Grauation Project 2 Group 2 Phosphoric Acid

Jordan University of Science & Technology
Chemical Engineering Department
A report on the
Design of Phosphoric acid plant
via Di-haydrate Method
Submitted in partial fulfillment of the graduation project (ChE 592) course
By:
YARA ABU OBAIDA 117846
OLA IBRAHIM 120376
AMIRA AYYASH 120420
MOHANAD ALSHIMI 123422
Supervised by:
ENG : SALAH ABU YAHYA
Submission Date 2/ 6 / 2021

SUMMERY
The objective of this project is to design a plant to produce 200,000 TONE/YEAR of Phosphoric acid
based on the most effective method, considering factors and presenting all possible methods concluding
the most effective method with the least disadvantages on both environmental and industrial levels, this
report aim to discuss the production of Phosphoric acid in Jordan with predicted plant location which
ended up choosing ma ’an governorate as the most suitable location to set up the plant taking in
consideration selection factors and other factors that depends on the location of the plant, the chosen
method of production was discussed in abundance from all aspects and based on the selection criteria also
is discussed in abundance. The study also included the market of raw material, product on both local and
global level, information included for the choice of production method and produced Phosphoric acid
properties, a mass and energy balance had been done on each equipment included in the production
process, input and output streams, pumps was labeled and identified, this report include the detailed design
for all equipment's with total Capital investment of the plant about 43 million dollars , and 5.5 million
dollars and 2.3 year payback period . the report include a HAZOP study with PID and this plant designed
to operating 300 day / year .
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TABLE OF CONTENTS :
SUMMERY .............................................................................................................................................................. 1
LIST OF FIGIURE .................................................................................................................................................. 4
1.INTRODUCTION............................................................................................................................................... 10
1.1 DEFINTION AND CHEMICAL PROPERTIES ..................................................................................... 10
1.2 PHYSICAL PROPERTIES ........................................................................................................................ 11
1.3 PREPARATION OF PHOSPHORIC ACID ............................................................................................. 12
1.4 USES OF PHOSPHORIC ACID ................................................................................................................ 13
1.5 REQURIEMT OF FEED PHOSPHATE ROCK ...................................................................................... 13
2.LITRERATURE SURVEY ................................................................................................................................ 15
2.1 HISTORICAL OVERVIEW ...................................................................................................................... 15
2.2 HEALTH AND SAFETY HAZARD: ........................................................................................................ 15
2.3 PROCESS OF MANUFACTURE .............................................................................................................. 16
2.3.1 DRY-KILN PHOSHPORIC ACID PRODUCTION ......................................................................... 16
2.3.2 THERMAL PROCESS ACID PRODUCTION ................................................................................. 17
2.3.3 WET PROCESS ACID PRODUCTION (WPAP) ............................................................................. 17
2.4 USES AND APPLICATIONS OF PHOSPHORIC ACID: ...................................................................... 20
3. MARKET SURVEY .......................................................................................................................................... 24
3.1 MARKET OVERVIEW .............................................................................................................................. 24
3.2 GLOBAL MARKET (IMPORTS/EXPORTS) ......................................................................................... 26
3.2.1 MARKET OF EXPORTS (Us) ............................................................................................................ 26
3.2.2 MARKET OF IMPORTS (US) ............................................................................................................ 28
3.2.3 GLOBAL OVERVIEW OF PHOSPHORIC ACID MARKET: ...................................................... 30
3.3 LOCAL MARKET (IMPORTS/EXPORTS) ............................................................................................ 31
3.3.1 MARKET OF EXPORTS (JORDAN) ................................................................................................ 31
3.3.2 MARKET OF IMPORTS (JORDAN) ................................................................................................ 33
3.4 PRICE TRENDS .......................................................................................................................................... 35
3.5 PRODUCTION CAPACITY .......................................................................................................................... 39
4.PLANT LAYOUT ............................................................................................................................................... 40
5.PLANT LOCATION .......................................................................................................................................... 42
6. PROCESS SELECTION ................................................................................................................................... 47
6.1 THERMAL PROCESS ............................................................................................................................... 47
6.2 DRY KILN PROCESS ................................................................................................................................ 48
2
6.3 WET PROCESS ........................................................................................................................................... 49
6.3.1 DI-HYDRATE ....................................................................................................................................... 50
6.3.2 HEMI-HYDRATE PROCESS ............................................................................................................. 52
6.4 SELECTIVITY COMPARISON................................................................................................................ 54
6.4.1 COMPARISON OF PRODUCTION METHODS ............................................................................. 54
6.4.2 COMPARISON OF HEMIHYDRATE AND DI-HYDRATE WET-PROCESS PRODUCTION
METHODS ..................................................................................................................................................... 56
6.4.3 ADVANTAGES AND DISADVANTAGES FOR HH AND DH ...................................................... 57
7. PROCESSES DESCRIPTION.......................................................................................................................... 59
7.1 BLOCK FLOW DIAGRAM (BFD) ........................................................................................................... 59
