4.

1 Overall Material Balance

Basis: 1500 tons/day of DAP

Analysis of DAP based on %age availability of nutrients.

N2 = 18%

P2O5 = 46%

H2O = 1%

4.1.1 Phosphoric Acid Requirements:

Analysis of commercially available H3PO4,

H3PO4 = 71.77%

H2O = 13.187%

Inerts = 15.04%

Now

For 18-46-0 grade Di-ammonium Phosphate:

100 TPD of DAP has P2O5 = 46 TPD

1 TPD of DAP has P2O5 = 46/100 = 0.46

1500 TPD of DAP has P2O5 = 1500 x 0.46 = 690 TPD

Since from the Phosphoric Acid analysis is, (52 % P2O5).

52 TPD of P2O5 is obtained from = 100 TPD of Phosphoric Acid

1 TPD of P2O5 is obtained from = 100/52

690 TPD of P2O5 is obtained from = (100/52) x 690

= 1326.92 TPD of Phosphoric Acid

Total H3PO4 required = 1326.92 TPD

Now, the ratio of phosphoric acid fed to the reactor to that of scrubber is 1.71:1. [7]

So,

H3PO4 fed to Reactor = 1326.92 x (1.71/2.71)

= 832.38 TPD

H3PO4 fed to Scrubber = 1326.92 – 832.38

= 494.54 TPD

4.1.2 Ammonia Requirement:

Analysis of commercially available Ammonia.

NH3 = 99.5%

And Available Nitrogen is

N2 = 82%

Nitrogen Requirement:

100 TPD of DAP requires Nitrogen = 18 TPD

1 TPD of DAP requires Nitrogen = 18/100 = 0.18

1500 TPD of DAP requires Nitrogen = 0.18 x 1500 = 270 TPD

Ammonia Requirements:

For 14 TPD Nitrogen, Ammonia required = 17 TPD

For 1 TPD Nitrogen, Ammonia required = 17/14 = 1.2143

For 270 TPD Nitrogen, Ammonia required = 1.2143 x 270 = 327.86 TPD

And 5% Ammonia is fed in excess to account for the losses.

So, Now

Total Ammonia Required = 327.86 x 1.05

Total Ammonia Required = 344.25 TPD

Ratio of Ammonia fed to Cross pipe reactor to that fed to Granulator is 1.92:1 7

So,

Ammonia fed to Reactor = 344.25 x

(1.92/2.92)
= 226.36 TPD

Ammonia fed to Granulator = 344.25 – 226.36

= 117.89 TPD

4.1.3 Dilution Water requirement in the scrubber acid (35%):

Specification of feed using is:

H3PO4 = 71.77%

P2O5 = 52%

H2O = 13.187%

Inerts = 15.04%

For optimum result, the P2O5 contents of H3PO4 are reduced to 35% is scrubber by the
addition of extra water.

As we know that P2O5 content is 52 % in 71.77% H3PO4.

So,

P2O5 coming in feed = 0.52 x 979.28

 = 509.23 TPD

But we have to reduce it to 35 %

So,

Total feed volume = 509.23 x (1/0.35)

= 1454.94 TPD

Dilution Water = 1454.94 – 979.28

= 474.66 TPD

4.2 Material Balance around Reactor

Input Streams:

 Phosphoric Acid from Storage Tank

 Ammonia from Storage Tank
 Scrubber stream
Output Streams:

 Product to Granulator
 Vapor Vent
4.2.1 Scrubber Stream:

H3PO4 Balance:

H3PO4 fed to Scrubber = 979.28 TPD

As the feed is 71.77% H3PO4 acid

So, = 979.28 x 0.7177

= 702.83 TPD

NH3 Balance:

As N:P feed ratio to Reactor is 1.4:1 [5]

Let “a” be the NH3 in scrubber stream

Total NH3 fed to Reactor = (453.71+ a)

Total H3PO4 fed to the Reactor = 702.83+1201.84

= 1904.67 TPD

So, Ratio is calculated as:

[(453.71+a) / 17] ÷ [1904.67 / 97] = 1.4

453.71+a = 467.4

a = 14.69 TPD

Inert Balance:

H3PO4 fed to Scrubber = 979.28 TPD

Inert (15.048 %) = 979.28 x 0.15048

= 147.36 TPD

Water Balance:

As we have to maintain the 52% P2O5 contents in the form of H3PO4 in the reactor. Therefore,

H3PO4 (52% P2O5) contains = 71.77 % H3PO4

If H3PO4 (1 % P2O5) contains = (71.77/52) % H3PO4

As H3PO4 coming from scrubber has (35% P2O5) contents.

