2 O 1 Phosphoric Acid Feed 25.59 - 13.82 - - - - - (54 % P2O5) 2 Ammonia Feed 6.58 5.42 - - - - - - 3 Sulphuric Acid Feed 1.80 - - - - - - - 4 Filler Feed 1.20 - - - - - - - 5 Water to Scrubber 7.5 - - - - - - - (mm3) 6 Product to Storage - - - - 30.00 5.40 13.80 - 7 Fumes & Water Vapor - - - - 12.67 0.02 0.02 - to Stack TOTAL 42.67 5.42 13.82 - 42.67 5.42 13.82 - -SEC 8/4- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 20:20:00 IN, MTPH OUT, MTPH Total N P2O5 K2 O Total N P2O5 K2 O 1 Phosphoric Acid Feed 11.15 - 6.02 - - - - - (54% P2O5) 2 Ammonia Feed 7.31 6.02 - - - - - - 3 Sulphuric Acid Feed 13.50 - - - - - - - 4 Filler Feed 1.2 - - - - - - - 5 Water to Scrubber 7.5 - - - - - - - 6 Water in Air System - - - - - - - - 7 Product to Storage - - - - 30.00 6.00 6.00 - 8 Fumes & Water Vapor - - - - 10.66 0.02 0.02 - to Stack TOTAL 40.66 6.02 6.02 - 40.66 6.02 6.02 - -SEC 8/5- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 16:20:00 IN, MTPH OUT, MTPH Total N P2O5 K2 O Total N P2O5 K2 O 1 Phosphoric Acid Feed 11.15 - 6.02 - - - - - (54% P2O5) 2 Ammonia Feed 5.85 4.82 - - - - - - 3 Sulphuric Acid Feed 11.55 - - - - - - - 4 Filler Feed 1.20 - - - - - - - 5 Water to Scrubber 10.5 - - - - - - - 6 Water in Air System - - - - - - - 7 Product to Storage 30.00 4.8 6.0 - - - - - 8 Fumes & Water Vapor - - - - 10.25 0.02 0.02 - to Stack TOTAL 40.25 4.82 6.02 - 40.25 4.82 6.02 - -SEC 8/6- HINDUSTAN DORR-OLIVER LIMITED SECTION‐9  EXPECTED RAW MATERIAL & UTILITIES  REQUIREMENT  PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 9 EXPECTED RAW MATERIAL & UTILITIES REQUIREMENT 9.1 ROCK PHOSPHATE BENEFICIATION PLANT The estimated Raw Material & Utilities per MT of product for the Battery Limit Rock Phosphate Beneficiation Plant will be as follows: ROM Rock Phosphate (recovery – 73.3 %) Consumption : 1.36 MT / MT Process Water Consumption : 122 m3/h Instrument Air Consumption : 400 Nm3/h Plant Air Consumption : 400 Nm3/h Fuel Oil Consumption : NIL Steam Consumption : NIL Portable Water : 10 m3/day i. The above estimated Raw Material & Utilities are for Battery Limit Rock Phosphate Beneficiation Plant. ii. Process Water Consumption is for process purpose only and does not include any other water such as flushing, cleaning and other non-process application. 9.2 PHOSPHORIC ACID PLANT The estimated Raw Material & Utilities per MT of product for the Battery Limit Phosphoric Acid Plant will be as follows: Rock Phosphate (32 % P2O5) Consumption : 3.2 MT / MT of P2O5 Sulphuric Acid Consumption (100 % H2SO4) : 2.9 MT/ MT P2O5 -SEC 9/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Active Silica Consumption : 6.5 kg /MT Defoamer Consumption : 2 kg/MT P2O5 max. Steam Consumption : 13-14 MTPH Normal 30 MTPH for Start-Up Process Water Consumption : 4.5 m3/MT Cooling Water Consumption @ 30°C : 77 m3/MT Instrument Air Consumption - Total plant : 1000 Nm3/h Plant Air Consumption - Total plant : 200 Nm3/h Power : 130 KWH/MT i. The above estimated Raw Material & Utilities are for Battery Limit Phosphoric Acid Plant. ii. The actual raw material and utilities consumption figures will depend on the analysis of the beneficiated rock phosphate. iii. Process Water Consumption is for process purpose only and does not include any other water such as flushing, cleaning and other non-process application. iv. Steam Consumption is for process purpose only and does not include for any other purpose such as flushing, cleaning, etc. 9.3 DI-AMMONIUM PHOSPHATE PLANT The estimated Raw Material & Utilities per MT of product for the Battery Limit Di- Ammonium Phosphate Plant will be as follows: ITEM UNITS 18:46:0 20:20:0 16:20:0 RAW MATERIALS Phosphoric Acid (100% P2O5) Kg/MT 465 205 205 -SEC 9/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Ammonia, (100%) Kg/MT 224 249 198 Sulphuric Acid, (100%) Kg/MT 43 423 305 UTILITIES Power KWH/MT 49 52 52 Process Water m3/MT 0.3 0.28 0.28 Fuel Oil Kg/MT 6 8 8 Steam Kg/MT 40 40 40 i. The above estimated Raw Material & Utilities are for Battery Limit DAP Plant. ii. The above Raw Material Consumption is based on grades of 18:46:0, 16:20:0 and 20:20:00. The actual Raw Material Consumption will depend upon the actual grade formula. iii. The Ammonia Consumption will depend upon the analysis of phosphoric acid. iv. The estimated raw material is based on availability of the nutrients in the product and adding the losses through the stack. v. Process Water Consumption is for process purpose only and does not include any other water such as flushing, cleaning and other non-process application. vi. Steam Consumption is for process purpose only and does not include for any other purpose such as flushing, cleaning, etc. vii. Fuel Oil Consumption is estimated limited to that used for Dryer. viii. Total Power Consumption is for Battery Limit Plant excluding Raw Material Section, Lighting, A/C, Lift, Intermittent Non-Process Drives such as Pressurising Fan, Hoist & Sump Pump. -SEC 9/3- HINDUSTAN DORR-OLIVER LIMITED SECTION‐10  PRODUCT QUALITY  PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 10 PRODUCT QUALITY 10.1 PHOSPHORIC ACID (43 - 54 % P2O5) a) Phosphoric Acid (43 % P2O5) Parameter Specification Typical P2O5 41.00 - 44.00 % 42.55 S. G. @ 40 °C 1.47 - 1.52 1.4897 Total suspended solids 0.6 % max 0.31 Fe2O3 0.25 - 2.00 % 0.73 Al2O3 0.25 - 1.80 % 0.48 CaO 0.30 % max 0.23 MgO 0.20 - 0.80 % 0.24 Sulphate as SO4 2.50 % max 1.93 Chlorine as Cl 0.12 % max 0.0872 Fluorine as F 2.0 % max 1.47 b) Phosphoric Acid (54 % P2O5) Parameter Specification Typical P2O5 51.00 - 55.00 % 53.48 S. G. @ 40 °C 1.61 - 1.67 1.6209 -SEC 10/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Total suspended solids 1 % max 0.36 Fe2O3 0.25 - 2.00 % 0.72 Al2O3 0.25 - 1.80 % 0.4 CaO 0.30 % max 0.1 MgO 0.20 - 0.80 % 0.37 Sulphate as SO4 2.50 % max 2.02 Chlorine as Cl 0.10 % max 0.0275 Fluorine as F 1.0 % max 0.36 10.2 DI-AMMONIUM PHOSPHATE PLANT The products from the Di-Ammonium Phosphate Plant will be DAP (18-46-0), 20-20- 0 and 16-20-0 grades of fertiliser. The specification of the products will meet the F.C.O requirements. The specification of the products will be as follows: 10.3.1 Diammonium Phosphate (18-46-0) i) Moisture, % by weight, max. : 1.5 ii) Total nitrogen, % by weight, min. : 18.0 iii) Ammoniacal nitrogen, % by weight : 18 min. iv) Neutral ammonium citrate soluble phosphates (as P205), % by weight : 46.0 min. v) Water soluble phosphates (as P205) : 41.0 % by weight, min. vi) Particle size : Not less than 90% of the material shall pass through 4 mm IS sieve and be retained on 1 mm IS sieve. Not more than 5% shall be below than 1 mm sieve -SEC 10/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 10.3.2 Ammonium Phosphate Sulphate (20-20-0) i) Moisture, % by weight, max. : 1.0 ii) Total nitrogen, % by weight, min. : 20.0 iii) Ammoniacal nitrogen : 20.0 % by weight, min. iv) Neutral ammonium citrate soluble phosphates (as P205) : 20.0 % by weight, min. v) Water soluble phosphates (as P205) : 17.0 % by weight, min. vi) Sulphur (as S) : 13.0 % by weight, min. vii) Particle size : Not less than 90% of the material shall pass through 4 mm IS sieve and be retained on 1 mm IS sieve. Not more than 5% shall be below than 1 mm IS sieve 10.3.3 (16-20-0) i) Moisture, % by weight, max. : 1.0 ii) Total nitrogen, % by weight, min. : 16.0 iii) Ammoniacal nitrogen : 16.0 % by weight, min. iv) Neutral ammonium citrate soluble phosphates (as P205) : 20.0 % by weight, min. v) Water soluble phosphates (as P205) : % by weight, min. vi) Sulphur (as S) : % by weight, min. -SEC 10/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S vii) Particle size : Not less than 90% of the material shall pass through 4 mm IS sieve and be retained on 1 mm IS sieve. Not more than 5% shall be below than 1 mm IS sieve 10.3.4 Tolerance Of Limits Tolerance Limit in nutrients will be as per Fertilizer Contract Order (FCO) and will be as follows: -SEC 10/4- HINDUSTAN DORR-OLIVER LIMITED SECTION‐11  BY‐PRODUCT