INTERNSHIP PROJECT REPORT

COROMANDEL INTERNATIONAL LIMITED.

Submitted in partial fulfilment of the requirement for the award of

B. Tech in Chemical Engineering

Under the guidance of

I.H RAO (SR. MANAGER OPERATIONS)

By
M.AISHWARYA
13131A0824

DEPARTMENT OF CHEMICAL ENGINEERING

GAYATRI VIDYA PARISHAD COLLEGE OF
ENGINEERING (AUTONOMOUS),
VISAKHAPATNAM.

ACKNOWLEDGEMENT:
I would like to express my sincere gratitude to the management of M/s
Coromandel International Limited for providing us the opportunity to do industrial
training in their industry.
I am indebted to MR.J. CHANDRAMOULI (ASST. MANAGER HR) for cooperation in completion of the industrial training.

WE ARE ALSO SO THANKFUL TO

MR. B. VENKATACHALAM

DGM (PROJECTS).

MR.S. RAVIKIRAN

SR.GM(OPS &MAINTAINENCE)

MR.E. RANGANAYAKULU

SR.GM(PROJECTS)

MR.J. P BHAGAT

Mgr. TECHNICAL SERVICES

MR. K. RAJASHEKAR

Mgr. PROJECTS

MR. I. H. RAO

SR. MANAGER(OPERATIONS)

MR. P. VENKATESHWARA RAOSR. MANAGER(EHS)

MR. D. BABURAO

ASST. MANAGER.

For their immense co-operation. A special thanks to all employees of Coromandel

-international limited, Kakinada for their co-operation and guidance.

CONTENTS:

COMPANY PROFILE
INTRODUCTION
TO FERTILIZERS
ENVIRONMENTAL, HEALTH
SAFETY
GRANULATION PLANT
OFFSITES
BAGGING PLANT
CONCLUSION

AND

INTRODUCTION TO COROMANDEL
The Company was initially promoted by The Government of Andhra Pradesh and
the Asias largest cooperative, M/s. Indian Farmers Fertilizer Co-operative Limited
(IFFCO), and was incorporated as Joint Venture Company on 17 th December, 1981
with a capital outlay of Rs.108 cores to produce 300,000 MT of Di-Ammonium
Phosphate Fertilizer. The Plant was expanded from time to time and the installed
capacity has been revised to 11.25 lacks MT per annum with capability to produce
wide range of products.
M/s. COROMANDEL entered into a sale purchase agreement with the
Government of Andhra Pradesh on 12th July 2003. M/s. Coromandel has obtained
ISO-9001, ISO-14001 certification and has also obtained OHSAS 18001 in
December 2006.
M/s. Coromandel have a proposal is to expand the capacity of NPK
fertilizers manufacturing by 4.25 Lacks /year by adding C train of pipe reactor
system to the existing A and B trains of manufacture. The existing A and B trains
are used for the manufacturing of both Di- Ammonium Phosphate and NPK grade
Fertilizers with an annual capacity of 11.25 lacks tons. The technology adopted at
present is the pipe reactor system and the technology was provided by M/s. INCRO
Spain. The pipe reactor system was identified for its environmental and other
techno economic advantages.
The Company is accredited with ISO 14001 1999, ISO 9001 2000 & ISO
18001 2006, PSMS and awarded with FAI award for improvement in overall
performance for the year 2004-05 from Fertilizer Association of India.

PLANT LOCATION:
Plant located at the sea-port of Kakinada, A.P., and India
Latitude: 16O.57 North
Longitude: 82O.14 East
Total Land Area: 704.75 acres.
Plant Area: 223 acres.
Green Belt and others 481.75 acres.

INTRODUCTION TO FERTILISERS:
FERTILISERS:
Fertilizers are those substances, which must be added to the soil in order
to remove the deficiency of essential elements required for plant growth.
THE NEED OF FERTILIZING A LAND IS THEREFORE THREE FOLD.
1
2

To supplement what has been eaten up by the plants.

To supply them an additional tonic and good food. So that they may grow
more healthy and produce a better yield.
3 To maintain the pH of the soil in the range of 7-8.
4 By facilitate optimum growth and health.
ESSENTIAL REQUIREMENTS:
Every compound containing nitrogen or phosphorus or calcium etc. cannot be
used as a Fertilizer. The chief requisites of Fertilizer are:
1 The element present in the compound must be easily available to the plant.
2 The substance must be soluble in water. It should be stable, so that it may be
made available to the plant for a long time.
3 It should maintain the pH of the soil in the vicinity of 7-8
4 It should not be a poison for the plant .It is also interesting to note that soil
fertilization is not merely a matter of supplying certain compound in given

proportion. The most important factor, which is of prime importance in the

functioning of fertilizers, is the movement of water in the soil.
Another factor of importance in the functioning of the fertilizers is the
action of CO2 on the material in the soil. CO 2 is soluble in water and forms
carbonic acid which has a high solvent power for the carbonates of Ca and Mg
and oxides of Fe and Mn. These compounds are nearly insoluble in pure water.
Hence carbonic acid helps to circulate many fertilizing substances in the soil,
which are otherwise hardly available.
CLASSIFICATION OF FERITILIZERS:
FERTILIZERS ARE CLASSIFIED AS:
1 Straight fertilizer
2 Compound fertilizer
3 Complex fertilizer
STRAIGHT FERTILIZERS
A Fertilizer intended to supply only one nutrient is known is known as straight
fertilizer. This is used to supply additional nitrogen there by reducing leaching
loss. E.g.: Urea - NH2CONH2
COMPOUND FERTILIZERS:
A Fertilizer intended to supply more than one nutrient is called compound
fertilizer. Compound fertilizer production involves a chemical reaction.
COMPLEX FERTILIZERS:
These are prepared by mixing appropriate amounts of compound fertilizers like
ammonium salts, super phosphates, and potassium salts etc. and in this manner
they supply more than one essential element to the soil.

BASIC PARAMETERS OF FERTILIZER SPECIFICATION:

SIGNIFICANCE OF NUTRIENT LIMITS:
The main purpose of using fertilizer is to supply nutrients. Hence it is desired to
guarantee some minimum amount of nutrients that shall be contained in a
fertilizer. Nitrogen is guaranteed not only as a total but also in different forms
such as Ammonia (NH3), nitrate (NO2), and urea form. In case of phosphate,
values are given in terms of total P205, water soluble P2O5 and citrate soluble
P2O5 potassium and Zinc are given as water-soluble K2O and Zn respectively.

SIGNIFICANCE OF IMPURITIES:
Impurities are unwanted chemicals, which are present in fertilizer due to their
inherent presence in raw material during manufacturing process. There is
always limit below which their removal is not economical. Keeping this is
mind, a maximum limit is provides beyond which the impurity is either harmful
to plants and soil or affects the keeping quality of fertilizers.
SIGNIFICANCE OF PARTICAL SIZE LIMITS:
Surface area per unit of fertilizer depends on the particle size. If the particles are
too small more surface area is exposed resulting in interaction with soil particles,
which may cause nutrient fixation.

PLANT NUTRIENTS:
Plants for their growth require 17 elements, namely carbon, hydrogen, oxygen,
potassium, nitrogen, calcium, magnesium, sulphur, zinc, cobalt, born, copper,
manganese, molybdenum, chlorine and iron out of these three, namely carbon,
hydrogen, and oxygen are supplied by air and water and so these are called natural
nutrients. The remaining elements are supplied by soil. If the soil is deficient in
meeting the requirement, then those are supplied through fertilizers. Nutrients
required in large amounts are termed as macronutrients and those required in small
quantity are called micronutrients.

There are six macronutrients. Plants cannot take up nutrients in very

chemical form. The chemical forms in which nutrients are available to plants are
given in table. The following are the forms in which nutrients are available to
plants.
Nutrients

Element

Symbol Chemical forms available

to plants

Macro-nutrients

Nitrogen

Phosphorus

Ammonical
(NH3+),
Nitrate (NO3+)
H3PO4, H2PO4-HPO4-2

Potassium
Calcium

K
Ca

K+
Ca++

Magnesium
Sulphur
Iron
Manganese
Copper
Zinc
Molybdenum
Boron
Chlorine
Cobalt

Mg
S
Fe
Mn
Cu
Zn
Mo
B
Cl
Co

Mg++
So4+2
Fe++
Mn++, Mn+4
Cu+2, Cu+
Zn++
MoO42+
Bo4+, Bo3ClCo++

Micro nutrients

NUTRIENT FUNCTIONS:
The role of various nutrients in the plant growth has been studied extensively
but is not yet fully understood. Some of the important findings are, however
briefly given below.
NITROGEN:
Nitrogen is also a special constituent of the chlorophyll without which
photosynthesis is not possible. Nitrogen makes up 16-18% of the plant protein
and constitutes 1-4% of the dry weight of the plants and is required in large
amounts than any of the plant nutrients. A plentiful supply of nitrogen may
cause relatively more protoplasm to be produced than cell walls and the leaves

are soft and juicy and also less robust to withstand the wind and rain. Leaves are
as usually dark green. Restricted supply of nitrogen may cause the leaves thin
small and mature quickly and become yellow soon.
THE MAIN SOURCES OF NITROGEN ARE
Fertilizers
Organic nitrogen compounds formed in the soil by reoccurring natural process.
PHOSPHORUS:
Most soils contain phosphate in the form of complex calcium phosphate, iron
and aluminum complexes and organic compounds. Such sources are insoluble
and so the plants can make very little use of them. It has been found that certain
high-energy phosphate bonds are involved in the respiratory and photosynthetic
processes.
POTTASIUM:
It is found that a major proportion of the potash in a plant resides in the straw or
haulm. It has been found that it is essential for healthy growth of plants and
cannot be replaced even by closely related elements as sodium and lithium. In
the plant it either occurs as a part of the anion of organic acid or as a soluble
inorganic salt in the tissues. Formation and movement of carbohydrates in the
plant is contributed by potassium and a deficiency of potassium and a
deficiency of potassium quickly reduce the carbohydrate content. Potassium has
also been found to contribute to the vigor and resistance of plants. Signs of the
potassium deficiency in the plant are readiness to wilt and the yellowing of the
plant, a falling of the leaves, and leaf scorch and poor development of fruit.
Plants growing with sufficient potash dont wilt or scorch so easily in warm dry
weather.
MAGNESIUM:
Magnesium acts as a carrier of phosphate and therefore plays an important role
in the formation of phospholipids and in synthesis of nucleoproteins.
Magnesium is also a mineral constituent of chlorophyll and makes up 2.7% of
the weight of chlorophyll.
GLOSSARY OF TERMS:

GRADE:
The minimum analysis of a fertilizer containing primary nutrients fertilizer
compounds is commonly referred to by a sequence of three numbers. The first
of which represents the percentage of nitrogen expressed as N 2. The second the
percentage of phosphorous expressed as P2O5 and the third percentage of
potassium expressed as K2O.
E.g. 18-46-0 (N-P-K), indicates 18% (wt) of N 2 of total and 46% (wt) of
P2O5 of total and 0.0% (wt) of potash.
NOTE:
Plants do not take phosphorous as P2O5 and potassium as K2O5 even then they
are expressed in fertilizer as P2O5 and K2O because early chemists when
analyzing plant for various elements, they found that when these elements were
expressed as oxides, it sum up to hundred indication total analysis. Since then it
has been a practice to express various plant nutrients found in plant in oxide
form. All such nutrient except nitrogen, which was not found in plant ash, is
expressed as oxides. For instance P as P 2O5, Ca as CaO, Mg as MgO and K as
K2O etc.