7.2 PROCESS FLOW DIAGRAM (PFD)........................................................................................................ 61
7.3 DESCRIPTION OF STAGES IN PROCESS FLOW DIAGRAM FOR PHOSPHORIC ACID
PRODUCTION BY DI-HYDRATE PROCESS.............................................................................................. 63
7.3.1 PHOSPHATE ROCK GRINDING (BALL MILL) ........................................................................... 63
7.3.2 THE REACTOR STAGE ..................................................................................................................... 64
7.3.3 FILTRATION STAGE ......................................................................................................................... 68
7.3.4 ABSORBER STAGE (SCRUBBER) ................................................................................................... 70
7.3.5 MULTIPLE EFFECT EVAPORATOR ............................................................................................. 73
8. MATERIAL AND ENERGY BALANCE ....................................................................................................... 76
8.1 Mill (V-100)................................................................................................................................................... 76
8.2 REACTOR (R-100) ...................................................................................................................................... 77
8.HORIZANTAL VACCUM BELT FILTER (F-100) ................................................................................... 78
8.4 COUNTER-CURRENT ABSORBER (V-101) .......................................................................................... 80
8.5 BALANCE ON MIXER(MIX-100) ............................................................................................................ 81
8.6 MULTI EFFECT EVAPORATOR ............................................................................................................ 82
8.7 PUMPS .......................................................................................................................................................... 83
9. EQUIPMENTS SIZING AND MECHANIC DESIGN .................................................................................. 85
9.1 BALL MILL DESIGN(V-100) .................................................................................................................... 86
9.3 REACTOR DESIGN(R-100) ...................................................................................................................... 93
9.3 HORIZONTAL VACUUM BELT FILTER DESIGN(F-100) ............................................................... 101
9.4 PUMPS DESIGN ....................................................................................................................................... 108
9.5 THE ABSORBER( V-101) ........................................................................................................................ 112
9.5 DESIGN OF MULTIEFFECT EVAPORATOR(E-100,101,102) ......................................................... 124
9.6 STORAGE TANKS ................................................................................................................................... 129
9.7 TANK DESIGN (T-103) ............................................................................................................................ 132
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9.8 TANK DESIGN (T-100) ............................................................................................................................ 133
9.9 MIXER DETAILED DESIGN(MX-100) ................................................................................................. 134
9.10 PIPELINE SYSTEM: .............................................................................................................................. 138
10. ECONOMIC ANALYSIS AND EVALUATION ........................................................................................ 159
10.1 COST OF EQUIPMENT......................................................................................................................... 159
10.2 ESTIMATION OF CAPITAL INVESTMENT BY PERCENTAGE OF DELIVERED
EQUIPMENT METHOD ................................................................................................................................ 164
10.3 EVALUATION REVENUE ................................................................................................................ 169
11. HAZARD AND OPERABILITY STUDY (HAZOP) ................................................................................. 171
12.CONCLUSIOS ................................................................................................................................................ 175
13.RECOMMENDATIONS ................................................................................................................................ 176
REFERENCES. .................................................................................................................................................... 177
APPENDIX A: PHYSICAL AND CHEMICAL PROPERTIES OF MATERIALS ..................................... 182
APPENDIX B: MATERIAL BALANCE .......................................................................................................... 184
APPENDIX C: ENERGY BALANCE ............................................................................................................... 205
APPENDIX D : COST ESTIMATION .............................................................................................................. 229
APPENDIX E : DESIGN CALCULATIONS ................................................................................................... 241
LIST OF FIGIURE
Figure 1: Phosphoric acid and its esters (lardbucket, 2012) . .................................................................. 11

Figure 2: Regions indicating precipitated gypsum crystals dihydrate DH, hemihydrate HH, and anhydrate
AH gypsum. Regions are defined by temperature of solution and the P2O5% content of the phosphoric
acid solution. (EFMA, 2000) . .................................................................................................................. 18
Figure 3: Phosphoric acid volume (%), by End-user industry. .................................................................21
Figure4 : Uses of phosphoric acid, Fertilizers. (INTELLIGENCE, 2019)................................................21
Figure 5: Uses of Phosphoric acid. (PUBLICTION, 2016) ......................................................................23
Figure 6: Phosphoric acid market size, by application ,2016-2027 (US Billion) (GVR, 2020-2027). .....25
Figure 7: The value of exports of phosphoric acid & poly-phosphoric acid of the US market (ECONOMY,
2020) ......................................................................................................................................................... 27
Figure 8:Value of Imports of phosphoric acid & poly phosphoric acid in (US market). (2008-2019).
(ECONOMY, 2020) ................................................................................................................................... 29
Figure 9 : Global Phosphoric acid market share. (GVR, 2020-2027) ......................................................30
Figure 10: The value of exports of phosphoric acid and poly phosphoric acid by Jordan market.
(TRENDECONOMY, 2019) ...................................................................................................................... 32
4
Figure 11: The value of Imports of phosphoric acid and poly-phosphoric acid by Jordan market.
