Ammonium Nitrophosphate Production Process

A PROJECT REPORT
ON
AMMONIUM NITROPHOSPHATE-F
(PHASE-2)
Submitted in partial fulfilment towards the Bachelor’s Degree in
The Chemical Engineering
Prepared by
KUMAR R. MORI
CH056 (ID-16CHUTG028)
UNDER THE GUIDANCE OF
Dr. MAHENDRA S. GAIKWAD
Department of Chemical Engineering Faculty of

Technology, Dharmsinh Desai University,College
Road,Nadiad-387 001. April-2020
DECLARATION
I Kumar R. Mori declare that, the project report on ANP-F and comprises
my original work towards the degree of Bachelor of Technology in Chemical
Engineering at Dharmsinh Desai University and is not copied from any published
or proprietary source. I further declare that this work is not submitted elsewhere
towards degree or diploma in any university or college. The whole content of this
project work is genuine and distinctive.
Kumar R. mori,
CH-56 (ID 16CHUTG028),
Semester: VIII,
Department of Chemical Engineering,
Faculty of Technology,
Dharmsinh Desai University,
Nadiad.
PREFACE
Technical studies can’t be prefaced without practical training. Hence plant training
has great value for an engineering student. Technical knowledge gives theoretical aspect of
technology, but practical training gives knowledge of industrial activities. My aim in plant
training is to carry our detailed study of industrial instrument and process control besides
education aspects. I also tried to observe important aspect of industrial management,
discipline, and safety precautions. I saw how engineers coordinated with running of plant.
In present work, I discussed what I studied in ANP-F PLANT, of Gujarat Narmada

Fertilizer & Chemicals Ltd. at Bharuch. The report contains some general information
about detailed process description, salient features of the plant, diagrams, mass balance,
energy balance, equipment design, safety rules along with utilities and ETP.
I must say that this type of training will fill the gap between theoretical and practical
knowledge. Once again I want to say thanks to all those who helped me in this endeavor
directly or indirectly.
KUMAR R. MORI
III
.
ACKNOLEDGEMENT
A journey is easier when you travel together. Interdependence is certainly more than
independence. This thesis is result of 8 weeks of hard work whereby, I have been accompanied
and supported by many people. At this moment I would like to take this opportunity to gratitude
all of them. With immense pleasure, I would like to present this report on “ANP-F”. I am
thankful to all that have helped me a lot for successful completion of project and for providing
valuable guidance throughout my training and project report work.
First and foremost, I convey my sincere thanks to Dr.H.M.Desai, Vice Chancellor, DDU,
Nadiad for allowing me to take vocational training at GNFC Bharuch. I would like to thank
Prof. D.G.Panchal, Dean Faculty and Dr. M.S.Rao, Head of Chemical Engineering
department for their kind support during my industrial training. I would like to thank Dr.
M.S.Gaikwad, Assistant Professor, Chemical engineering department for guiding me
throughout my training period and helping me in preparing this report. I also thank all the
other faculty members in chemical engineering department and supporting staff for their
help.
First, I am thankful to Mr. H.K.PAREKH who is Training Manager of GNFC,

Mr. M.I. Shamshee who is the AGM Of ANP-F Plant, Mr. S.S.Shah who is Sr. Manager of
the ANP-F plant, Mr. paras patel who is Sr. shift engineer and Mr. hiren patel who is Shift
engineer.
I am also thankful to all others in ANP-F Plant who had provided me with
constant help and encouragement in making this project success.
Kumar R. Mori
IV
Phase 2
Ammonium Nitrophosphate-F
V
Contents
Acknowledgement......................................................................................................VII
List of Figures..............................................................................................................XI
List of Tables..............................................................................................................XII
Abbreviation..............................................................................................................XIII
Nomenclature............................................................................................................XIV
CHAPTER 1 INTRODUCTION...................................................................................1
1.1 Introduction of Ammonium Nitrophosphate....................................................2
1.2 Historical background......................................................................................2
1.3 Raw materials used for ANP production.........................................................2
1.4 Product specification........................................................................................2
1.5 Application of Ammonium Nitrophosphate fertilizer(20:20:0).......................3
1.6 Capacity............................................................................................................3
1.7 Market value.....................................................................................................3
1.8 Competitors......................................................................................................3
1.9 Technology provider........................................................................................3
1.10 MSDS............................................................................................................3
1.10.1 Phosphoric acid...................................................................................4
1.10.2 Ammonium Nitrate.............................................................................6
1.11 Thermodynamic and physio-chemical properties........................................10
CHAPTER 2 SELECTION OF PROCESS.................................................................13
2.1 Various processes for production of Ammonium Nitrophosphate................14
2.2 Availability of raw materials and its cost.......................................................14
2.3 MSDS.............................................................................................................14
VI
2.3.1Nitric acid.............................................................................................14
2.3.2 Rock phosphate...................................................................................18
2.4 Detailed description of process......................................................................21
2.5 Process block diagram....................................................................................31
2.6 Process flow diagram.....................................................................................32
CHAPTER 3 MATERIAL BALANCE.......................................................................33
3.1 Material balance around Reactor...................................................................34
3.2 Material balance around Lamella separator...................................................35
3.3 Material balance around KAN tank...............................................................36
3.4 Material balance around Crystalizer..............................................................36
3.5 Material balance around Nitrate conversion unit...........................................37
3.6 Material balance around Pressure filter..........................................................38
3.7 Material balance around Carbonization tower...............................................38
3.8 Material balance around Evaporator..............................................................39
3.9 Overall Material balance diagram.................................................................42
3.10 Summary of Material balance......................................................................43
CHAPTER 4 ENERGY BALANCE...........................................................................44
4.1 Introduction....................................................................................................45
4.2 Energy balance around Reactor.....................................................................46
4.3 Energy balance around DIS Cooler................................................................47
4.4 Energy balance around Crystalizer................................................................48
4.5 Energy balance around Preheater...................................................................48
4.6 Energy balance around Evaporator................................................................49
CHAPTER 5 UTILITIES.............................................................................................51
VII
5.1 Cooling tower.................................................................................................52
5.1.1 Functioning of cooling tower..............................................................53
5.1.2 General terms used in cooling water systems.....................................53
5.1.3 Typical problems in cooling tower.....................................................54
5.2 Borsig unit(cooling brine system)..................................................................55
5.3 Steam generation plant:..................................................................................56
5.4 DM water plant..............................................................................................57
CHAPTER 6 DETAILED DESCRIPTION OF EQUIPMENTS................................59
6.1 Detailed description of Equipments...............................................................60
CHAPTER 7 EQUIPMENT DESIGN.........................................................................62
7.1Design of Continuous stirred tank reactor......................................................63
7.1.1 Process design:....................................................................................63
7.1.2 Mechanical design:..............................................................................64
7.2 Design of Shell and tube heat ex-changer......................................................70
7.3 Design of Storage tank design........................................................................77
CHAPTER 8 PUMPS AND CONTROL VALVES....................................................81
8.1 Types of control valves..................................................................................82
8.1.1 Linear motion control valves..............................................................82
8.1.2 Rotary motion control valves..............................................................82
8.2 Valve services................................................................................................83
8.3 Pumps.............................................................................................................83
CHAPTER 9 SAFETY................................................................................................85
9.1 List of safety equipments...............................................................................86
9.1.1Respiratory protective equipments.......................................................86
VIII
9.1.2Personal protective equipments............................................................86
CHAPTER 10 PLANT LOCATION & PLANT LAYOUT........................................89
10.1 Plant layout...................................................................................................90
10.2 Plant layout...................................................................................................92
CHAPTER 11 COST ESTIMATION..........................................................................94
11.1 Introduction..................................................................................................95
11.2 purchased equipment cost............................................................................98
11.3 Direct cost....................................................................................................99
11.4 Indirect cost................................................................................................100
11.5 Fixed charges.............................................................................................101
11.6 Plant overhead cost....................................................................................101
11.7 General expenses........................................................................................101
11.8 Total production cost..................................................................................102
11.9 Profitability analysis...................................................................................102
11.10 Rate of return............................................................................................103
11.11 Pay out period..........................................................................................103
11.12 Break even point......................................................................................103
CHAPTER 12 CONCLUSION..................................................................................107
REFERENCES...........................................................................................................109
IX
List of Figures
Figure 2. 1 Block diagram of ANP plant.............................................................31
Figure 2. 2 Process Flow diagram of ANP front plant.........................................32
Figure 2. 3 Flow diagram on ANP rear plant.......................................................32
Figure 3. 1 Material balance around Reactor.......................................................35
Figure 3. 2 Material balance around Lamella separator.......................................35
Figure 3. 3 Material balance around Crystallizer.................................................36
Figure 3. 4 Material balance around Nitrate conversion unit...............................37
Figure 3. 5 Material balance around Carbonization tower...................................38
Figure 3. 6 Material balance around Evaporator..................................................39
Figure 3. 7 Material balance around Neutralization tank.....................................40
Figure 3. 8 Material balance around Dryer..........................................................40
Figure 3. 9 Overall Material balance diagram.....................................................42
Figure 5.1 Schematic diagram of cooling tower..................................................52
Figure 5.2 Schematic diagram of Refrigeration cycle.........................................56
Figure 7. 1 Schematic diagram of Torrispherical head........................................65
Figure 7. 2 Schematic diagram of Elliptical head................................................66
Figure 7. 3 Blank diameter vs Head inside diameter for various thickness of

ASME Elliptical heads.................................................................................67
Figure 7. 4 Reynolds number vs Power number..................................................68
Figure 7. 5 Graph of Ft(correction factor) vs S....................................................72
Figure 7. 6 Constants for bundle diameter according to tube pitch.....................73
Figure 7. 7 Shell inside diameter vs bundle diameter..........................................73
X
Figure 7. 8 Heat transfer factor vs Reynolds number for 25% segmental baffle.75
Figure 7. 9 Recommended fouling coefficient.....................................................75
Figure 7. 10 Friction factor vs Reynolds number for shell..................................76
Figure 7. 11 Friction factor vs Reynolds number for tube...................................77
Figure 10. 1 Plant layout......................................................................................93
XI
List of Tables
Table 1. 1 Thermodynamic and physio-chemical properties of compounds.......10
Table 1.2 Thermodynamic and physio-chemical properties of compound..........11
Table 3. 1 Material balance around Reactor........................................................35
Table 3. 2 Material balance around Lamella separator........................................36
Table 3. 3 Material balance around KAN tank....................................................36
Table 3. 4 Material balance around Crystallizer..................................................37
Table 3. 5 Material balance around Nitrate conversion unit................................37
Table 3. 6 Material balance around Pressure filter..............................................38
Table 3. 7 Material balance around Carbonization tower....................................39
Table 3. 8 Material balance around Evaporator...................................................39
Table 3. 9 Material balance around Neutralization tank......................................40
Table 3. 10 Material balance around Dryer.........................................................41
Table 3. 11 Summary of material balance around each equipments....................43
Table 4. 1 Data required for energy balance........................................................45
Table 4. 2 Energy balance around Reactor..........................................................46
Table 4. 3 Energy balance around Cooler............................................................47
Table 4. 4 Energy balance around Crystalizer.....................................................48
Table 4. 5 Energy balance around Preheater........................................................48
Table 4. 6 Energy balance around Evaporator.....................................................49
Table 6.1 Detailed description of equipments......................................................60
Table 9.1 List of personal protective equipment s...............................................88
Table 11. 1 Purchased equipment cost.................................................................98
Table 11. 2 Fixed capital investment and Total capital investment.....................98
XII
Table 11. 3 Direct cost.........................................................................................99
Table 11. 4 Indirect cost.....................................................................................100
Table 11. 5 Direct production cost.....................................................................100
Table 11. 6 Fixed charges..................................................................................101
Table 11. 7 Plant overhead cost.........................................................................101
Table 11. 8 General expenses.............................................................................101
Table 11. 9 Total production cost......................................................................102
Table 11. 10 Profitability analysis.....................................................................102
Table 11.11 Rate of return.................................................................................103
Table 11.12 Pay-out period................................................................................103
XIII
Abbreviation
CS Carbon Steel
ETP Effluent Treatment Plant
SSR Stainless Steel Reactor
MOC Material Of Construction
RPM Revolution Per Minute
PPE Personal Protective Equipment
M.W. Molecular weight
LMTD Logarithmic Mean Temperature Difference
NPSH Net Positive Suction Head
CAS Chemical Abstracts Service
P & ID Piping and Instrumentation Diagram
PBD Process Block Diagram
LD50 Lethal dose
CN Calcium nitrate
NP acid Nitrophosphate acid
LC50 Lethal concentration
AN Ammonium nitrate
ANP Ammonium Nitro-Phosphate
PFD Process Flow Diagram
ACB Ammonium carbonate
XIV
Nomenclature
A Area m2
ƍ Density kg/m3
D Diameter m
Q Heat Load kJ/hr
Hf Heat Of formation J/mol
H Height m
l Length m
m Mass Flow Rate kg / hr
f Permissible Stress N/m2
P Pressure Pa
Nre Reynolds Number -
Cp specific Heat kJ/kg*k
p Power hp
Xa conversion -
v velocity m/s
T Temperature °C
Tf Fabrication Thickness mm
µ Viscosity mPa.s
V Volume m3
v0 Volumetric Flow Rate m3/hr
XV
XVI
CHAPTER 1 INTRODUCTION
1
1.1 Introduction of Ammonium Nitrophosphate
Ammonium Nitrophosphate also known as Nitric Phosphate,this is a group of

fertilizer in which phosphate rock is acidulated with Nitric acid unlike in super
phosphate where sulfuric acid or phosphoric acid is used to acidulate the rock.There
are several methods available and depending upon modification of process all nitro
phosphate contains 50% of N as nitrate and 50% of N as ammonium.The water
soluble P2O5 varies from 30% to 80% depending upon process used.
1.2 Historical background
The Nitrophosphate process (also known as the Odda process) was a method for
the industrial production of nitrogen fertilizers invented by Erling Johnson in the
municipality of Odda, norway around 1927.
Although Johnson created the process while working for the Odda smelteverk, his
company never employed it. Instead, it licensed the process to Norsk Hydro, BASF,
HOECHST, and DSM. Each of these companies used the process, introduced
variations, and licensed it to other companies. Today, only YARA (Norsk Hydro),
BASF, Borealis Agrolinz Melamine GmbH, and GNFC still use the Odda process.
Due to the alterations of the process by the various companies who employed it, the
process is now generally referred to as the Nitrophosphate process.
In India the production of Nitrophophate started in 1965 at Trombay,Mumbai. At

that time ,one grade contained 30% water soluble P2O5 and the other grade contained
50-60% water soluble P2O5. Production of Nitrophosphate containing 85% water
soluble P2O5 started in India in 1991.
1.3 Raw materials used for ANP production
Rock phosphate
Nitric acid (60%)
1.4 Product specification
2
-The final product from whole ANP plant is produced as, Ammonium
Nitrophosphate fertilizer (20:20:0) ;containing 20 wt % N2 and 20 wt % P2O5.
Specifications:
Moisture, (%weight), maximum -1.5
Total nitrogen (ammoniacal and nitrate),( % weight), minimum -20.0
Nitrogen in ammoniacal form percent by weight, minimum -10.0
Available phosphorous as P2O5 percent by weight, minimum -20.0
Water soluble phosphorous as P2O5 percent by weight, minimum -12.0
1.5 Application of Ammonium Nitrophosphate fertilizer(20:20:0)
Narmada phos granules are uniform, grey in color and free flowing. Therefore
they are easy to apply uniformly in the soil.
Narmada phos contains 20% N and 20% P2O5 available to plants. This ensures
balanced fertilization for basal application at sowing time.
In addition to N and P2O5, narmada phos contains calcium and micro-nutrients

which are essential for the normal growth of the plant
1.6 Capacity
Actual production capacity:475 Metric tons per day of Ammonium