MOLE RATIO:
This is the abbreviation for molecular ratio and is defined as the ratio of number
of moles of ammonia reacted with one mode of phosphoric acid. Since each
mole of NH3 contains one atom of nitrogen and each mole of H 3PO4 contains an
atom of phosphorous, mole ratio is defined as N/P.
E.g.: Mole ratio of pure Mono-Ammonium Phosphate is 1.0
Mole ratio of pure Di-Ammonium Phosphate is 2.0
RECYCLE RATIO:
The recycle ratio is the ratio of weights of recalculating fertilizer and product.
E.g.: If 180 MTPH of material is recalculated to obtain 30 MTPH of production,
the recycle ratio is 180/30 i.e. 6:1.
AMMONICAL NITROGEN:

It represents the quantity of Nitrogen, which is present in the form of ammonia

fertilizers.
UREA NITROGEN:
It represents the quantity of Nitrogen present in the fertilizer in the form of urea
to increase the Nitrogen content to reach the given specification.
TOTAL NITROGEN:
It is the sum of Ammonical and Urea Nitrogen. It represents the total amount of
Nitrogen content present in the fertilizer.
WATER-SOLUBLE PHOSPHATE:
It represents the amount of P2O5 in the form of DAP and MAP.
CITRATE SOLUBLE PHOSPHATE:
It represents the amount of P2O5 in the form of Calcium Di Phosphate, Iron and
Aluminium Phosphate.
AVAILABLE PHOSPHATE:
It is the sum of Water Soluble Phosphate and Citrate Soluble Phosphate.
CITRATE IN-SOLUBLE PHOSPHATE:
It represents the amount of P2O5 in the form of Calcium, Iron, and Aluminium
Tri Phosphate.
TOTAL PHOSPHATE:
It is the sum of available Phosphate and Citrate in Soluble Phosphate.
RAW MATERIAL SPECIFICATIONS:
AMMONIA SPECIFICATIONS
State
:
liquid
NH3 content
:
99.5% w/w
Water content
:
0.5% w/w
Oil content
:
20ppm
Temperature
:
0-5%OC
(Min +3 Kg/Cm2 over equilibrium pressure)

PHOSPHORIC ACID SPECIFICATIONS:

Density
: 1.66 gm/CC
P2O5
: 53%
H2SO4
: 1.52 3.3 %
CaO
: 0.04% max
MgO
: 0.24 1.1%
Fe2O3
: 0.24 1.1%
Al2O3
: 0.12 0.8%
Fluorine
: 0.17 0.38%
Chlorine ppm
: 82-124ppm
Suspended Solids: 0.16% - 0.88%
CONSUMPTION NORMS: (NORMS TABLE) :NORMS P2O5 NH3
KG/MT

H2SO4

UREA

POTASH FILLE POWER

R
OVERALL
KWH/MT

GAS
OVERALL
SM3/MT

DAP

467

223

44

11

35

46

10

20:20:0

207

242

450

18

55

16

17:17:17 178

149

158

172

303

124

20

14:35:14 357

182

65

249

53

11.5

10:26:26 267

130

51

460

48

10.5

12:32:16 327

149

50

278

48

10.5

Production temperature : 50-70C

Crushing strength
: 2.5-4Kg/Cm2
Angle of repose
: 30-35

POLLUTION CONTROL STANDARDS:

Liquid effluent: NIL

Emission level of the stack:
Mg/nm3

Maximum

Actual

Ammonia

325

60

Fluorine

10

0.05

Particulate matter

150

59

Sulphur Dioxide

31

2.3

The relation between ammonia and phosphoric acid are cared out in two steps to
achieve the product at MR of 1.8-1.85. This reduces the emission of ammonia
when slurry exceeds the MR of 1.45.
UTILITIES:
PROCESS WATER:
Pressure
:
3 Kg/cm2
Temperature
: Ambient
PH
:
7.8 8.3
Total hardness as CaCo3
136ppm
:
Calcium hardness as CaCo3
:
64ppm
Mg hardness as CaCo3
:
72ppm
Cl
:
30ppm
2So4
:
20ppm
Total dissolved solids at 105C
:
140ppm
UREA:
State
Total nitrogen
Biuret
Moisture
Particle size
Bulk density

:
:
:
:
:
:

Uncoated Prilled
46%(min.)
1.5%(min.)
1%(min.)
-6 + 16 Mesh Tyler
721Kg/cm3

FILLER:
Colour
Moisture
Screen analysis
SiO2
Bulk density
Temperature

: light brown
: 0.5% (max)
: -18 to + 80 mesh Tyler 100%
: 80
: 1400 1600Kg/m3
: Ambient

STEAM:
Specification
: medium temperature, dry saturated steam
Pressure
: 7.0 kg/cm2.g(min)
Temperature
: 170C
PLANT AIR (SERVICE AIR):
Specification
: condensate free air
Pressure
: 7.0 kg/cm2.g
Temperature
: Ambient
INSTRUMENT AIR:
Specification
Pressure
Temperature
Dew point

: Dry, oil & dust free

: 5.6 kg/cm2.g
: Ambient
:-40C

NATURAL GAS:
Boiling Point
: 161.5C
Melting Point
: 1182.6C
Vapor density (air=1)
: 0.6
Specific gravity (water=1)
: 0.422 at 160C
Physical state
: colorless, odorless gas
Solubility in water at 30C
: soluble
Flash point (liquid)
: 22.5C
Auto ignition temp.
: 650C
GRADE TRIMMING AGENTS:

Filler from Godavari riverbed and urea are received by roadway and
stored in raw material storage Godown.

DEFOAMER:
The avoid space between liquid media is termed as foam. Oleic acid is used as
defoamer , which is handled with barrels. Defoamer or anti foaming agent is not
an essential raw material judicious use of it helps in avoiding operational upsets
and ensures smooth running of the plant. Normally, defoamers used are AZ
2OL oleic acid, NEIGEN, HICCO, spac(brand name) , tall oil, turkey red oil, or
equivalent.
ANTI CAKING AGENTS:
It is a pale cream to brownish colour paste at room temperature on spraying
the granulator of NPK, DAP product it controls the cake formation of the
material.
GENERAL DESCRIPTION OF THE PROCESS
The main raw materials used for manufacturing of NPK grade
fertilizer are phosphoric acid (54% P2O5), Ammonia, Sulphuric acid (98%), Urea &
river sand as filler and muriate of potash.
Ammonia reacts with weak phosphoric acid using state of the art Pipe Reactor
Technology to produce Ammonium phosphate/sulphate slurries, which are sprayed
inside the granulator directly on the granulator solids bed, composed of all recycled
product. In the granulator the slurry is further ammoniated to obtain the required
mole ratio (N/P) and to fix the required percentage of total Nitrogen in the product.
Whenever Sulphuric acid is not used or partially used Urea is fed to the granulator
to obtain the required total nitrogen percentage.
To obtain the required grade of P 2O5 and Total Nitrogen,
sieved river sand is fed to the granulator through fines conveyor. River sand acts as
a grade-trimming agent. Muriate of potash (MOP) is fed to the granulator through
fines conveyor as an additional raw material to get the required percentage of K 2O
value in the product. The granulator product having 2 to 3% moisture is directly

discharged by gravity to the dryer where the moister content of the product is
required to less than 1%. The dried product is then passed through various screens
for sieving and to obtain the desired product size. The oversize product separated
from screens are crushed in crushers and recycled back to the granulator. The fines
separated in screens are also recycled back to the granulator. The finished product
leaving the screens is passed through the rotary cooler where the final temperature
of the product is cooled down to 50/55 OC before sending the product to storage godown through conveyor belts for storing or for bagging.
The final product is also, if required from the storage go-down through
screens to remove the undesired size of the product, sent to the respective bins of
the bagging plant through conveyor belt for bagging. The final product bagged in
50 Kg bags is dispatched to various destinations for selling.
The unreacted ammonia vapors from the granulator along with dust
carried over will be scrubbed in two-stage acid circulation scrubbing system, to
recover and recycle ammonia and dust by way of reaction and absorption. The
gases after scrubbing shall go to the stack. Similarly the dust and traces of
ammonia released in dryer and cooler are passed through dust cyclones in first
stage and then second stage-scrubbing system before they are released through
stack.
CHEMISTRY OF THE PROCESS:
Ammonium Phosphate is produced by reacting Ammonia and Phosphoric Acid under
controlled conditions such that the proper quantities of N and P205 are contained in
the final product.
The principal chemical reactions involved are shown below :
NH3
17
Ammonia
NH4H2PO4
115

+ H3PO4
= NH4H2PO4 + 1200 Kcal
98
115
+ Phosphoric Acid = Mono ammonium Phosphate
+ NH3
17

= (NH4)2 HPO4 + 900 Kcal

132

Mono ammonium + Ammonia = Di ammonium Phosphate

Phosphate
Generally, the proportions of N and P2O5 are controlled to yield a mixture of
mono ammonium Phosphate and Di ammonium Phosphate in the product
Fertilizer.

Wet process phosphoric acid normally contains small amounts of free

Sulphuric acid which reacts with NH3 as follows:
H2SO4
98

Sulfuric Acid

2 NH3
2x17

+ Ammonia

(NH4)2SO4 + 1500
132

= Ammonium Sulphate

The above reactions are exothermic, liberating a considerable amount of

Heat and evaporating large amount of water from the reacting masses.
Wet process phosphoric acid normally also contains small amounts of F in
the form of fluosilicic acid (H2SiF6), which reacts with ammonia as follows:
6NH3

+ H2SiF6
144

+ 2H2O = 6NH4F

Ammonia

+ SiO2

+ Fluosilicic Acid + Water = Ammonium + Silica

Fluoride
The other impurities present in Phosphoric acid like Al2O3, Fe2O3, MgO,
CaO.
Compounds, which contribute towards, total N and P2O5 in the product.

For NPK Products

(14:35:14 , 12:32:16 & 10:26:26 ):

The main chemical reaction is the Ammonia neutralization with Phosphoric acid ,
and is a lesser extent with Sulphuric acid.
H2SO4

Sulfuric Acid

+ Ammonia = Ammonium Sulphate

H3PO4

+ NH3

Phosphoric Acid

+ Ammonia = Mono ammonium Phosphate

NH4H2PO4
Mono ammonium
Phosphate

2 NH3 = (NH4)2SO4+ 1500 Kcal /Kg NH3(I)

+ NH3

= NH4H2PO4 + 1200 Kcal /Kg NH3(I)

= (NH4)2 HPO4 + 900 Kcal /Kg NH3(I)

+ Ammonia

= Di ammonium Phosphate

1st reaction takes mainly place in the scrubbing system but also in the
Pre neutralizer.
2nd reaction takes place in the Pre neutralizer, Pipe Reactor and scrubbing
System.
3rd reaction occurs partially in pre neutralizer and Pipe reactor and it is
Completed during the Ammoniation in the granulator bed.
In case of NPK Grades produce, the process is to be used will the same
Proposed for DAP Production (mixed PR & PN process).
In case of NPK Products, Potash (Solid) will be added along with the
grade trimming agents like filler, spillage materials and Urea will fed to
the secondary elevator through metering conveyor , together with all the
Plants recycle solids.
When Phosphoric Acid reacted with NH3, at atmospheric pressure and at
Temperature of 130 to 135oC for NPK Grades, Mono ammonium

Phosphate will form, it is an intermediate Product for further

ammoniation of mono ammonium phosphate and potash addition through
the recycle material before Granulator. Granulator is mainly accomplish
by a series of Chemical and Physical reactions between the different raw
materials.
Wet process phosphoric acid normally also contains small amounts of F in
the form of fluosilicic acid (H2SiF6), which reacts with ammonia as
follows:
6NH3
Ammonia

+ H2SiF6
+ 2H2O = 6NH4F
+ SiO2
144
+ Fluosilicic Acid + Water = Ammonium + Silica
Fluoride

The other impurities present in Phosphoric acid like Al2O3, Fe2O3, MgO,
CaO.
Compounds, which contribute towards, total N and P2O5 in the product.
DETAILED PROCESS DESCRIPTION
RAW MATERIAL SECTION:
The main function of the RMS is to store and supply the liquid and solid
raw materials to both trains as their requirements.
AMMONIA:
Anhydrous liquid Ammonia and generated vapour Ammonia during
unloading operation from the Ammonia storage system are delivered to the DAP
plant and are handled by office facilities.
PHOSPHORIC ACID:
Phosphoric Acid is pumped to the day tank from the battery limits. The day
tank is provided with a roof and a capacity of 1350 MT. The tank is made up of
mild steel and provide with internal rubber lining of inter connecting pipelines are

rubber lined to avoid corrosion attack of Acid. The day tank is provided with top
entering turbine type agitator to avoid settling of solids for easy pumping. The acid
is reclaimed from this tank by centrifugal slurry pumps and delivered to both trains
and also provided with acid re-circulation system when the plant is stopped, which
accomplishes free from settling of solids.