(TRENDECONOMY, 2019) ...................................................................................................................... 34
Figure 12: Sulfuric acid price trend during (2010-2020). (US Producer Price Index: Chemicals and Allied
Products: Sulfuric Acid, 2020) .................................................................................................................. 36
Figure 13: Sulfuric acid price fluctuation in Jordan during (2009-2018) (CEIC, Jordan Exports: Domestic:
SITC: Chemicals: ow Phosphoric Acid, 2009-2018) ................................................................................ 36
Figure 14: Phosphoric acid price change % in the US (2010-2020). (YCHARTS, US Producer Price Index:
Phosphatic Fertilizer Manufacturing: Phosphoric Acid, Superphosphates, and Other Materials, 2008-
2020) ......................................................................................................................................................... 37
Figure 15: Phosphoric acid price change in Jordan in JOD (2009-2018). (CEIC, Jordan Exports:
Domestic: SITC: Chemicals: ow Phosphoric Acid, 2009-2018) .............................................................. 38
Figure 16: prevailing wind in Ma’an region ............................................................................................40
Figure 17: predicted plant layout for phosphoric production plant .........................................................41
Figure 18: Site location that chosen in Maan,Governorate in Jordan ......................................................46
Figure 19: thermal process of phosphoric acid production (epa.gov) ...................................................48
Figure 20 : dry kiln process of phosphoric acid production ...................................................................49
Figure 21:the DH process of phosphoric acid production (Kellog, 2009) ................................................52
Figure 22 : the HH process of phosphoric acid production (Yara Belgium SA, 2012) ...........................54
Figure 23 : Block Flow Diagram for phosphoric acid production............................................................59
Figure 24 : Process Flow Diagram for phosphoric acid production .......................................................61
Figure 25: the balls miller (becker, 1983) .................................................................................................63
Figure 26 : the single reactor with two compartments (UNIDO)..............................................................68
Figure 28: the packed absorption tower (Team, 2000) ............................................................................72
Figure 29: multi-effect evaporator (nishantarora, nov,2017) ..................................................................75
Figure 30: material balance on mill ..........................................................................................................76
Figure 31: CSTR Reactor R-100................................................................................................................77
Figure 32: Titling pan Filter (F-100) ........................................................................................................78
Figure 33: Absorber (V-100) .....................................................................................................................80
Figure 34: Mixer (MIX-100) ......................................................................................................................81
Figure 35 : Multi Effect Evaporator ..........................................................................................................82
Figure 36: Reboiler (E-100) ........................................................................ Error! Bookmark not defined.
Figure 37: Pump (P-100 A/B)....................................................................................................................83
Figure 38: Pump (P-101 A/B)....................................................................................................................83
Figure 39: Pump (P-102)...........................................................................................................................84
Figure 40 below shows the cross-sectional view of the miller, including the movement of the grinding
media along with the movement of the shell of the mill. ........................................................................... 88
figure 41: cross sectional veiw of ball mill ................................................................................................88
Figure 42:CSTR mixing patterns ...............................................................................................................94
Figure 43: The 6-blade disk impeller. ........................................................................................................97
Figure 44: Horizontal belt filter HBVF. ..................................................................................................102
Figure 45: Filter medium of filter (cloth). ...............................................................................................103
Figure 46:Centrifugal pump ....................................................................................................................108
Figure 47: the gas absorber column ........................................................................................................ 113
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Figure 48: the packed bed absorber column .......................................................................................... 114
Figure 49: the types of random packing .................................................................................................. 115
Figure 50: the ceramic INTALOX saddles packing ................................................................................ 116
Figure 51: VERTICAL FORCED CERCULATION EVAPORATOR .......................................................124
Figure 52:Dimensions of the bottom cone. ..............................................................................................129
Figure 53 : Safe Working Pressure for PVC Pipes (the engineering toolbox, n.d.) ................................140
Figure 54: PID diagram for Reactor (R-100) .........................................................................................173
Figure 55: Purchase cost of Ball and Rod miller, for wet grinding.........................................................229
Figure 56: Purchased cost for Filters vs. area in m2 in US dollars in 1987...........................................231
Figure 57: Purchased cost of packed columns including installation and auxiliaries (Peters M. S., Plant
Design and Economics for Chemical Engineers) ................................................................................... 233
Figure 58:the purchased cost of storage tank .........................................................................................235
Figure 59: : Purchased cost of specialty pipe per length ........................................................................237
Figure 60:Table of size produced vs. energy equation(). .........................................................................241
Figure 61:The torque factor and media bulk density if grounded material.............................................243
Figure 62: The specific charge and arm of gravity of ball mill...............................................................243
Figure 63: Ball miller configuration. ......................................................................................................245
Figure 64:Disk Turbine Agitator Parameter............................................................................................249
Figure 65:Figure 4: belt width vs. Effective belt filter area in m2. .........................................................253
Figure 66: Horizontal vacuum belt filter edges. ......................................................................................253
Figure 67: number of transfer unit NOG as a function of Y1/Y2 with mGm/Lm as parameter ..............265
Figure 68:Generalized pressure drop correlation ...................................................................................267
Figure 69: the generalized pressure drop and flooding correlation ........................................................268
Figure 70: strigles latest generalized pressure drop correlation diagram ..............................................272
Figure 71: generalized correlation for flooding and pressure drop in packed columns .........................273
Figure 72: Design of storage tank ...........................................................................................................282
Figure 73: Dimension of bottom cone. ....................................................................................................282
Figure 74: Purchase cost of concrete tanks vs. diameter ........................................................................283
LIST OF TABLES
Table 1: Requirement of phosphate rock feed. ...........................................................................................14

Table 2: NFPA 704 of phosphoric acid (CAMEO, 2020). .........................................................................16
Table 3: site selection criteria....................................................................................................................45
Table 4 Comparison of the three production methods of phosphoric acid. ...............................................55
Table 5: Comparison of DH AND HH wet process methods of phosphoric acid production....................56
Table 6: Advantages and disadvantages of HH and DH processes. ..........................................................57
Table 7: The summary of equipment in the PFD .......................................................................................62
Table 8: material balance on Mill .............................................................................................................76
Table 9: Material balance on reactor (R-100)...........................................................................................77
Table 10: Energy balance on Reactor (R-100) ..........................................................................................78
Table 11: Material balance on Filter (F-100) ...........................................................................................79
Table 12: Energy balance on Filter (F-100) ..............................................................................................79
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Table 13: Material balance on Absorber (V-100)......................................................................................80
Table 14: Energy balance on Absorber (V-101) ........................................................................................80
Table 15: Material balance on Mixer (MIX-100) ......................................................................................81
Table 16: Energy Balance on Mixer (MIX-100) ........................................................................................81
Table 17 : Material Balance around Multi Effect Evaporator ..................................................................82
Table 18: Energy Balance around Multi Effect Evaporator ......................................................................82
Table 19: Balance on Reboiler (E-100) ....................................................... Error! Bookmark not defined.
