IDOCUMENT CODE I NPP-WP-IMS-001 I REV . # I 00 IREV. DATE I 25.08.

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5.2 Rock Phosphate Dissolution [ UNCONTROLLED I
Chemistry
NP fertilizer is a compound fertilizer. It is produced by nitric acid route i.e. rock
phosphate is dissolved in nitric acid to produce phosphorous acid. Calcium nitrate
is produced as by-product. Rock phosphate mainly consists of 3Ca3 (p04h.CaX 2.
where X is one of the following elements and/or groups: F, CL, OH , % C0 3, e.g.
CalOF2(P04)s. Rock phosphate is dissolved in nitric acid to convert its available
water insoluble phosphorous (P 20 S ) content into water and citrate soluble
phosphorous. Only water or citrate soluble phosphorous is available to plants for
their use. Rock phosphate dissolution in nitric acid (57-60%wt) yields phosphoric
acid and calcium nitrate as major and calcium sulphate, metal (Mg, Fe, AI, K, and
Na) nitrates, calcium fluorosilicate, hydrogen fluorides, and carbon dioxide as
minor compounds. The residue is acid insoluble or inerts which are around 2-4%
(wt) of the rock phosphate.
Chemical reactions involved in rock phosphate dissolution with nitric acid are

CaC0 3 + 2 HN0 3 ~ Ca(N0 3h + H20 + CO 2 ORIGINAL

CaF2 + 2HN0 3 • Ca(N0 3h + 2HF WHEN IN RED

Ca(N0 3h + Si0 2 + 6HF --.~ CaSiF 6 + 2Hr---I0 3 + 2H 20

Ca3 (P0 4h + 6HN0 3 ~ 3Ca (N0 3h + 2H 3P0 4

Important side reactions are

Fe20 3 + 6HN0 3 ~ 2Fe(N0 3h + 3H 20

AI 20 3 + 6HN0 3 --.~ 2AI(N0 3h + 3H 20

Process
Continuous stirred tank reactors (CSTR) 6-40-2002NB and 6-40-2003NB are
equipped with anchor type agitators 6-40-131 ONB and 6-40-1330NB respectively
which used to mix and dissolve rock phosphate in nitric acid. Ag itators have VFD
motors to change their speed as per requirement. Its maximum speed is 34
revolutions per minute. Each reactor consists of four baffles to enhance agitation.
Two trains of reactors are installed to have operational and maintenance flexibility .
Both trains operate in parallel; each train consists of two reactors in series to
achieve adequate residence time for rock dissolution in nitric acid which is around
85 minutes. Rock phosphate is measured by weigh belt feeder's 6-40-1801NB
according to rock load input from control room (DCS). Rock phosphate is
conveyed to first dissolution reactor 6-40-2002NB through weigh belt feeder 6-40­
1801NB and sealing screw 6-40-1208NB. Seal screw besides rock conveying
also provides sealing against fumes to escape through rock inlet chute of reactor.
Rock phosphate is fed into the first reactor 6-40-2002NB of each train under ratio
control with battery limit (fresh) nitric acid . Nitric acid ratio against master flow rock
phosphate is controlled to maintain desired free acid ratio (0.4 to 0.6)in final
digesting slurry. Part of total nitric acid required to dissolve rock phosphate in
dissolving reactors comes from CN filtration section . Nitric acid used for CN cake
repulping and CN cake washing in CN filtration section is recycled to dissolving
reactors 6-40-2002NB, called as "wash acid". Wash acid is fed into dissolving
reactors under ratio control with rock flow. In cascade control rock phosphate
being master flow, controls ratio of both fresh nitric acid and wash acid to
dissolving reactors. Digesting slurry from first dissolution reactor overflows to
second dissolution reactor 6-40-2003NB under gravity. After mixing in second
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dissolution reactor slurry overflows to the decanter feed tank 6-40-2088 for inerti='-_ _ _ _ __
separation . From decanter centrifuges after inerts separation, digesting slurr ORIGINAL
flows to buffer tank 6-40-2005 . In buffer tank 6-40-2005 digesting slurry free aci
ratio is maintained around 0.4 to 0.6 for complete digestion of rock phosphate i WHEN IN RE
nitric acid. Exothermic dissolution reactions tend to raise the operatin
temperature of dissolution reactors up to 80°C. At higher temperature NOx, HF
and C02 emission rate from dissolution reactors is increased tremendously. High
NOx& HF emission creates health, safety & environmental issues whereas high
C02 production causes excessive foaming in dissolution reactors. Optimum
operating temperature for complete dissolution of rock phosphate in nitric acid is
70°C . To control reactors operating temperature, battery limit nitric acid is cooled
down in nitric acid coolers 6-40-2120 and 6-40-2124 from 60°C to about 40°C .
Dissolution reactors operate at slight sub atmospheric pressure (0.1 kg/cm2g)
induced by gas scrubbing system . To reduce NOx emission from 3000 ppm to
300 ppm 40%wt urea solution is added into dissolution reactors. Gases produced
during rock dissolution are treated in scrubbing system prior their emission into
atmosphere. Hydrogen fluorides are scrubbed in scrubbing system and
discharged to liquid effluent handling section . Water base antifoam solution is
used to control foaming inside dissolving reactors. Mechanical foam breakers
mounted on agitator shaft are also contributing to suppress foaming inside
dissolving reactors 6-40-2002A1B and 6-40-2003A1B . [
_ UNCONTROLLED ]
5.3 Inert Separation ---------.J
Rock phosphate contains around 2-4%wt acid insoluble mainly inerts and quarts.

The- -pfes8n-ee-etf--inerts in digesting slurry is very hazardous for process

equ ipment's. They cause erosion in pumps, agitators , heat exchangers, valves,

vessels and pipelines. Inerts presence or accumulation in process tanks reduces

their operating capacity. Inert also cause chocking and resistance to flow inside

pipelines and valves.