SULPHURIC ACID:
A cylindrical tank is provided to store Sulphuric Acid of 93-98%
concentration. There are 4 storage tanks each have capacity of 2400 MT and is
made up of mild steel. Sulphuric Acid is received from Subhodaya Enterprises
Ltd., by roadway and is unloaded into Sulphuric Acid main Storage tanks. The
main storage tanks are provided with a dyke wall around the tank to avoid the acid
attack on the soil which ultimately protects the strength and the structure of the
soil. This storage system is provided with another cylindrical day tank of capacity
2500 MT. The acid is reclaimed from this tank by transfer pumps to both trains.
Solid raw materials like Urea, Filler are stored in raw material storage
yard. These raw materials are reclaimed by a pay loader to raw material hopper,
which in turn discharges to raw material transfer conveyor provided with magnetic
separator for separating the iron and magnetic particles in the feed material.
Transfer conveyor discharges to the raw materials transfer elevator, is provided
with a clod breaker at its feed hopper to break feeble agglomerates of lumps. The
elevator of 24.5m heights has a capacity of 30MTPH and discharges to the raw
material distribution conveyor, which feeds to the respective Urea and filler bins by
operating gates at the conveyor discharges.

PIPE REACTOR:
The main phosphoric acid and ammonia reaction takes place, is
composed of pipe reactor, installed in the granulator itself. Part of the
neutralization reaction takes place in the pipe reactor, which is installed so that the
slurry of ammonium phosphate is poured directly onto the solids bed of the
granulator. This slurry has temperatures normally ranging from 130 to 155 OC and
moisture content between 4 to 12% depending on the grade and the required
granulation moisture in the granulator solids bed.
The pipe reactor is a tubular reactor, developed by INCRO, S.A, of small
dimensions, that is composed of a mixture and reaction head to which the slurry
distributing tube is fitted. In the former, the phosphoric acid and the ammonia
phosphate and the vaporization of water. The reaction is completed along the
distribution tube and the pressure in the system propels the formed slurry, which is
distributed directly over the solids bed inside the granulator at the same time that
the steam and the unfixed ammonia escape towards the granulator pre-scrubber.
The ordinary operation range for pipe reactor is between 10 to 25 th of
ammonium phosphate slurry, and up to a maximum of 40th. The reactors reacting
head is designed so that a good mixture of the phosphoric acid and ammonia is
produced, achieving a high efficiency reaction. The slurry distribution tube has two
slots through which the emerging slurry will be distributed. It also has, some
collars that will totally or partially close the slots depending on the operative
capacity required in the reactor and on the solid bed area on to which the slurry
will be poured out. The system pressure maintained around 2-4 Kg/Cm 2. the flow
to the reactor is controlled by the magnetic flow meter.
Steam is used to purge the raw material feed lines, the cross and reactor
pipe. On every occasion the reaction is interrupted. Steam purging is automatically
activated, when raw material flows are diverted to recycle. Steam purge time is
controlled to 3-5 min. steam can also be used with water and phosphoric acid in
washing cycle for the pipe reactor.
The crystal growth of deposit could be modified to produce a soft
deposit by altering levels of Fe, Al, Mg and F in phosphoric acid. The build up
considerably reduced when acid containing reduced when acid containing smaller
levels of Mg with higher levels of Fe, Al and F usedNote: at the sample point on

the PCR, the slurry is only partially reacted and is not same as the slurry that falls
on the recycle bed in ammoniator-granulator.
MAIN REACTIONS:
NH3 + H3PO4
NH4H2PO4 + NH3

NH4H2PO4 ; H = -32.14KCAL
(NH4) 2HPO4 ; H= -19.26KCAL

SIDE REACTIONS:
2NH3 + H2SO4
6NH3 + H2SiF6 + 2H2O
CaSO4 + H3PO4 + 2NH3
Fe2O3 + 2H3PO4
Al2O3 + 2H3PO4

(NH4)2SO4
(NH4)F + SiO2
H4)2SO4 + 3H2O
FePO4 + 3H2O
2AlPO4 + 3H2O

In Pipe cross reactor the scrubber liquor of Specific Gravity 1.5 and mole ratio 0.9
is from pipe reactor feed tank and liquid ammonia from ammonia pumps.
PIPE REACTOR SYSTEM:
In 1991, the central government removes subsides on phosphates
fertilizer unit. In order to offer a lowest price to farmers the basic cost of
production has to be reduced by adopting conservative measures there was
minimum scope to reduce the consumption norms of ammonia and phosphoric acid
by having strength measures. It was felt, there was much scope to reduce the
energy consumption norms by adopting pipe reactor technology.
Pipe Reactor Technology:
There are four difficult systems of pipe reactor technology in operation.
They are:
1 Single gun or single pipe reactor without preneutraliser.
2 Pressure reactor or draught tube reactor without preneutraliser
3 Double gun or double pipe reactor fitted one in granulator and the other in
dryer.
4 Mixed system using both the pipe reactor in granulator and pre-neutralizer
for ammonia reaction.

While any of the systems can be adopted for a new installation to produce NP or
NPK, grade complex fertilizer.
There are two types of pipe reactor namely pipe tee reactor and pipe cross reactor.
Pipe cross reactor is the new version of pipe reactor tee reactor comprises two
opposite side arms instead of one in the case of pipe tee reactor.
This
enables pipe cross reactor to operate with three liquid streams instead of two in
case of pipe reactor.
Advantages of pipe reactor process:
1 With a low addition cost, the plant capacity can be almost doubled, thus the
cost production can be reduced.
2 Pipe reactor can be extremely flexible and precise control of reactants is
possible due to short residence time in the pipe reactor.
3 The plant can be started at full rate. Start up and shutdowns can be
accomplished with fewer efforts and thus some losses can be provided.
4 The power consumption is reduced due to its low recycle ratio.
5 Consumption norms are also reduced due to its higher rate of production.
Due to above advantages, the A-train in the DAP plant is fitted with
Retrofitted pipe reactor technology offered by M/S. Incitec Limited, Australia
through M/S. Hindustan Dorr-Oliver, Mumbai. The retrofitted train was
commissioned July/August 1995 and it is running now with pipe reactor system.
The retrofitted process is a single gun pipe cross reactor process with
minimum modification. A pipe cross reactor is provided which is introduced in the
granulator. Ammonia spargers in the granulator for further ammoniation of the bed
will remains as it is in position wise, in conventional plant with little modification
and hence the granulometry of the material will not get disturbed.
Increase in ammonia escape from the granulator is not envisaged and hence no
much modification will be required in the scrubbing and hence no much
modification will be required in the scrubbing section. Four new nozzles to
introduce scrubber liquor are provided to the duct from the granulator connected to
the fumes scrubber to scrub the over escape of ammonia from granulator.

ENVIRONMENTAL,
HEALTH & SAFETY
Every process industry is exposed to many Hazards and incidents. To
prevent the accidents in a industry safety plays a very important role.
COROMANDEL has a promising integrated safety policy PSMS i.e., Process safety
management system and OSHAS (Occupational Health and Safety Assessment
Series.) There are some specific dos and donts in the safety so as to prevent the
accidents.

DOS & DONTS:

1 Do understand the instructions clearly and in case of any doubt clarify
them Before acting
2 Do use personal protective equipment recommended and learn correct way
of using it
3 Do take a position on windward side (I.e. your position should be such that
wind blows from your back towards the equipment, valve machine
being operated). While issuing or collecting samples or draining any
line or vessel or equipment.
4 Do maintain a log of all events carried out by you chronologically without
emissions and commissions.
5 Do wear safety helmet and safety shoes while in the factory premises
6 Do learn the location of safety cupboards, first aid boxes, fire hoses, fire
hydrants and fire extinguishers, eye wash fountains, showers.

7 Do step the job or report immediately to supervisor concerned if any

unsafe conditions or act is observed or in the event of any doubt.
8 Do keep the work area neat and tidy.
9 Do not smoke or use naked light/flame etc., in no smoking zones.
10 Do not adopt any make shift arrangements.
11 Do not attempt to operate or set in motion any machine or stop any
running machine without authority to do so.
12 Do not indulge in horseplay.
13 Do not wear loose fitting clothing
14 Do not position yourself in line with valve spindle while opening or
closing.
15 Do not distract others to allow yourself to be distracted by other.

16 Do not leave tools or materials where they are likely to fall accidentally
on persons working at lower levels
17 Do not temper with any instruments.
18 Do not wear synthetic clothes.
19 Do not park or allow to park or side scooters, mopeds etc., in the no
smoking zones.
20 Do not enter into any equipment vat fit or vessel without proper
authority.
21 Do not enter indulge in chit chatting.
22 Do not allow outsiders, visitors and other than your plant staff to come
to your section.

23 Do not allow others job interferes with your job or vice versa.

GRANULATION PLANT
AMMONIA GRANULATOR:
This is provided to accomplish reaction between the slurry and ammonia
which results increase in mole ratio and to granulate the ammonium phosphate
slurry using solid raw material and recycle solids.
The granulator is a rotary drum having its axis inclined at an angle of 8 o to the
horizontal. It is made of steel and 3.35m in diameter and 6.7m in length. The upper
end of the granulator is closed and its lower end is left open. A girth gear is
provided on the granulator, a 200HP reversible motor through a reducing gearbox
and a pinion drives which rotates at a speed of 8.8RPM. Two tires are mounted on
either side of the girth gear and these are supported on re-unions internally the
granulator is provided with:
1 A slurry header containing five projected flooding type nozzles to spray the
slurry from the pipe reactor.
2 Lip plate ammonia spargers of 3mm, schedule 80 pipe made of SS-3161
containing 96 holes of 5mm diameter to inject liquid.
3 A 6``, schedule 120 heavy carbon steel pipe to support the slurry heard and
ammonia spargers.
All these provisions enter into the granulator through upper end i.e., enclosed
end. A circumferential weir (brim) is provided near the lower end. The solid raw
materials like filler, urea and the recycle solids are maintained in the granulator
from secondary elevator. A continuous bed of solids is maintained in the granulator
on which the slurry from PN gets sprayed. The final mole ratio of the product is
maintained using liquid ammonia obtained from offsite Horton spheres directly.
The liquid ammonia spargers are provided in such a way that during normal
running the bed of material completely covers the spargers, thus ammonia diffuses

and thorough reaction takes place. During ammoniation, the following reaction
takes place.
NH4H2PO4 + NH3

(NH4)2HPO4; H = -19.26K CAL

The slurry containing 48% MAP and 52% DAP is converted to

82%DAP and 18% MAP by ammoniation. The slurry at a mole ratio 1.4 1.45 is
reacted with ammonia and simultaneously granulated and resulting the ammoniator
= granulator discharge at a mole ratio of 1.8 1.85 in order to get DAP grade.
The PR slurry is sprayed on recycle material in AG and granulation
takes place by layering and agglomeration processes. The ammoniation is also
carried out simultaneously along with granulation. The recycle granules and
crystals are act as nucleus for formation of new granules. The primary mechanism
of granulation is the addition of successive layer of a thin coating of slurry to a
recycle stream of dried granules. The application of this film at the surface of
granules slows the resulting bigger granules to dry quickly and thoroughly.
In layering granulation the nucleus (fine granule) is coated with a layer
of slurry and then dried. The resultant nodules are recycled through granulator
several times until each nodule is build up to the correct size to pass into the
product section of product screen. This is carried out on recycle fertilizer solids.
The agglomeration granulation consists of coating and cementing small
crystals of fertilizer and filler with slurry to form nodules. The coatings deposits at
each cycle are relatively thick and several-agglomerated nucleus may be cemented
together with in the envelope. Some oversize granules are always produced when
near product size nodules are re-circulated. These oversize granules are broken
down in pulverized and recycled back to AG, mixing is very thorough and AG
discharge mass consists mainly of nodules coated with slurry.
The recycle ratio (the ratio between re-circulating fertilizers to product)
has a great effect on granulation. It is maintained at about 6:1. As large quantity of
water in the slurry (about 15%) requires more quantity of recycle material for good
granulation. Drop in recycle ratio, accomplishes the formation of large
agglomerated lumps and wet discharge from granulator and reduces the dryer
outlet temperature. The recycle equipments contain the recycle solid material of
60- 70 MT and whole mass is circulated three times per hour.