Table 20: Balance on Pump .......................................................................................................................83
Table 21: Balance on Pump (P-101 A/B) ..................................................................................................84
Table 22: Balance on Pump(P-102) ..........................................................................................................84
Table 23: LIST OF EQUIOPMENTS PRESENT IN PROCESS OF PRODUCTION OF .........................85
Table 24: BALL MILLER V-100 DESIGN DATASHEET. ..........................................................................92
Table 25:Design results summary for Reactor (R-100) .............................................................................96
Table 26: The geometric proportions (shape factors) of the mixing system which are considered typically
"standard" design. .....................................................................................................................................98
Table 27: the geometry for mixing system .................................................................................................98
Table 28: Design results summary for agitator design in Reactor (R-100).............................................100
Table 29: DETAILD FILTER DESIGN DATASHEET .............................................................................107
Table 30: Design results summary for Pump P-101 ................................................................................ 110
Table 31: Design results for pump P-100 ................................................................................................ 111
Table 32: specification sheet of absorber V-101......................................................................................122
Table 33: DESIGN SUMMERY OF MULTI EFFECT EVAPORATOR ...................................................128
Table 34: Design results summary for Tank Tk-103 ................................................................................132
Table 35: DESIGN SUMMERY OF MIXER (MX-100) ...........................................................................137
Table 36: Design Results Summary for Pipe (L1). ..................................................................................141
Table 42: Design Results Summary for Pipe (L11). .................................................................................147
Table 44:Design Results Summary for Pipe (L13). ..................................................................................149
Table 52:Design Results Summary for Pipe (L21). ..................................................................................157
Table 54: Summary of The Equipment cost in Dollars,$. ........................................................................159
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Table 55: Ratio factors and calculations for estimating capital investment items based .......................164
Table 56: Annual cost of raw material in million$/yr. .............................................................................165
Table 57: Annual operating labor cost. ...................................................................................................165
Table 58: Calculations of total utilities cost. ...........................................................................................166
Table 59: Annual Total Product Cost. ......................................................................................................167
Table 60: evaluation summery .................................................................................................................170
Table 61:HAZOP guide word ..................................................................................................................172
Table 62: Hazop study for the reactor .....................................................................................................174
Table 63: Properties of the materials ......................................................................................................182
Table 64: Properties of Phosphoric acid .................................................................................................182
Table 65: Conditions of streams ..............................................................................................................183
Table 66: Results summary of the pipeline system cost ...........................................................................238
Table 67:Operating labor requirements. .................................................................................................239
Table 68: Equipment electricity consumption..........................................................................................240
Table 69: The geometric proportions (shape factors) of the mixing system which are considered as typical
"standard" design.................................................................................................................................... 249
Table 70: parameters identification .........................................................................................................250
Table 71:Values of KL and KT for various types of impellers...................................................................251
Table 72: design data for ceramic INTA lox saddles packing ...............................................................264
LIST OF EQUATIONS
Equation 1: Ca5(PO4)3Cl + 5 H2SO4 + 10 H2O → 3 H3PO4 + 5 CaSO4·2 H2O + HCL (BYJU'S, 2020).12
Equation 2: Ca3(PO4)2 + 2H2SO4 Ca(H2PO4)2 + 2CaSO4. .......................................................................15
Equation 3 P4 + 5O2 → 2P2O5 ΔH=-3012 KJ/mol (Gilmour, Phosphoric Acid: Purification,
Uses, Technology, and Economics 1st Edition, 1990) .............................................................................. 47
Equation 4 P2O5 + 3H2O → 2H3PO4 ΔH =-188KJ/mol (Gilmour, Phosphoric Acid: Purification,
Uses, Technology, and Economics 1st Edition, 1990) .............................................................................. 47
Equation 5: Ca10(PO4)6F2 + 34C + 5SiO2 + 10O2 → 3\2 P4 + 5Ca2SiO4 + 34CO + F2 .......................48
Equation 6: P4 + 5O2 → 2P2O5 ................................................................................................................48
Equation 7 : P2O5 + 3H2O → 2H3PO4 ......................................................................................................48
Equation 8: Ca10(PO4)6 F2 CaCO3 + 11H2SO4 +11xH2O → 6H3PO4 + 11CaSO4xH2O + 2HF + CO2 +