Nitrophosphate fertilizer
Over capacity:700 Metric tons per day of Ammonium Nitrophosphate fertilizer
1.7 Market value
Ammonium nitrophosphate:995 rs/50 kg bag
1.8 Competitors
Rashtriya chemical & fertilizers
Adarsh chemicals and fertilizers
Agro phos india ltd
3
Asian fertilizers ltd
Coromandel international ltd
Deepak fertilizers & petrochemicals corporation ltd
Gujarat state fertilizers and chemicals ltd
Godavari fertilizers and chemicals ltd
National fertilizer ltdnagarjuna fertilizer & chemicals ltd
Liberty phosphate ltd
Krishna phoschem ltd
1.9 Technology provider
BASF - Germany
Detailed engineering by:
TKIS -India
1.10 MSDS
1.10.1 Phosphoric acid

 Identification of component
Product name: Phosphoric acid
Synonyms: Ortho phosphoric acid; hydrogen phosphate.
 Physical and Chemical properties
Physical state: Clear liquid
Viscosity:3.86 mpa.s
Boiling point: 158deg c @ 760.00mm hg
Freezing/melting point:42.35 deg c
Flash point: Not applicable.
Rating: (estimated) health: 3; flammability: 0; reactivity: 0 solubility: Miscible.
4
Specific gravity: 1.6850 g/cm3
Molecular formula: H3PO4
Molecular weight:98.00
 Hazards identification
Eye: Contact with liquid is corrosive to the eyes and causes severe burns. May cause
chemical conjunctivitis and corneal damage.
Skin: Contact with liquid is corrosive and causes severe burns and ulceration. May
cause skin rash (in milder cases), and cold and clammy skin with cyanosis or pale
color.
Ingestion: Causes gastrointestinal tract burns. Causes severe pain, nausea, vomiting,
diarrhea, and shock. May be harmful if swallowed.
Inhalation: Harmful if inhaled. May cause severe irritation of the respiratory tract
with sore throat, coughing, shortness of breath and delayed lung edema. Causes
chemical burns to the respiratory tract. Aspiration may lead to pulmonary edema.
Chronic: Prolonged or repeated skin contact may cause dermatitis. Prolonged or

repeated eye contact may cause conjunctivitis. Effects may be delayed.
 First aid measures
Eyes: Get medical aid immediately. Do not allow victim to rub or keep eyes closed.
Extensive irrigation with water is required (at least 30 minutes).
Skin: Get medical aid immediately. Immediately flush skin with plenty of soap and
water for at least 15 minutes while removing contaminated clothing and shoes.
Destroy contaminated shoes.
Ingestion: Do not induce vomiting. If victim is conscious and alert, give 2-4 cupfuls
of milk or water.
Inhalation: Get medical aid immediately. Remove from exposure to fresh air
immediately.
 Fire fighting measures
5
General information: As in any fire, wear a self-contained breathing apparatus in
pressure-demand, NIOSH (approved or equivalent), and full protective gear. During a
fire, irritating and highly toxic gases may be generated by thermal decomposition or
combustion.
Extinguishing media: Use extinguishing media most appropriate for the surrounding
fire. Cool containers with flooding quantities of water until well after fire is out. Use
water spray, dry chemical, carbon dioxide, or appropriate foam.
 Accidental release measures
General information: Use proper personal protective equipment as indicatedin

section 8.
Spills/leaks: Absorb spill with inert material (e.g. Vermiculite, sand or earth), then
place in suitable container. Clean up spills immediately, observing precautions in the
protective equipment section.
Provide ventilation.
 Handling and storage
Handling: Wash thoroughly after handling. Remove contaminated clothing and wash
before reuse. Keep container tightly closed. Do not get on skin or in eyes. Do not
ingest or inhale. Use with adequate ventilation.Store in a cool, dry, well-ventilated
area away from incompatible substances. Keep away from metals. Do not store in
metal containers. Store away from alkalies.
 Exposure controls, personal protection
Engineering controls: Facilities storing or utilizing this material should be equipped

with an eyewash facility and a safety shower. Use only under a chemical fume hood.
Personal protective equipment
Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described

by OSHA's eye and face protection regulations in 29 CFR 1910.133 or european
standard en166.
Skin: Wear appropriate protective gloves to prevent skin exposure.
Clothing: Wear appropriate protective clothing to prevent skin exposure.
6
 Stability and reactivity
Chemical stability: Stable under normal temperatures and pressures.
Conditions to avoid: Incompatible materials, metals, excess heat
Hazardous decomposition products: Phosphine, oxides of phosphorus,
 Toxicological information
Cas# 7664-38-2:Draize test, rabbit,
Eye: 119 mg severe;draize test, rabbit,
Skin: 595 mg/24h severe;

Inhalation, rat: Lc50 = >850 mg/m3/1h;
Oral, rat: Ld50 = 1530 mg/kg;
Skin, rabbit: Ld50 = 2740 mg/kg
 Ecological information
Environmental: The acidity of phosphoric acid may be reduced readily by natural

water hardness minerals, but the phosphate may persist indefinitely. During transport
through the soil, phosphoric acid will dissolve some of the soil material, in
particular,carbonate based materials. Dangerous to aquatic life in high concentrations.
 Disposal considerations
Chemical waste generators must determine whether a discarded chemical is classified

as a hazardous waste. Us epa guidelines for the classification determination are listed
in 40 cfr parts 261.3. Additionally, waste generators must consult state and local
hazardous waste regulations to ensure complete and accurate classification.
1.10.2 Ammonium Nitrate

 Product identification
Synonyms: Ammonium salt
Cas no.: 6484-52-2
Molecular weight: 80.04
Chemical formula: NH4NO3
7
 Composition/information on ingredients
Ingredient:ammonium nitrate
Cas no : 6484-52-2
Hazardous: yes
Emergency overview
Danger! Strong oxidizer. Contact with other material may cause fire or explosion.
May be harmful if swallowed or inhaled. Causes irritation to skin, eyes and
respiratory tract.
Health rating: 1 - slight flammability rating: 0 - none
Reactivity rating: 3 - severe (oxidizer) contact rating: 2 - moderate lab protective

equip: Goggles; lab coat
Storage color code: Yellow (reactive)
Potential health effects
Inhalation: May cause irritation to the respiratory tract; symptoms may include
coughing, sore throat, and shortness of breath.
Ingestion: Large oral doses of nitrates may cause dizziness, abdominal pain,
vomiting, bloody diarrhea, weakness, convulsions, and collapse. Harmful if -
swallowed. May cause methemoglobinemia resulting in cyanosis.
Skin contact: Causes irritation to skin. Symptoms include redness, itching, and pain.
Eye contact: Causes irritation, redness, and pain.
Chronic exposure: Small repeated oral doses of nitrates may cause weakness,
depression, headache, and mental impairment.
 First aid measures
Inhalation: Remove to fresh air. Get medical attention for any breathing difficulty.
8
Ingestion: If swallowed, do not induce vomiting. Give large quantities of water.
Never give anything by mouth to an unconscious person. Get medical attention
immediately.
Skin contact: Remove any contaminated clothing. Wash skin with soap and water for
at least 15 minutes. Get medical attention if irritation develops or persists.
Eye contact: Wash thoroughly with running water. Get medical advice if irritation
develops.
Fire: Not combustible, but substance is a strong oxidizer and its heat of reaction with
reducing agents or combustibles may cause ignition. May support combustion in an
existing fire.
Explosion: Contact with oxidizable substances may cause extremely violent

combustion.sealed containers may rupture when heated. Sensitive to mechanical
impact.fire extinguishing media: Use flooding amounts of water in early stages of
fireinvolving ammonium nitrate. Use any means suitable for extinguishing
surrounding fire.
Special information: In the event of a fire, wear full protective clothing and niosh
approved self-contained breathing apparatus with full face piece operated in the
pressure demand or other positive pressure mode.
Remove sources of heat and ignition. Collected waste may be transferred to a

closed,preferably metal, container and sent to a RCRA approved waste disposal
facility.alternatively, sweep spill into noncombustible container and dissolve in large
amount of water. Add soda ash. Mix and neutralize with 6m-hcl. Neutralized sludge
may be sent to an approved waste disposal facility.
Keep in a tightly closed container, stored in a cool, dry, ventilated area. Protect
against physical damage.. Do not store above 540C (1300 F) preferably below 300C.
Containers of this material may be hazardous when empty since they retain product
residues (dust, solids); observe all warnings and precautions listed for the product.
9
-Personal respirators (NIOSH approved):
For conditions of use where exposure to the dust or mist is apparent, a half-face
dust/mist respirator may be worn. For emergencies or instances where the exposure
levels are not known, use a full-face positive-pressure, air-supplied respirator.
Warning: Air purifying respirators do not protect workers in oxygen-deficient

atmospheres.
Skin protection: Wear protective gloves and clean body-covering clothing.
Eye protection: Use chemical safety goggles.
 Physical and chemical properties
Appearance: Colorless crystals.
Odor: Odorless.
Solubility: 118g/100g water @ 0c (32f).

specific gravity: 1.73 @ 23c (77f)
ph: 5.4
Boiling point: 210c (410f) decomposes.
Melting point: 170c (338f)
Stability: Stable under ordinary conditions of use and storage. Hygroscopic.

Hazardous decomposition products: Emits nitrous oxides when heated to
decomposition. Liberates ammonia in reaction with strong alkali
Hazardous polymerization: Will not occur.
Conditions to avoid: Heat, flame, ignition sources, dusting and incompatibles.

Moisture and combustible materials. Shock sensitive.
Oral rat ld50: 2217 mg/kg.
 Ecological information
Environmental fate:
10
When released into the soil, this material is expected to leach into groundwater. When
released into the soil, this material is not expected to evaporate significantly. When
released into water, this material is expected to readily biodegrade.
Environmental toxicity: No information found.
 Disposal considerations
Whatever cannot be saved for recovery or recycling should be handled as hazardous

waste and sent to a RCRA approved waste facility. Processing, use or contamination
of this product may change the waste management options. State and local disposal
regulations may differ from federal disposal regulations.
11
1.11 Thermodynamic and physio-chemical properties
Table 1. 1 Thermodynamic and physio-chemical properties of compounds

Carbon Nitrogen Calcium
Name Ammonia Nitric oxide
dioxide dioxide nitrate
Physical
Gas Gas Gas Gas Solid
state
Colour Colorless Colorless Colorless Brown Colorless
Strong
Sharp sweet Chlorine
Odour pungent None Na
Smell like
odour
Boiling
-33.34 Na -152 21.15 Na
point(℃)
Melting
-77.73 -56.6 -164 -9.3 561
point(℃)
Freezing
-77.73 -78.5 -164 -9.3 561
point(℃)
Molecular
wt.(g/gmol 17 44.01 30.01 46.0055 164.088
e)
Taste Bitter Na Na Mild sweet Na
specific
volume(m 1.16 0.506 0.746 0.532 0.0004
3/kg)
specific
0.826 1.51 1.037 1.56 1.4-1.5
gravity
Density
0.86 1.98 1.34 1.88 2504
(kg/m3)
12
0.0056g/
Solubility( 31%w/w 1.45 g/l 1212 g/l
100ml at Hydrolysis
H2O) At 25(℃) At 25(℃) At 20(℃)
20(℃)
Vapor
6448 98.80
pressure(k 857.3 Na Na
At 25(℃) At 20(℃)
pa)
Viscosity( 0.000276 0.0000147 0.0000191 0.0000133

Na
kg/ms) At -40(℃) At 20(℃) At 25(℃) At 25(℃)
Std
enthalpy of
-46 -393.5 91.29 33.2 -938.2
formation(
kj/mol)
Std molar
entropy 193 214 210.76 240.1 193.2
(j/mol*k)
specific
At 32ºf 0.91
heat((kj/kg 0.846 0.995 0.8086
4.6
*k)
Table 1.2 Thermodynamic and physio-chemical properties of compound

Ammoni Ammoniu
Calcium Nitric Calcium Phosphori
Name um m
carbonate acid oxide c acid
nitrate carbonate
Physical Solid Fine Solid Viscous

Solid Liquid
state powder powder powder liquid
White/ Pale
Colour White White Yellow White
grey yellow
Odour Na Strong Odourless Strong Odourless Odourless
13
smell of odour,suff
NH3 ocating
210 (68% 158

Boiling Decompo Decompo
decompo w/w) 2850 Decompos
point(℃) ses ses
ses 120.5 es
(70%
Melting
169.6 58 1339 w/w) 2613 42.3
point(℃)
-41
Molecula
r
80.043 96.086 100 63.011 56.0774 97.99
wt.(g/gm
ole)
specific
volume( 0.00057 0.00066 0.00037 0.709 0.000299 0.000492
m3/kg)
(68%
Density
1725 1500 2710 w/w) 3340 2030
(kg/m3)
1.41
4.46g/ml
Solubilit Highly 1g/ml 0.013g/l Completel Forms
At
y(h2o) soluble At 20(℃) At 25(℃) y soluble hydroxide
14.95(℃)
Std
enthalpy
of Na Na -1207 -207 -635 -1288
formatio
n(kj/mol)
Std Na Na 92 146 40 158

molar
14
entropy
(j/mol*k)
specific
heat(kj/k 1.67 2.6 0.83 1.72 Na 1.08
g*k)
15
CHAPTER 2 SELECTION OF PROCESS
16
2.1 Various processes for production of Ammonium Nitrophosphate
Various processes have been developed to eliminate the calcium nitrate, as

follows:
1. Removal by crystallization followed by centrifuging or filtration (Odda process)
2. Conversion to calcium sulphate by using sulfuric acids (sulphonetric process)
3. Conversion to mono calcium phosphate by using phosphoric acid(phosphornitric

process)
4. Conversion to calcium carbonate by using carbon dioxide (carbonitric process)
In all these processes the nitrogen is restored by adding ammonia at some point.
Potash may also be added to obtain a variety of NPK grades. Based on all above
process Odda process is best because it involves reaction of phosphate rock with nitric
acid. A primary advantage of this method is that little or no S inputs are required.
With the nitrophosphate process, excess Ca from the phosphate rock is converted to
valuable calcium nitrate fertilizer(CAN) instead of gypsum. The nitrophosphate
method was first developed in Norway and much of the global production still occurs
in Europe.
2.2 Availability of raw materials and its cost
Availability:
Rock phosphate is available from Jordan.
17
HNO3 is available from WNA plant of GNFC itself.
NH3 is available from ammonia plant of GNFC itself.
Cost:
Rock phosphate:10000 Rs/MT
Nitric acid:26 Rs/L
2.3 MSDS
2.3.1Nitric acid
Section 1 - product information
MSDS name: Nitric acid, 20-70%

synonyms: Azotic acid; engraver's acid; aqua fortis.
Section 2 identification
CAS # :7697-37-2
Chemical Name : Nitric acid
Percent : 60-71%
TLV(TWA) :2 ppm
Hazard : Corrosive
Section 3 - hazards identification
Emergency overview
Appearance: Clear to yellow liquid.