THE VARIOUS FACTORS EFFECTING THE GRANULATION ARE AS

FOLLOWS:
1. Mole ratio of material in the granulator
2. Evaporation rate in the drum
3. Particle size, temperature of recycles material
4. Slurry quality i.e., viscosity and composition
The pH of AG outlet is maintained about 7.6 which gives an indication of
the mole ratio of material at 1.85. As the ammoniation carried out, the liberated
heat evaporates the moisture content of solids and results outlet solid moisture
content reduced up to 2.5 3.5. The ammoniation also helps in reducing recycle
ratio as it accomplishes in evaporation if moisture.
The inner surface of the granulator is provided with flexible rubber panels which
prevents the buildup on the inside of the shell. Breather holes are provided on the
surface of granulator, which helps in free moment of rubber panels. Occasionally
the granulator is rotated in reverse direction to remove the scale and build up
material.
The granulated product near open end of the AG discharges though over
flow weir. A chute is provided beneath the open end of the granulator, which
receives the granulated product through a grizzly and diverts them to the dryer.
During ammoniation ammonia losses are inevitable. So in order to recover the unreacted ammonia from the granulator, ammonia along with water vapour and air is
directed to fumes scrubber.

CONDITIONS:
1. Mole Ratio
2. Solid temperature
3. Moisture content
4. Solids Ph
5. Residence time

-----> 1.8 1.85

------> 75-80oC
-----> 2.5 3%
------> 7.6
------ >6 minutes.

COMBUSTION CHAMBER:
The combustion chamber supplied the hot quenched gasses to the drier.
This is an oil-fired furnace, which utilizes natural gas (NG) as fuel. In past they
used to use LSHS (low sulphur heavy stock). The combustion chamber has a
cylindrical structure placed in a horizontal position. The shell of combustion
chamber is made up of steel, which is internally lined with fire clay bricks which
serve as refractory material.
A burner is provided at one end of the furnace. NG at a high pressure is supplied to
the burn by means of atomizing air to ensure complete combustion and to avoid
formation of coke in the combustion chamber. Air required for combustion of fuel
is supplied by primary act blower at a pressure of 8 Kg/cm 2 driven by a 20HP
motor, provided with a suction filter and damper.
Pilot burner is also provided with LPG connection, which is used during start up. A
spark generated by transformer can ignite LPG. A separate line to pilot assembly
supplies air required to burn the LPG. As combustion proceeds the hot flue gases
are produced at a temperature of 600oC. These hot gases get quenched with air
from quench air fan and temperature of hot quenched gasses drop down to 300 oC.
The quench air fan is driven by a 50HP motor provide with a suction damper to
adjust the dryer fan suction. The inlet temperature of hot quenched gases to dryer is
adjusted by quantity fuel supplied to the burner.
The hot quenched gasses then enter the bottom of the vertical well, which is lined
with fine clay bricks. The top portion of the well is connected to dryer with sharp
bend to convey the hot gases to dryer. Plenum well is a part of this well where
forces and induced draughts are balanced. The vertical well is provided to safe
guard the products from degradation due to direct radiation from the flame. Any un
burnt oil, if present also gets separated.

ROTARY DRYER:
The crushing strength of granules is low for granules with higher
moisture content. To avoid the formation of granules into powder, it moisture
content is reduced by rotary dryer; the function of the dryer is to reduce the
moisture content of granules discharging from granulator to improve the crushing
strength and to avoid the caking of granules. The granulator discharge is dried from
3.0% to 1% moisture using hot quenched gases from the combustion chamber.
It is rotary drum type placed at an inclination of 1.91 o to the horizontal. It
is 24.4m long and 3.6m in diameters. Externally, it is provided with knocker ring
lifters on the upper end of the shell. A girth gear is mounted on the drier, which is
driven at a speed of 3.5RPM using a 350HP motor through a reducing gearbox.
Two tires are placed on either side of the girth supported on trunions. Graphite dry
lubricants are provided for a trunion of each pair to accomplish continuous
lubrication of tires. Thrust rollers or guide rollers are arranged to prevent end wise
travel of the dryer.
Internally it is provided with four types of flights, viz., spiral or helical
flights as well as cascade flights are provided with chains. At the lower end of the
dryer, trimmer bars are also provided. A spill back chute is also provided which
removes the excess material from the dryer, thus avoid the fall of material into the
combustion chamber.
The wet granules from the granulator chute gravitate to the upper end of
the dryer. The hot quenched gases from combustion chamber also enter the dryer
through vertical well. During initial stages, the granules contain higher moisture
content hence they tend to form a scale on the inner surface of the dryer near their
entrance. The provided knocker rings help to remove the adherent scale, as they
strike the dryer shell by knocking from outside during the rotation of dryer. As the
dryer had absorbs the shocks by striking with knocker rings, the provided chains
gravitates freely and adherent scale whatever around it, is removed. At the feed end
of the dryer, provided spiral flights assist in importing the initial forward motion to
the solids before they reach other flights. The remaining flights lift the material and
exposing them thoroughly too hot gases for effective drying.

The heat is neither supplied with in the dryer nor lost to surroundings. Operation is
adiabatic and the gas will lose sensible heat and cool down as the evaporated
moisture absorbs latent heat of vaporization. In an adiabatic operation, the wet
solid contacted with the hottest gas.
As long as unbound surface moisture is present, the solid will be heated on to the
wet bulb temperature of the gas, and for this reason even heat sensitive solids can
frequently be dried by fairly hot gas in co-current operation. In any event the wet
bulb temperature can never exceed the boiling point of the liquid at prevailing
pressure. At the out let of the dryer the gas will have been considerably cooled, and
no damage will result to the dry solids. In this co-current drying process, the
fertilizer material is protected from degradation as ammonia is evolved at 90 o C
and urea gets melted at a 130oC.

Co-current drying also permits grater control of the moisture content of

the discharged solid, when the solid must the solid must not be completely dried.
By controlling the quantity of gas passing through the dryer consequently its
existed temperature and humidity are controlled. As the temperature in the drier
above the boiling point of the moisture to be evaporated, the humidity of the gas
has only a minor influence on the rate of drying and it is easiest to work directly
with rate of heat transfer.
The dryer outlet temperature should into be reached below the 90 oC
where the drying rate drops as well as hot gases reaches their dew pint, causes in
caking and lumps formation. The drop in outlet temperature also causes the
problems like chocking of cyclone hopper and sealing in dryer as well as in dust
recovery system.
The dried granules form the lower end of the dryer, gravitates
through the trimmer bars to the bottom of primary elevator. Any lumps formed in
the granulator and dryer are broken up autogenously by the trimmer bars
arrangement prior to passing through the lump crusher. The flue gases along with
entrained dust leave end of the dryer and enter the dryer cyclone. As quick drying
of product is required, co-current drying is employed.
CONDITIONS:
Moisture content of wet solids ---------------- 2.5 3.0%

Moisture content of dry solids

Flue gas inlet temperature
Flue gas outlet temperature
Temperature of dried solids
Residence time

---------------- 1%
-----------------190-210oC
-----------------75- 90oC
----------------75 80oC
----------------- 8 minutes

SCREEN DRAG FEEDER (SDF):

It is also called drag chain feeder, receives the solid material from
primary elevator and distributes the material to scalping screens. It has a length of
9.3m. It contains number of flights, made up of steel, both ends of which are
attached to chains two in number. Sprockets are provided at both ends of feeder,
one of which is driven by an electric motor of 40HP. The flights, chains and
sprockets are enclose in a rectangular box to avoid dust problem. The bottom
portion of this box is provided with fines conveyor by means of a pipe. Excess
product by passes the screens and recycles to fines conveyor through this pipe.

Gate covers the entire width of the conveyor with a crossed opening. It is also
helps in equal distribution of solid materials over the screens. Inspection doors are
also provided on each side o the conveyor. Rectangular boxes are also provided to
check the percentage of gates opening. The feeder box is maintained at slight
negative pressure by means of dust fan to avoid dust problem.
SCREENING:

The material from SDF, contains product size material along with over size and
fines I.e., undersize. Screening is adapted to separate product size material from
over size material from over size and fines. Two stage screening issued in which
single deck screens are provided for efficient operation. The screen separates the
oversize material from remaining fertilizer is called scalping screens and that is
separates product from fines is called as product screens. Each train is provided
with three scalping screens and three product screens.
SCALPING SCREENS:
The dried material it is distributed over the scalping screens, scalping
screens have been providing with a mesh of 4mm dia. To separate oversize material
from the remaining fertilizer. Oversize material over the scalping screens is
directed to oversize pulverizes. Product size and fines are gets collected in scalping
screen hopper, is VSC hopper, made up of steel. A variable speed belt conveyor
(VSC) is provided at the bottom of screens. Each VSC hopper has 3m in length.
The overflow line from this hopper is also provided to product, fines conveyor.
Excess product size material over flow through this line to the recycle system, thus
preventing depletion of the circulating material by changing the speed of VSC
discharges the material at inlet of product at inlet of product screens.
PRODUCT SCREENS:
Product screens are provided with a mesh size of 2mm dia to separate
product size material from fines. Product size collected over the screens is directed
to the cooler feed conveyor. Fines separated from product size material is collected
is product screen hopper i.e., fines shopper from which the material gravitates to
the fines conveyor; scalping screens as well as product screens are placed inclined
to the horizontal. These are also providing with vibrators which are driven by
individual 1HP MOTOR. Both screen hoppers are maintained at slight negative
pressure by dust fan to avoid the dust evolution.
Single-deck sieving is supervisor to double-deck sieving because there is no
connection between the area required for upper size limit and the area required for
the lower and the area required for the lower size limit and the conditions are
unlikely to be optimal for both screens. Also cleaning and general access to single
screens are easier. Because the screens can be matched more efficiently when they

are each single deck equipment costs are usually into different from those of
double screens.
LUMP CRUSHER:
The purpose of the lump crushed is to break the +3mm material into
-3mm material. It consists of a fixed shaft containing 16 teeth on its periphery. The
teeth get matched with provided stationary grooves. The shaft can be rotated by
means of an electric motor of 25HP. On rotation, the oversize material gets crushed
and the gets reduced. The material then discharged into the bottom of primary
elevator. The primary elevator elevates the material to screen drag feeder. The
height of the elevator is 36m and its capacity is 210MTPH.
OVERSIZE PULVERIZER:
Each train is provided the three over size pulverizers (OSP). There are
also called as twin rotary chain mills. OSP crushes the material to fines less than
4mm with too minimum generation of dust. Each pulveriser consists of two
hammer rotors or chain rotors having circular links made up of steel. A stationary
rod having chain links is also providing between and at slight elevated position to
motors of 60 HP. The material gets crushed between two rotors by the striking of
the links. The crushed material obtained gravitates to the fines conveyor. The
rotors and the stationary rod are enclosed in steel casing to avoid dust problem. The
capacity of pulverizers is about 55MTPH. Product size material from scalping
screens is gravitates to the cooler feed conveyor (CFC), which further conveys this
material to product cooler. This is a belt conveyor of 9m lengths and is driven by
an electric motor.