QUALITY PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 11 BY-PRODUCT QUALITY A] PHOSPHORIC ACID PLANT 1) GYPSUM Gypsum (20-25 % moisture) is one of the by-products of the Phosphoric Acid Plant. Gypsum filtered in the Di-hydrate filters has to be transported to the Gypsum pond as Gypsum by the Conveyors. The expected Gypsum generation will be 85 MTPH (on dry basis) and 113 MTPH (on wet basis) from 350 MTPD Phosphoric Acid Plant. The Gypsum obtained via the HDH process is very good in quality and can be used as a raw material in cement industries. The specifications of Gypsum are as follows, Gypsum (Dry Basis) : 85 MTPH Gypsum (Wet Basis) : 113 MTPH Total P2O5 content in the Gypsum : < 0.35 Total F Content in the Gypsum : < 1% The Gypsum from the Phosphoric Acid Plant will be sent to Gypsum Pond via series of Conveyors. Having the capacity of 125MTPH. 2) FLUOSILICIC ACID (H2SiF6) Fluosilicic acid (FSA) is produced in the fluorine recovery section of the Phosphoric Acid Plant. The flashed vapours containing mainly water and fluorine compounds pass through a high-efficiency droplet separator prior to entering the fluorine recovery section with the acid droplets reporting back to the flash chamber. FSA By- product is drawn off by a self regulating variable speed pump and delivered to the storage area. The residual water vapour, almost free of fluorine compounds, passes through a direct contact condenser fed with cooling water. The condenser water is collected in a barometric seal tank which overflows to the return trench and returned by gravity to the cooling tower. -SEC 11/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S EXPECTED COMPOSITION VALUE UNIT F as H2SiF6 > 18 % wt. Cl 0.05 % wt. max P 2O5 0.02 % wt. max H2SO4 0.02 % wt. max Ca 0.1 % wt. max SiO2 solids Not filtered % wt. max H 2O balance % wt. The obtained FSA by-product cannot be disposed directly and needs to be neutralized before disposal via means of an effluent treatment plant. An alternate option is the production of Aluminium Fluoride (AlF3). AlF3 can be used as a major Raw Material for Alumina Smelters. ALUMINIUM FLUORIDE PLANT The Plant incorporates the following facilities:  Production of 3,000 MTPY of Aluminium Fluoride  Neutralize the effluent of the Aluminium Fluoride Plant facility  Incorporate storage and other auxiliary installations required for the production and neutralization facilities. Process Description Aluminium Fluoride Production The process consists of treating a Fluosilicic acid solution of a minimum concentration of 17 %with alumina trihydrate to produce the trihydrate of ALUMINIUM FLUORIDE. Fluosilicic acid is pre-heated and reacted with dried alumina trihydrate to produce the soluble form of AI F3 according to the following reaction: -SEC 11/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Al2O3 · 3H2O + H2SiF6 2 AlF3 + SiO2 + 4 H2O This reaction is exothermic and has to be performed under closely controlled conditions. It takes place batch wise in stirred reactors, where hot Fluosilicic acid and alumina trihydrate are admitted in carefully metered and adjusted quantities. During the reaction, the formation and precipitation of Silica (SiO2) is almost spontaneous, whereas the formation and precipitation of Aluminium Fluoride takes place in a metastable solution over a longer period. The separation of the precipitated silica from the Aluminium Fluoride solution must take place before the crystallization of the ALUMINIUM FLUORIDE commences. This is done by feeding the slurry onto a belt filter as soon as the reaction is complete. The saturated Aluminium Fluoride solution emanating from the belt filter flows into a crystallizer battery in which the Aluminium Fluoride trihydrate precipitates under controlled 'conditions. The crystallization is completed in about five hour time. The crystals are subsequently separated from the mother liquor by means of filtration or centrifugation. The Aluminium Fluoride crystals at this