Danger! May be fatal if inhaled. Causes severe eye and skin burns. Causes severe
respiratory and digestive tract burns. Strong oxidizer. Contact with other material may
cause a fire. Acute pulmonary edema or chronic obstructive lung disease may occur
from inhalation of the vapors of nitric acid. Corrosive to metal.
Target organs: Lungs, eyes, skin, mucous membranes.
Potential health effects
Eye: Causes severe eye burns. Direct contact with liquid may cause blindness or
permanent eye damage.
18
Skin: Causes skin burns. May cause deep, penetrating ulcers of the skin. Concentrated
nitric acid dyes human skin yellow on contact.
Ingestion: May cause severe and permanent damage to the digestive tract. Causes
gastrointestinal tract burns. May cause perforation of the digestive tract. May cause
systemic effects.
Inhalation: Effects may be delayed. Causes chemical burns to the respiratory tract.
Inhalation may be fatal as a result of spasm, inflammation, edema of the larynx and
bronchi, chemical pneumonitis and pulmonary edema Depending on the conditions,
the vapor or fumes of nitric acid may actually be a mixture of nitric acid and various
oxides of nitrogen. The composition may vary with temperature, humidity, and
contact with other organic materials.
Chronic: Exposure to high concentrations of nitric acid vapor may cause
pneuomonitis and pulmonary edema which may be fatal.
Section 4 - first aid measures

Eyes: Get medical aid immediately. Do not allow victim to rub eyes or keep eyes
closed. Extensive irrigation with water is required (at least 30 minutes).
Skin: Get medical aid immediately. Immediately flush skin with plenty of water for at
least 15 minutes while removing contaminated clothing and shoes. Wash clothing
before reuse. Destroy contaminated shoes.
Ingestion: Do not induce vomiting. If victim is conscious and alert, give 2-4 cupfuls
of milk or water. Never give anything by mouth to an unconscious person. Get
medical aid immediately.
Inhalation: Get medical aid immediately. Remove from exposure and move to fresh
air immediately. If not breathing, give artificial respiration. If breathing is difficult,
give oxygen. Do not use mouth-to-mouth resuscitation. If breathing has ceased apply
artificial respiration using oxygen and a suitable mechanical device such as a bag and
a mask.
Notes to physician: Treat symptomatically and supportively.
Section 5 - fire fighting measures

General information: As in any fire, wear a self-contained breathing apparatus in
pressure-demand, msha/niosh (approved or equivalent), and full protective gear.
Strong oxidizer. Contact with other material may cause fire. During a fire, irritating
and highly toxic gases may be generated by thermal decomposition or combustion.
19
Use water spray to keep fire-exposed containers cool. May react with metal surfaces
to form flammable and explosive hydrogen gas. Approach fire from upwind to avoid
hazardous vapors and toxic decomposition products.
Section 6 - accidental release measures
General information: Use proper personal protective equipment as indicated in
section 8.
Spills/leaks: Avoid runoff into storm sewers and ditches which lead to waterways.
Clean up spills immediately, observing precautions in the protective equipment
section. Absorb spill using an absorbent, non-combustible material such as earth,
sand, or vermiculite. Do not use combustible materials such as sawdust. Provide
ventilation. Evacuate unnecessary personnel. Approach spill from upwind. Use water
spray to cool and disperse vapors and protect personnel.
Section 7 - handling and storage

Handling: Wash thoroughly after handling. Remove contaminated clothing and wash
before reuse. Do not breathe dust, mist, or vapor. Do not get in eyes, on skin, or on
clothing. Keep container tightly closed. Avoid contact with clothing and other
combustible materials. Discard contaminated shoes. Do not use with metal spatula or
other metal items. Use only with adequate ventilation or respiratory protection.
Storage: Do not store near combustible materials. Do not store in direct sunlight.
Keep container closed when not in use. Store in a cool, dry, well-ventilated area away
from incompatible substances. Keep away from metals. Store away from alkalies.
Separate from organic materials. Inspect periodically for damage or evidence of leaks
or corrosion.
Section 8 - exposure controls, personal protection

Engineering controls: Facilities storing or utilizing this material should be equipped
with an eyewash facility and a safety shower. Use adequate general or local exhaust
ventilation to keep airborne concentrations below the permissible exposure limits. Use
a corrosion-resistant ventilation system.
Exposure limits
Chemical name Acgih Niosh Osha - final pels
Water None listed None listed None listed
20
2 ppm twa; 5 mg/m3 2 ppm twa; 5 mg/m3
Nitric acid 2 ppm twa; 4 ppm stel
twa 25 ppm idlh twa
Nitric acid: 2 ppm twa; 5 mg/m3 twa

personal protective equipment
eyes: Wear chemical splash goggles and face shield.
Skin: Wear butyl rubber gloves, apron, and/or clothing.
Clothing: Wear appropriate clothing to prevent skin exposure.
Section 9 - physical and chemical properties
Physical state: Liquid
Appearance: Clear to yellow
Odor: Strong odor - acrid odor - suffocating odor
ph: 1.0 (0.1m soln)
Vapor pressure: 51 mm hg @ 25 deg c
Vapor density: 2.17 (air=1)
Evaporation rate:Not available.
Viscosity: 0.761 cps @ 25 deg c
Boiling point: 86 deg c
Freezing/melting point:-42 deg c
Decomposition temperature:Not available.
Solubility: Soluble in water.
Specific gravity/density:1.4
Molecular formula:HNO3
Molecular weight:63.01
Section 10 - stability and reactivity

Chemical stability: Stable. Decomposes when in contact with air, light, or organic
matter. The yellow color is due to release of nitrogen dioxide on exposure to light.
Conditions to avoid: High temperatures, light, confined spaces.
Section 11 - toxicological information
Cas# 7697-37-2:
Inhalation, rat: Lc50 = 260 mg/m3/30m;
inhalation, rat: Lc50 = 130 mg/m3/4h;
21
inhalation, rat: Lc50 = 67 ppm(no2)/4h;
Section 12 - ecological information
Environmental: Terrestial: During transport through the soil, nitric acid will dissolve
some of the soil material, in particular, the carbonate based materials. The acid will be
neutralized to some degree with adsorption of the proton also occurring on clay
materials. However, significant amounts of acid are expected to remain for transport
down toward the ground water table. Upon reaching the ground water table, the acid
will continue to move, now in the direction of the ground water flow.
Section 13 - disposal considerations
Chemical waste generators must determine whether a discarded chemical is classified
as a hazardous waste. Us epa guidelines for the classification determination are listed
in 40 cfr parts 261.3. Additionally, waste generators must consult state and local
hazardous waste regulations to ensure complete and accurate classification.
Section 14 - regulatory information
Clean air act:
This material does not contain any hazardous air pollutants.
This material does not contain any class 1 ozone depletors.
This material does not contain any class 2 ozone depletors.
Clean water act:
Cas# 7697-37-2 is listed as a hazardous substance under the cwa.
2.3.2 Rock phosphate

 Identification of the material
Product name: 73/75 grade rock phosphate.
Synonyms: Phosphate rock
Product description: Fertilizer raw material, production of phosphoric acid. Light

grey, odour free, loose solid.
 Composition/information on ingredients
Name : Phosphate rock
Cas #1306-05-4
% by weight: 100%
22
Poisons: Not at all
First aid measures
Inhalation: Remove victim from area of exposure - avoid becoming a casualty. Seek
medical advice if effects persist.
Skin contact: If skin contact occurs, remove contaminated clothing and wash skin
with running water. If irritation occurs seek medical advice.
Eye contact: If in eyes, wash out immediately with water. In all cases of eye
contamination it is a sensible precaution to seek medical advice.
Ingestion: Rinse mouth with water. If swallowed, give a glass of water to drink. If
vomiting occurs give further water. Seek medical advice.
Notes to physician: Treat symptomatically.
specific hazards: Non-combustible material.
Fire-fighting advice: Non-combustible material. Decomposes on heating emitting

toxic fumes. Fire fighters to wear self-contained breathing apparatus and suitable
protective clothing if risk of exposure to products of decomposition.
Wear protective equipment to prevent skin and eye contact. Avoid breathing in dust.
Work up wind or increase ventilation. Cover with damp absorbent (inert material,
sand or soil). Sweep or vacuumup, but avoid generating dust. Collect and seal in
properly labelled containers, bags or drums for disposal or re-use.
Handling advice: Avoid skin and eye contact and breathing in dust.
Storage advice: Store in a cool, dry, well ventilated place and out of direct sunlight.
Exposure controls/personal protection
 Occupational exposure limits:
23
No value assigned for this specific material by the national occupational health and
safety commission. However, exposure standard(s) for constituent(s):
Nuisance dust: 8hr twa = 10 mg/m3
As published by the national occupational health and safety commission.
TWA - the time-weighted average airborne concentration over an eight-hour working

day, for a five-day working week over an entire working life.these exposure standards
are guides to be used in the control of occupational health hazards.
Personal protective equipment:
Safety shoes, safety glasses, gloves, dust mask. Wear overalls, safety glasses and
impervious gloves. Avoid generating and inhaling dusts. If dust exists, wear dust
mask/respirator. Always wash hands before smoking, eating, drinking or using the
toilet. Wash contaminated clothing and other protective equipment before storage or
re-use.
 Physical and chemical properties
Physical state: Loose solid
Colour: Light grey
Odour: Odourless
Specific gravity: 1.4-1.6
This material is considered stable.
Ingestion: No adverse effects expected, however large amounts may cause nausea
and vomiting.
Eye contact: May be an eye irritant. Exposure to the dust may cause discomfort due
to particulate nature. May cause physical irritation to the eyes.
Skin contact: Repeated or prolonged skin contact may lead to irritation.
Inhalation: Breathing in dust may result in respiratory irritation.
24
Long term effects:
This product may contain low levels of fluoride (f) as an impurity. Chronic ingestion,
eg. Improper or inadvertent use as a dietary phosphorus supplement for ruminants
(cattle and sheep), may result in fluorosis.
 Ecotoxicological information
Avoid contaminating waterways.
 Transport information
Road and rail transport
Not classified as dangerous goods by the criteria of the australian dangerous goods
code (adg code) for transport by road and rail.
Marine transport
Not classified as dangerous goods by the criteria of the international maritime

dangerous goods code for transport by sea.
Air transport
Not classified as dangerous goods by the criteria of the international air transport
association (IATA) dangerous goods regulations for transport by air.
 Regulatory information
Classification: Based on available information, not classified as hazardous. .
2.4 Detailed description of process
Rock phosphate grinding (unit - 31):
The rock phosphate delivered to battery limit is elevated to the vibrating

distributor 31h002 via bucket elevator 31h001. On the single deck screen 31s001 the
oversize fraction is separated while the passing fraction of rock phosphate is fed to the
on-size bucket elevator 31h007 which is elevated the rock to the silos for on-size
material 31t001 a/b the retaining oversize fraction is discharged to the crusher 31s002.
Subsequently the crushed rock phosphate is recycled to the screen via bucket elevator
31h001.
25
The silos for on-size rock phosphate 31t001 a/b are equipped with bin activators
31h003 a/b to ensure continuous discharge of ground rock via star wheel extractors
31h008 a/b the rock phosphate is released to conveyor belt 32h001.
Digestion of rock phosphate (unit - 32):
The rock phosphate supplied from the grinding unit via conveyor belt 32h001 is
fed to the dedusted rock phosphate buffer silo 32t10. The desired quantity of rock
phosphate is supplied to the first dissolving reactor 32r001 via belt-type phosphate
scale 32w001. On demand the nitric acid (60%) fed to the dissolving reactor 32r001
can be cooled via nitric acid cooler 32e001/e004. Under ideal condition the
exothermic reaction of the rock phosphate with acids is as follow
Ca3(PO4)2 + 6HNO3---> 3Ca(NO3)2 + 2 H3PO4
After passing through the three digesters the largely reacted dissolving solution
(dis) flows to the dissolving solution tank .
The carbonates contained in the rock phosphate react with the nitric acid under
formation of CO2.
M(CO3) + 2 HNO3----> M(NO3)2 + H2O + CO2
Where m means the metal components inside rock phosphate. This leads
temporarily to foam formation. If necessary an anti-foam agent is added to the
dissolving reactor manualy.
Sand removal (inert separation unit - 32):
The rock phosphate contains some wt% of sand (SiO2) irrespective of its origin
and quality. The major part of the sand from the dissolving solution has to be
desanded as sand is abrasive in nature & it can cause erosion in pipes & equipments.
The removal of sand from the dissolving solution (dis) is achieved by installation of
inert separator . The separator is of the lamella plate type.
The lamella separator is preferably used for separating suspended matter

contained in small quantities in a suspension. The dis flows through the inclined
plated from the bottom to the top in a laminar flow pattern. The suspended matter
larger than about 100 microns settles on these plates slips down due to its gravity, and
is collected in a “sludge room”. The overflowing desanded dissolving solution
26
(DDIS) is withdrawn at the top, get cooled in water cooler while the sand slurry is
discharged at the bottom via a sluice system.
The sand is getting filtered on vacuum belt filter & then washed with nox water ,
effluent water from and occasionally with nitric acid. Dissolving liquid separated
piped to suction and wash water collected into tank . The sand leaving the belt filter is
collected in washing tanks 32t006 a/b. Before being released, it is necessary to
remove the traces of P2O5, n, f etc. This is realized by washing the sand once again
with water after this washing step, the sand remains some time in the bin until the
water has dropped off. When this is the case, the sand is subjected to a quality control
and then transported by truck to storage site.
Crystallization on CNTH (unit - 33):
The desanded dissolving solution (DDIS) contains in the main phosphoric acid
and calcium nitrate. The objective of the crystallization is to have as much calcium
nitrate as possible crystallized as tetrahydrate (CNTH = Ca(NO3)2*4H2O) by cooling
the DDIS. As much as calcium will remove, solubility of final ANP product will
improve.
Two group of 5 agitated crystallizers are installed: 33r001 to 33r005 and 33r006
to 33r010. As regards the coolant the 5 agitated vessels of each group are arranged in
series. Each agitated vessel is discontinuously filled with DDIS and discharged to CN
filter feed tank 33t004 as soon as the desired final temperature has been reached. The
crystallizers are equipped with cooling coils through which a calcium nitrate solution
(cob) is pumped as coolant. This cooling brine itself is cooled in the refrigeration unit
and a shall ensure the crystallization of CNTH crystals at a temperature of approx
0celcius.
For avoiding a gradual incrustation of the cooling coils of the crystallizeres and a
consequential reduction of the cooling efficiency it is necssary to melt off the cooling
coils by means of a hot brine. A second brine loop, namely the hot brine loop, has
been provided for this purpose.
In the system installed, the hot brine is, as far as possible, separated from the cold
brine in order to avoid unnecessary energy losses.
CNTH separation (unit - 33):
27
By gravity flow the cooled dissolving solution containing the crystals is supplied
from CN-filter arranged underneath. The CN-filter 33 n009 serves the purpose of
separating the CNTH - (Ca(NO3)2*4H2O) crystals formed in the crystallizers from the
NP acid. The separated CNTH crystals are washed on the vacuum filter with cold
nitric acid and calcium nitrate - ammonium nitrate solution (KAN) to recover most of
the p2o5 bounded to the crystals.
All the filtrates obtained, a mixture of nitric acid, phosphoric acid, calcium
nitrate, and traces of ammonium nitrate solution, called wash acid (wna), pass through
separators 33 t002 and pumped to wash acid buffer tank 32 t005 by wash acid transfer
pump 33 p003. A part of this wash acid is recirculated to the washing section of CN
filter 33 n009 for improving the washing of CN crystals.
The seperated cake of CNTH crystals is discharged from CN filter 33 n009 to