PRODUCT COOLER:
Particles, which are hot are sometimes plastic and easily sticking together
or deform so that pack into the interstices between particles. Coiling of particles
before storage is therefore desirable. For this a product cooler is provided to cool
the hot product using ambient air immediately to avoid caking of granules.
It is cylindrical drum having its axis is placed at an inclination 3.37 o to the
horizontal. It is 15.24m in length and 2.27m in diameter; it based on four trunions
and is by girth gear system at speed of 6.5 RPM by a 100HP motor. Inside the
cooler lifting flights extending from the cylinder wall for the full length of the
cooler are provided.
The hot product at a temperature of 75 85 OC enter the top end of the cooler feed
conveyor and passes counter currently to the direction of ambient air. The flights
lift and material and show them down in a moving curtain through the air, thus
exposing them thoroughly to the cooling action of the cool air. Solids leave from
the lower end of the cooler at a temperature of 35 45 OC. by drop in temperature
the relative humidity of the product increases and there by storage characters are
improved. The along with entrained dust at a temperature of 80 OC we directed to
the cooler cyclone. The cooled product from product cooler is sent to begin plant or
bulk storage using product conveyor.
Temp. Of cooled product: 55-65OC
Retention time: 2.44min
FINES CONVEYOR:
The fines conveyor also called drag chain conveyor, receives the various
solid materials like urea and filler from raw material bin, seed from RMTS, fines

from fines hopper, and crushed material from over size pulverizes, material from
cyclone hoppers and excess fertilizer from SDF and VSC hopper. It transfers the
whole mass to the secondary elevator. It has a length of 19.7m and a capacity of
300MTPH.
It contains number of flights, made up of steel, both ends of which are
attached to chains, two in number, sprockets are provided at both of the conveyor
one of which is driven by an electric motor of 50HP through fluid coupling. The
flights, chains and sprockets are enclosed in a rectangular box to avoid dust
problem. The material is conveyed by scraping with flights. Belt conveyor is not
suitable for these operations. The fines conveyor Is maintained under slight
negative pressure to avoid dust evolution by dust fan. The secondary elevator
provided at the discharge end of the fines conveyor, which elevates the recycle
material to a height of 20m and discharges them to the granulator.
AMMONIA AND DUST RECOVERY SYSTEM
This system is provided not only to avoid ammonia and dust losses from the
plant but also to help in pollution control.
It is equipped with cyclones, venturi scrubbers, spray type scrubbers, weak
acid scrubber liquor storage sumps, circulating pumps, exhaust fans and a
stack.
Due to the exothermic reaction taking place in the preneutraliser the water in
the PN evaporates and the evaporated water along with un reacted ammonia
from the PN is given to this system for recovery of ammonia.
Unreacted ammonia from granulator also enters this system. As the material
in the granulator is in wet condition, dust evolution is less minute quantities.
The gasses from dryer and air from cooler contains much amount of dust in
dry state. Dust line collects the dust air from screen hoppers, oversize
pulverizes, conveyors, SDF and fines conveyor. These gases are directed to
cyclones.
The dust line is given tangentially to cyclones. The coarse dust particles will
move radically towards the wall of the cyclone due to centrifugal action.
The particles reach the wall and losses its energy by colliding the wall and
slide down then gets collected in cyclone hopper provided at the bottom of

the cyclone from where it is fed to the fines conveyor through a trickle
valve.
Fine particles of dust will not be removed in the cyclones. Hence these gases
are directed to scrubbing section.
In scrubber section, six scrubbers are provided. Ammonia and dust present in
the effluent gases obtained from pre-neutralizer, ammoniator-granulator
(AG), and dryer cyclone are Recover in this system. It is provided with six
scrubbers out of which four are venture scrubbers and two are spray type
scrubbers 1. Pre-Scrubber
2. Fumes Scrubber 3. DryerScrubber

4. Cooler Scrubber 5.
PROCESS:

Dust-Scrubber

6.

Tail gas-Scrubber

The hot vapours from preneutraliser and granulator are mixed and then directed to
Granulator Fumes Pre-Scrubber. The effluent gases from dryer cyclone are directed
to dryer scrubber. The effluent gases from cooler cyclone and dust cyclone are
sucked by cooler fan and dust fan and they are directed to cooler and dust scrubber
respectively. During manufacturing process of DAP / NPK fertilizers the main
pollutants that are releasing to the atmosphere are ammonia, dust, fluoride and
sulphur dioxide. The main nutrients that are escaping during the manufacturing
process are unreacted ammonia and dust and are required to be recovered for plant
economy as well as for protecting the environment by providing Cyclones, Venturi,
Cyclonic wet scrubbers, Dust scrubber and finally Tail gas scrubber.

The venturi scrubbers contain a venture portion and a cyclonic separator.

The effluent gases are directed on to the top of the venture portion having
rectangular cross section. It has a weir along its length at the top of the converging
section to which scrubber liquor is pumped. A variable throat is also provided
between converging and diverging sections, which help in adjustments of gas flow.
The liquid from the overflow weirs cascades down the sides of the converging
section and contacts with the accelerating gas stream at the throat here the high
velocity of gas atomizes the liquid into droplets small enough to impact upon the
vapours so as to absorb them.
The mixed gas & liquid then pass through the diffusing section where the
forces of diffusion & agglomeration act to increase the size of droplets & wetted
particles to point, where they may be separated from the moving gas in the
cyclonic separator. For this mixed separate, liquor enters through six nozzles
around its periphery. The acid after scrubbing gets collected at the bottom of the
separator & gravitates to the sump through vacuum seal leg.
Cooler scrubber is a hollow cylinder with a conical bottom. The top portion
of scrubber contains a bench of modules i.e., mist eliminators which separates
entrained acid passes over along with gas steam. It is provided with a ring header,
externally, from gasses from the cooler cyclone is injected near bottom of the
scrubber, and gravitates to the sump through seal leg. The scrubbed gas from the
entire scrubber passes to the TGS & vented through the stack.
The fumes scrubber effluent gases contain ammonia and fluorine vapours.
These are scrubbed with hot scrubber liquor at high Ph, where fluorine holds in gas
stream along with small quantity of ammonia. This is followed by the high
moisture and low Ph scrubber acid, scrubbing in tail gas scrubber. The high
moisture reduces scrubber temperature and hence fluorine escapes in minimized.
The scrubber effluent gases from dryer scrubber still contain ammonia
vapours, which are further scrubbed, with low mole ratio scrubber liquor in tail gas
scrubber. For this scrubber effluent gases from fumes scrubber and dryer scrubber
are sucked by fumes fan and dryer fan respectively and even the scrubbing gases

form cooler and dust scrubber are sucked by their respective fans and get
discharged to tail gas scrubber nearly to its bottom through a duct line. Modules in
cooler scrubber and tail gas scrubber and tail gas scrubber are flushed frequently,
with pressured water to maintain them as free of block age.
68.
Each scrubber is provided with individual sump at her bottom, viz., fumes
sump cooler sump, dust sump, tail gas sump and scrubber effluent tank (SET).
Sumps help to maintain the liquid level above the bottom and of seal legs. Each
sump is provided with overflow launder except SET. Scrubber liquor form tail gas
sump overflow to cooler sump. The over flow launders from fumes sump, dust
sump are connected to SET.
The scrubber liquor from SET is pumped to fumes scrubber dryer scrubber
and dust scrubber by fumes scrubber liquor pump respectively. Part of scrubber
liquor from SET is pumped continuously by scrubber effluent pump to PN as well
as ring header of fumes scrubber and cooler scrubber by means of cooler and tail
gas scrubber circulating pumps.
Phosphoric acid to scrubbing system is added at weir box of fumes scrubber
and in cooler sump to full fill the P2O5 consumed in pre-neutralizer through
scrubber liquor. To reduce the SPG of scrubber liquor, water is added to cooler
sump and SET. De-foamer is also added, to reduced foaming in cooler sump and
SET inlet launders.
CONDITIONS:
S.NO
SCRUBBER
LIQUOR
1
PH
2
MR
3
SPG
4
H2O

PRESSURE DROP ACROSS

SET SCRUBBER LIQUOR

COOLER SUMP

4.5-5.9
1.26-1.35
1.34-1.38
20-30%

1.5-2.5
0.4-0.6
1.1
50-60%

1 venture portion: 225mm of WC

2 Cyclonic portion: 75mm of WC
SCRUBBER LIQUOR PUMPING PRESSURE AT
1 weir box: 0.35kg/cm2
2
Cyclonic Spray: 1.76Kg/m2
NOTE:
Flushing of fumes and dryer fan with water to avoid sealing, which causes
misalignment of fan impeller.
OPERATIONAL CONTROL OF PROCESS:
As the phosphoric acid used for preliminary raw materials in fertilizer
industry produced by the wet process containing impurities with different
compositions which in turn causes ammonia fixation. Due to this operation control
in necessary to achieve production with required grade. The rate of production of a
particular fertilizer depends on the product demand, capacity of fertilizer plant and
availability of raw materials.
I. Control of the feed rates of raw materials:
1. Phosphoric acid:
The feed rate of phosphoric acid is constant for product rate of a particular
fertilizer. The amount of P2O5 fed to plant determines the instantaneous production
rate and not product take out rate. The volumetric feed rate of phosphoric acid will
depend upon the concentration of the acid (with respect P2O5) and its specific
gravity. The acid split between fumes scrubber and preneutraliser to hold the mole
ratio in the scrubber liquor at about 1.3 to 1.354.
2. Ammonia:
About 60 to 75% of liquid ammonia to the plant is fed to the preneutraliser
is to adjusted to keep the mole ratio in the slurry at 1.4 1.35. the slurry mole ratio
should not increase beyond 1.5, otherwise the partial pressure of ammonia
increases and losses of ammonia to a great extent. The balance of the ammonia is
fed to the granulator is adjusted to keep the desired mole ratio in product.

3. GRADE TRIMMING AGENTS:

The feed rates of grade trimming agents like urea and filler will depend up on
slurry conditions and granulator operations.
A) UREA: Urea supplies additional nitrogen required to the product. In
percentage of P2O5 content is remaining constant and percentage of nitrogen
content is low in product, urea feed is to be increase to get the required grade of
fertilizer. According to FCO, 2% urea nitrogen is maintained in the product.
B) FILLER:
If the percentage of nitrogen and percentage of P 2O5 contents is high in
product, the filler feed is to be increased to bring down the nutrients to required
grade by trimming. If the scrubber liquor specific gravity raised (solid content).
Filler additional to the plant is also increased. It also acts as no clear to granule.
PLANT WATER BALANCE:
All of the process water feed to the plant is fed to the scrubbing station
feed water mixes with re circulating scrubber liquor and fresh phosphoric acid to
make up the scrubber liquor. The quantity of the re circulating scrubber liquor in
the system is held constant by feeding fresh water to SET to replace the portion of
scrubber liquor fed to the preneutraliser and the evaporation losses in the scrubbers.
II. SCRUBBER SYSTEM CONTROL:
The control of the scrubber system involves mole ratio, specific gravity
and Ph of the foam generation. As the ammonia slip and dust evolution raised due
to normal condition, the mole ratio, specific gravity and Ph of scrubber liquor is
maintained at optimum value. The foam generation in the plant may be due to,
A. High temperature of the slurry
B. High PR feed tank level
C. Bad quality of phosphoric acid, which is made from certain phosphate rocks,
shows a property for generation of persistent foam in the scrubber system and
in the PR feed tank.

The foam generation results in losses of raw material sand serious upsets in
the process. To reduce this problem an anti-foaming agent like oleic acid should be
added on continuous basis for more effective to the SET of the scrubbing system.
Water is sprayed on the surface of foam as last alternative. However, the spraying
of water will results in diluting the slurry to some extent and hence deceases in
production rate. Defoamer addition on continuous basis is the best choice to avoid
the foam generation in the scrubber system.
The control of the scrubbers using pipe reactor for DAP production involves a high
level of ammonia losses from the granulator and pipe reactor which can easily
exceed 30% of the ammonia fed to the process. This is due to,
1 Excessive ammonia sparging
2 Blocking of ammonia sugar
3 Blocked pipe reactor
4 Excessive dryer temperature increases ammonia losses and feeding the
hotter recycle material increases ammonia slip in the granulator.
THE MAIN OBJECTIVES OF THE SCRUBBER SYSTEM CONTROL
ARE:
1 Ensuring a stable flow and composition of scrubber liquor to the pipe
reactor.
2 Maintaining the mole ratio, specific gravity and Ph of scrubber liquor
at optimum level controls scrubber blockages.
3 Maintain high scrubbing efficiency.
To provide a suitable reactor feed slurry, the process is designed to operate in either
of two modes discussed in detailed below.
SCRUBBER LIQUOR AT 1.4 MOLE RATIO, MOISTURE CONTENT 3540%:
This mode contains primary and secondary stage scrubbing system.
Ammonia, which slips through primary scrubber system due to excess ammonia,
gets scrubbed in the secondary scrubbing system with dilute acid medium under
normal conditions of operation. The stack emissions are controlled within
acceptable limits. During excessive slips upsets, the secondary system overloads,
Ph raises to 8 or 9 and ammonia slips through. No solidifications occur because of
high water content.