stage conform to the chemical formula Al2O3 3H2O and contain in addition about 10 to 15 % of free moisture. The free moisture is removed in a flash dryer. The calcination of Al2O3 · 3H2O to anhydrous AIF3 takes place in an indirectly fired rotary kiln. The calcined product is cooled to ambient temperature and conveyed to the storage silo by a pneumatic system. The slightly acidic mother liquor can be partially recycled and used as adsorption liquid in the H2SiF6 adsorption unit of the phosphoric acid plant. The quantity that can be recycled depends on the impurity level of P205, in the mother liquor. The effluent gases from the process (dryer, calciner, vessel ventilation, etc.) are filtered and scrubbed to remove solids and gaseous fluorine before being vented to the atmosphere. The liquid effluent from this process consists of water from the gas scrubbers, mother liquor and the plant spillage. These are collected and passed through the neutralization facility. -SEC 11/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Process Description Neutralization of Plant Effluent The neutralization of the Plant effluent is achieved by continuously treating it with milk of lime, according to the following reactions: 2AIF3 + 3 Ca(OH)2 3CaF2 + 2AI(OH)2 2HF + Ca(OH)2 CaF2 + 2H2O H2SiF6 + 3 Ca(OH)2 3CaF2 + 4H2O + SiO2 The reactions are pH controlled. The slurry leaving the reactor is pumped into a thickener from where the clean overflow with a fluoride content of approximately 50 ppm of F is pumped to final disposal. A portion of the overflow will be recycled to the· lime slaker of the Neutralization Section. The clean effluent recycled to the process whether as absorption medium or for other uses may contain fine particles of suspended matter. The underflow of the thickener with an average solid content of approx. 15 % is pumped onto a filter press to separate the solids to be conveyed to a near dumping area. The Final Product ALF3 specifications are as follows, Final Appearance : White free-flowing solid Expected composition Value Unit AlF3 assay minimum 91.0 % wt. min SO3 0.01 % wt. max SiO2 0.02 % wt. max P2O5 0.005 % wt. max Na2O 0.2 % wt. max Fe2O3 0.02 % wt. max CaO 0.02 % wt. max -SEC 11/4- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S LOI (550 °C -1h) 0.5 Al2O3 Balance Physical properties Size <0.045 mm 5 % wt DIN 4188 (~325 Mesh Tyler) Fluidity (Flowability) Index 55 sec/kg Density (Loose) >1400 kg/m3 Plant : 3000 MTPY On stream factor : 300 operating days Daily capacity : 10 MTPD CONSUMPTION AND PRODUCTION FIGURES A] Raw Materials (per MT of aluminium fluoride ≥ 90% AlF3) Consumption Norms Value Unit H2SiF6 (as 100%) 1.05 MT/ MT Al(OH)3 (as 100%) 1 MT/ MT -SEC 11/5- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S B] Utilities & Energy (per MT of aluminium fluoride ≥ 90% AlF3) Consumption Norms Value Unit Process water (DW) 5 m3/ MT Cooling water (CW) 590 m3/ MT Electric power 436 kWh/MT Compressed Air 1090 Nm3/ MT Fuel 700 x 103 kJ/MT C] Effluents, by-products & off-gases 1) Diluted Sulphuric acid Quantity per ton AlF3 (expected) : 28 T H2SO4 : 70 - 75 % wt. HF : 0.2 % wt. max 2) Silica Quantity per ton AlF3 (expected) : 0.9 T SiO2 : 40 (approx.) % wt. H2SiF6 : 2 - 5 % wt. H2O : balance 3) Off-gas Quantity per hour (approx.) : 4,000 m3/h F : 3 ppm Max. -SEC 11/6- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 4) Wastewater Quantity per ton AlF3 (expected) : 4 m3 F : 1 % wt 5) Wastewater sludge (synthetic fluorspar) Quantity per ton AlF3 (expected) : 0.15 - 0.40 m3 CaF2 : 40 - 45 % wt H2O : 30 Max. % wt D) The diluted Sulphuric Acid Produced from AlF3 will be recycled back to the Phosphoric Acid Plant. E) The solid generation from the AlF3 plant will be used as a land filling within the complex. -SEC 11/7- HINDUSTAN DORR-OLIVER LIMITED SECTION‐12  ENVIRONMENTAL REGULATIONS PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S SECTION - 12 ENVIRONMENTAL REGULATIONS 12.1 ROCK PHOSPHATE BENEFICIATION PLANT Environmental considerations and regulations in most countries of the world mandate essentially pollution free emissions and effluents from phosphatic fertilizer plants. In addition, economic considerations make it highly desirable to recover the maximum value from the processed materials. 