CN-melt tank 33 t005. For cleaning purposes of the filter cloth and to avoid
incrustations inside discharge chute part of the ammonium nitrated solution (an)
required for dissolution of the CNTH crystals is supplied to washing device
underneath the filter cloth and is drained to the CN melt tank 33 t005 discharge chute.
According to the desired density of the KAN the remaining an can directly be added
to the melt tank.
KAN obtained may be used to cool the cooling brine.therefore the KAN solution
is pumped to storage tank 41 t001 & 41 t001 a in unit 41 via brine precooler 34 e001
in unit by CN melt pump 33 p006. Downstream pump 33 p006 part of the cold KAN
is derived and fed to CN filter 33 n009 for displacement washing.
Treatment of nitrous gases (unit 32):
Due to the digestion reactions part of the nitric acid is reduced to nitrogen oxides
( no,no2). The waste gases released from the dissolving reactors are combined with
the contaminated waste gases from storage tanks, inert separator, inert filter and wash
acid buffer tank before treated in the nox scrubbing system.
The nox scrubbing(water) system consists of two packed absorption column

arranged in series including circulation pumps.
28
The waste gases released from column 32 c002 are drawn off to drop catcher 32
f002, the liquid is recycled to column 32 c002 and the gases are discharged into the
atmosphere via fan 32 k001.
Scrubbing water is drawn from waste water pot 32 d013 and fed to the top of 2nd
nox-scrubber 32 c002 by means of supply pump 32 p021. Pump 32 p012 is required
to supply the obtained scrubbing water from 2nd nox-scrubber 32 c002 to no-scrubber
32 c001 and to establish a loop including cooling via nox-scrubbing cooler 32 e012.
Cooling brine system (unit 34):
The coolant used is an approx. 40% solution of Ca(NO3)2 in water. The reason for
using Ca(NO3)2 instead of the usual coolants (glycol,freon) is to make sure that in
case of leakages of the cooling coils, no foreign matter will get into the DDIS and
especially no organic substances which later might become a risk during the
ammonium nitrate processing.
Having passed the refrigeration unit the cooling brine is fed to the coolest
crystallizer at a temp. Of approx. 0 degree celsius and is returned from the warmest
one to the cold brine head tank 34 t002. The warm cooling brine may be cooled in
brine precooler 34 e001 with KAN. Subsequently it is cooled in the two ammonia
evaporators 34 e002/e003 arranged in series and the refrigeration unit 34 u001.
The hot brine loop is used to reduce gradual incrustation of the cooling coils
inside the crystallizers.
Calcium nitrate conversion (unit 41):
The conversion of calcium nitrate towards calcium carbonate takes places

according to the following equation:
(NH4)2CO3 + Ca(NO3)2----> CaCO3 + 2 NH4NO3
Accordingly ammonium carbonate (NH4)2CO3 is required to implement the

conversion reaction while the precipitated calcium carbonate(CaCO3) is separated on
a subsequent lime filter.
Ammonium carbonate synthesis:
29
Ammonia gas (ag) reacts with gaseous carbon dioxide(CO2) in carbonation tower
41 c001 to form ammonium carbonate (ACB) according to the following reaction:
2 NH3 + CO2 + H2O --->(NH4)2CO3
This reaction takes place in the liquid phase. For this purpose ammonium nitrate
solution (AN) with a concentration of approximately 60% is fed to the top of the
packed carbonation tower. The obtained ACB/an solution must have a concentration
of less than 38 % wt% ACB in order to avoid crystallization.
The CO2 gas to be used must have a min, CO2 concentration of 85% by vol. Must
be free of organics and must not exceed limits for hydrogen and other components .
The higher the gas temp., the more water is entrained and , consequently, the reaction
products are diluted.
The obtained ACB/an solution is recycled to the carbonation tower by circulation

pump 41 p001 via coolers 41 e001 a/b/e002.
Calcium nitrate conversion:
The KAN in CN-buffer tank 41 t001 is circulated via CN circulation pump 41

p015 and transferred to the conversion reactors via CN solution pump 41 p013.
Depending on the ACB/an solution temp.the KAN can be preheated in

carbonation tower cooler iii 41 e002 with aid of circulated ACB/an solution to
maintain a temp. Of approx. 51 dec c in the conversion reactors.
The two agitated conversion reactors 41 r001 a/b are arranged in parallel. The
following main reaction takes place.
(NH4)2CO3 + Ca(NO3)2---> CaCO3 + 2 NH4NO3
The reactors operate with a slight ACB surplus but if the surplus is too large, the
precipitating lime becomes very fine and can hardly be washed on the subsequent
lime belt filter 41 n002. In case of ACB deficit (i.e. Ca(NO3)2 surplus), the lime
becomes slimy and cannot be filtered.
The size distribution of the precipitated lime depends not only on the KAN/ACB
ration but also on the parameters indicated below:
 type of rock phosphate
30
 residence time in reactors
 conversion temperature
 concentration of ACB solution.
 concentration of KAN solution.
The reaction mixture of an and lime flows over from conversion ractors 41 r001
a/b to lime thickener 41 n001 via overflow vessel 41 d008.
The overflow from lime thickener represent an an solution of approx. 60%

which is collected in agitated an filter feed tank 41 t006.the thickener underflow
which is a concentrated lime suspension (lis) is conveyed to belt type lime filter 41
n002. The optimum overflow/underflow ratio is approx. 1:2 upto 1:4 (hence 30 20%
overflow in relation to the overflow throughput).
Lime separation
The design of the lime filter and the process configuration complies with the CN
filter 33 n009.
The filtrate originating from the lime filter(an 60%)passed separator 41 d002 and
collects partly in the an filter feed tank 41 t006 which is arranged on a lower level.
The main portion of filtrate is directly transferred to top of carbonation tower 41 c001
via an return pump 41 p002 and is used to produced ACB.
In order to prevent lime incrustations in the carbonation tower 41 c001, the

filtrate is piped from lime filter 41 n002 through the suction line of an-return pump 41
p002 to said an filter feed tank because an filtrate from belt filter has a lower content
of suspended lime solids than the an solution from the lime thickener overflow.
The water content of the lime cake must be analyzed at the belt filter discharge
end and amounts to 8-12 % under normal operating conditions. If this value is higher
the calcium has finer grain sizes. Moreover, higher residual moisture will cause
higher energy requirements for the lime drying process in can plant.
Parts of the wet lime cake (liw) discharge from the lime filter is transferred to can
plant via wet lime belt conveyors 41 h003/h002 and scale for wet lime 41 w002. In
the can plant the lime is dried and used as filter for production of can product
containing 25 to 26% n.
31
The remainder wet lime is weighed via scale for wet lime 41 w001 and
transported to lime disposal via wet lime belt conveyor 41 h004.
Final filtration and Acidification of AN
The an solution and filtrate collected and stored in the agitated an-filter feed tank
41 t006 still contains suspended lime solids which have to be removed prior to using
the an for subsequent production. Therefore the an solution is pumped through an
filters 41 n003 a/b/c to the tank 41 t004.
The three pressure filters are arranged in paralled. One being in operation while
the other has to be cleaned and preloaded. Filter 41 n003 c is available as standby unit
if the first or second filter fails. The filtered an solution obtained in this unit still
contains ammonium carbonate as a result of the ACB surplus required in the
conversion reactors. The ACB content is eliminated in an-correction tank 41 t004
using nitric acid.
(NH4)2CO3 + 2HNO3 → 2NH4NO3 + CO2 + H2O
Thus the ph value is reduced from 7 to 3.5. The adjusted an solution is pumped to
the an buffer tank 41 t005 via an-correction pump 41 p010.
Neutralization and evaporation of NP acid (unit 35):
After the removal of calcium nitrate from the dissolving solution (in unit 33) the
so called nitro phosphate acid (NPA) mainly contains.
Phosphoric acid
Some free nitric acid
Some calcium nitrate
Fluorine
Other metallic elements.
The neutralization of NPA is performed by the injection of gaseous ammonia.
Different major reactions are possible between calcium and phosphoric acid during
neutralization.
The neutralized NP melt consists mainly of dicalcium phosphate, ammonium
nitrate and map.for adjustment of the required N/P2O5 ratio NP acid solution is fed to
NP + an tank 35d003 via mother liquor pump 33p007 as well as concentrated an
solution (94%) in proportioned quantities via neutralizer feed pump 35p001 the
32
solution is pumped to the first neutralization section which is designed as forced
circulation loop working under atmospheric pressure.
The section consists of loop pump 35p002 which ensures a defined recycle ratio,
NH3 injector 35f002 and separator 35d001. The closed forced circulation loop
includes loop pump 35p003, NP solution heater 35e001 and separator 35d002.the
granulator feed tank 35d005 is equipped with agitator 35n003 and steam treated coil,
second stage neutralization is carried out in 35d005 tank.by means of granulator feed
pump 35p005 the NP melt is supplied to the drum granulator 36s001 in unit 36 via
strainer 35f003. To ensure a homogenous melt part of the melt is recycled back to the
granulator feed tank. The vapours and off gases from the separator and tanks
containing mainly ammonia are treated in the packed neutralizer off gas scrubber
35c001.
The waste gases are sucked via exhaust fan 35k001 and released to atmosphere
after passing drop catcher 35f004. The gases are treated with an acidified ammonium
nitrate solution which is circulated via scrubber pump 35p006. The excess of
scrubbing acid is discharged to wet scrubber 36c060.
NP – granulation (unit-36):
The concentrated and neutralized NP melt is fed to the drum granulator 36s001,
in which the NP melt is sprayed on to a rolling bed formed by recycle granules.
The recycled ANP comprises the oversize granules separated on coarse mesh
screen 36s004 and crushed in subsequent mill 36s007, the fines separated on fine
mesh screen 36s005 and dust from dedusting cyclones 36f001.
The nominal recycle ratio is five times the massflow of NP melt supplied to the
granulator.the recycled ANP comprises the oversize granules separated on coarse
mesh screen 36s004 and crushed in subsequent mill 36s007, the fines separated on
fine mesh screen 36s005 and dust from dedusting cyclones 36f001.the nominal
recycle ratio is five times the massflow of NP melt supplied to the granulator.
To improve the granulation low pressure steam can be supplied to the drum
granulator via steam sparging device. The moisture content in the granules exist
granulator is approx. 2 wt. %.
The wet granules leaving the drum granulator drop down into the subsequent
rotary drying drum 36s002. The granules are dried to the desired final moisture
content of 1.3 wt. % by means of hot air.
33
Therefore ambient air is supplied by combustion blowers 36k001 to combustion
chamber 36b001 where it is mixed with air supplied by fan 36k002.
The burner can be fired with natural gas or lpg. The mixed air is heated up to
approx. 230 degree cecius and piped to the drying drum. Beside the hot air from the
combustion chamber the combined off gases from the granulator drum, the vibrating
screens, the mills and the bucket elevator are sucked off through the drying drum. The
gases pass the drying drum in a co-current manner.
The exhaust gases from the drying drum are dedusted in cyclone battery 36f001.
While the separated dust is recycled to granulator via pendulum flap, and passed
through 36c060 for scrubbing of unseparated dust finally.
The dried granules are discharged to the bucket elevator for hot granules 36h003 and
elevated upto the screening section the granules are fed to the coarse mesh screen
36s004 through the conveyer belt 36w004.
The oversize is separated and fed to the chain mill 36s007 where it is crushed to
the required size distribution. The passing on size and fines fraction drops towards to
fine mesh screen 36s005 by gravity flow.
While the undersize fraction is recycled to the granulator the on size is fed to the
fluidized bed cooler (FBC) 36a001 via flow control device 36h017 and belt conveyer
36h004.
Depending on the hygroscopic nature of the product to be cooled it must be
ensured that the relative humidity of the cooling air will be below a certain limit.
Therefore ambient air is heated up to 4500C in air heater 36e003 before blown to the
1st stage of FBC via air blower 36k004.
In the FBC the product is cooled down from approx. 10000C to 4000C
The exhaust gases from FBC are sucked off and passed through scrubber 36c060 and
finally discharged to atmosphere via 36v001 stack.
The cooled ANP product leaving the FBC is transported to the coating drum
36s003 via hot product scale 36w002.for adjustment of the desired nutrient content
20% N and 20% P2O5, gypsum has to be added to the product.
The gypsum is delivered from battery limits to gypsum silo 36t001 via belt
conveyer the gypsum is extracted from the silo continuously by means of bin activator
36h015.the mass flow of gypsum is controlled by weighing scale. 36w003 in
accordance to the NP melt discharged to granulator 36s001.
34
Gypsum is supplied directly to the drum granulator by belt conveyor 36h021. The
gypsum is added before the granulation process in drum in order to produce a most
uniform product concerning colour and size distribution.Oil/amine coating agent
which is stored in agitated feed bank 36d001 is pumped to spray nozzles arranged
inside rotary coating drum 36s003 via metering pump 36p001.
The coated product leaving the coating drum is elevated upto top of subsequent
screen 36s006 by bucket elevator 36h018. Off-spec material as under size or oversize
product is separated and recycle to bucket elevator 36h003.the subsequent screen can
be bypassed for maintenance purposes by flow control device 36h026. The total mass
flow of final product is weighed on product scale 36w001 before delivered to bagging
unit 74.
During shutdown periods granulator and drying drum is supplied and flushed
with hot air provided by air heater 36e008 and air blower 36k008.these measure will
minimize incrustation and choking of equipment by humid dust of product.
35
2.5 Process block diagram
36
Figure 2. 1 Block diagram of ANP plant
37
2.6 Process flow diagram
Figure 2. 2 Process Flow diagram of ANP front plant
Figure 2. 3 Flow diagram on ANP rear plant
38
CHAPTER 3 MATERIAL BALANCE
39
In any chemical process industry, chemical reactions are always involved in the
manufacturing of product from raw materials. The raw materials are fed as the input
to the system and the product comes out at the output. The balancing of inputs and
outputs gives information regarding following factors;
The amount accumulated inside the reactor accounts for the losses in vent.
The amount of raw material unreacted during the reaction.
The percentage of back reaction taking place in case of reversible reactions, etc.
Material balance calculations are governed by the law of conservation of mass.

The general equation of mass balance is as follows: Input-output = accumulation.
Thus material balance calculation aids to estimate the raw material
requirement and the laboratory analysis of the input and output streams around each
of the equipment can be used to find the individual flow rates of the components
present in the stream.
Basis:
Production of ANP(20:20:0)=475 MTPD=19791.66667 kg/hr
P2O5 content present in ANP=19791.66667*0.20 =3958.33 kg/hr
1000 kg of rock(Raw material) contains 334 kg of p2o5
So,required rock phosphate for ANP product is
=(1000*3958.33)/334 =11851.297 kg/hr
3.1 Material balance around Reactor
Reaction:Ca3(PO4)2+6HNO3→ 2H3PO4+3Ca(NO3)2 (conv=95%)
Amount of Ca3(PO4)2=11851.297 kg/hr
40
Moles of Ca3(PO4)2=11851.297/310=38.22 kmoles/hr
Moles of HNO3(10% excess)=38.22*1.1=252.317 kmoles/hr
Actual Amount of HNO3(60%)=(252.317*63/0.6)= 26493.38 kg/hr
H3PO4 formed=2*(38.23-1.91)*98=7118.42 kg/hr
Ca(NO3)2 formed=3*(38.23-1.91)*164=17868.69 kg/hr
Ca3(PO4)2
H3PO4
reactor
HNO3
Ca(NO3)2
Figure 3. 1 Material balance around Reactor
Table 3. 1 Material balance around Reactor

Mass Mass
Component Mw Moles In Mole Out
Inlet(kg/hr) Outlet(kg/hr)
Cp 310 38.22999163 11851.29741 1.911499581 592.5648703
NA(60%) 63 252.3179448 26493.3842 10.89554761 2167.640525
Pa 98 72.6369841 7118.424441
H2O 18 10597.35368
CN 164 108.9554761 17868.69809
41
Sand 414.7954092 414.7954092
Total 38759.47701 38759.47701
3.2 Material balance around Lamella separator
Sand is separated from the above solution.
Ca3(PO4)2 contains 3.5% of sand=11851.297*0.035=414.795kg/hr
DIS solution Lamella separator
DDIS solution
Sand
Figure 3. 2 Material balance around Lamella separator
Table 3. 2 Material balance around Lamella separator

Mass Mass
Component
Ddis 38759.47701
Sand 414.7954092
DIS 38344.6816
Total 38759.47701 38759.47701
42
3.3 Material balance around KAN tank
The crystals are washed with NH4NO3 solution,which is added by maintaining

ratio of CN/AN =10. So the amount of KAN solution is [14294.95847(CN)
+14294.95847/10] = 15724.45 kg/hr.
Table 3. 3 Material balance around KAN tank

Mass Mass
Component
CN Crystals 14294.95847
NH4NO3 1429.4958
DIS 15724.45
Total 15724.45 15724.45
3.4 Material balance around Crystalizer
80% of Ca(NO3)2 is converted into CN crystals.
So crystals formed=17868.698*0.80 =14294.958kg/hr
The remaining solution is called as NP acid.
DDIS crystalizer
NP acid
CN crystals
Figure 3. 3 Material balance around Crystallizer
43
Table 3. 4 Material balance around Crystallizer
Mass
Component Mass inlet(kg/hr)
outlet(kg/hr)
DDIS 38344.6816
CN crystals 14294.95847
NP acid 24049.72313
Total 38344.6816 38344.6816
3.5 Material balance around Nitrate conversion unit
Reaction:Ca(NO3)2+(NH4)2CO3→ 2NH4NO3+CaCO3 (conv=100%)
KAN solution
Conversion reactor
ACB AN(60%)
CaCO3
Figure 3. 4 Material balance around Nitrate conversion unit