SCRUBBER LIQUOR AT 0.3 MOLE RATIO, 60-70%:

Moisture content approximately 30% of phosphoric acid added to the
scrubber seal tank. In both the scrubbing modes a central scrubber liquor tank is
used as buffer so that variations in the scrubbing system are damped out before
being carried through to the tee reactor. The moisture content is adjusting the water
flow to the tank.
Problems in plant operations:
1. Blocking of PCR due to scale build up
2. Blocking of Scrubber due to higher ammonia escape to scrubbing system
3. over granulation due to reduction in recycle ratio.
III. PRODUCT COOLING SYSTEM:
As the production rate rose, this system is provided to cool the product in
existing cooler with relatively low temperature air and to supply the vapour
ammonia required in the granulator. In this system, an air cooler and an air heat
exchanger are provided.
In the product cooling system (PCS), dehumidification of air is takes
place. This is an enclosed box having canvas cloth as one of its face. As mild steel
duct provided at the opposite face of the cloth connects the dehumidifier with
product cooler. It contains ammonia coils in air drum is provided on the top of the
enclosed box. A liquid ammonia-circulating pump is also provided for the
circulation of liquid ammonia through ammonia coils.
The saturated air thus produced at a temperature of 100 oC should not be
directly exposed to hot granules because due to difference in relative humidity
between the streams, condensation takes place within the cooler and leads to
caking problem. To overcome this problem, the saturated air is then sent to pass
over the steam coil, which raises the temperature of the air to 180 oC. Thus the
relative humidity of the air decreases. The air then leaves to the cooler.
IV. AMMONIA VAPOURISER:
In winter season the ambient air temperature is at the process-desired
temperature, so the PCS is not taken into working. There by no vapour ammonia
generation takes place. But vapour ammonia is required in the granulator. For this

purpose ammonia vaporizer is providing in which vapour ammonia is produced

from liquid ammonia using steam as heating medium.
The system consists of a vertical surge drum and a shell and tube type
vaporizer. The liquid ammonia taken on the shell side of the vaporizer form surge
drum and med pressure steam at a pressure of 7kg/Cm2 is passed on tube side form
the top of vaporizer. Thus generated vapour ammonia is sent to surge drum. The
condensate is collected and sent to SET. The PCS as well as ammonia vaporizer are
insulated with PUF. The vapour ammonia at a pressure of 2.5- 3.5 Kg/Cm 2 and
temperature of 40oC from both surge drums is sent to the granulator
V. PROCESS CONTROL:
The objectives of the process control with pipe cross reactor are steady
continuous operation at maximum possible production rate consistent with product
quality meeting the specification. An optimum utilization (yield) of raw materials.
The control of the PCR operation involves with following parameters for
increasing production capacity of the plant with required grade. They are
1 Short retention time of reactants.
2 Operating at lesser moisture load by utilizing the heat of reaction.
3 Operating at lesser recycle ratio by maintaining the optimum granulation
conditions.
4 Lower energy consumption by controlling the wetness of the granulator
discharge.
The pipe reactor gives an instant response on control of the granulation. The
feed rates of ammonia and phosphoric acid are controlled to obtain the optimum
mole ratio for good granulation. The balance of ammonia is spared in the recycle
bed of granulator to optimize the product fraction in the granulator discharge,
which also helps for maintaining AG discharge in good condition. The process
water is added directly or as scrubber liquor to the PCR to quench the heat of
reaction and to aid in granulation. The moisture, which is required for effective
granulation, is only fed along with slurry on the recycle bed of AG.
The moisture content of the slurry is controlled by feeding the scrubber
liquor, which in turn controls the dryer outlet temperature to avoid ammonia losses.

The heat released due to the exothermic reactions maintains the high
temperature in the pipe reactor and granulator. Hence the total ammonia is not
reacted and UN reacted ammonia along with generated steam is vented off to the
scrubbing system for recovery of ammonia and carry over dust. The performance
of instrumentation on PCR is very critical to its operation as there is no opportunity
for checking the composition of the slurry entering into AG. This is accomplished
by sending scrubber liquor with constant composition from SET. The product
fraction in AG discharge should be very high; otherwise recycle will increase and
bleed off falls down.

OFFSITES
Away from the plant is called off sites. This department will collect the
raw materials (for the manufacture products) & store that raw material. They
are mainly Ammonia, Phosphoric Acid, Sulphuric acid, water and steam.
MAIN SECTIONS:
1 Water treatment plant.
2 Steam generation Plant.
3 Solar plant.
4 Ammonia storage and handling.
5 Phosphoric Acid storage and handling.
6 Sulphuric acid Storage and handling.
WATER TREATMENT PLANT
Water is one of the most important raw materials for chemical
industries. In COROMANDEL it is used as boiler feed water, cooling tower
water, process water and potable water, firewater.

The chief source of raw water for the plant is Aratla Katla reservoir of
Godavari River in East Godavari District. This raw water contains various
impurities like dissolved mineral matter, turbidity, sediment, color & organic
matter, dissolved gases & microorganisms.
ANALYSIS
Turbidity
PH
P-Alkalinity
M-Alkalinity
Total Hardness
TDS
Chlorides as Cl
Sulphate as SO4
Conductivity
Total hardness

OF

RAW

WATER:

: 6ppm
: 7.3 8.3
: Nil
: 118ppm
: 104ppm
: 214ppm
: 24ppm
: 18ppm
: 376 s/cm
: 100ppm

This water should not be directly fed to the boiler due to be following reason ;
1. FORMATION OF SCALES:
If water containing Ca & Mg salts i.e., hard water is used for producing
steam continuously, the dissolved salts deposit on the boiler tubes as a scale.
The scale has low thermal conductivity and hence increases fuel consumption.
It also leads to tube failure due to corrosion and erosion.
2. Corrosion:
The hydrolysis of the Chlorides of Ca & Mg produces free acids in
water. These acids react with iron walls of the boiler causing corrosion.
Dissolved oxygen also corrodes the boiler.
3. Tube failure:
The scale on the boiler tubes reduces the rate of heat transfer and hence
they are often heated to red-hot. Hence the boiler tubes become softer and
weaker and this cause distortion of boiler tubes.

4. Danger of explosion:
Whenever thick scales crack, due to uneven expansion, water suddenly
comes in contact with overheated tubes. Hence a large amount of steam is
produced suddenly, which may even cause explosion of the boiler.
PROCESS DESCRIPTION:
The plant receives the raw water through pipeline into the cylindrical
dome tank. The water from the dome tank is then pumped either to the open
pond of 7500 m3 or raw water storage tank of 2700 m3 capacity or Flash mixer
according to the requirement. The water from these tanks is again pumped to
flash mixer.

FLASH MIXER:
Alum is injected to the main pipeline from the water pumps to flash
mixer as coagulant. Flash mixer is a small rectangular tank having a stirrer
where lime is added to maintain water at higher Ph due to cause of adding the
alum ph comes down. Max floc-T is also adding in the flash mixer, it is used
for the kill the algae. HCL, Drewchloro, and Hypo these are adding through by
using Generax system. These three chemicals are using for to kill micro
organisms. The water from the flash mixer passed into the clariflocculator from
its bottom.
SEDIMENTATION WITH COAGULATION :
In plain sedimentation finely divided & colloidal impurities, will not
settle down under ordinary conditions, as their settling vacuities are very small
& it needs very long detention period to travel up to tank bottom which is not
practicable. Its there for necessary that these smaller particles are converted
into large ones with higher settling velocities. This is done by coagulation. For
this purpose certain chemicals known as coagulants are added to water in the
tank and thoroughly mixed. The coagulates react with alkaline salts & form a
thick gelatinous precipitate known as flock. This flock has a property of
entangling or attracting fine suspended particle and colloids to form a big flock

which settles relatively rapidly by absorbing colour & carrying bacteria. This
process is called flocculation. In COROMANDEL alum is used as a coagulant
chemical.
The result of sedimentation with coagulation is that, the coloring matter,
bacterial etc., is reduced to great extent. The bottom of the clarifloculator is
blown down at regular intervals so as to reduce the extent of residual matter.
The clarified water tank used in the process is thoroughly cleaned from time to
time to remove the deposits. The water is allowed to retain in the tank for about
2-3 hours and then run in to the filter unit.
Fine particles may be agglomerated to increase their size and permit
settling along with settable solids, so that coagulation of fine particles make
larger ones by flocculation and these are then removed by sedimentation. The
total process is clarification process. The added coagulant assistant in these
operations, which under alkaline conditions form, hydrated colloidal floes of
their hydroxides.

CLARIFLOCULATOR:
The clarifloculator is a circular tank with an inner wall and a sloping
bottom is a combined unit consisting of clarifloculator tank and mechanism
installed concentrically inside a conventional clarifier tank. The clarifloculator
mechanism provides control of the floes formation and the clarifier mechanism
is collects the solids as fast as they settle, conveying them towards central
outlet by means of a blades attached to the slowly revolving paddle arm.
The feed is introduced through the hollow center pier of the clarifloculator
tank. It enters the flocculator compartment below the liquid surface through
openings in the center pier. Here two provided stirrers rotating opposite
direction produce a gentle controllable to and for motion to provide most
effective contact between newly formed floes and incoming liquid without
damaging the flow structure. By this action floes are given intimate impact
with finely divided particulate, which are there by scrubbed out of suspension.
The completely flocculated liquid flows through the opening at the bottom of
clarifloculator tank into clarifier compartment while the settle solids are
conveyed to this opening by means of redial bladed attached to paddle arm.

The solids are given time to settle and be raked inwards as the liquid flows
radically out ward and clear effluent discharged over peripheral weirs. The
collected settled solids from the bottom of clarifloculator are drained
periodically.

The clarified water from the clarifloculator is passed to the clarification tank
through a launder. The clarified water as service water is pumped to DAP
plant, raw material unloading platform and to cooling tower. The water from
this tank is pumped to the sand filters.
FILTRATION:
For Filtration, 2 filters (pressure Type) are installed in
COROMANDEL. The principle of sand filtration is basis in formation of
slurry surface layer consisting finely deviated clay, algae, bacteria etc. the layer
acts as the filtering medium and the finely deviated suspended matter which
escape sedimentation in the clarifloculator, is arrested along with various types
of bacteria by the filter bed. A thin film of layer suspended matter formed on
filter bed, after filtration has proceeded for some time, it is called as vital layer.
Filtration is continued until the resistances build up to such level at which the

rate of filtration is too slow. The bed is then cleaned by scoring with
compressed air and an upward current of liquid carries the solid away.

PRESSURE SAND FILTER:

It is cylindrical bed type filter consists of fine sand, a middle layer of
coarse sand and a bottom layer of graded gravel, supported on a perforated
metal screen. In operation, the water to be filtered is introduced at the top on to
a baffle, which prevents distributing the sand bed by a direct stream.
The capacity of the sand filter is 23M3 /hr and the pressure maintaining in the
pressure sand filter is 0.8 KG/Cm2. The water from the Pressure sand filter is
divided into two sections. They are a) Portable water b) Softening process.

POTABLE WATER TANK:

The water from the pressure sand filter is taken into a tank called
portable water tank where the water is chlorinated for the removal of germs
and bacteria. Chlorination is carried out in the clarification tank by injecting
either chlorine gas from the cylinders of bleaching powder. The chemical
action produces hypo-chlorousacid (HOCL).
CaOCl2
Cl2 + H2O

Ca (OH) 2 + Cl2
HCl + HOCl

Bacterias + HOCl

Bacterias are killed

SOFTENING PROCESS:
The process of removing the hardness of water is termed as softening.
As the evaporation rate in boiler is low the soft water is enough to produce
steam. As soft water contains sodium salts, which are highly soluble even at
high temperatures, the boiler is free from scaling. Due to this the Ca and Mg
salts, the potable water is converted into sodium salts in the softening process.
The system consists of Base exchanger (BE) and strong acidic cation
Exchanger (SAC). The water from the filters to the softening process in split
into two streams to pass in a parallel way through both BE and SAC.