So,

1904.67 TPD of H3PO4 formed MAP (Mono-Ammonium Phosphate) is:

= (mol weight of MAP / mol weight of H3PO4) x 1904.67

MAP (Mono-Ammonium Phosphate) = (114/97) x 1904.67

= 2238.48 TPD

Now,

Number of moles of H3PO4 = 1904.67/97

= 19.64 moles

Chemical Equation:

NH3 + H3PO4 NH4HPO4

From equation 19.64 moles of H3PO4 react with 19.64 moles of NH3.

So,

Reacted Ammonia NH3 = 19.64 x 17

= 333.88 TPD

Now,

Total Ammonia entering to the Reactor = NH3 from Storage + NH3 from
Scrubber

= 452.71 + 14.69

= 467.4 TPD

Total unreacted Ammonia NH3 = 467.4 – 333.88

= 133.52 TPD

As the temperature is very high in reactor so we assume that only 35.26% NH3 entering to
scrubber:

= 47.08 TPD

And 47.08 is the 9.9% of the total stream (W) going to the scrubber.
So, 0.099 W = 47.08

W = 475.56 TPD

And
Water in this stream is = 475.56 x (1-0.099)

= 428.48 TPD
4.2.2 Product to Granulator:

MAP (Mono-Ammonium Phosphate) is formed = 2238.48 TPD

Water Balance:

Water In = Water Out

Water (Phosphoric acid storage) + Water (From Scrubber) = Water (Vapor vent) + Water (Granulator)

220.83 + 825.91 = 428.48 + Water

(Granulator)

Water to granulator = Water (Granulator) = 619.26 TPD

Unreacted Ammonia:

As calculated before total unreacted Ammonia = 133.52 TPD

Unreacted Ammonia fed to Granulator = 133.52 – 47.08

= 86.44 TPD
Inert Balance:

Total Inert = Inert (Phosphoric acid storage) + Inert (From Scrubber)

= 251.85 + 147.36

= 399.21 TPD
4.2.3 Summary of the Material Balance around the Reactor

Input Streams:

Streams H3PO4 P2O5 (52%) NH3 N2 (82%) H2O nerts

TPD) TPD) TPD) TPD) TPD) TPD)
Ammonia
Storage 452.71 371.2
Tank

Phosphoric
Acid
Storage 1201.87 870.78 220.83 251.85
Tank

Scrubber
stream 702.83 509.23 14.69 12.05 825.91 147.36

Total 1904.67 1380.01 467.4 383.25 1046.74 399.21

Output Streams:

Streams H3PO4 P2O5 (52%) NH3 N2 (82%) H2O nerts

TPD) TPD) TPD) TPD) TPD) TPD)
Vapor Vent
Stream 47.08 38.60 834.48
Product to
Granulator 1904.67 1380.01 333.88 273.8 212.26 399.21

Total 1904.67 1380.01 380.96 312.4 1046.74 399.21

4.3 Material Balance around Granulator:

Input Streams:

 From Reactor
 Vapors from Reactor
 Ammonia from Storage Tank
 Recycle Stream from Screens
Output Streams:

 Product to Cooler
 Stream to Scrubber
4.3.1 Recycle stream from Screens:

Water Balance:

As recycle ratio us 1:3 [5]

So, we have

Total recycle = 3000 x 3 = 9000 TPD

And we have only 1% water in finish product.

Water contents = 9000 x 0.01 = 90 TPD

Inerts Balance:

NH3 + NH4H2PO4 (NH4)2HPO4

MAP DAP
114 TPD 131 TPD

Here,

1 mol MAP produce = 1 mol of DAP

114 TPD MAP produce = 131 TPD of DAP

 1 TPD MAP produce = 131/114 TPD of DAP

2238.48 TPD MAP produce = (131/114) x 2238.48

DAP produce = 2572.3 TPD

As, 3000 TPD of DAP product contains 2572.3 TPD of pure DAP.