KAN solution contains 50% CN + 50% AN(60%)
KAN feed=15724.45432 = kg/hr
AN from KAN feed=15724.45*0.50=7862.227 kg/hr
CN from KAN=15724.45*0.50=7862.227 kg/hr
Moles of CN = 7862.227/ 164 = 47.94 kmol/hr
AN formed=47.94 *2*80=7670.46 kg/hr
CaCO3 formed=47.94*100=4794 kg/hr
44
ACB required=47.94*96= 4602.28 kg/hr
Table 3. 5 Material balance around Nitrate conversion unit

Mass Mass
Component Mw Moles In Mole Out
CN From
164 47.9404095 7862.227159
KAN
Ac 96 47.9404095 4602.279312
AN(60%) 80 95.88081901 7670.465521
Lime 100 47.9404095 4794.04095
AN(60%)
7862.227159 7862.227159
From KAN
Total 20326.73363 20326.73363
3.6 Material balance around Pressure filter
Separation of AN and lime by pressure filter.
Table 3. 6 Material balance around Pressure filter

Mass Mass
Component
Mixture 20326.73363
AN 15532.69268
Lime 4794.04095
Total 20326.73363 20326.73363
3.7 Material balance around Carbonization tower
45
NH3
Carbonization tower
CO2
ACB
H2O
Figure 3. 5 Material balance around Carbonization tower

Reaction:2NH3+CO2+H2O→(NH4)2CO3 (conv=95%)
ACB produced=4602.279 kg/hr
Moles of ACB=46022.279/96 =47.94 kmole/hr
NH3 required=(2*47.94*17)/0.95=3586.877495 kg/hr
CO2 required=(47.94*44)/0.95=2392.968160 kg/hr
H2O required=(47.94*18)/0.95 =908.344 kg/hr
Table 3. 7 Material balance around Carbonization tower

Mass Mass
Component Mw Moles in Mole out
inlet(kg/hr) outlet(kg/hr)
NH3 17 100.9271779 1715.762024 5.046358895 85.78810122
CO2 44 50.46358895 2392.968160 2.523179448 111.0198957
H2O 18 50.46358895 908.3446011 2.523179448 45.41723006
ACB 96 47.9404095 4602.279312
Total 4844.504539 4844.504539
3.8 Material balance around Evaporator
AN(60%) solution is concentrated upto AN(94%).
Amount of AN(94%)=(15532.69268*0.6)/0.94=9914.48 kg/hr
H2O
46
AN(60%) evaporator
AN(94%)
Figure 3. 6 Material balance around Evaporator
Table 3. 8 Material balance around Evaporator

Component Inlet(kg/hr) Outlet(kg/hr)
AN 15532.69268
H2O 5618.20799
AN(94%) 9914.484689
Total 15532.69268 15532.69268
47
3.9 Overall Material balance diagram
48
Figure 3. 7 Overall Material balance diagram
3.10 Summary of Material balance
49
Table 3. 9 Summary of material balance around each equipments
Input Output
Equipment
(total mass flow in kg/hr) (total mass flow out kg/hr)
Reactor 38759.47701 38759.47701
Lamella separator 38759.47701 38759.47701
Crystalizer 38344.6816 38344.6816
KAN tank 15724.45432 15724.45432
Carbonization tower 4844.504539 4844.504539
Conversion reactor 20326.73363 20326.73363
Pressure filter 20326.73363 20326.73363
Evaporator 15532.69268 15532.69268
Neutralizer reactor 24078.6966 24078.6966
Dryer 24078.69659 24078.69659
50
CHAPTER 4 ENERGY BALANCE
51
52
4.1 Introduction
All chemical processes involve certain chemical reactions at particular conditions

of temperature and pressure to produce a desired product. To achieve these conditions
of heating or cooling a stream and for proper functioning of equipment, various
entities such as brine solution, cooling water, chilling water, high pressure, medium
pressure, low pressure steam, electricity etc. are used. These entities are called
UTILITIES. Utilities do not take part in the process but they only make the conditions
favourable for any process.
Energy balance is a calculation done to calculate the load on utilities. It is used to

calculate the amount of utilities required by the system to reach favourable conditions
required by the system.
Table 4. 1 Data required for energy balance

Cp(kJ/kg*k)
Heat of
available
Componenet formation
from plant
∆Hf(kJ/kmol)
manual
HNO3 2.8 -207000
DDIS solution 2.386
CN brine 2.8
An(60%) 2.51
An(94%) 1.67
Water 4.1
Cp 3.51 -4120000
Pa 1.08 -1288000
CNTH crystals 1.53
53
NP acid 1.94
CN 0.61 -938200
Sand 0.68
Steam latent heat(kJ/kg) 2700
4.2 Energy balance around Reactor
Reaction:Ca3(PO4)2+6HNO3→ 2H3PO4+3Ca(NO3)2
Reference temperature(TR) = 273 k
From material balance,
Ca3(PO4)2 in= 11851.297kg/hr
HNO3 in =26493.3842 kg/hr
H3PO4 out=7118.424 kg/hr
Ca(NO3)2 out=17868.69 kg/hr
Sand out=414.795 kg/hr
Table 4. 2 Energy balance around Reactor

Dissolving
1 reactor(reaction
temp=68 ℃)
Cp HNO3 CN
Tin 306 293
Tout 341 341 341
Pa Sand Cw
Tin 306 306
54
Tout 341 341 318
Enthalpy ∆H = m*cp*∆t
Total energy in= hca3(PO4)2 + hhNO3 + hsand
=11851.297*3.51*(306-273) + 26493.3842*2.8*(293-273) +
414.795*0.68*(306-273)
∆H1 = 2865673.303 kJ/hr
Total energy out = hCN + hpa + hsand + Hca3(PO4)2 + hHNO3
= 17868.698*0.61*(341-273) + 7118.42*1.08*(341-273)
+ 414.795*0.68*(341-273) +592.564*3.51*(341-273 )+2167.64*2.72*(341-273)
∆H2 = 1837302.967 kJ/hr
Heat of reaction ∆HR = hf(product) - hf(reactants)
=[2*hf(pa)+3*hf(CN)] - [1*hf(cp) +6*hf(na)]
=[2*(-1288000)+3*(-938200)] -[(-4120000)+6*(-207000)]
= -28600 kJ/hr
Total enthalpy change= ∆H2+∆HR-∆H1
= -1056970.336kJ/hr
Amount of cooling water required= 1056970.336/(cp(h2o)*∆t)
=1056970.336/(4.178*(318-306))
= 21036.747 kg/hr
4.3 Energy balance around DIS Cooler
Table 4. 3 Energy balance around Cooler

2 DIS cooler
55
DIS solution Cooling water
Tin 341 306
Tout 321 316
Amount of DIS solution = 38344.6816 kg/hr
Energy in= Hdis
= 38344.6816*2.386*(341-273)
∆H1 = 6221347.901 kJ/hr
Energy out= Hdis
= 38344.6816 *2.386 *(321-273)
∆H2= 4391539.695 kJ/hr
Total enthalpy change =∆H1 -∆H2 = 1829808.206 kJ/hr
Amount of cooling water required= 1829808.206/(cp(h2o)*∆t)
= 1829808.206/(4.178*(316-306))
= 43775.3159 kg/hr
4.4 Energy balance around Crystalizer
Table 4. 4 Energy balance around Crystalizer

Crystalizer
DDIS Brine CNTH crystals
Tin 321 268
Tout 291 281
56
NP acid
Tin
Tout 281
Crystals out=14294.95847 kg/hr
NP acid out = 24049.6816 kg/hr
DIS in = 38344.6816 kg/hr
Energy in∆H1= hddis =38344.6816*2.386*(321-273) =4391539.695 kJ/hr
Energy out ∆H2= hCN + hNP
= 14294.95847*1.53*(281-273) + 24049.6816*1.94*(281-273)
=548221.9947 kJ/hr
Total energy out=3843317.7 kJ
Brine required for cooling= 3843317.7/(cp(brine)*∆t)
=3843317.7/(2.8*(291-268))
=59678.84627 kg/hr
4.5 Energy balance around Preheater
Table 4. 5 Energy balance around Preheater

4 Preheater
Steam
AN
condensate
Tin 418 318
Tout 395 348
57
Amount of an solution = 15532.6927 kg/hr
Energy in ∆H1= han =15532.6927*2.51*(318-273) =1754417.64 kJ/hr
Energy out ∆H2= han =15532.6927*2.51*(348-273)=2924029.40 kJ/hr
Total enthalpy change =2924029.40-1754417.64
= 1169611.76 kJ/hr
Amount of steam condensate required= 1169611.76/(cps*∆t)
=1169611.76/(4.25*(418-395))
= 11965.3377 kg/hr
4.6 Energy balance around Evaporator
Table 4. 6 Energy balance around Evaporator

5 Evaporator
An(60%) H2O An(94%) Steam
Tin 348 ƛ(kJ/kg)
Tout 365 365 2700
ƛ(kJ/kg)=2200
Assuming that only sensible heat of steam is utilized.
Amount of an(60%)=15532.6927 kg/hr
Amount of an(94%)=9914.48469 kg/hr
Water out=5618.20799 kg/hr
58
Energy in ∆H1= han =15532.6927*2.51*(348-273) = 2924029.4 kJ/hr
Energy out∆H2 = han+ hh2o
=9914.484 *1.67*(365-273) + 5618.20799*2200
= 12360057.578 kJ/hr
Total enthalpy change =14595278.2-4483511.74=9436028.178 kJ/hr
Amount of steam required= 9436028.178/2700
= 3494.825 kg/hr
So , from above energy balance ,
Amount of steam required = 3494.825 kg/hr
Amount of brine required =59678.84627 kg/hr
Amount of cooling water required = 64812.06333kg/hr
Amount of steam condensate required = 11965.3377 kg/hr
59
CHAPTER 5 UTILITIES
60
The entities that are used to achieve optimum conditions for a process but not
taking part in the process are called utilities. The basic utilities required in any
process are cooling water , steam , cooling brine solution.All these have their
particular role to achieve the optimum conditions for a process, heating, cooling,
etc. These streams do not take part in the process. The steam generation section or
boiler house produce steam at various pressures. Cooling tower produces cooling
water, electricity is drawn from power house to run the equipment in the industry.
Thus utilities play a major role in the proper functioning of any industry.
5.1 Cooling tower

Cooling tower is a familiar sight in all industries. A tower through which water
is circulated to remove the heat generated from various heats generating operations
and the hot water comes back to the cooling tower. This water is cooled in the cooling
tower collected in the sump and recirculated, the cycle continues. This is basic
definition of cooling tower.There are three types of cooling towers:
1. Natural draft:Natural re-circulation of air-cools the hot water
2. Forced draft:Using a fan, air is forced in the cooling tower
3. Induced draft :Air is sucked through the water shower using a fan
61
Figure 5.1 Schematic diagram of cooling tower
5.1.1 Functioning of cooling tower

Water is lost through the cooling tower by evaporation during the process of heat
exchange. Fresh water is added to the cooling tower to make up the losses.
Evaporated water leaving along with air is pure water. While incoming water
contains dissolved solids and suspended matters, etc. Therefore there is always a
concentration of dissolved solids in the recirculating cooling water due to
evaporation. This solids build up in recirculating water should not exceed certain
limits else deposition in heat exchanger may take place. In order to remove such
dissolved solids, part of water removed periodically or continuously is known as blow
down (bleed off).
Make up water (m) = water lost by evaporation (e) + blow down (b)
5.1.2 General terms used in cooling water systems

1. Acidity:- It shows presence of acid in water, ph of water less than 7.
2. Alkalinity:- It shows presence of alkali in water, ph of water is more than 7.
3. Hold up capacity of the system:- It is an amount of water contained in basin and

sump of cooling tower + water contained in piping and equipment.
62
4. Blow down:- Since pure water is evaporated out of the system, the dissolved and the
suspended solids are concentrated in the circulating water. Beyond certain limit, these
solids will cause massive scale and corrosion. In order to balance this, a certain
amount of water is removed from the system by blow down.
5. Make up water:- This is the water, which is to be added to replace the water lost
by evaporation, blow down, drift and leakages
6. Drift:-Some water droplets escape along with the evaporation. A usual drift
loss in conventional cooling towers is in the range of about 0.05 - 1 % of the re-
circulation rate.
7. System losses:- Circulating water is lost in the plant through pumps, valves or
leakages through flanges, etc.
8. Evaporation losses:- The water lost to the atmosphere in the cooling process is
evaporation. The rate of evaporation depends upon the temperature differential and
the circulation rate. It amounts to about 0.1% of the circulation rate for each 10 of
temperature drop.
9. Cycle of concentration:- Due to evaporation of water in cooling tower the

impurities get concentrated in recirculating water. Number of times the impurities
get concentrated in recirculating water is known as cycle of concentration (c.o.c.).
5.1.3 Typical problems in cooling tower

1. Scaling:- The salt like calcium carbonate, calcium sulphate and calcium phosphate
in the cooling water has reverse solubility, i.e. At high temperature their
solubility decreases. This causes precipitation and scaling in heat exchange.
Cooling water is heated in the heat exchangers where temporary hardness salts
decompose and form scales.
Cooling water is concentrated in the system due to evaporation in tower. Due to

concentration, sparingly soluble salts like calcium sulphate tend to precipitate out and
form scales. Thus scale of calcium carbonate, calcium sulphate and calcium
phosphate are often found in the heat
exchanger.
2. Corrosion:- Cooling water is corrosive to mild steel, copper, etc. Due to higher
TDS. More are the dissolved salts in water more are the corrosiveness. Also various
63
galvanic cells are formed in the heat exchangers due to differential metal,
combination, concentration, temperature, velocities and stress strain on metal.
Corrosion is generally observed all over the cooling system. But it is more near
welding, joints and under the deposition.
3. Microbiology:- Cooling water is ideal medium for microbiological growth.it

provides optimum temperature, oxygen, nutrient and sufficient surface area for
growth. Algae, bacteria and fungus are commonly found in cooling system. If not
controlled in time, microbiological growth can plug heat ex-changer and causes
corrosion and reduce cooling tower efficiency.
4. Fouling:- Fouling of system is mainly due to suspended matter in the cooling

water. The suspended matter comes through make up water and by scrubbing of air
born dust in the cooling tower. The suspended dust, dirt may coagulate and
accumulate in heat exchangers. Contaminants like oil, grease, algae also foul the
system.
5.2 Borsig unit(cooling brine system)
The refrigeration process of an absorption refrigeration plant is based on the

mode of function of the compression refrigeration plant. The basic principles of the
compression refrigeration are:
Under applied heat, the liquid refrigerant is evaporated in the evaporator. Heat
admission to the refrigerant indicates a cooling of the product.
The refrigerant vapors are drawn in by the compressor and compressed. The back
pressure of the compressor must be at such a level that a liquefaction of the vapors in
the condenser with the available cooling medium is possible the liquefied refrigerant
is expanded to the pressure of the evaporator via the control valve and is again
available in liquid form for the evaporator. Thus, the cycle of the constantly
circulating refrigerant is closed.
In same refrigerant cycle, in principle, is found in the absorption refrigeration