BASE EXCHANGER:
In contains Zeolite (Hydrated sodium alumino Silicate Na 2O. Al2O3,
xSiO2, yH2O) bed, which is provided with freely moving sodium ions for
exchanging with Ca and Mg ions in the passing water.
Na2Ze + Mg (HCO3)2
Na2Ze + CaCl2
Na2Ze + MgSo4

MgZe + 2NaHCO3
CaZe + 2NaCl
MgZe + Na2SO4

REGENERATION:
After certain time of operation as all the cations in Zeolite bed are
replaced by cations present in water the bed exhausted, it has to be regenerated.
Generally brine solution is used for regeneration. Due to higher sodium ion
concentration, reverse ion exchange takes place the bed gets Na 2Ze from the
water along with salts is drained.
CaZe + 2NaCl
Na2Ze + CaCl2
MgZe + 2NaCl
Na2Ze + MgCl2

STRONG ACID CATION EXCHANGER (SAC) :

In this exchanger all the cations are removed. It contains anion
exchanging resin which is insoluble, cross linked long chain organic polymer
with a micro porous structure and the functional group attached to the chain
(R-H are responsible for ion exchanging properties. As the passage water
contains cations through the resin, results in the forwarded reaction.
CaCl2 + 2RH+
R2Ca + 2HCl
+
MgSO4 + 2 RH
R2Mg + H2SO4
+
Ca(HCO3) + 2RH
R2Ca + 2H2CO3
Here the mineral salts have been converted into their respective mineral
acids and the alkaline salt changes into corresponding acid. Hence the SAC
other water low pH and are acidic.
REGENERATION:
As the resin will be exhausted after a certain time of operation, it has to
be regenerated. Generally Sulphuric acid is used for regeneration. Due to high
H+ ion concentration reverse ion exchange takes place and resin gets RH + form
and the salts along with water and acid are drained.
R2Cac (or R2Mg) + H2SO
2RH + CaSO4 (or MgSO4)
Water must be passed in 1:3 ratio of base exchanger and strong acid cation
exchanger to degassifier tank to maintain sufficient pH of boiler feed water.

DEGASSIFIER:
The softened water from both BE and SAC get mixed and directed to top
of the degasified tower where bed of ranching rings are provided. The blower
continuously blows up air through the bottom of the tower. AS the carbonic
acid (H2CO3) being weekly-ionized form in the water, is decomposed into CO 2
and H2O by the blowing air. The degasified soft water is gets collected and
stored in the degassed water tank of 11m3 capacity. As the degasified soft water
contain low pH about 0.5, sodium hydroxide is injected to bring the pH about
8.5 where free mineral acids get neutralized.
HCL + NaOH
H2SO4 +2NaOH

NaCl + H2O
Na 2SO4 + 2H2O

The soft water from the degassed water tank is pumped to water storage tanks
to solar plant. The sodium sulphate and phosphates is injected to the soft water
tank in the boiler house to remove dissolved nascent oxygen in the soft water.

SOFT WATER ANALYSIS:

Hardness
Oxygen

: <5ppm
: <3ppm

PH

: <8.5 9

Free CO2

: Nil

Total dissolved Solids : 400ppm (max)

Conductivity

: 50ppm of Na2SO4

STEAM GENERATION HOUSE

The construction of boiler is of Revotherm chambers supplied by M/s.
THERMAX BOILER LTD.
The Revotherm in general is a horizontal fired, smoke tube type, wet back
packed boiler. The boiler is a high efficient three pass, which can be fired on any
liquid or gaseous fuel. It has well-insulated shell so that the heat losses are low.
Previously the fuel used in the boiler was LSHS, which has any disadvantages.
Firstly the temperature of the fuel has to be raised before being fired, secondly the
heating value is very low and finally the non combustible material in LSHS is also
more which causes exhaustion of excess amount of CO2 in this stack flue gas.
The boiler consists of two cylindrical steel shell arranged vertically with each
other. The inner shell is closed at the back by a plate, which is connected to the rear
tube plate by steel bars. The inner shell is also extended up to the rear back plate.
This forms the combustion chamber and the furnace. The space between the two
shells forms the water room in which tube are fitted. The area between the water
surface and the inner shell forms the steam space.

The front side of the boiler is fitted with a refractory lined door. The door
when opened gives total access to the furnace, burner, smoke tubes and spiral
agitators. The cylindrical boiler shell is fully covered with glass wool insulation
and enclosed in an aluminum sheet at site.
Air is supplied from wind box via a combustion (quench) air fan. The air
is passed down the air register to the firing end, at which the primary air swirler is
provided. The swirler has fully curved vanes so that when air passed through it at
any angle of approximately 600 without much energy the pressure head available
from the fan unit is converted into velocity causing air to flow tangentially toward
in hollow cone. This action causes the pressure to drop in the zone immediately in

front of the atomizer which results in air being thrown out from the air swirler to be
drawn back towards the center and flow back to the atomizer, in the form of
continuously circulation eddy currents. This action is what stabilizers the flame
and what prevent air from burning aimlessly the middle of the furnace. This is
called the primary combustion zone. The certain proportion of the air is passed
around the outside of the swirler, which provides the secondary combustion, and
also in holding the flame shape.

GAS POKER ASSEMBLY:

Natural gas is supplied through 25 nb of four number and gas is metered by
orifice plate which has mounted individual poker assembly connection with
common gas passage. To facilitate proper distribution of gas, a divider plate has
been provided with individual poker outlet nozzle.
BOILER DATA SHEET:
Equipment: Revotherm boiler by M/s. Thermax India Ltd.
Boiler Capacity: 7 TPH and 9 Kg/Sq.cm
Type of Burner: Forced draught gas burner
Location/Mountings: Horizontally fired, front plate of boiler
Flue Gas Temp: 180-220 o C
Steam Out let Temp: 155- 160o C
Natural Gas to Air Ratio: 1:1.5
Natural Gas Pr at Boiler Inlet: 1.5Kg/Cm2
Burner:
Burner Capacity: 5.5 x 106 Kcal/ Hr
Gas flow Rate/Burner: 484 Kg/Hr
SOLAR PLANT
Solar energy which is most abandoned energy by nature. The solar
energy is received be earth in the form of electromagnetic waves. Energy is
received by earth in the form of electromagnetic waves. It is a non-conventional

energy source that is lasts forever. Coromandel has succeeded in moving step
forward to utilize the solar energy by implementation the solar energy system.
Solar plant specifications:Purpose
: pre heating
Water inlet temp
: 30oC
Water outlet Temp
: 80oC
No. Of Collectors modules : 1305
Area of each module
: 2q.m
Storage Tank system
: 4x60000capacity (lit)
Solar Insulation Available : 5.0 KWh/sq.m/day
Pumps
: centrifugal Pumps
Total Project Cost
: Rs/1, 55, 00, 000
PROCESS DESCRIPTION:The solar plant consists of 4 tanks in which 2 tanks combined represent
a system. It has 2 insulated storage tanks in which one is used to recirculation the
water to solar plant panels and the other tank is used to pump the hot water to
boiler at 80C.
Totally there are 1305 solar plates in which each plate consists of water
tubes, which are placed under the black, body which is a perfect absorber. The
water will be circulated through centrifugal pumps to the plates and this water will
be again collected into the tank from plates. The circulation continues until the
water temp is raised to 80C and then the water is send to another tank through 3way pneumatically valve and from the bottom of tank the hot water is pumped to
boiler through centrifugal pump. Similarly the other two tanks also have same
system.

5. AMMONIA STORAGE AND HANDLING :

As the ammonia is the chief and hazardous raw material, its storage
and handling plays a key role in plant maintenance. Coromandel has 2
atmospheric storage tanks each of 5000 MT capacity, 1 new atmospheric
storage tank of capacity 10000 MT and newly constructing storage tank

capacity 12,500 MT. And there is also a refrigeration system for maintaining
the pressure and temperature. The plant has a flare stack system In case of tank
pressures increases and also refrigeration system is not in worked condition to
maintain the sufficient pressure in tanks by using flare stack to burn the toxic
ammonia and vapours..

ATMOPHERIC AMMONIA STORAGE TANKS:

The atmospheric ammonia storage facility serves to store effectively
(2x5000, 1x10000 MT) and (12.500 MT) liquid ammonia at slightly above
atmospheric pressure. Ammonia is almost invariably stored and transported in
liquid state, therefore it must be either compressed or refrigerated or some
combination of two.
The Ammonia is being imported from the other countries by the sea
way on ship. Importing activities are done by the deep-water seaport at
Kakinada.
I .DESIGN CRITERIA:
LIQUID AMMONIA IMPORT FROM SHIP:
Maximum imported rate
: 500TPH
Temp
: -32/-33C
Pressure
: 6.6 kg/cm2
Pipe line length
: 2.6 Km
Capacity of line
: 220MT/Hr
CAPACITY OF AMMONIA IN PLANT:
Atmospheric NH3 tank
:
5000 MT
Atmospheric NH3 tank
:
5000 MT
Atmospheric NH3 tank
:
10000 MT
New Atmospheric NH3 Tank
:
12,500 MT
Total Storage Capacity
: 32,500 MT
SPECIFICATIONS OF AMMONIA:
State
:
liquid
NH3 content
:
99.5%
Water content
:
0.5%

Oil content
Temperature

:
:

20ppm
-33 C

II) AMMONIA STORAGE TANKS:

A) ATMOSPHERIC STORAGE TANKS:
The huge amounts of liquid ammonia is stored in the 4 atmospheric
storage tanks of two having a capacity of 5000 MT and one of 10000MT and
one of 12,500 MT of liquid NH 3 excluding the vapour space and dead level of
pump suction slightly above the atmospheric pressure. These tanks are of
cup-in-tank type (Double integrity). Both the inner and outer tanks are made
of low temperature carbon steel. The outer tanks are insulated with 130 mm
thick polyurethane foam (PUF). Insulation is protected with corrugated
Aluminium sheet cladding. The tanks top and below the roof is insulated with
mineral wool stacked to a thickness of 250mm on a deck suspended from the
dome roof. Totally the insulation is provided in such a way to withstand the
liquid ammonia at 33 C.
The tanks are provided with the 2 pressure relief valves and 2 vacuum
relief valves. The pressure relief valves are arranged in such a way that if the
tank pressure increases and comes beyond the safety measures then the valve
automatically opens and sets the pressure of the tank to a safety limit, similarly
the vacuum relief valves are used to avoid the formation of vacuum in the tank
and also for maximum withdraw condition. There is also a provision made that
if the vapour generation is more than the vapour is drawn and cooled to liquid
state by refrigeration method and the liquid ammonia is brought back to Atm.
Tanks again.

At the initial stage of plant running there were no Atm. Tanks. During
that period ammonia was brought by railway wagons from Visakhapatnam
storage terminal. But due to improved facilities in Kakinada Sea port the
ammonia is being directly imported from the overseas.
III) REFRIGERATION SYSTEM:
PRESSURE CONTROL IN STORAGE TANKS:
The refrigeration system is provided to control the pressure in the
atmospheric tanks. Although insulation is provided some leaks makes the heat
losses and that tends to evaporation of ammonia into vapour form due to that
simultaneously the tank pressure increases. For which refrigeration system is
provided such that it takes the vapours generated from tank and it is
compressed in screw compressors (3 and 2 new in number in which one will
start automatically if over pressure increased) at the time of compression the
vapours will be mixed with oil, these oil vapour mixture having temperature of
60-70C and these are separated by gravity in Oil Vapour Separator and these
oil will be recalculated again through cooler and filters. Oil is cooled in cooler
with cooling water passing through shell side of the cooler. Cooling water is
coming from cooling tower.