We can write as:

3000 TPD of DAP = 2572.3 TPD of DAP (Pure) + 1% water + Inerts

So,

Inerts = 3000 - 2572.3 - 30

Inerts in DAP = 397.7 TPD (In 3000 TPD of DAP)

Total Inerts = 397.7 x 3 (In 9000 TPD of DAP)

= 1193.1 TPD

DAP Balance:

3000 TPD of DAP = TPD of DAP (Pure) + 1% water + Inerts

9000 TPD of DAP = TPD of DAP (Pure) + 3 x 1% water + Inerts

So,

DAP (Pure) = 9000 - 90 - 1193.1

DAP (Pure) Recycle to Granulator = 7716.9 TPD

4.3.2 Product to Cooler

DAP Balance:

Total DAP = DAP (Formed) + DAP (Recycle)

Total DAP = 2572.3 + 7716.9

Total DAP = 10289.2 TPD

Inerts Balance:

Total Inerts = Inerts (In formed DAP) + Inerts (In Recycle DAP)

Total Inerts = 399.21 + 1193.1

Total Inerts = 1592.31 TPD

Water Balance:

As DAP product coming out from granulator having 3.5% water contents.

Let “G” be the total mass of product coming out from Granulator.

So,

10289.2 + 1592.31 + 0.035 x G = G

11881.51 = 0.965 G

Total product coming out from Granulator = G = 12312.45 TPD

And 3.5% water contents = 0.035 x 12312.45

= 430.94 TPD

4.3.3 Stream to Scrubber

Water Balance:

Water In = Water Out

Water (In reactor product) + Water (In Reactor vapors) + Water (In recycle stream) = Water (In cooler stream) +Water (In scrubber
stream)

212.26 + 834.48 + 90 = 430.94 + Water (In scrubber stream)

Water (In scrubber stream) = 705.8 TPD

Ammonia Balance:

If “S” is the total Vapor Stream to Scrubber and having 94.6% water contens.

As, 94.6% Water of Stream “S” = 705.8 TPD

S = 746.1 TPD

So,

Ammonia Contents (To Scrubber) = 746.1 - 705.8

= 40.3 TPD
4.3.4 Summary of Material Balance around Granulator

Inputs Streams:

Streams H3PO4 P2O5 (52%) NH3 N2 (82%) H2O nerts

TPD) TPD) TPD) TPD) TPD) TPD)
Reactor
Stream 1904.67 1380.01 333.88 273.8 212.26 399.21
Vapors
rom 47.08 38.6 834.48
Reactor
Recycle
Stream of 5768.43 4140 1967.1 1620 90 1193.1
Screens

Ammonia
From 235.79 193.35
Storage
Total 7673.1 5520.01 2583.85 2125.75 1136.74 1592.31

Output Streams:

Streams H3PO4 P2O5 (52%) NH3 N2 (82%) H2O nerts

TPD) TPD) TPD) TPD) TPD) TPD)
Product to
Cooler 7673.1 5520 2543.55 2085.70 430.94 1592.3
Vapors to
Scrubbers 40.3 33.05 705.8

Total 7673.1 5520.01 2583.85 2125.75 1136.74 1592.3

4.4 Material Balance around Scrubber

Input Streams:

 Phosphoric Acid from Storage

 From Granulator
Outputs Streams:

 To Reactor
 Vent Off

4.4.1 Phosphoric Acid from Storage

Phosphoric acid fed to Scrubber = 979.28 TPD

And it contains 71.77% H3PO4, 13.187 % H2O, and 15.048% Inerts

H3PO4 = 702.83 TPD

H2O = dilution water + 129.13

= 475.66 + 129.13

= 604.78 TPD

Inerts = 147.4 TPD

4.4.2 From Granulator:

Ammonia NH3 = 40.3 TPD

Water contents = 705.8 TPD

4.4.3 To Reactor:

H3PO4 = 702.83 TPD

NH3 = 14.69 TPD

H2O = 825.91 TPD

Inerts = 147.36 TPD

4.4.4 Vent Off:

Ammonia NH3 Balance:

Ammonia In = Ammonia Out

40.3 = 14.69 + HN3 (vent off)

HN3 (vent off) = 25.61 TPD

Water Balance:

Water In = Water Out

604.78 + 705.8 = 825.91 + H2O (Vent of)

H2O (Vent of0 = 484.67 TPD

4.4.5 Summary of Material Balance around Scrubber

Input Streams:

Streams H3PO4 P2O5 (52%) NH3 N2 (82%) H2O nerts

TPD) TPD) TPD) TPD) TPD) TPD)
Phosphoric
Acid from 702.83 509.23 604.78 147.4
Storage
Vapors to
Scrubbers 40.3 33.05 705.8

Total 702.83 509.23 40.3 33.05 1310.58 147.4

Output Streams:

Streams H3PO4 P2O5 (52%) NH3 N2 (82%) H2O Nerts

TPD) TPD) TPD) TPD) TPD) TPD)
To Reactor 702.83 509.23 14.69 12.1 825.91 147.4
Vent Off 25.61 20.1 484.67

Total 702.83 509.23 40.3 33.05 1310.58 147.4

4.5 Material Balance around Cooler

Input Streams:

 From Granulator
Output Streams:

 Cooler out
 Water vapors

4.5.1 From Granulator:

DAP = 10289.2 TPD

H2O = 430.95 TPD

Inerts = 1592.31 TPD

4.5.2 Cooler Out:

Water Balance:

Let “C” be the total final product coming out from cooler and having only 1% water conten.

So,
Total final Product DAP = C = 10289.2 + 1592.31 +
0.01C

(1-0.01) C = 11881
C = 12001.53 TPD

And

Water Contents = 0.01 x 12001.53

= 120.01 TPD

4.5.3 Water Vent:

Water In = Water Out

430.94 = 120.01 + Water (Vent)

Water (Vent) = 310.93 TPD

4.6 Material Balance around Screens

Input Streams:

 From Cooler
 From Crusher
Output Streams:

 Recycle
 Carrier to Crusher
 Product to Conveyor

4.6.1 From Cooler

Total Feed = 12001.53 TPD

DAP = 10289.21 TPD

Water H2O = 120.01 TPD

Inerts = 1592.31 TPD

4.6.2 Recycle

Total Feed = 9000 TPD

DAP = 7716.9 TPD

 Water H2O = 90 TPD

Inerts = 1193.1 TPD

4.6.3 Coarser to Crusher

Let’s suppose that 38% of the feed from cooler is off coarse particle. So sent to crusher.

Total feed to Crusher = 0.38 x 12001.53

= 4560.58 TPD

Water Balance:

1% of 4560.58 TPD = 45.61 TPD

Inerts Balance:

38% of 1592.31 Inerts = 605.1 TPD

4.6.4 Product to Conveyor

DAP Balance:

DAP (From cooler) + DAP (To crusher) = DAP (Recycle) + DAP (From Crusher) + DAP (Final)

10289.2 + 4560.58 = 7716.9 + 4560.58 + DAP (Final)

DAP (Final) = 2572.3 TPD

Water Balance:

Water In = Water Out

120.01 = 90 + Water (In final product)

Water (In final product) = 30.01 TPD

Inerts Balance:

Inerts In = Inerts Out

1592.31 = 1193.1 + Inerts (In final product)

Inerts (In final product) = 399.21 TPD

4.6.5 Summary of Material Balance around Screens:
Input Streams Output Streams
Granules Destination Oversize – Right Undersized-
of output 4+6 mesh Size- 9+12 12+25mesh Streams
Streams (7-4 mm) mesh (2-1 mm) Total
(4-2mm)
Equipment (TPD) (TPD) (TPD) (TPD) (TPD)
From 12001.53
Cooler 3000 3000
To chain
Mill 4560.58 4560.58

From Recycle
Crusher 4560.58 Stream 9000 9000

Total Input 16562.11 Total

Streams Output 4560.58 3000 9000 16560.58
Streams