plants. The compressor also draws refrigerant vapors from the evaporator and leads
these in a compressed state to the condenser. The refrigerant usually used for these
absorption refrigeration plants is ammonia.
64
The suction side of the thermic compressor is the absorber. Ammonia-water
solution is sprayed here and simultaneously cooled by cooling water.
By means of absorption, the ammonia vapors of the evaporator are drawns and
the sprayed solution which is known as a “poor solution: Ahead of the inlet to the
absorber is enriched and called a “rich solution” Downstream of the absorber.
The desorber forms the discharge side of the thermic compressor. The enriched
ammonia-solution which is supplied to the desorber with the solution pump
evaporates here partially with heat supplied from the outside.
The rising vapor has a high ammonia concentration and also water vapor.
In the rectification column subsequently arranged after the desorber the ammonia
concentration in the vapor is increased to such a level that vapors alsmost free of
water reach the condenser.
By means of differential pressure between the desorber and the absorber the poor
solution makes its way into the absorber via the control valve. Therefore the solution
cycle of the thermic compressor, of the absorption refrigeration plant, is closed. The
heat exchanger included in the solution cycle as well as the solution cooler serve to
improve the heat balance of the absorption of refrigeration plant.
The absorption capacity of the solution circulating in the plant is limited so that
an enrichment under the operating conditions in the absorber is only possible up to a
certain limit value. If the solution circulating in the plant is put through two absorbers
in a row, where the second absorber is working at a higher pressure.
65
Figure 5.2 Schematic diagram of Refrigeration cycle
5.3 Steam generation plant:
GNFC has three boxes. Boilers were supplied and commissioned by M/S
Foster Wheeler Power Products. UK Ltd. and TGs were made of M/S. BHEL Ltd.
Each boiler is designed to generate 51 steam at the rate of 275 T/hr. at a pressure of
105 Kg/cm2 abs and at a temperature of 510ºC at the outlet of the Boiler. All the three
boilers are connected to a single common-header to supply high pressure steam of
different consuming points. Normally, two boilers are kept in service, which are
sufficient enough to meet the steam requirement of the complex and the third boilers
kept as stand by which will be either under wet preservation of under maintenance,
inspection etc. The normal steam generation of each boiler is about 220 T/hr. Boilers
are of mono wall, radiant, single drum, front fired, water wall type and were initially
designed to fire natural Gas and Coal in 8 burners arranged in 4 tiers. From the very
beginning it coal firing was not used as decided by Government of India a Natural
Gas was sufficiently available. Later on due to restriction of NG to 3.0 MSM3 by
M/S. GAIL, the fuel firing system of boilers have been modified so as to fire NG as
well as Natural Gas Liquid (NGL) with the help of M/S. Thermax Babcock and
66
Wilcox Ltd. in order to avoid the production loss in Ammonia and urea plants. The
earlier NG consumption of the complex was up to the tune of 3.4 to 3.6 MSM3.
Steam:
Steam is the vaporized form of water. This vapor is commonly visible as a cloud
escaping from the spout of tea kettle in which water in the tea kettle produces 1600
times more volume in steam form. These properties of steam, its ability to carry a
large amount of heat and the large quantity of steam which can be made from a small
amount of water, make steam an ideal substance for transferring heat conveniently
and economically to every corner of the plant. Another property of steam is the way
its volume varies with change in temperature and pressure of the same.
We take advantage of these properties by generating steam at high pressure to

operate steam turbines, drive generator, compressor and pumps. The low pressure
exhaust steam from the turbines is then used for process requirements.
5.4 DM water plant
The suspended and biological impurities are already removed in Pre-treatment

plant. The dissolved impurities must be removed completely before it’s used as Boiler
feed. The process used for removal of dissolved impurities is known as
demineralization. The process is Ion Exchange process.
Process:
Strongly Acidic Cation Unit: When water with some dissolved salts is passed
through a resin bed, which is charged with H+ ions (RH), the ionized cations Ca++,
Mg++, Na+, etc. come in contact with the resin, replace the H + ions moved out of resin
matrix, neutralize the charged negative ions SO 4-, Cl-, CO3-, etc. and combined with
them to form corresponding acids like H2SO4, HCl, H2CO3, etc. The process of ion
exchange can be represented as:
2RH + CaSO4 → R2Ca + H2SO4
RH + NaCl → RNa + HCl
2RH + CaCO3 → R2Ca + H2CO3
67
The cation exchanger resin is regenerated with 4% HCl. The process of Regeneration
can be represented as:
R2Ca + 2HCl → 2RH + CaCl2
RNa + HCl → RH + NaCl
Degasser Tower: The outlets of cation exchangers having H2SO4, HCl, H2CO3, etc..
Out of these acids H2CO3 can be easily removed by mechanical method in acidic
media. Here atmospheric air is used for stripping the water & remove the CO 2 from
broken H2CO3 with it.
H2CO3 →H2O + CO2
Weak Base Anion Unit:The degassed water is passed through the bed of WBA unit,
the negative ions like SO4- or CO3- (strong anions) displace of OH-ions from the resin
matrix (ROH) & get themselves fixed in matrix place.
The process of ion exchange can be represented as:
ROH + HCl → RCl + H2O
2ROH + H2SO4 → R2SO4 + H2O
2ROH + H2CO3 → R2CO3 + 2H2O
Strong Base Anion Unit: The water from WBA outlet enters the Strong Base Anion
Unit where the Resin absorbs the residual anions, silica and carbon dioxide present in
the water.
2 ROH + H2SiO3 → R2SiO3 + 2H2O (DM Water)
The Weak Base Anion exchanger & Strong Base Anion Unit resin is regenerated with
4% NaOH. The process of Regeneration can be represented as:
RCl + NaOH → ROH + NaCl
R2SO4 + 2NaOH → 2ROH + Na2SO4
R2CO3 + 2NaOH → 2ROH + Na2CO3
R2SiO3 + 2NaOH → 2ROH + Na2SiO3
68
Mixed Bed Units: The anion treated water enters the mixed bed unit containing a
mixture of Cation & Anion resins. The anion treated water is further purified in this
unit.
The quality of D.M. Water is given below.
•PH: 6.3 to 7.3
•Silica: 0.01 ppm.(Max 50 ppm)
CHAPTER 6 DETAILED DESCRIPTION OF

EQUIPMENTS
69
6.1 Detailed description of Equipments
Table 6.1 Detailed description of equipments

Name of
No of equipment Data
Equipment MOC
Temp=70 c
Pressure=1.01325 N/mm2
Reactor 3
SS-304
Diameter = 3169 mm
Height = 2905 mm
Lamella No of plates=110
Separator 1 Temp = 70 c Cast iron
Type = centrifugal
Pumps Flow rate = 8 m3/hr
48 Suction pressure = 1 kg/cm2 SS-316
Absorber Pressure = 25.5 bar

2 SS-316
Temp = 70 c
70
Blowers Pressure = 2.4 bar
8 SS-316
Diameter = 8 m
Storage tanks
30 Height = 8 m SS-316
Belt conveyers Motor speed = 200 RPM

Rubber
10
Rock
Capacity = 20 ton
Silos 3 Cast iron
Crusher Motor speed = 110 RPM SS

5
Bucket
Motor speed= 90 RPM
Elevator 2 Cast iron
=2800 mm
Vacuum belt
D=3400 mm Plastic
Filter 2
T = 30˚c, f = 27 m3 Belt
Evaporators 6 Temp = 90 ℃
SS-316
Pressure = 860mbar
Heat Temperature = 30-150 ℃
Ex-changers 22 Length = 4-5 m SS-316
Pressure = 250 mbar

Separators
14 Temp = 90 ℃ Cast iron
71
Auxiliary Temp = 50 c
Equipment 2 Pressure = 0.95 bar SS-316
Temp = 8 ℃
Crystallizers
10 Flow rate = 27 m3 SS-316
Temp = 50 c
Scrubber 2
Pressure = 0.95 bar SS-316
72
CHAPTER 7 EQUIPMENT DESIGN
73
7.1Design of Continuous stirred tank reactor
7.1.1 Process design:

 Conversion= 95%
 Density of Ca3(PO4)2(limiting reactant) = 1673.90 kg/m3
 Density of HNO3 = 1463 kg/m3
 Amount of Ca3(PO4)2=11851.297 kg = 38.22 kmol
 Amount of HNO3 fed = 26493.38 kg = 252.317 kmol
 Volume of Ca3(PO4)2
= 11851.297/1673.90
Va0 = 7080.05 L
 Volume of HNO3
= 26493.38/1463
Vb0 = 18108.9434 L
 Total volume
V = Va0 +Vb0= 7080.05 + 18108.9434
V = 25188.99443 L
 Reaction
Ca3(PO4)2+6HNO3(60%)------>2H3PO4+3Ca(NO3)2
(CONV=95%)
Na0 = 38.22 kmol
Nb0 = 252.317 kmol
Ca0 = 1.5 mole/L
Cb0 = 10.01 mole/L
According to stoichiometry,
(Ca0 – Ca) = (Cb0 - Cb)/6
Where,
74
Ca = Ca0(1 – Xa)
Cb = Cb0 – 6*(Ca0 – Ca)
Cb = Cb0 – 6*Ca0*Xa
Kinetic data
(-R) =3.4*10-3*(Ca)(Cb) (mol)/(L*sec)
= 3.4*10-3 Ca0 (1 – Xa) * (Cb0 – 6*Ca0*Xa)
= 3.4*10-3 Ca02 (1 – Xa) (M – 6*Xa)
M = Cb0/Ca0 = 10.97/1.5
=7
(-Ra) = 3.4 *10-3* 1.59762 (1 – Xa) (7 – 6*Xa)
equation of Design for Continuous stirred tank Reactor,
V = Ca0*v0*Xa / (-Ra)
V = Ca0*v0*Xa /3.4*10-3 Ca02 (1 – Xa) (M – 6*Xa)
Where,v0 =25 m3/hr = 6.944 L/sec
V = (6.944*0.95)/(3.4 *10-3* 1.5* (1 – 0.95)* (7 – 6*0.95))
V = 19899 L
V ≈ 20 m3
So we will design reactor for 25m3.
7.1.2 Mechanical design:

Volume(v)= 25 m3
Operating pressure =101325 Pa
Design pressure Pd= 1.02*101325 =106390 Pa
Operating temperature=50 ℃
Design temperature= 75 ℃
75
MOC = SS 304
Fall=121209830 Pa
J=0.8, c=2 mm
Dimension optimization
Applying lagrange multiplier method for optimization,
Lagrange function,
F(r,H,ƛ) = (2*pi*r*H+2*pi*r*r) + ƛ (pi*r*r*H-25)
Taking differentials of f(r,H,ƛ) w.r.t r,H,ƛ and equals to zero,
Df/dr=2*pi*H + 4*pi*r + 2*pi*r*H*ƛ=0 (1)
Df/dH=2*pi*r + ƛ*pi*r*r=0 (2)
Df/dƛ=pi*r*r*H-25 =0 (3)
From eq. (1),(2),(3)
H=2r=D
From eq (3)
Pi*r*r*H=25
Pi*r*r*2r=25
D=3.169 m
H= 3.169 m
Volume of elliptical bottom = 0.131 D3 = 4.17
New volume = 2 - 4.17 =20.83 m3
New height =2.905 m
Thickness of vessel
Tc = (Pd*D)/(2*fall*j-Pd)
= 106390*3.169
76
2*121209830*0.8-106390
= 1.74 mm
Td=1.74 + 2 =3.74 mm
Tf = 5 mm
 Closer design
Torrispherical head(top)
Figure 7. 1 Schematic diagram of Torrispherical head

J=0.8
Crown radius rc=D=3.169 m
Knuckle radius rk=0.06*rc=0.238 m
Pd=106390 Pa
fall=121209830 Pa
MOC =SS 304
C = 2 mm
Tc = Pd*rc*cs/(2*f*j+Pd(cs-0.2))
Where,
Cs=(1/4)(3+ sqrt(rc/rk))
=(1/4)(3+sqrt(3.169/0.238))
77
=1.66
Tc= 106390*3.169*1.66
(2*121209830*0.8+106390*(1.66-0.2))
= 2.884 mm
Td = 4.884 mm
Tf = 5 mm
Outer diameter Do=3.169+2*0.005= 3.179 m
Sf=3*tf=15 mm but minimum sf required is=25 mm
AB = D/2-rk= 1.35 m
BC=rc-rk=2.93 m
Depth of disc b=rc-ac=rc-sqrt(BC2-AB2)
=0.57 m
Head height oa=tf+b+sf=5+ 0.57 + 25 = 0.6m
Th<1 inch
So blank dia=Do+(Do/42)+2*sf+(2/3)rk
=3.179+(3.179/42)+2*0.025+(2/3)*0.238
= 3.46 m
 Elliptical head(bottom)
78
Figure 7. 2 Schematic diagram of Elliptical head
a=D=3.169 m
b=a/2=1.5845 m
K=a/b=2
Tc= Pd*D*v , v=stress concentration factor
(2*f*j-0.2*Pd) =(1/6)(2+k2)
=1
= 106390*3.169*1
(2*121209830*0.8-0.2*106390)
=1.739 mm
Td=3.739 mm
Tf= 5 mm
Sf=25 mm
From figure 7.3, Blank diameter≈154 inches=3.9116 m
79
Figure 7. 3 Blank diameter vs Head inside diameter for various thickness of
ASME Elliptical heads
Agitator design
Da=1m
Width(bw)=200 mm
n=50 RPM
No of baffles=4
µ=100 mPa
ƍ=1260 kg/m3
Length of shaft=2.3 m
C=1.5 mm
MOC = is-2062 grade st 42 -w
Ultimate tensile stress (σu)=4200 kgf/cm2
Yield stress (σy)=2300 kgf/cm2
Shear stress (σs)=550 kgf/cm2
E =1950000 kg/cm2, fos= 2
Nre = n*Da2*ƍ/µ = 50*1*1260 / 60*100*100*10-3 = 10500
80
Figure 7. 4 Reynolds number vs Power number
From graph
Power number Np=6
Power requirement (p)= n3Da5 ƍ Np/ g = 1260*503 *6*15 / 9.81*603 = 446 kgf m/s
=446/75
=5.95 hp
Considering 10% of power loss in sealing and 20% power loss in transmission
system.
So actual power requirement = 5.95*1.1*1.2 ≈ 8 hp
Shaft diameter calculation
Average torque on shaft T = p*75*60/2*pi*n = 8*75*60/2*3.14*50 ≈115 kgf m
Tmax = 1.2 to 1.5 of T
=1.2*T
=1.2*115
≈138 kgf m =13800 kgf cm
81
Max shear stress created in shaft
Σs= Tmax/zp
Where zp=polar sectional modulus for circular shaft
=3.14*Ds3 /16
550 = 13800*16/3.14*Ds3
Ds=50.36 mm
This Ds will be checked for bending moment.
Mb = Fm*l
Fm = Tmax/(0.75*rb) where,rb = Da/2 =0.5
=138/(0.75*0.5)
=368 kgf
Mb = 368*2.3 =846.4 kgf m
Equivalent bending moment
Me = (1/2)*(Mb + sqrt(Mb2 + Tmax2))
=0.5*(846.4+sqrt(846.42+ 1382))
=852 kgf m =85200 kgf cm
Stress created by me,
Σy= Me/z where z=3.14*Ds3/32
=85200*32/(3.14*5.0363)
=6794.89 > 2300 kgf/cm2
So new diameter will be,
2300 = 85200*32/3.14*Ds3
Ds3 = 377.32
Ds = 72 mm
82
Now this Ds will be checked for critical speed of agitator,
Maximum deflection in shaft δ= Fml3/3EI
Where I = 3.14*Ds4/64
δ=(368*23003*64)/(3*19.5*105*3.14*7.24)
=5.8 cm
Critical speed nc =60*4.987/sqrt(δ)
=60*4.987/sqrt(5.8)
=124.24 RPM
Actual n= 50 RPM
Condition to be satisfied:
[ (n/nc)*100 <70% or (n/nc)*100 >130%]
(n/nc)*100= (50/124.24)*100 = 40.24%
So shaft diameter Ds=72 mm
Blade thickness
Maximum stress created in blade material
F=tmax/z
F=ultimate strength (σu)/fos
=4200/2
=2100 kgf/cm2
For blade z = (1/6)*Bt*Bw2 where, Bt = blade thickness
Bw = blade width
2100 =(13800*6)/(Bt*202)
Bt = 0.9 mm
Bt =0.9+2*c = 0.9 +2* 1.5= 3.9 mm ≈ 4mm
83
7.2 Design of Shell and tube heat ex-changer
Data available
Suction, P1=2.1 kgf/cm2
Discharge, P2=24.6 kgf/cm2
Z1-Z2=1.2m
Diff. head=92m
Temp=50˚
Density=970kg/m3
Viscosity=0.114cp
Efficiency=58%
Volumetric flowrate= 25.71m3/h
Velocity = 2m/s
Length of pipe = 50m
Mass flow, m= Q*ρ = 249387 kg/hr
Area of pipe, A = Q/V = 0.003571 m2
Diameter of pipe , d=0.067445m
Optimum diameter =0.05m
C.S.A of pipe = Al = (3.14/4)*d2 = 0.001963m2
Fluid velocity = V1= Q/Al= 3.639066m/s
ΔP = 4.07 *1010 *G1.84*µ0.16*ρ-1*D-4.84= 2.068063kPa/m
Reynolds number = ρvD/µ = 2083.67
84
Friction factor, f =0.78/Re0.25=0.006488
Frictional loss in system,