12.2 PHOSPHORIC ACID PLANT The phosphoric acid plant will be designed for production capacity of 350 MTPD (100 % P2O5) using the Hemi-Dihydrate Technology. The major raw materials will be Rock Phosphate and 98 % H2SO4 1) GAS SCRUBBING SYSTEM FLOW DIAGRAM Please refer diagrams A2-120013S-F-003 (Flash Cooler Scrubbing Section), A2- 120013S-F-004 (HH Off-Gas Scrubbing Section) and & A2-120013S-F-005 (Filtration Off-Gas Scrubbing) systems. The Phosphoric Acid Plant contains two major scrubbing sections, one for the HH Off-Gas & one for the DH Off-Gas. The prime purpose of the scrubbing section is to recover any P2O5 content in the exit gas, and to recover majority of the fluorine content. Recovery of fluorine from the Flash Cooler Vapors is extremely important in order to protect the environment and also to reduce the content in the recycled cooling water system. The off-gas from the Hemihydrate reactors even though having a relative small volumetric flow contains relatively high fluorine content and the fluorine must be removed before being directed to the stack to protect the environment. -SEC 12/1- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S The scrubbing system consists of a wet scrubber circulated with a saturated solution of Fluosilicic acid (FSA) to remove any entrained droplets of phosphoric acid. This is followed by three sets of venturi scrubbers with inter-stage cyclonic droplet separator void towers, respectively. The final void tower acts as a primary demister but a second demister of chevron design is fitted prior to the variable speed fan. After the fan the gases goes to the suction of vacuum fan to the first stage DH scrubber. The volume flow of gases through the DH section is relatively large and even though the concentration is low it is a large volume and to protect the environment must be scrubbed down in order to meet the local emission norms. The scrubbing section proposed also consists of three stages of venturi with inter stage cyclonic droplet separator void towers. The final void tower is fitted with a bed of floating-balls acting as a primary demister but a second chevron demister is fitted prior to the variable speed fan. After the fan the gases are combined with those from the HH reaction off-gas section before going to the stack. The first stage scrubber receives gases from HH filter and hydration off gas along with the gases from the DH filter, Silica filter fan, HH Off gas fan and finally goes to suction fan discharging to the inlet of the stack. -SEC 12/2- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S STACK SPECIFICATIONS - A4-120013S-F-012 GENERAL Flow rate 1,50,000 Am3/hr Gas Temperature 50-55 °C Emission (Particulate material) < 50 mg/Nm3 Emission (Fluorine) < 5 mg/Nm3 MOC FRP No of sampling points Four (90° apart) Size of sampling 100 mm Ø DATA SHEET Quantity One (1) Position Vertical DESIGN DATA Gas from equipment Process Exhaust Gas Design gas flow rate 1,50,000 Am3/hr Temperature 50-55 °C Density 1.04 to 1.08 kg/m3 Relative pressure +50 to +100 mmWC COMPOSITION (% w) Air 85.94 H2O 9.77 - F Traces CO2 4.29 Relative humidity 90-95 % Normal Dust 20-40 mg/Nm3 Maximum Dust 50 mg/Nm3 Normal Fluorine 3-4 mg/Nm3 Maximum Fluorine 5 mg/Nm3 CONSTRUCTION 5.0 M above Buidling Height. The stack Height Elevation will be 60 m from the ground. Diameter 2.6 m Supports Building/Self Supported -SEC 12/3- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Draft damper No Cowl No MOC FRP Inner coating No Insulation No NOZZLES Mark Size Quantity Service 600 mm x N1 1000mm 1 Gas Inlet (W x H) 1100 mm x N2 1900mm 1 Gas Inlet (W x H) N3, N4, N5, 100 mm Ø 4 Sampling points (*) N6 Notes: (*) Equally spaced 90° located