The ammonia from oil vapour separator at 60-70C is cooled in a 1-3

pass shell & tube heat exchanger by sending vapours on shell side and
circulating cooling water on tube side. The moderately cooled ammonia at
40C is collected in receiver having capacity of 1m3. The uncondensed
ammonia and nitrogen vapours from receiver are sent to inert gas remover
(helical type heat exchanger) on shell side and liquid ammonia on tube side.
The ammonia from receiver at 40C is flows through expansion valves for
decreasing temperature up to 30C and flows return to the storage tanks.

REFRIGERATION SYSTEM DURING PRECOOLING AND SHIP

UNLOADING:
During ship unloading, as the lines are at moderate temperatures the
liquid displacement causes sudden cooling and more vapour generation so that
The lines should be pre cooled before unloading. This accomplished by cooling
the lines with liquid ammonia from the tank to bring the temperature to liquid
ammonia temperature. During precooling time the line temperature comes up

to -260C when the pipeline temperature will reach the pre cooling will be
stopped. At this time the line is ready for unloading the liquid ammonia from
jetty to storage tanks (-32.50C). During these operations the ammonia vapour
generates more so thats why three compressors will be running at that time.

SPECIFICATIONS OF COMPRESSORS:
Type
: Reciprocating screw type
Capacity
: 124kg/hr
Suction pressure
: 2.4Kg/cm2
Suction Temperature : 118C
Discharge pressure
: 18 kg/cm2
The heat duty
: 3,53,410 kcal/hr
IV) AMMONIA UNLOADING FACILITIES:
A. SHIP UNLOADING OPERATION:
Liquid ammonia is imported from overseas at a temperature of

o
33 C in the refrigerated ships and the ammonia is discharged through
the discharge pumps in the ship. The lines are connected through the
mobile marine unloading arm. As the unloading line gets heated due
to heat leaks it should be pre cooled otherwise due to the sudden flow
of ammonia at low temperature causes undesirable stresses and also
develops more pressure in the tanks. So for this pre cooling line is
used to cool the discharge line. The ammonia from tanks is pumped
through transfer pumps to the pre cooling line and this ammonia will
be recalculated

There is also a separate vaporizer in which steam will be used to

vaporize the ammonia condensate from pre heater and is recycled back to the
pre-heater.
B) UNLOADING FROM TANKS:
The ammonia from atmospheric tanks is pumped through the
vertically erected submersible centrifugal pump with Pressure: 25 Kg/ cm 2
.Temperature is raised by sending the vapour ammonia on shell side to the 1-1
pass shell and tube heat-exchanger (Pre heater) where the liquid ammonia is
passed through the tube side.

V) FLARE STACK SYSTEM:

The flare system is provided to flare vapour ammonia vented from
spherical tanks or from various safety valves. The flare system designed for a
flow rate of 22,000 Kg/Hr. the system consists of pilot burner, flare burner
molecular seal to flare header for maintaining continuous supply of nitrogen to
flare header from maintaining positive pressure in it. LPG is also supplied to
pilot burners for start up. The flare stack designing helps to vent the vapour
ammonia at 25 ppm unburntly.
PROPERTIES OF ANHYDROUS AMMONIA:
(i) Molecular formula: NH3
ii)Molecular weight: 17
(iii)Boiling point at 1 atmp: - 33.4 oC

(iv)Melting print at 1 atmp:-

77.4 oC

(v) Critical temperature: 133oC

(vi) Specific gravity at -33.4oC compared to water at 4oC:0.6819
(vii) Liquid density at -33.4oC and one atmosphere: 681.9 kg/cu.m or 0.6819
gm/ml.
(viii) Specific volume of vapour at 0oC and 1 atmosphere: 1.30 cu.m/kg.
(ix) Latent Heat at - 33.4oC:327.4K cal/Kg
(x) Relative density of vapour compressed to dry air at 0oC and 1 atmp: 0.597
(xi) Vapour Density at 33.4oC and one atmosphere: 0.8899 Kg/Cu.m
(xii) Ignition temp: 651oC
(xiii) Toxicity/Hazard: combustible, explosive mixture with air corrosive to eyes,
skin and lungs.
(xiv) Threshold limiting value (TLV): 50 PPM
(xv) Critical pressure :- 11.4 M Pa
(xvi) Ammonia smell can be detected at : 25 PPM
Anhydrous Ammonia is stored and transported as liquefied gas either without
cooling under a gauge pressure which at 20 oC is approximately 0.76M Pa (7.6bar)
or with refrigeration, at lower temperature and pressure. Mixture of ammonia gas
and air can explode if ignited, when the proportion of ammonia gas is within the
limits of 16 to 26 percent by volume.
VI) PHOSPHORIC ACID STORAGE & HANDLING SYSTEM:
The phosphoric acid that we use contains 54% P2O5.the handling of
phosphoric acid is very difficult as it tends to form sludge. Totally there are
nine tanks 4 tanks of 12,000MT, one tanks of 10,000 MT, 2 tanks of 7,500 MT
and 2 tanks of 5000 MT capacity. The phosphoric acid is sent to DAP through
centrifugal pumps. There is also a day tank near DAP of 1100 MT capacity.

Specifications of Phosphoric. acid :

Specific gravity
: 1.892 at 25C
Boiling point
: >130C
Heat of fusion
: 25.8 Kcal/g
Heat of solution : 1.2 x 105cal/g
Density of
Phosphoric acid : 1.66gm/c.c
P2o5 content
: 53.81%
Fe2O3
: 0.49%
Al2O3
: 0.43%
MgO
: 0.89%
F
: 0.27%
CaO
: 0.07%
H2SO4
: 2.11%
Suspended Solids : 0.10ppm
7) SULPHURIC ACID STORAGE & HANDLING SYSTEM:

Sulphuric Acid ,king of the acids which is used in

COROMANDEL, is 99% concentrated. So that its handling should be done
carefully as it is an hazardous chemical. There are 4 cylindrical tanks each of
capacity 2400 MT. The Sulphuric acid is pumped to DAP through 2 centrifugal
pumps and there is also a day tank of capacity 2500 MT at DAP plant. There is
another small Sulphuric acid tank located at water treatment plant of capacity
of 12MT which is used for regeneration purpose.

SPECIFICATIONS OF SULPHURIC ACID:

H2SO4
: 98%
Pressure
: 3.5 Kg/cm2
Temperature
: Ambient
Density
: 1.82 g/cc

Boiling Point
Melting/Freezing Point

: 338C
:

3C

Solubility in water at 30C

: Sinks and dissolves in water.
Specific Gravity at 20C (H2O=1) : 1.84

BAGGING PLANT

Bagging plant is the last operation in the COROMANDEL. In this

section the product coming from DAP plant is packed or bagged here

through conveyors with polymer bags having size 560 x 860 mm with 50 kg
weight.

THIS PLANT HAS TWO SECTIONS,

1 Old bagging plant
2 New bagging plant.
The cooled fertilizer at a temperature of 40-50 oC from the DAP is plant is
conveyed through the 2 belt conveyors. The bagging plant is provided in
such a way that the product can be bagged otherwise it can be stored in silos
of capacity 25,000MT &18,000MT (New Bagging).
The product from product conveyors is fed through chutes to the conv.1A
and Conv.1B and these conveyors separate the various streams i.e., to
bagging machines,, storage silo and new bagging plant one stream of
product i.e., to bagging machines is fed through conveyors to reversible
conveyors and from there it is fed again to 2 reversible conveyors through
chutes and these reversible conveyors feeds the product to surge bins and
from there product is b aged through bagging machines which will
accurately weigh 50Kg product. The load cell is provided to fill the bag with
exactly 50 Kg products and this cell will be operated pneumatically.
Similarly the new bagging machine, which will bag nearly 22 bags/minute
while as the manual bagging machines in old bagging plant bags nearly 10
bags/minute.
STORAGE SILO:

Silo is provided to store the product if the bagging is not in operation

or some other causes. There are 2 two silos each of capacity 25,000MT. The
conveyor from screen house is sent through the top off silo to the traveling
tripper, which is useful to pour the length of the silo. The stored product will
be reclaimed through pay loaders and they pour on to the conveyors through
hopper. This product is sent for screening through the bucket elevator. The
oversize and fines in the product, which will be formed during storage, are
separated and the product is directed to the bagging conveyors certain
precautions are to be taken while storing, that not to be much exposed to
surroundings due to moisture.
AUTO BAGGING MACHINE:
The bag filling plant is used for bagging of DAP/ NPK granules and
mainly consists of parts discussed below:
1 Automatic Bag fitter
2 Spreading Spout
3 Integrated Bag top transport system
4 Bag transport with link belt conveyor
The bags for singling out are supplied by magazines which are adjustable for
different bag widths. The capacity of magazines varies from 120approximately 600 bags foil thickness of the bags.
AUTO BAGGING FITTER:
The automatic supply of bags is carried out by ABF. It consists of
rigid frame with following components:
I Lifting table for positioning of bag magazines.
II Magazine feed attachment.

III Vacuum system with singling out and bag opening suckers.
IV Rubber chain and positioning motor.
V Swinging frame with bag opening device.
SPREADING SPOUT:
The bag filling spout is a swinging spout with an integrated spreading
device and it is fixed on the supporting frame. All parts in contact with the
product are made up of SS. Integrated clamps on the spreading spout fix the
bag tight on the spout and integrated take over fingers stretch the bag at its
open end. Then the spout swings in a vertical position, during this movement
the spout opens already so that the product can flow into the bag and at the
same time two spreading fingers swing into bag. As soon as the bag is filled,
the clamps and take over fingers release the bag and it drops on to link belt
conveyor underneath. Then the filling spout swings back in its side wards
position and is ready for the next bag. At the same time the spreading fingers
stretch the open end of the bag. Then a closing device closes, to keep the
open end of the bag together. Thereafter the spreading fingers swing out of
the bag.
INTEGRATED BAG TOP TRANSPORT SYSTEM:
It consists mainly of:
1 The scissor- like bag transporting upper part. Two swiveling arms
equipped with transport belts close and fix the formed bag mouth.
2 The link belt conveyor, which removes the bag from the filling
station and transfers it to the sewing / sealing Machine.
3 The lateral guide plates, which keep the bags in upright position
during transport.

SPECIFICATIONS OF PACKING BAGS:

1 Length of the bag :- 90cms(Avg.)
2 Width of the bag :- 55cms(Avg.)
3 Breaking strength :- 113Kgf(Avg.)
4 Weight of the bag :- 120gm
5 Material of the bag :- HDPE (High Density Poly Ethylene)

DUST EXTRACTION SYSTEM:

While transferring the DAP the fines will be over carried by the air
and this makes much dust and pollution so for this the dust at various points
are collected near the chutes, hoppers etc and this lines are connected to
main line which will scrubbed to remove the dust in venturi scrubber
.
Process water is used as the scrubbing liquid and this water is
recirculated through pumps. The scrubbing liquid is used until its
concentration increases and then new water is introduced. The air from
scrubber is sent through the fan to the stack, which is of force draught mist
eliminator is provided to prevent the carry out of moisture.
Process:
1 The feed in the bins are filled with using various conveyors from DAP
plant.
2 The new bagging plant has a one P.L.C unit having capacity 1200
bags per hour & one bin with manual operating system having two
hoppers with capacity 12 bags per minute.
3 The product coming from DAP plant is converted to this section at old
screening section through conv.101, with using flap gates.

DE-DUSTING METHODS:
Dust emissions may be generated during unloading, handling, grinding,
and curing of phosphate rock, in addition to granulation and crushing of
superphosphates.
Emissions of gaseous hydrofluoric acid (HF), silicon tetrafluoride
(SiF4), and chlorides may also generated from acidulation, granulation
and drying.
Emissions from granulation can be reduced by the application of surge
hoppers.

Use of plate bank product cooling systems to reduce air flow

requirements.
Also based on the solids present in the acid ,the dust generation varies.

 The presence of suspended solids, Al2O3, Fe2O3,Cl2

also causes the dust generation.
By varying the acid quality also .the dust generation also varies.

CONCLUSION:
The processes are studied, the
problem of dust generation is
observed when there is a change
in acid composition and presence
of solids. This can be reduced by
maintaining minimum pressure
drop and also by maintaining the
acid quality.