1

Technical Services
CAPITAL BUDGET 2010 - 11
Project no -

TITLE Fluorine recovery From Reactor and New Concentrator

LOCATION PAP Plant area

INVESTMENT
(PROPOSED) 1043.00
in lakhs

STARTING DATE Apr-10

ENDING DATE Mar-11

To further reduce the Fluorine emissions from Reactor and new

OBJECTIVE concentrator and also generate value added product Hydrofluorosilisic
acid

The original Phosphoric acid plant is not provided with Fluorine recovery
system (FRU) either from reactor or from concentration section. The
FRU reduces the Fluorine emission by recovering and converting the
Fluorine gases to a value added product Hydrofluorosilisic acid which is
a raw material for Aluminum fluoride manufacture. Moreover, Pollution
Control authorities are insisting on installation of FRU. In order to meet
this norm and also to recover this fluorine as a value added product this
JUSTIFICATION
project is proposed. The present proposal includes FRU from reactor
and the new concentrator of 350 TPD capacity. The existing cooling
tower system is sufficient to handle the FRU load as the present load on
the cooling tower is only 50% of the design capacity. However the FRU
will increase the pressure drop in the gas flow path which can be taken
care of by augmenting the vacuum system capacity with the help of an
Ejector.

SAVINGS/PAYBACK Rs 298 Lakhs/ 3.5 years

Cost estimation based on M/s Abencs report on Fluorine recovery

BASIS OF ESTIMATE
system dated April 2009
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Fluorine Recovery Unit (FRU) for PAP plant

Index

Executive Summary

Chapter Description Page No.

1 Introduction 5

2 Basis of Design 5

3 Proposed System 8

3.1 Process Description 8

3.2 Utility requirement 10
3.3 Equipment List and data sheet 10
3.4 Instrument List 11
3.5 Piping List 12
3.6 Civil and Structural Requirement 13

4 Project Cost Estimate 13

5 Benefits Estimate and Pay back Calculation 14

6 Time schedule 15
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EXECUTIVE SUMMARY
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1 Introduction

1.1 Paradeep Phosphates Limited has an installed capacity of 900 TPD

Phosphoric acid plant. The plant is of Di hydrate process and produces 27%
P2O5 concentration. This weak phosphoric acid is further concentrated to
52% with a concentration section. The concentration section installed capacity
is 650TPD and consists of two nos 150 TPD concentrators (east and west) and
one no 350 TPD concentrator.Phosphoric acid from reaction and filtration
section after clarification is stored in an intermediate storage tank from where
the acid is being pumped to evaporators. The evaporators are a single effect
rubber-lined flash Chambers with forced circulation graphite heat exchangers.
The evaporating system has a dedicated cooling tower system
.
1.2 This proposal explores the possibility and suggests the installation of FRU in
the existing plant to recover hydrofluorosilicic acid which is used in the
production of Aluminum fluoride

1.3 The Objectives of the FRU system are two fold.

1.3.1 To meet the pollution control board requirement.

1.3.2 To recover FSA (fluorosilisic acid) which is used in manufacture
of Aluminum Fluoride (AlF3). The AlF3 is used in the production
of Aluminum metal

2 Basis of Design

2.1 Material Balance

2.1.1 The material balance for the total complex is given in the Table 1.
The concentrated phosphoric acid to be produced captively is
195775 TPA.
2.1.2 The loading of concentrators is dependent on the steam availability
and considering maximum steam is available for 250 days, the
concentrators can be loaded upto a maximum of 650 TPD.
2.1.3 With an overall concentrator OSD of 330 days, the minimum
loading of the concentrators will be 410-420 TPD. This is shown in
Table 2
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Concentrated Phosphoric acid Requirement: Table 1

All figures in
Tonnes
20:20:0
Products DAP 10:26:26 12:32:16 0 Total
Tonnage considered 850000 200000 150000 300000 1500000
Specific Consumption
P2O5 0.470 0.270 0.332 0.211
Total P2O5 requirement 399500 54002 49800 63300 566602
Weak Acid Consumption 28% 28% 28% 100%
Total Weak P2O5 consumption 111860 15120.56 13944 63300 204225
Envisaged P2O5 Capacity 400000
P2O5 to be imported (strong) 166602
Strong P205 to be produced 195775
Days for which PA plant will run 310
Days for which concentration unit will
run 330
Daily Production of Strong PA 593
Daily Production of Weak PA 1290

Loading pattern of Concentrators : Table 2

Concentrator
Parameter unit Quantity Loading
Maximum concentrator load TPD 650 Max load
No of days maximum steam available days 250
Concentrated Phos acid with max load TPA 162500
Balance Conc Phosphoric acid required TPA 33275
Total OSD of Concentrators days 330
Load of concentrators when max steam not
available TPD 416 Min load