H2O (Gilmour, Phosphoric Acid: Purification, Uses, Technology, and Economics 1st Edition, 1990) . .50
Equation 9: 3Ca3(PO4)2CaF2 + 10H2SO4 + 5H2O ==> 6H3PO4 + 10CaSO4.1/2H2O +2HF (Yara Belgium
SA, 2012) .................................................................................................................................................. 53
Equation 10 power dissipated by an impeller in the turbulent flow region .............................................250
Equation 11: velocity gradiant calculation equation ................................................................................251
Equation 12: mechanical design equation ...............................................................................................257
Equation 13: ergun equation ....................................................................................................................274
Equation 14: pressure calculation equation for filter ...............................................................................275
Equation 15: design equation of evaporator . ..........................................................................................277
Equation 16: drum calculation equation ..................................................................................................279
Equation 17: thikness calculation relashinship ........................................................................................280
8
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1.INTRODUCTION
1.1 DEFINTION AND CHEMICAL PROPERTIES
The common name of Phosphoric acid is Ortho-Phosphoric acid. The chemical formula of Ortho-phos-
phoric acid is H3PO4. H3PO4 (Ortho-phosphoric acid) is weak acid. Generally Phosphoric acid used is 85
percent aqueous solution in chemical Laboratory. Lower the dissociation constant or pKa higher the acid-
ity. Therefore acidity of phosphoric acid decreases with consecutive removal of hydrogen ion. All three
hydrogen of Phosphoric acid are acidic, with First dissociation constants pKa1 = 2.14, second dissociation
constant pKa2 = 7.20, and third dissociation constant pKa3 = 12.37. After removing all three hydrogen the
left compound is PO43−.It is called as Phosphate or Orthophosphate ion. Orthophosphoric acid reacts with
alcohol to form ester and it is commonly called as organophosphates. Coming to Physical properties of
Phosphoric acid it is colorless and in liquid phase the melting point and density of phosphoric acid are
42.35°C and 1.834 g / cm3 respectively.
There are many uses of Phosphoric acid like entering the industry of detergents. It can be easily commer-
cially available in both solid as well as liquid phase. Generally, it is used in food processing and fertilizers
industry. Phosphoric acid is odorless inorganic acid. When it is heated for decomposition it release in form
of toxic fumes of phosphoric oxides. It has some harmful effect when it get contact with organs like eyes
and respiratory system and skin .when these organ get contact with phosphoric acid flush immediately
with water .After first aid medical attention is required. Phosphoric acid is main constituent in teeth as
well as in bone. It is also responsible for several metabolic processes (ChemicalBook, 2019).
10
As the Phosphoric acid reaction with bases form three classes of salts. When the molecules of phosphoric
acid are exposed to high temperature elevations it forms a compound which called dimers, trimers and
even long polymeric chains it can be observed in poly phosphoric acids and meta-phosphoric acids
(BYJU'S, 2020) .
Figure 1: Phosphoric acid and its esters (lardbucket, 2012) .
1.2 PHYSICAL PROPERTIES
Phosphoric acid exists as both clear colorless liquid and invisible transparent white crystal-like solid.
The pure solid of phosphoric acid melts at 42.35°C and has a density of 1.834 g / cm3. Liquid form of
phosphoric acid is usually an 85% aqueous solution. Shipped as both a solid and liquid. Phosphoric acid
in general is Corrosive to metals and textures. Phosphoric acid in nature is non-toxic and non-volatile
(BYJU'S, 2020) .
11
1.3 PREPARATION OF PHOSPHORIC ACID
Phosphoric acid is produced mainly in the industrial segment through a wet process, in which sulfuric
acid is reacted with tricalcium phosphate rock.
Equation 1: Ca5(PO4)3Cl + 5 H2SO4 + 10 H2O → 3 H3PO4 + 5 CaSO4·2 H2O + HCL (BYJU'S, 2020)
The resulting phosphoric acid solution only contains 32-46% concentration of H3PO4, so it is then con-
centrated (by evaporation of excess water) to produce higher concentration commercial grades of phos-
phoric acid. Another method that is used in obtaining phosphoric acid is the thermal process. In this,
phosphorus is heated or burnt at high temperature in the presence of air. The burning results in the genra-
tion of phosphorus pentoxide which is then condensed to form a white powder. It is then hydrated in a
separate process to obtain phosphoric acid (BYJU'S, 2020) .
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1.4 USES OF PHOSPHORIC ACID
Phosphoric acid has many applications as it is considered non-toxic and mildly acidic nature, due to its
properties it is used in food flavoring, beverages, dental products, cosmetics, and skin care products. In-
dustrially, it is used mainly in the production of phosphate fertilizers. It is also widely used as an etching
agent, electrolyte, pH modifier, rust removal agent, household cleaning agent, dispersing agent and sani-
tizing agent (SOFTSCHOOLS, 2005-2020) .
1.5 REQURIEMT OF FEED PHOSPHATE ROCK
The table below shows the requirement of the feed phosphate rock, at which it minimize the emissions
during the process, and minimize the cost of getting rid of the toxic compounds, and the acceptable percent
in the feed of each and the effect of the existence of these compounds on the process:
13
Table 1: Requirement of phosphate rock feed.
Component Effect on the wet process Acceptable percent
Grade of The lower grade means that more amount PBL <66 or P2O5<31%, because the
P2O5 of rock must be bought, transported and range ((26-30%)57-65BPL) is
grinded considered low grade
CaO When CaO content increases, the The content between (46-54) and
content consumption of sulfuric acid increases CaO: P2O5 ratio Less than 1.6
MgO The increases of MgO in phosphate rock is (.2 - .8) so the acceptable percent is <
undesirable because it increases the 1
consumption of sulfuric acid also reduces
the rate of filtration
Low amounts are used to reduce the The acceptable percent is less than 2-
corrosion with F- ion 3%
high amounts reduce the P2O5 recovery
and decrease the plant capacity.