at accessible platform from building for manual analysis. -SEC 12/4- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 2) GYPSUM (Reference Diagram: A4-120013S-F-013) Gypsum (20-25 % Moisture) is a solid by-product of the Phosphoric Acid Plant. Gypsum is produced from the DH Filter. This Gypsum will be transported to the Gypsum pond via a series of conveyors. HDO has considered a One (1) Year storage area requirement for the gypsum material. The Gypsum pond will be double HDPE lined. The specifications of Gypsum are as follows, Type : Di-Hydrate Gypsum Flow Rate : 2750 MTPD Moisture : 20-25 % 3) FLUOSILICIC ACID (Reference Diagram: A4-120013S-F-013) The Off gas from the HH & DH will be scrubbed in the gas scrubbing section using water as scrubbing liquor. The scrubbing liquor will contain 3 – 5 % FSA. The liquor will be discharged to the fluorine recovery system of the evaporation system. The concentration of phosphoric acid from 42 % P2O5 to 54 % P2O5 leads to fluorine evaporation and this necessitates the need for Fluorine recovery section. The off- gases containing fluorine will be scrubbed in a fluorine recovery section producing FSA with a concentration of fluorine equivalent to 18% H2SiF6. Fluorine scrubbing is effected in a single duct with high irrigation in a co-current manner this enables a single large diameter spray nozzle to be used with minimum possibility of plugging. The operation of the FSA system is effected in a continuous batch-wise manner. After contacting the absorbing liquor the remaining gases make a severe curve to initially separate the larger particles of liquor. The gases then pass through the High Efficiency FSA droplet separator to remove any finer particles of liquor and then pass to the vacuum system. The vacuum system consists of a direct contact condenser irrigated with cooling tower water. This is followed by a simple spray of process water and separator to reduce the fluorine content of gases entering the liquid ring vacuum pump. This FSA will be used as one of the raw material for production Aluminum Fluoride (AlF3). The specifications of FSA are as follows, -SEC 12/5- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S EXPECTED COMPOSITION VALUE UNIT F as H2SiF6 > 18 % wt. Cl 0.05 % wt. max P 2O5 0.02 % wt. max H2SO4 0.02 % wt. max Ca 0.1 % wt. max SiO2 solids Not filtered % wt. max H 2O balance % wt. The plant will be designed considering all instrumentation & instruments for safe & ease of operation. -SEC 12/6- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S 12.3 DI-AMMONIUM PHOSPHATE PLANT THE DAP plant is designed for production capacity of 600 MTPD using the pipe reactor technology. The Scrubbing Systems are provided with ZERO LIQUID EFFLUENT when run on continuous basis. HDO proposes to have three washing steps to achieve the stack gas emission norms. FLOW DIAGRAM We are enclosing herewith the Flow Diagram No. A4-120013S-F-010/011 describing the scrubbing system of the DAP/NP Plant. Fumes Scrubbing System Gases evolved in the Granulator containing dust & ammonia are sucked towards Inclined Venturi where part of ammonia is absorbed by spraying scrubber liquor. Then next washing step would be composed by a single Granulator Pre-scrubber to which the gas stream coming from inclined venturi would be fed. It would consist of a Venturi Scrubber of low pressure drop, followed by a separation cyclonic tower. This Scrubber will have a Tank below from where the slurry will overflow to Scrubber Effluent Tank. After the Pre-scrubber, the gas will flow to Granulator Scrubber which is again Venturi Cyclonic Scrubber. This will have Tank with Recirculation Pump. Dust Collection Air leaving the Dryer will contain some ammonia escaped from the product, as well as the dust carried away and water evaporated from product while drying. This air is sent to the Cyclones in order to separate the main part of carried dust. These Cyclones are equipped with cleaning chains as well as with vibrators