2.2 Fluorine balance

2.2.1 Most phosphate rocks contain an average of 3-4% fluorine. In the

Di-hydrate phosphoric acid manufacture the fluorine released is
distributed as depicted in the following block diagram and pie
chart.
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Basis : 1 TPH P2O5 production

Fluo r in e e m is s io n
Flu o r ine
c o n te nt in Flu o r in e
ga s e ous c o n te nt in
f or m w ea k a c id
26% 23 %

Flu or in e
c on te n t in
Gy ps um
5 1%

2.2.2 As depicted in the Block diagram the fluorine in gaseous form will
be released in the reactor, belt filter, and vacuum cooler condenser
and when the weak acid is concentrated.
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2.3 Areas to install FRU

2.3.1 From the Material and Fluorine balance the concentrators are to be
loaded to a minimum of 420TPD. To match this requirement the
new Concentrator of 350TPD is to be considered for FRU
installation.
2.3.2 The other major area from where the gases directly emanate is the
reactor and installing FRU in this area will reduce the fumes load
on the scrubber and will further reduce the fluorine emission from
the stack. A common circulation tank can be used for installing
FRU for both the reactor and new concentrator scrubbing system.

3 The Proposed System

Please refer Drawing 1
3.1 Process Description
3.1.1 The gases from the reactor and the new concentrator flash chamber
are taken to the ventury scrubber through an entrainment separator.
The entrainment separator will remove the phosphoric acid
entrained droplets as the final product should contain less than
200ppm P2O5.
3.1.2 The HF in the gases is scrubbed by the circulating fluorosilisic acid
(FSA). As depicted in the drawing two separate circulation pumps
circulate the FSA solution to the ventury scrubbers. The scrubbed
gases will then pass to the cyclone separator
3.1.3 The scrubbed gases from the reactor side ventury scrubber will be
taken to the existing scrubber. The scrubbed gases from the new
concentrator side ventury scrubber will be taken to the existing
barometric condenser. The FSA common tank will pump out FSA
of 18-22% based on the level control of the tank

3.1.4 Problems associated with the system :

3.1.4.1 By the addition of equipment in the gas path of the

concentrator unit, the pressure drop will increase by 20-
25mmHg. Please see Table3 for the operating conditions
before and after the installation of the FRU system
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Operating Parameters of the concentrators :Table 3

Flash Flash
Evaporator Chamber Saturation chamber
capacity pressure temp temp
TPD mmHg deg.cels deg.cels
Design conditions
150 58.5 41.5 77
350 58.5 41.5 77
Actual Running parameters
200(west) 81 47.2 79.6

190(east) 85 48 79.8
400(New) 98 51 78.2
Additional pressure drop after the introduction of scrubber is
20mmHg. Expected parameters
150 78.5 47 82.5
350 78.5 47 82.5

3.1.4.2 Limiting Factor: The temperature of the system including

the concentrators and pipelines should not exceed 80
deg.cels. This is to safeguard the Rubber lining of the
system
3.1.4.3 Inference from the table: Introduction of FRU increases the
pressure and the resultant temperature is well beyond the
safety limit.

3.1.5 How to overcome the Problem

The temperature of the system will not rise if the pressure is maintained as
per design conditions. This can be achieved by augmenting the vacuum
system by ejector or a liquid ring vacuum pump in series with the existing
ejectors.However to install an ejector will be easier and this option is
considered in the proposal.
Please refer Drawing 2 and P&ID.
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3.2 Utility requirements :

The requirements are mentioned in Table 4

Table 4
s.no parameter units
1 Power kwh
Calculated from equipment
1.1 FSA circulation pump 2 online 233 data
1.2 FSA transfer pump 1 online 6 of M/s Abencs report
Total 238
tph
2 Steam @ 7barg 1.76 Taken from the present
ejector in 350TPD conc
m3/hr
3 Make up water 10
Nm3/hr
4 Instrument air 8

3.3 Equipment List:

The total equipment list is attached at Table 5

Table 5
Equipment List
s no Equipment name Equipment details quantity
1 Ventury scrubber CS with R/L 2
2 Cyclone Separator CS with R/L 2
Dia : 4.5 m
height : 9 m
3 Entrainment CS with R/L 2
separator
4 FSA circulation Capacity : 800m3/hr 2
pump Head : 29 mLc
Casing & impeller
=- UHMW PE