SiO2 The increase in amounts of SiO2 cause The acceptable range is around 2%
erosion in equipment but some amount in
SiO2 is useful to reduce the hydrofluoric
acid formation and produce the
fluorosilicic acid instead
Fluorine Fluorine causes corrosion if not enough The desirable percent is around 3.7%
(F) silica present and post precipitation if
other elements (Na, K) combine with
fluorine
Na2O Precipitate from the acid as Na2SiF6 .5
Cl High amounts of chlorine cause corrosion The acceptable range is (0 - .5)

in the equipment
SO3 The excess of SO3 will increase the excess The acceptable range is around 1%
sulfuric acid
organics The organics increase the viscosity of the Maximum range depending on
fluid and the stability of the foam organic matter
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2.LITRERATURE SURVEY
2.1 HISTORICAL OVERVIEW
There are many phosphorus compounds are commercially available for example Phosphoric acid. Due to
wide application and uses inorganic acid like phosphoric acid marketed second largest after Sulphuric acid
in United States. In ancient times alchemists identify many inorganic acid but they didn’t able to identify
phosphoric acid. Even though it was produced in ancient times. Phosphoric acid was discovered by
Henning Brand in 1630-1710.Its name derived from its major element Phosphorus .Phosphorus was
isolated from bone ash by scientist Scheele. Then Scheele treat phosphorus with nitric acid (HNO3) and
phosphoric acid produced. (ChemicalBook, 2019)
Super-phosphates achieved by treating Sulphuric acid with calcium phosphate Ca3(PO4)2 . Which is given
below in chemical equation :
Equation 2: Ca3(PO4)2 + 2H2SO4 Ca(H2PO4)2 + 2CaSO4.
The chemical formula of Super-phosphates is Ca(H2PO4)2. Super-phosphates is monobasic calcium

phosphate. (ChemicalBook, 2019)
2.2 HEALTH AND SAFETY HAZARD:

Phosphoric acid is mostly non-toxic and does not cause harm to the skin or any part of the body in low
concentration. It is dangerous only at higher concentrations and can cause severe skin irritation or burns
and even damage to the eyes. H3PO4 can also cause irritation in the respiratory tract if vapors are inhaled.
Phosphoric acid should be stored industrially in a metallic or coated fiberboard container (with polyeth-
ylene inner package) and kept in a cool and well-ventilated place (BYJU'S, 2020) .
The table below shows the clarification of phosphoric acid in terms of NFPA, and its level of harm and
hazardous. The values given below based on the NFPA (National Fire Protection Association), At
which the chemical compound is classified according to its effect on health, flammability and instability.
15
Table 2: NFPA 704 of phosphoric acid (CAMEO, 2020).
Diamond Hazard Value Description
Health 3 Can cause serious and permanent injury.
Flammability 0 Will not burn under typical fire conditions.
Instability 0 Normally stable, even under fire conditions.
Special
2.3 PROCESS OF MANUFACTURE

Phosphoric acid is manufactured and produced by two distinct and popular methods: (1) the thermal
process and (2) the wet process, the third method which is the dry-kiln process which is a promising and
alternative method because of its reduced environmental footprint and effect and potential cost saving.
Wet process and thermal process differ in their degree of product purity and both serve different markets
depending on the end-use industry (AGENCY, 1980).
2.3.1 DRY-KILN PHOSHPORIC ACID PRODUCTION

Dry kiln method is one of the common methods of phosphoric acid production from phosphate ore,
including a combination of carbon, silica and heat in the process, the process guarantees alluring financial
aspects, extended phosphate mineral use, a top notch concentrated phosphoric corrosive item, and a more
modest ecological impression. sending the composite pellets into a dry kiln for a decrease response;
sending the high-temperature slag balls leaving the rotating oven (Dry kiln) to a cooling gadget for far
reaching usage; presenting the smoke containing P2O5 and fluorine leaving the oven into a hydration tower
for engrossing phosphorus by hydration, at that point going same through a phosphoric corrosive fog
catching pinnacle and a fog eliminating and isolating pinnacle progressively, and the fluorine-containing
seethe released from the fog eliminating and isolating pinnacle entering a resulting fluorine recuperation
strategy. (US Patent No. 14/958893, 2016)
16
2.3.2 THERMAL PROCESS ACID PRODUCTION
Thermal process of acid production involves the burning process of elemental phosphorus (yellow) to
form a product of phosphorus pent oxide which is then hydrated. Thermal process’s acid product is low
in impurity and it is also used mainly in the production of water builders, detergents, animal feed and food
additives. (AGENCY, 1980) .
It also takes place in the production of certain kinds of fertilizers, it is also included in the metal treatment
process and dentifrices. Thermal process can only be used when a high purity of product is required and
that is due to the energy intensive process at which it produces the Phosphorus acid in the thermal method
(AGENCY, 1980) .
2.3.3 WET PROCESS ACID PRODUCTION (WPAP)

Most of Phosphoric acid is produced using the wet-process method. The wet-process Phosphoric acid
method (WPA), at which the product acid from this process is the main intermediate for phosphorus
fertilizer production, now most of the produced Phosphoric acid worldwide across Phosphoric acid plants
is produced using wet-process (Dorozhkin, 1997).