hf=2*f*L*v/(g*D)=12.98m =127.401 J/kg
Pressure head=P1-P2/g*p
= 231.8796m
Velocity head = V2/2g = 0.674964
Total head, H = 246.7414m
Vapor pressure of liquid ,Pv= 26200 N/m2
Theoretical power requirement, wp =H*m*g = 16768.04 W
NPSH =(u2/2g + P1/p*g – Pv/ pg) =19.5637 m (available)
7.3 Design of Storage tank design
Storage tank reaquired for storing AN solution. During shut down of ANP rear plant
AN is stored in storage tank.
Volume=400 m3
MOC= SS 304
fall=121209830 Pa
ƍfluid=1540 kg/m3
Operating temp= 20 ℃
Design temp= 20+25= 45 ℃
Operating pressure=101325 Pa
j=0.8, plate size=3x1.5 m
Corrosion allowance= 1.5 mm
E=200 GPa
85
Dimension optimization
Applying lagrange multiplier method for optimization,
Lagrange function,
F(r,H,ƛ) = (2*pi*r*H+2*pi*r*r) + ƛ (pi*r*r*H-400)
Taking differentials of f(r,H,ƛ) w.r.t r,H,ƛ and equals to zero,
Df/dr=2*pi*H + 4*pi*r + 2*pi*r*H*ƛ=0 (1)
Df/dH=2*pi*r + ƛ*pi*r*r=0 (2)
Df/dƛ=pi*r*r*H-400=0 (3)
From eq. (1),(2),(3)
H=2r=D
From eq (3)
Pi*r*r*H=400
Pi*r*r*2r=400
r=4 m
D=8 m
Here D<12 m,
Bottom plate thickness(tb)= 6 mm
Bottom diameter (db)= D +2*tb+ (2*65/1000)
=8+2*0.006+0.13
= 8.142 m
Internal loading due to liquid filled,
P= ƍ*(H-0.3)*9.87=1540*(8-0.3)*9.87= 117002.886 N/m2
Design pressure Pd=1.05*P=122853.0303 N/m2
Thickness of vessel,
86
Tc=(Pd*D)/(2*fall*j)
=122853.0303*8*1000
2*0.8*121209830
=4.7696 mm
Td =4.7696+c=6.2696 mm
Tf=8 mm
Perimeter of the tank(p)=pi*D=3.14*8=25.133 m
Calculation of number of plates required,
No of plates required to cover periferi of tank in one course
n= (p-n*0.002)/(length of plate)
=(25.133-n*0.002)/3
n= 9
No of plates required to cover hight of tank
x =( H - x*0.002)/(hight of plate)
=(8-x*0.002)/1.5
=6
Total plates required= n * x = 9 * 6 = 54 plates
Calculation of thickness of the courses,
Height compensated by Tf= 8 mm
0.008 = 1540*(H-0.3)*9.87*8
2*0.8*121209830
H = 13.05 m > 8 m , new height= 8-1.5=6.5 m
So we can reduce the thickness of plate.
87
Lets take it 5 mm
Height compensated by Tf= 5mm
0.005 = 1540*(H-0.3)*9.87*8
2*0.8*121209830
H= 8.47 m > 6.5 m
So we can use 5 mm thick plate to whole height of tank because 5 mm thick plate can
withstand height upto 8.47 m which is greater than 8 m.
 Roof design
Self supported conical roof
Class a tank
Internal loadings= 200 kg/m2=200*9.81 =1962 N/m2
External loadings=225 N/m2
The slope of cone is limited to tan θ<(1/5) or (1/6)
Let tan θ=1/5
So θ=tan-1(1/5)=11.31º
Loadings on roof
P =pressure based on class of vessel + external pressure
=1962 + 225
=2187 N/m2
Thickness of roof
Tr= (D/sin θ)*sqrt(p/0.204*E)
=(8/sin(11.30))*sqrt(2187/(0.204*2*(10^11)))
=9.5 mm
So 5 mm<Tr<12mm
Roof is self supported.
88
CHAPTER 8 PUMPS AND CONTROL VALVES
89
8.1 Types of control valves
8.1.1 Linear motion control valves
Linear motion valves have a closure member that moves with a linear motion to
modify the rate of flow through the valve. Linear motion valves are generally named
for the shape of their closure member. Common linear motion valves include,
Globe, Gate, Diaphragm
Globe valve :- Globe valves are so named for their globular shaped cavity around the
valve seat area.globe valves have good throttling characteristics but because the flow
path is not linear they have a relatively high pressure drop across the valve.
Gate valve:-The closure member of a gate valve is a flat face, vertical disc, or gate
that slides down through the valve to block the flow.gate valves are designed to
operate in their fully open or fully closed position and herefore are found only in
flow shut-off applications.
Diaphragm valves:- The closure member of a diaphragm valve is a flexible surface

(the diaphragm) that is deformed. Diaphragm valves are used mostly for shut-off
service of slurries, corrosive or viscous fluids but may also be used in flow throttling
applications as well..
8.1.2 Rotary motion control valves

Rotary valves have a closure member that moves with a rotary motion to
modify the rate of flow through the valve.like linear motion valves, rotary motion
valves are generally named for the shape of their closure member.common rotary
motion valves include ball,butterfly and plug valve.
Ball valve
90
The closure member of a ball valve is shaped like a ball with a port for fluid
flow. A ball valve allows straight-through flow in the open position and shuts off flow
when the ball is rotated 90 degrees. Ball valves are used in shut-off and throttling
applications.
Butterfly valve
The closure member of a butterfly valve is a circular disc or vane with its pivot
axis at right angles to the direction of flow in the pipe.like ball valves, a butterfly valve
allows straight-through flow in the open position and shuts off flow when the ball is
rotated 90 degrees.
Plug valve
The closure member of a plug valve is a cylindrical shaped plug with flow port.
Like a ball valve, a plug valve allows straight-through flow in the open position and
shuts off flow when the ball is rotated 90 degrees.like ball valves, plug valves are
found mostly in flow shut-off applications. However plug valves are available in much
larger sizes that ball valves.
8.2 Valve services
A control valve is an inline device in a flow stream that receives commands from
controller and manipulates the flow of a gas or fluid in one of three ways:
Interrupt flow (Shut-Off Service)
Divert flow to another path in the system (Divert Service)
Regulate the rate of flow (Throttling Service)
Shut-Off Service:-
Control valves for flow shut-off service have two positions.

In the open position flow is allowed to exit the valve.
In the closed position flow is blocked from exiting the valve.
Divert Service:-
Control valves for divert service also have two positions, however flow is never
blocked.
91
In one position, flow is allowed from the common port to port A.In the other position,
flow is allowed form the common port to port B.
Throttling Service:-
Control valves for throttling service have many positions.
The position of the valve determines the rate of flow allowed through the valve.
8.3 Pumps
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by

mechanical action. Pumps can be classified into three major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps. Pumps
operate by some mechanism and consume energy to perform mechanical work by moving
the fluid. Pumps operate via many energy sources, including manual operation,
electricity, engines, or wind power, come in many sizes, from microscopic for use in
medical applications to large industrial pumps.
Centrifugal Pump :-
Centrifugal pumps are a sub-class of dynamic axisymmetric work-absorbing

turbomachinery. Centrifugal pumps are used to transport fluids by the conversion of
rotational kinetic energy to the hydrodynamic energy of the fluid flow. The rotational
energy typically comes from an engine or electric motor. The fluid enters the pump
impeller along or near to the rotating axis and is accelerated by the impeller, flowing
radially outward into a diffuser or volute chamber (casing), from where it exits.
92
CHAPTER 9 SAFETY
93
9.1 List of safety equipments
9.1.1 Respiratory protective equipments

1. Self contained breathing apparatus sets of 30 minutes and 10 minutes
2. Continuous air line masks.
3. Trolley mounted self contained breathing apparatus set 2.5 hours
4. Canister gas mask.
5. Dust mask/cloth mask. (air purifying respirator)
9.1.2 Personal protective equipments

PPE is equipment that will protect the user against health or safety risks at work.
It can include items such as safety helmets, gloves, eye protection, high-visibility
clothing, safety footwear and safety harnesses. It also includes respiratory protective
equipment (rpe)
 Impoortance of PPE:
Making the workplace safe includes providing instructions, procedures, training

and supervision to encourage people to work safely and responsibly.
Even where engineering controls and safe systems of work have been applied,
some hazards might remain. These include injuries to:
The lungs, eg from breathing in contaminated air
The head and feet, eg from falling materials
The eyes, eg from flying particles or splashes of corrosive liquids
The skin, eg from contact with corrosive materials
The body, eg from extremes of heat or cold
PPE is needed in these cases to reduce the risk.
Types of PPE:-
Eyes:
Hazards: Chemical or metal splash, dust, projectiles, gas and vapour, radiation.
Options: Safety spectacles, goggles, face screens, face shields, visors.

Note: Make sure the eye protection chosen has the right combination of
impact/dust/splash/molten metal eye protection for the task and fits the user properly.
94
Head and neck:
Hazards: Impact from falling or flying objects, risk of head bumping, hair getting
tangled in machinery, chemical drips or splash, climate or temperature.
Options industrial safety helmets, bump caps, hairnets and firefighters' helmets.
Note
 Some safety helmets incorporate or can be fitted with specially-designed eye
or hearing protection.
 Don't forget neck protection, eg scarves for use during welding.
 Replace head protection if it is damaged.
Ears:-
Hazards: Noise – a combination of sound level and duration of exposure, very

high-level sounds are a hazard even with short duration.
Options: Earplugs, earmuffs, semi-insert/canal caps.
Note
 Provide the right hearing protectors for the type of work, and make sure
workers know how to fit them.
 Choose protectors that reduce noise to an acceptable level, while allowing for
safety and communication.
Hands and arms:-
Hazards: Abrasion, temperature extremes, cuts and punctures, impact, chemicals,

electric shock, radiation, vibration, biological agents and prolonged immersion in
water.
Options: Gloves, gloves with a cuff, gauntlets and sleeving that covers part or all
of the arm.
Note
 Avoid gloves when operating machines such as bench drills where the gloves
might get caught
 Some materials are quickly penetrated by chemicals – take care in selection,
 Barrier creams are unreliable and are no substitute for proper PPE.
 Wearing gloves for long periods can make the skin hot and sweaty, leading to
skin problems. Using separate cotton inner gloves can help prevent this.
Feet and legs:-
95
Hazards: Wet, hot and cold conditions, electrostatic build-up, slipping, cuts and
punctures, falling objects, heavy loads, metal and chemical splash, vehicles.
Options: Safety shoes.
Table 9.1 List of personal protective equipment s

No. Protection Type of safety appliances
1 Head Safety helmet
2 Eye Safety goggles, welder’s goggles
3 Face Face shield, acid and alkali proof hood
4 Ear Ear plug, car muff
5 Hands Canvas hand gloves, canvas leather hand gloves
Fingers Asbestos hand gloves, rubber, PVC, surgical hand gloves

6 Body Cotton aprons and cotton boiler suit, PVC aprons
Pressurized neck to toe overall,
PVC neck to toe overall asbestos suit

7 Foot & leg Safety shoes, gum boots
96
CHAPTER 10 PLANT LOCATION & PLANT LAYOUT
97
10.1 Plant layout
For the success of any industries, it’s geographical location of a final plant must
be considered. Plant should be located where the minimum cost of production and
distribution can be obtained.factors like room for expansion and safe living
condition for plant, operation as well as surrounding community are also important.
The plant location for any industry should be obtained before a design project reaches
the detailed estimate stage. The selection of a place for locating a plant is one of the
problems, perhaps it is the one of the task for the entrepreneur while launching the
new enterprise. Selection of location is on pure economic considerations will ensure
an easy and regular supply of raw material , labour,efficient plant layout to reduce the
cost of production. Once a mistake is made in locating a plant,it becomes extremely
difficult and costly to correct it.a plant should be located at a place where inhabitants
are interested in success. The product can be sold profitably and production cost is
minimum.the choice of plant location is among the most serious decisions that top
management will ever make. Plant location significantly impact costs, as well as the
speed with which the firm can supply the products where the end users will need
them.furthermore, changing the location of plant is very difficult and costly. Mistakes
in the selection of process can have very long-term ramifications.
Factors for choice of plant location
1. Raw materials.
2. Climate.
3. Water and fire availability.
4. Market availability.
5. Energy availability.
6. Government policies.
7. Water supply.
8. Transportation facility.
9. Waste disposal.
10. Site characteristics.
98
11. Community factor.
12. Labour supply.
Raw materials
For the plant location source of raw material is one of the most important factor. As
the manufacturing unit is consider, in the conversion of the raw material in product,
the plant is located where the raw material supply is maximum. This fact is true if
the large volume of raw material is consumed. Because the location near the raw
material permits reduction in transportation & storage charges. As we consider this
factor we should keep in mind price of raw material , distance from the source of
supply , availability & reliability of supply etc.
Climate
There are certain industries which are depends on the nature of production. Based
on the product of the industries this factor is affected to plant location of particular
industry. As general selection of cold climate may be increase the cost of construction
of the shelters around the process equipment.We should also have to design cooling
tower & air conditioning equipment as per that cold climate which is costly.so
excessive humidity or extremes of hot or cold climate affects economy of the
plant.so this factor should be kept in mind while selecting the plant location.
Water and fire availability
Every industries required water but for certain industries water is the main
source as a raw material. This type of industries we can see located along the river. Eg.
Nhpc power plant, which is use water for production of power. There are certain
industries in which fire is needed for their working.
Market availability
Since good are produced for sale, it is very essential that a plant should be
located near to the market.The advantages are as below.
1) reduction in cost of transportation of finished goods to the market.

2) availability of render prompt services to the consumer.
99
3) the ability to adjust production program to suit the likes and dislikes of
consumers.
Energy availability
Power is essential to move the wheels of an industry using electricity have to be

located where the supply of power is available more. Electricity for ANP plant as well
as for township available from GNFC power plant & from GEB if required.
Labour supply
GNFC will be appointing labor contractors for continuous supply of labour.