5 FSA seal tank Capacity : 30 m3 1

dia: 3.5m
Height :3.5
CS with R/L with
carbon bricks at the
Bottom

6 FSA transfer pump Capacity : 47 m3/hr 1

s no Equipment name Equipment details quantity
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Head : 24 mLc
Casing & impeller
=- UHMW PE

7 Storage Tank Capacity : 100 m3 1

dia: 12 m
Height :9
CS with R/L with
carbon bricks at the
Bottom
8 Loading pump Capacity : 40 m3/hr 1
Head : 18 mLc
Casing & impeller
=- UHMW PE

9 Ejector Single stage ejector 1

with a non-condensable
load of 180 kg/hr air,
CO2
and fluorine
MOC : Alloy 20

3.4 Instrument List (Pl refer P&ID) and Table 6

Table 6
s.no Item description nos Type of control type of indication
Make up water Flow
Element Orifice meter ,
Flow Indication
Controller ,Flow Control
1 Valve 1 Close loop control panel indication
FSA bleed off Flow element
Magnetic flow meter Teflon
lined, Flow Indication
2 Transmitter 1 open loop panel indication
FSA bleed off purge
bubbler type Level
Indicators, Level Indication
transmitter and Level
3 Control Valve 1 Close loop panel indication
4 Pressure Indicators 6 Open loop local indication

3.5 Piping List

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Table 7
size,mm MOC
1 Duct for gases from reactor to entrainment separator 1400 CSRL
Duct for gases from 3rd con Flash chamber to entrainment
2 separator 1400 CSRL
Duct for gases from Entrainment separator of react to ventury
3 scrubber 1400 CSRL
Duct for gases from Entrainment separator of 3rd Conc
4 ventury scrubber 1400 CSRL
5 Duct for gases from cyclone sepa of 3rd con to bar condenser 1400 CSRL
6 Duct for gases from cyclone sepa of reactor to scrubber 1400 CSRL
7 pipeline circulation pump suction 500 HDPE
8 pipeline circulation pump discharge 350 HDPE
9 pipeline transfer pump suction 80 HDPE
10 pipeline transfer pump discharge 50 HDPE
11 Cyclone separator downtake (reactor scrubber) 500 HDPE
12 Cyclone separator downtake (3rd Con scrubber) 500 HDPE
13 Make up water line 50 HDPE
14 Duct from bar condenser to new ejector 750 CSRL
15 duct from new ejector to old ejector 250 CSRL
16 Medium pressure steam line 150 CS

3.6 Civil and structural requirement :

The major equipment namely the scrubbers, the entrainment separators and
the cyclone separators are to be supported with civil foundation and cross
structural beams

4 Project Cost Estimate

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4.1 The cost estimate is based on the study report given by M/s Abencs
Engineering Pvt Ltd. Table 8 shows the item wise cost.

Table 8
Cost estimate for FRU with ejector
system
s.no Item nos cost
(Rs lakhs)

1 Scrubber with spray

nozzle assembly 2 40
2 Scrubber separator 2 66
3 Entrainment separator 2 40
4 FSA seal tank 1 10
5 FSA circulation pump 4 105
6 FSA transfer pump 2 15
7 FSA loading pump 2 12
8 FSA storage tank 1 70
9 Additional Ejector in the 1 25
evaporator circuit
10 instrumentation 49
11 electricals 30
12 Ducting and piping 75
13 Modification and insta 25
llation at site
14 Basic and Detailed engg 150
and project Management
15 Civil design and site 90
construction
Total Cost 802

Contingencies @ 10% 80.2

Contractor O/H + site expen 160.4

penses + travel expenses
@20% of total cost

Grand total 1043

5 Savings and Payback Calculations

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5.1 Basis of Calculations

FSA generation at 22% for 750 TPD
1 concentrator 158 TPD
FSA generation at 22% for 350 TPD
2 concentrator 79 TPD

3 FSA generation at 100% for 350 TPD 17 TPD

4 Annual production@ 300 OSD 5214 TPA

Cost of FSA unit for reactor and 350 TPD
5 Concentrator 1043 Rs lakhs

5.2Payback calculations
s.no Item Rs/T
A Operating Cost 4211
A1 Power 1117
A2 Steam 762
A3 Make up water 8
A4 Labour 7
A5 Depreciation @ 5.28% 1056
Annualized
A6 Insurance @ 1% 200
A7 Maintenance cost @5% 1000
B Cost of investment @13% 7230

C total cost 11441

D Profit @ 50% of total cost 5721

E Selling price at Factory 17162

F Annual savings Rs Lakhs 298

per annum
G Payback years 3.5

6 Time schedule
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6.1 Considering major milestones like equipment delivery and erection the total
project will take 12-14 months from the date of sanction of the project.