In this process, Phosphoric can be obtained by the digestion of phosphate rock feed in certain acids such
as hydrochloric, nitric, phosphoric or sulfuric. The use of sulfuric acid is the conventional and common
technique and is normally referred to as “wet process” (Tariq F Al-Fariss, 1991).
In this process, a by-product is precipitated at which is calcium sulfate (gypsum CaSo4). Depending on
the temperature, as well as P2O5 concentration and SO4 content of the solution, either calcium sulfate
dihydrate (DH), hemihydrate(HH) or anhydrite (AH) will be formed and precipitated as shown in Fig. 1
(Tariq F Al-Fariss, 1991) .
17
According to Fig. 1. It can be noticed that the crystallization form of the gypsum by-product is affected
mainly by the temperature of the solution, and the P2O5 content of phosphoric acid, as the temperature is
in the range form (240 C°-and above) the form of crystals is Anhydrite, and above 90 C° to 240C° crystals
are hemi-hydrate and temperature below 90C °crystals of gypsum is in the dihydrate region.
Figure 2: Regions indicating precipitated gypsum crystals dihydrate DH, hemihydrate HH, and anhydrate AH gypsum. Regions are defined
by temperature of solution and the P2O5% content of the phosphoric acid solution. (EFMA, 2000) .
18
 Wet Process Phosphoric Acid Production Type
Wet-process acid production (WPAP) contains different process depending on operational conditions and
the crystal type of produced calcium sulfate and they are:
– Dihydrate process
– Hemihydrate process
Different processes of wet Phosphoric acid production are needed because of different rocks feed and
gypsum disposal systems. The storage of product and transfer of phosphoric acid is the same for all the
acids produced and does not depend on the method of production (EFPA, 2000) .
1. HEMI-HYDRATE WET PROCESS ACID PRODUCTION (HH)

Hemi-hydrate Phosphoric acid production is the new invented technology at which it is being applied in
many phosphoric acid production plants.
In this process phosphoric acid can be produced directly with a concentration of 40-52% with consequent
valuable saving in energy consumption and that is what make this process the leading process in wet
phosphoric acid production (EFPA, 2000).
2. DI-HYDRATE WET PROCESS ACID PRODUCTION (DH)

Dihydrate processes for Phosphoric acid production are still the most popular one until now. Many plants
for phosphoric acid production nowadays still operate using this process due to its ease and simplicity, the
major advantage of this process is its flexibility and reliability.
Since it has high adaptability to phosphorus ore, and it accepts any kind of phosphorus ore.
19
In this process more moisture is allowed and permissible in the phosphate feed, and there is more
acceptance to the use of weak sulfuric acid since the overall water balance in the dihydrate system is not
so critical (Abu-Eihah, 2001) .
Despite di-hydrate process drawbacks, which include relatively low acid concentration produced which is
about (28−30% P2O5) and higher energy consumption than other processes, simple startup and shutdown
operation, and easy scalability still make the di-hydrate process the most widely used technique for
phosphoric acid production (Dekker, 1989).
2.4 USES AND APPLICATIONS OF PHOSPHORIC ACID:

Phosphoric Acid Uses:
Phosphoric acid is classified depending on the end-user industries, at which it is segmented into main
segments from the largest usage to other usages of phosphoric acid as follows:
 Fertilizers
By far the Most of phosphoric acid produced is used in fertilizers industry as it is considered the major
raw material for almost all phosphate fertilizer used in agriculture, at which phosphoric acid is mainly
converted into three Phosphate salts that are used in fertilizers. They are Triple Superphosphate (TSP),
Di-Ammonium hydrogen Phosphate (DAP) and Mono-Ammonium Dihydrogen Phosphate (MAP)
(INTELLIGENCE, 2019) .
DAP fertilizer type is the world’s most widely consumed phosphorus fertilizer in agriculture. It is
popular and used mainly due to its relatively high nutrient content and its unique physical properties.
DAP fertilizer is an excellent synthetic source of necessary elements such as phosphorus (P) and
nitrogen (N) for plant nutrition needs. It provides the necessary amount and needed proportion of
20
phosphorous and nitrogen for the farming of grains such as barley, wheat, fruits, and vegetables. The
global demand for DAP fertilizer is estimated about 30 million tons a year (INDORMA, 2020).
The figure below shows the segments of Phosphoric acid markets based on end-user industries, and
the dominate segment is fertilizers as it has the highest market share.
Figure4 : Uses of phosphoric acid, Fertilizers. (INTELLIGENCE, 2019)
Figure 3: Phosphoric acid volume (%), by End-user industry.
 Synthetic Detergents
Phosphoric acid and phosphates are considered key ingredients in industrial used detergents (I&I
detergents). In household chores detergents, phosphate-based formulations of detergents also offer
certain advantages over other «alternative formulas». These at which are called «builders» serve
as complexing (softening), emulsifying, dispersing and buffering agents (PRAYON).
21
 Food and drink additives
Phosphoric acid is also used as a food additive in industry. Phosphoric acid works as an acidity
regulator in foods like cereal bars, jams, processed and treated meats, cheese, etc (PRAYON) .