to avoid build-up inside the cyclone walls. After the Cyclones, the gas will be sucked to Dryer Scrubber by Dryer Fan. Dryer Scrubber will be venturi cyclonic type. The liquor will flow to Scrubber Effluent Tank. The pumps will be provided to pump the scrubber liquor to Pipe Reactors, and to Dryer Scrubber Venturi. -SEC 12/7- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Similarly, air from Rotary Cooler will be taken in the Cyclones and then sucked to Cooler Scrubber by Cooler Fan. Cooler Scrubber will be venturi cyclonic type. The Scrubber will be provided with Cooler Scrubber Sump and Cooler Scrubber Venturi Pump. The overflow of the tank will be sent to Scrubber effluent tank. The scrubbed gas will be further sent to Tail Gas Scrubber via Cooler Fan. All the dedusting points such as all the conveyors, screens, pulverizers, etc. will be connected to Dust Cyclone. After the Cyclones, clean air will be sucked by Dust Fan installed downstream of Dust Scrubber. The Dust Scrubber will be provided with Dust Scrubber Sump. The scrubber liquor will be recirculated by Dust Scrubber Venturi Liquor Pump. All the Sumps will be connected to Scrubber Effluent Tank by overflow. The Scrubber Effluent Tank will have Two (2) Pumps; one pump will feed to Dryer Scrubber Venturi and one pump will pump scrubber liquor to Granulator Pipe Reactor, and Dryer Pipe Reactor. The clean scrubbed gas will be scrubbed in the Final Washing Step in Tail Gas Scrubber. The Final Tail Gas Scrubber will be vertical spray type packed bed tower. Scrubber will be provided with Mist Eliminator. The Tail Gas Scrubber will be provided with Tail Gas Scrubber Pumps. These pumps will be recirculation pumps. The stack will be mounted on the Tail Gas Scrubber. The Stack will have height 5M above the plant building height. -SEC 12/8- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S STACK SPECIFICATIONS (Reference Diagram: A4-120013S-F-016) GENERAL Flow rate 2,55,000 Am3/hr Gas Temperature 50-55 °C Emission (Particulate material) < 50 mg/Nm3 Emission (Ammonia) < 50 mg/Nm3 Emission (Fluorine) < 5 mg/Nm3 MOC MSRL No of sampling points Four (90° apart) Size of sampling 100 mm Ø DATA SHEET Quantity One (1) Position Vertical DESIGN DATA Gas from equipment Scrubbed Gas Design gas flow rate 2,55,000 Am3/hr Temperature 50-55 °C Density 1.04 to 1.08 kg/m3 Relative pressure +50 to +100 mmWC COMPOSITION (% w) Air As saturated air NH3 Traces (50 mg/Nm3) Dust Traces (50 mg/Nm3) F- Traces (5 mg/Nm3) Relative humidity 90-95 % Normal Ammonia 20-40 mg/Nm3 Maximum Ammonia 50 mg/Nm3 Normal Dust 20-40 mg/Nm3 Maximum Dust 50 mg/Nm3 Normal Fluorine 3-4 mg/Nm3 Maximum Fluorine 5 mg/Nm3 CONSTRUCTION Height 5.0 M above Buidling Height. The stack -SEC 12/9- PRE-FEASIBILITY REPORT FOR HINDUSTAN DORR-OLIVER LIMITED PHOSPHATIC FERTILIZER PLANT JOB NO. MYC-120013S Elevation will be 55 m from the ground level. Diameter 2.45 M Supports Building/Self Supported Draft damper No Cowl No MOC MSRL Inner coating No Insulation No NOZZLES Mark Size Quantity Service N1 2.45 m Ø 1 Gas Inlet N2 2.45m Ø 1 Gas Outlet N3, N4, N5, 100 mm Ø 4 Sampling points (*) N6 Notes: (*) Equally spaced 90° located at accessible platform from building for manual analysis. LIQUID EFFLUENT The plant is designed to produce zero liquid effluent. No liquid effluent will be generated on continuous basis while the plant is running on continuous basis under normal operating conditions. The liquid effluent generated during washing of the plant will be collected within the plant and will be reused in the plant and thus no liquid effluent will be generated when the plant in run on continuous basis. The plant will be designed considering all instrumentation & instruments for safe & ease of operation. The liquid effluent plant solid effluent will be designed for treatment of liquid effluent generated from cooling tower & Alf3 plant. The solid effluent generated from the plant will be used as a land filling within the complex. -SEC 12/10-