Digesting slurry from second reactor of each train overflows to decanter feed tank

6-40-2088 after passing through duplex strainers 6-40-2006A and 6-40-2006B .

Both strainers are installed inside decanter feed tank, one for each dissolution

reactor train. These strainers remove foreign material, scaling lumps, metal pieces

etc. from digesting slurry to prevent their carry over to decanter centrifuges.

Carrying over of these heavy particles to decanter centrifuges may result in their

wear &tear, unbalance and vibration . To remove acid insoluble's five screw

decanter centrifuges 6-40-1424, 6-40-1425, 6-40-1426, 6-40-1427, and 6-40-1428

are installed. All operate in parallel to each other. Each centrifuge capacity is 12.5

m3 per hour (max) at operating speed 1000 G. About 50%wt of total inerts in

digesting slurry is removed by these centrifuges. The digesting slurry from

decanter centrifuges after inert separation is collected in buffer tank, 6-40-2005 .

Decanter centrifuges 6-40-1424 and 6-40-1426 discard inter sludge to sludge

screw conveyor 6-40-1259. Whereas decanter centrifuges 6-40-1425, 6-40-1427

and 6-40-1428 dump their sludge to sludge screw conveyor, 6-40-1260 . Both

sludge screw conveyors 6-40-1259 and 6-40-1260 pour their sludge into sludge

screw conveyor, 6-40-1261 which itself feed sludge to inert belt filter 6-40-2317 for

its washing to recover entrained phosphoric acid (P20S). Vapor condensate /

demineralized water and RT filter filtrate are mixed with sludge for its repulping

prior its feeding to inert belt filter (RT filter) .

5.4 Inert Washing

Wet cake containing around 3.5%wt phosphate solution and 30%wt inert solids

separated by decanter centrifuges is fed to horizontal vacuum belt filter 6-14-2317

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2011 and vapor condensate tank 6-17-2010 is pumped to mother liquor tank,
scrubbers for demister cleaning, RT filter, nitric acid solution tank, ETP feed tank,
CN buffer tank, AC reactor, pressure filter, FFE separators demister pads and
liquid effluent pit.
Descaling
AN solution contains around 200 ppm lime which come with AN solution from lime
pressure filter as slippage. Lime causes scale deposit inside AN evaporator. Lean
nitric acid (20-25%wt) is re-circulated through the whole evaporator to remove
scaling . A recirculation tank 6-17-2027 (nitric acid solution tank) and re-circulation
pump 6-17-1121 is installed for evaporator cleaning. For scale cleaning,
evaporator is taken offline; drained and flushed with water. Nitric acid 57%wt from
battery limit header and vapor condensate / demineralized water is added in nitric
acid solution tank 6-17-2027 to prepare 25% lean nitric acid solution. Lean nitric
nd
acid solution is pumped through pump 6-17-1121to 2 effect evaporator. From 2nd
effect separator 6-17-2208 lean nitric acid is pumped through pumps 6-17­
1109/1189 to 1sl effect evaporator. From 1sl effect evaporator's separator 6-17­
nd
2207 lean nitric acid is pumped through pumps 6-17-1110/1190 back to 2 effect
in close circulation. After cleaning wash liquid is either collected in nitric acid
solution tank 6-17-2027 or disposed of into drain channel. i
ORIGINAL
5.18 Gaseous Effluent Handling UNCONTROLLED WHEN IN prf/ :

Process vent gases are scrubbed in liquid to minimize their hazardous impact on
environment before their emission into atmosphere. Scrubbers equipped with
liquid spray nozzles, recirculation pump are installed for gases scrubbing. Acidic
and basic gases are scrubbed and treated separately.
Acidic Gas Scrubbing
Two scrubbers with recirculation pumps and exhaust blower are installed for the
scrubbing and treatment of acidic gases.
(i) Reactor Vent Scrubber
Gases acidic in nature containing NOx from dissolution reactors, buffer tank,
decanter feed tank and decanter centrifuges are drawn by reactor vent scrubber
exhauster 6-40-1002 into reactor vent scrubber 6-40-2211 . Demineralized water is
added in scrubber to establish re-recirculation for effective scrubbing . Urea
solution (40%) is added into reactors and scrubber to for treatment of NOx. Urea
converts NOx into nitrogen and carbon dioxide according to following reaction

2HN0 2 + NH r CO-NH 2 • 2N2 + CO 2 + 3H 20

Urea solution is pumped from urea solution tank 6-40-2054 through pumps 6-40­
1163/1164 and is sprayed in reactor vent scrubber gases inlet duct for its effective
mixing and reduction of NOx into nitrogen and carbon dioxide.
Scrubbing liquid pumped by reactor vent scrubber re-circulation pumps 6-40­
1121/1162 is partly recycled and rest is transferred to dissolving reactors, mother
liquor tank, ETP feed tank under level control of the scrubber. Re-circulation liquid
is sprayed from scrubber top in counter current flow to gases rising upward inside
the scrubber. In this process vent gas NOx entrainment is reduced from 3000 ppm
to 300 ppm, prior their final discharge to atmosphere through 6-40-1002.
(ii) Acid Scrubber
Gases acidic in nature (NOx and acidic fumes) from CN melt tank, crystallizers,
crystal suspension tanks, 1st mother liquor tank, 2nd mother liquor tank, and 1st
stage neutralizers are drawn by acid scrubber exhauster 6-40-1017 into acid
scrubber 6-40-2213. Demineralized water is added in scrubber to establish re­
recirculation for effective scrubbing . Urea solution (40%) is added in scrubber to
convert NOx into nitrogen and carbon dioxide.