Moreover the plant being highly sophisticated with DCS control, the need for skilled
labour will be highly reduced. Skilled personnel are available in Gujarat, because of high
professional centers.
10.2 Plant layout
Equipment layout
ANP plant is divided in different sections. The equipment in ANP plant is at

different floor, this will enable not only in saving in floor space area, but also each
and every equipment will have easier accessibility for replacement or maintenance.
There is ample space around plant for initial construction and maintenance.
Future expansion
Enough attention has been given in allotting space on each section to take care to
future expansion or modification of plant capacity. Plant in its present condition is
capable of providing space for replacement of equipment with higher capacity.
Utilities servicing
The distribution of air, cooling water, steam and power is quite flexible in the
plant. There is one distribution cooling water headed and one common receive
cooling water from all of the heat exchangers of the plant.
Roads
The building will have approximate 25ft wide road on every sides of plant, thus
allowing any truck to reach plant location for replacement or dismantling of any
equipment.
100
Storage layout
Storage for ANP has been done in the storage tanks.
The ANP plant is continues so that raw material storage is not required. The raw
material NH3 and CO2 continuously come from Tank Farm and ammonia plant
respectively. ANP plant is divided in mainly two sections. The equipment in both
ANP plant is at different floor, this will enable not only in saving in floor space area,
but also each and every equipment will have easier accessibility for replacement or
maintenance.
Flow in this plant will be partially by gravity, major flow will be looked after by
pumping.
101
Figure 10. 1 Plant layout
102
CHAPTER 11 COST ESTIMATION
103
11.1 Introduction
An acceptable plant design must present a process that is capable of operating

under conditions which will yield a profit. Since net profit equals total income minus
all expenses, it is essential that the chemical engineer be aware of the many different
types of costs involved in manufacturing processes. Capital must be allocated for
direct plant expenses, such as those for raw materials, labor, and equipment. Besides
direct expenses, many other indirect expenses are incurred, and these must be
included if a complete analysis of the total cost is to be obtained. Some examples of
these indirect expenses are administrative salaries, product-distribution costs, and
costs for inter-plant communications.
A capital investment is required for any industrial process, and determination of

the necessary investment is an important part of a plant-design project. The total
investment for any process consists of fixed-capital investment for physical
equipment and facilities in the plant plus working capital which must be available to
pay salaries, keep raw material and products on hand, and handle other special
requiring a direct cash outlay. Thus, in an analysis of costs in industrial processes,
capital-investment costs, manufacturing costs, and general expenses including income
taxes must be taken into consideration.The preliminary cost estimation involves:
Estimation of capital investment

Estimation of Total product cost
Profitability Analysis
 Cost estimation with MOC

Here ss 304 is used as MOC.
Now cost of reactor
Cost of shell
Weight = volume * density
=(3.14/4)*(2.7972-3.1692)*2.321 *8000
=814 kg
104
Cost of MOC=weight*material cost per kg = 814* 300
=244200 rs
Cost of nozzle
Agitator nozzle
Weight=(π/4)*(do2-di2)*(ho+hi)*density =(3.14/4)*(00.1102-
0.1002)*(0.01766+0.0102)*8000
= 0.3674kg
Cost =0.3674*300
=110.25 rs
Weight of flange=(3.14/4) *(dfo2−dfi2) *flange thickness*density of material

=3.78 kg
Inlet nozzle
Weight=(π/4)*(do2-di2)*(ho+hi)*density
=(3.14/4)*(0.0902-0.0802)*(0.01587+0.00917)*8000
= 0.2673kg
Cost =0.2673*300
=80.198 rs
Weight of flange=(3.14/4) ∗ (dfo2−dfi2) ∗ flange thickness∗density of material

=3.5kg
Total cost of flanges
= total weight *cost per kg
= ((3.78+3.5*2)*300)
=3234 rs
Now cost of fabrication
Shell
Perimeter = 3.14*3.169 =8.75 m
Height=2.321 m
If we select(1m*1m)plates then plates required to cover perimeter by 1 m plate=9
plates required to cover height by 1m= 3
total no of plates required = 9*3=27
105
Total area=area of 1 plate*no of plates=1*1*27=27 m2
Cost of fabrication=860 rs/m2
Total cost=860*27= 23,220 rs
Torrispherical head
Weight=(3.14/4)*blank dia2*thickness*density of MOC
=(3.14/4)*3.02*3.02*0.005*8000
=286.38 kg
Fabrication cost =75rs/kg
Total cost=75*286.38=21479 rs
Elliptical head
Weight=(3.14/4)*blank dia2*thickness*density of MOC
=(3.14/4)*3.429*3.429*0.005*8000
=369.2 kg
Fabrication cost =90 rs/kg
Total cost=90*369.2= 33228 rs
Cost of welding [Length=1 m, Width =1 m ,No of plates=27]
Total length of welding =2*(length + width) *no of plates =2*(1+1) * 27= 108 m
Cost of welding = (total length of welding*60) =108*60 = 6480 rs

Weight of heads
Wt of torrispherical head=(3.14/4)*blank dia2*thickness*density of MOC
=(3.14/4)*3.022*0.005*8000
=286.38 kg
Cost of MOC = wt* cost per kg=286.38*300 = 85914 kg
Wt of elliptical head=(3.14/4)*blank dia2*thickness*density of MOC
=(3.14/4)*3.429*3.429*0.005*8000
=369 kg
Cost of MOC = wt* cost per kg=369*300=110760 rs
106
Total cost= cost of MOC + cost of fabrication + cost of welding + cost of nozzle +
cost of flanges + cost of insulation and glass assembly
=244200+110.25+2*80.198+3234+23220+21479+33228+6480+85914+110760
+400000
=928785.646 rs
Total no of reactors are 6,so total cost =6*1000000
=6000000rs
In this way cost of all equipments are calculated show in table below.
11.2 purchased equipment cost
Table 11. 1 Purchased equipment cost

Purchased
1 equipment
cost(PEC)
No of
Name Cost/unit Total cost
unit
Reactor 6 1000000 6000000
Lamella separator 1 3000000 3000000
Pumps 48 300000 14400000
Absorbers 2 4752787 9505574
Blowers 18 1345697 24222546
Storage tanks 30 2053596 61607880
Belt conveyers 10 500000 5000000
Silos 3 100000 300000
Crushers 4 9875463 39501852
107
Bucket elevator 3 3000000 9000000
Vacuum belt filter 4 2500000 10000000
Evaporator 6 2345948 14075688
Heat exchangers 22 2594560 57080320
Separators 14 100000 1400000
Auxilary
4 2725635 10902540
equipments
Crystalizers 10 9517536 95175360
Scrubber 3 1596785 4790355
Total(PEC) 365962115
Table 11. 2 Fixed capital investment and Total capital investment

PEC is 20% of FCI,so
2 1829810575
actual FCI
Total capital
3 2287263219
investment(TCI)
11.3 Direct cost
It includes,
1. Cost of equipment
2. Cost of Installation
3. Cost of Instrumentation & Control
4. Cost of Piping, Insulation and Painting
5. Cost of Electrical
6. Cost of Building
7. Cost of Yard improvement
108
8. Cost of Service facility
9. Cost of Land
Table 11. 3 Direct cost

4 Direct cost(DC)
Components Basis(%) Cost
Purchased equipment 20(FCI) 365962115
Installation 30(PEC) 109788634.5
Instrumentation 15(PEC) 54894317.25
Piping 15(PEC) 54894317.25
Electrical cost 15(PEC) 54894317.25
Building 10(PEC) 36596211.5
Yard improvement &

40(PEC) 146384846
service facilities
Land 2(FCI) 36596211.5
Total(DC) 860010970.3
11.4 Indirect cost
Table 11. 4 Indirect cost

5 Indirect cost(ic)
109
Engg. &
20(DC) 172002194.1
supervision
Construction &
20(DC) 172002194.1
contractor's fees
Contingency 10(FCI) 182981057.5
Start up expenses 8(FCI) 146384846
673370291.6
Manufacturing cost(MC)=direct production cost+fixed charges+plant

6
overhead costs
Table 11. 5 Direct production cost

Note:We don’t
Direct production know TPC value
A
cost(dpc) so it is assumed as
(x)
Maintenance &
2(FCI) 36596211.5
repairs(m&r)
Operating
1(FCI) 18298105.75
supplies
Operating
10(TPC) X*0.1
labour(ol)
Laboratory 10(ol) X*0.1*0.1
Patents &
6(TPC) X*0.06
royalties
110
Utilities 10(TPC) X*0.10
Raw material 25(TPC) 0.25*x
Total 0.52*x+54894317
11.5 Fixed charges
Table 11. 6 Fixed charges

Fixed
B
charges(fc)
Depriciation 10(FCI) 182981057.5
Taxes 12(FCI) 219577269
Insurance 1(FCI) 18298105.75
Interest 10(TCI) 228726321.9
Total(fc) 649582754.1
11.6 Plant overhead cost
Table 11. 7 Plant overhead cost

C Plant overhead cost(POC)=5% of TPC 0.05*x
7 MC(a+b+c) 490232022+0.57*x
11.7 General expenses
111
Table 11. 8 General expenses
General expenses(ge)=administrative cost

8 +distributing and selling cost+research and
development cost
Administrative cost 5(TPC) 0.05*x
D&s 10(TPC) 0.10*x
R&d 5(TPC) 0.05*x
Total 0.20*x
11.8 Total production cost
Table 11. 9 Total production cost

9 TPC= MC + GE
X=0.57*X+490232022+0.20*X
X 3062943789
11.9 Profitability analysis
Table 11. 10 Profitability analysis

10 Profit calculation
Selling price of product

20
ANP/kg
Yearly s.p of product ANP

3467500000
for 475 MTPD capacity
Gross profit(GP)=SP-TPC 404556211.4
112
Income tax(IT)(30%) 121366863.4
Surcharge(4%) on IT 4854674.537
Net profit=GP-IT-surcharge 278334673.5
11.10 Rate of return
Table 11.11 Rate of return

ROR(%) before income (gross
17.68734827
taxes profit/TCI)*100
ROR(%) after income taxes (net profit/FCI)*100 15.21111951
11.11 Pay out period
Table 11.12 Pay-out period

FCI/(net
Pp with no interest 3.966503746
profit+depreciation)
(FCI+interest)/(net
Pp with interest 4.462316714
profit+depreciation)
11.12 Break even point
Break-even point=(FCI/gross profit)=1829810575/404556211= 4.5 years
113
CHAPTER 13 CONCLUSION
114
This project work is based on the manufacturing of Ammonium Nitrophophate
which is a complex NPK fertilizer of composition(20N:20P:0K).
Various details of equipments are provided for easy understanding. Material and
energy balances are important part of any chemical industry and through which a
process is selected and the plant is operated.
Utilities are also very important in a chemical industry. An engineer must have
the knowledge about steam utility, cooling-chilling utilities,hot water utilities etc.In
every industry, the equipment s are labelled with specific codes. These codes must be
known before actually going in the plant for safety purpose.
Designing of equipment is one of the main role of a chemical engineer for the
handling of process streams from one equipment to another and also pumps along
with pipelines and control valves are required. Before going in any industry, safety
instructions are given. Every industry has some safety protocol which everyone
present inside the company should follow.
In the first chapter details about the product is discussed. In the second chapter
process routs are discussed and based on the selection of the process production is
carries out. In the third chapter according to the capacity of plant, Material balance is
carried out across each equipment present in the plant and final overall mass balance
diagram is prepared.
In the forth chapter the heat balance is carried out based on the mass flow of the
raw material & products & from that amount of utilities required like steam and
cooling water are calculated.
In the fifth chapter the utilities like steam, water ,brine-chilling solution &
cooling water is described briefly.In the seventh chapter based on the capacity of the
plant, major & minor equipment s like reactor , heat exchanger & storage tank are
designed.
115
In the eighth chapter control valves & its details are shown. In the chapter nine
and twelve safety and environment measures that are taken in the plant that is
discussed. In the tenth chapter plant location & plant layout is discussed and in the
eleventh chapter cost estimation has been carried out & obtained the pay back period
of 3.96 years, break even point is 4.5 years and rate of return about 15%.
116
REFERENCES
1.A short History of Fertiliser. FDCO.http://www.tandontech.net/fertiliser.html.
2.Nitrophosphate process .Wikipedia.

https://en.wikipedia.org/wiki/Nitrophosphate_process.
3.Octave Levenspiel;Chemical Reaction Engineering,Third Edition,Wiley:India,2006;

pp. 95.
4.Shuchen B. Thakore; Bharat I. Bhatt; Introduction to Process Engineering and

Design,Tata McGraw-Hill Publishing Company Limited,7 West Patel Nagar, New
Delhi:India,2007; pp. 155-175
5.Mv Joshi;Process equipment design,First edition,The macmillan company of India

limited: India,1976;pp. 201-217,440-444
6.Warren l. McCabe; Julian C. Smith; Peter Harriott; Unit operation of chemical

engineering,Fifth edition,McGraw-Hill :U.S, 1993; pp. 248-251
7.Max s. Peters;Klaus d. Timmerhaus; Plant design and Economics for Chemical

engineers,fourth edition, New york: U.S,1991; pp. 166-211.
8. Ammonium NItrophophate plant manual
9. B.I.Bhatt; S.M.Vohra; Introduction to Stoichiometry,fourth edition,McGraw-Hill.
117

Ammonium Nitrophosphate Production Process

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A PROJECT REPORT

Submitted in partial fulfilment towards the Bachelor’s Degree in

The Chemical Engineering

UNDER THE GUIDANCE OF

Dr. MAHENDRA S. GAIKWAD

Department of Chemical Engineering Faculty of

my original work towards the degree of Bachelor of Technology in Chemical

project work is genuine and distinctive.

In present work, I discussed what I studied in ANP-F PLANT, of Gujarat Narmada

First, I am thankful to Mr. H.K.PAREKH who is Training Manager of GNFC,

1.1 Introduction of Ammonium Nitrophosphate....................................................2

1.2 Historical background......................................................................................2

1.3 Raw materials used for ANP production.........................................................2

1.4 Product specification........................................................................................2

1.5 Application of Ammonium Nitrophosphate fertilizer(20:20:0).......................3

1.7 Market value.....................................................................................................3

1.9 Technology provider........................................................................................3

1.10.1 Phosphoric acid...................................................................................4

1.10.2 Ammonium Nitrate.............................................................................6

1.11 Thermodynamic and physio-chemical properties........................................10

CHAPTER 2 SELECTION OF PROCESS.................................................................13

2.1 Various processes for production of Ammonium Nitrophosphate................14

2.2 Availability of raw materials and its cost.......................................................14

2.3.2 Rock phosphate...................................................................................18

2.4 Detailed description of process......................................................................21

2.5 Process block diagram....................................................................................31

2.6 Process flow diagram.....................................................................................32

CHAPTER 3 MATERIAL BALANCE.......................................................................33

3.1 Material balance around Reactor...................................................................34

3.2 Material balance around Lamella separator...................................................35

3.3 Material balance around KAN tank...............................................................36

3.4 Material balance around Crystalizer..............................................................36

3.5 Material balance around Nitrate conversion unit...........................................37

3.6 Material balance around Pressure filter..........................................................38

3.7 Material balance around Carbonization tower...............................................38

3.8 Material balance around Evaporator..............................................................39

3.9 Overall Material balance diagram.................................................................42

3.10 Summary of Material balance......................................................................43

CHAPTER 4 ENERGY BALANCE...........................................................................44

4.2 Energy balance around Reactor.....................................................................46

4.3 Energy balance around DIS Cooler................................................................47

4.4 Energy balance around Crystalizer................................................................48

4.5 Energy balance around Preheater...................................................................48

4.6 Energy balance around Evaporator................................................................49

5.1.1 Functioning of cooling tower..............................................................53

5.1.2 General terms used in cooling water systems.....................................53

5.1.3 Typical problems in cooling tower.....................................................54

5.2 Borsig unit(cooling brine system)..................................................................55

5.3 Steam generation plant:..................................................................................56

5.4 DM water plant..............................................................................................57

CHAPTER 6 DETAILED DESCRIPTION OF EQUIPMENTS................................59

6.1 Detailed description of Equipments...............................................................60

CHAPTER 7 EQUIPMENT DESIGN.........................................................................62

7.1Design of Continuous stirred tank reactor......................................................63

7.1.1 Process design:....................................................................................63

7.1.2 Mechanical design:..............................................................................64

7.2 Design of Shell and tube heat ex-changer......................................................70

7.3 Design of Storage tank design........................................................................77

CHAPTER 8 PUMPS AND CONTROL VALVES....................................................81

8.1 Types of control valves..................................................................................82

8.1.1 Linear motion control valves..............................................................82

8.1.2 Rotary motion control valves..............................................................82