SCRUBBING SECTION:

Scrubbing section ensures maximum removal of both dust

and volatiles , i.e , mainly ammonia , hydrofluoric acid , some
silicon tetraflouride. It is called a dual mole scrubbing system
which gives maximum ammonia and fluoride removal from the
gas.

This section consists of 4 scrubbers:

1. Pre-scrubber
2. Dryer scrubber
3. Dust & fume scrubber
4. Tail gas scrubber

Gas flows in a series – parallel manner through the scrubbing

system. PN and Granulator gases flows to the Pre-scrubber , then
to the Dust and Fume scrubber and then to the TG scrubber. Dryer
gases from the dryer cyclone flows to the Dryer scrubber and
gases from the dust cyclone flows to the Dust and Fume scrubber
in parallel and thn to the TG scrubber.

1. Pre-scrubber:

The gases are first scrubbed in a pre- scrubber by a

solution of MAP(monoammonium phosphate ) and DAP ( di-
ammonium phosphate ) at a mole ratio of 1.3 N 2 : P2O5 ( pH 6 ) .
These ammonium phosphates are formed from the ammonia
escaping the PN and Granulator , reacting with phosphoric acid in
the Pre- scrubber tank and recirculated by pre-scrubber pump.
About 50 – 70 % ammonia in the gas is scrubbed out in
this process.
 2. Dust and Fume scrubber :

The gases from the pre – scrubber are scrubbed

again by a solution of dilute MAP and Phosphoric acid in the Dust
and Fume scrubber. This solution has a mole ratio 0.6 N 2 : P2O5
( pH 2.5-3.5 ).

This 2 stage scrubbing system is known as “Dual-

mole” scrubbing , since the Pre-scrubber operates at a
mole ratio of about 1.3 while the second operates at a
mole ratio below 1.

3. Dryer scrubber :

The same solution also scrubs the fumes from the

dryer in the dryer scrubber.

4. Tail gas scrubber :

Gases from the dryer scrubber and the Dust & Fume
scrubber are exhausted to the Tail Gas scrubber by Dryer
exhaust fan and the Dust & Fume exhaust fan. In the Tail Gas
scrubber the gases are scrubbed with a recirculated dilute
scrubber solution to remove the fine traces of dust , ammonia
and fluoride contents.

The scrubber liquor can be acidified with Sulphuric acid to

give a pH of 3-4 which is the optimum for ammonia and
fluoride recovery.

Fluoride recovery is enhanced by the cooling of the

scrubber liquor . This cooling effect is enhanced by the use of
TG vapouriser which utilizes some of the heat in the circulating
scrubber solution to vapourise liquid ammonia.
AMMONIA VAPOURISATION:

Prior to vapourisation, ammonia from battery limits is

preheated by low pressure steam from -300 c to +50 c in the
ammonia pre-heater.

Preheating the ammonia avoids the problem of freezing the

water or steam condensate in the vapourizers. Ammonia is
vapourised by the tail gas vapourizer and / or the steam ammonia
vapourizer operating in parallel.

The ammonia is vapourised in the tail gas vapourizer by

circulating tail gas scrubber liquor , which is the heating medium.
Only very small amount of ammonia that the TG vapourizer is
unable to vapourise is vpourized in the steam ammonia vapourizer
by using MP steam as the heating medium. Normally the
vapourisation requirements in this unit are small since it only
serves to supplement the TG vapourizer needs.

Tail Gas vapourizer serves to reduce the load and steam

requirements in the ammonia vapourizer.