 Heavy duty alkaline cleaning products
Phosphoric Acid a cleaner is a fast-acting cleaner, easy to use weather acid-base cleaner for pre-
cast concrete, masonry, concrete, grout and natural surfaces. Phosphoric Acid Cleaner removes
cement grout haze and mortar residue, joint cement, lime & hardwater deposits and precipitants,
efflorescence, rust and other dirt and grime. It is suitable for external and internal use. Phosphoric
Acid Cleaner is a milder alternative to other acid- base cleaners for concrete, grout, tile and natural
stone surfaces (PRAYON)
• Other uses of Phosphoric acid, which makes 4% of total uses:
◦ Acid cleansers
◦ Wetting agent
◦ Dispersant
◦ Water based lubricants
◦ Soft drinks (coca cola)
◦ Metal working fluids
22
In the Fig.4 below, it shows the uses and applications of phosphoric acid depending on the end-user
industry.
Figure 5: Uses of Phosphoric acid. (PUBLICTION, 2016)
23
3. MARKET SURVEY
3.1 MARKET OVERVIEW
Globally, Phosphoric acid is classified as the second largest consumed acid after Sulfuric acid, The global
market of Phosphoric acid was valued at the year of 2019 at the united states of USD 45.85 billion, and it
is expected to register a new compound annual growth rate (CAGR) of 3.7% from 2020 to the end of the
upcoming 7 years (GVR, 2020-2027).
Based on the application, the market of Phosphoric acid has been divided into agricultural (fertilizers),
food additives and animal feed, Phosphoric acid is industrially produced in three grades depending on the
market of use, and it differ in the concentration level. The three classified grades are food grade, agriculture
and industrial grade at which it enters the animal feed market and other uses. (GVR, 2020-2027) .
As the main usage of Phosphoric acid worldwide is in agricultural and it consumes 80% of the produced
phosphoric acid, the market of Phosphoric acid is centered around agricultural market. Fig. 5 below, shows
the market size of Phosphoric acid in the US by application on the forecast period (2016-2027).
24
Figure 6: Phosphoric acid market size, by application ,2016-2027 (US Billion) (GVR, 2020-2027).
25
3.2 GLOBAL MARKET (IMPORTS/EXPORTS)
3.2.1 MARKET OF EXPORTS (Us)
The Us market value of both export and import is considered as the largest market in the world, as its
export market value in the year of 2019 of phosphoric acid and polyphosphoric acid was $ 256 million of
total exports, Canada has the largest market of exports of phosphoric acid and poly phosphoric acid in the
US market of export. The total value of export market of polyphosphoric acid and phosphoric acid was
valued at the year of 2019 as 257$ million, Canada was largest market of export from at the year of 2019
from USA of export value of $ 104 million. (TRENDECONOMY, 2019)
The other directions of export of the market for the USA in 2019, showing both the share percent and the
value in $US dollars as follows:
 Canada with a share of 40% (104 million US$)
 India with a share of 31% (80 million US$)
 Mexico with a share of 21% (55 million US$)
 Germany with a share of 1.42% (3.65 million US$)
 Colombia with a share of 1.03% (2.67 million US$)
 Singapore - 1.18 million US$
 Korea - 1.09 million US$
 Netherlands - 1.03 million US$
 Ireland - 773 thousand US$
 Brazil - 474 thousand US$
According to the data above, it can be noticed that the largest share of export market is Canada followed
by India, as it I one of the largest consumers of the US phosphoric acid. (TRENDECONOMY, 2019)
26
The figure below shows the value of the market of Phosphoric acid & poly-phosphoric acid in the
forecast period (2008-2019), as it shows the increasing in export market value during the last 10 years,
as the demand from the countries that export phosphoric acid from the US increased.
Figure 7: The value of exports of phosphoric acid & poly-phosphoric acid of the US market (ECONOMY, 2020)
27
3.2.2 MARKET OF IMPORTS (US)
The market of Phosphoric acid and polyphosphoric acid is defined in terms of both imports and exports,
the US market of imports in the year of 2019 has a value of $204 million dollar of the total group of
phosphoric acid and poly-phosphoric acid (ECONOMY, 2020).
The main imports of Phosphoric acid and polyphosphoric acid to the USA in 2019 as follows:
 Belgium with a share of 28% (60 million US$)
 Mexico with a share of 24% (51 million US$)
 Morocco with a share of 22% (46 million US$)
 China with a share of 10.6% (22 million US$)
 Israel with a share of 6.18% (12.9 million US$)
 Other Asia countries with a share of 2.05% (4.29 million US$)
 Japan with a share of 1.77% (3.7 million US$)
 Canada with a share of 1.67% (3.49 million US$)
 France - 1.68 million US$
 Switzerland - 1.19 million US$
According to the data above, the largest market of supply to the US was the Belgium market and the
market of Mexico. (ECONOMY, 2020).
28
The figure below shows the value of imports of Phosphoric acid market during the forecast period
(2008-2019), as it can be noticed the value in $ of imports increased during the last 10 years.
Figure 8:Value of Imports of phosphoric acid & poly phosphoric acid in (US market). (2008-2019). (ECONOMY, 2020)
29
3.2.3 GLOBAL OVERVIEW OF PHOSPHORIC ACID MARKET:
The global market of phosphoric acid has largest share of USA, Asia Pacific (China), North America,
Europe (UK) and Middle East. Asia Pacific has the largest share of phosphoric acid based on
supply/demand balance as it is supply lead. The world market of phosphoric acid is growing due to the
growing in the industries that demand phosphoric acid as a raw material such as agriculture and food
grades and other end-uses industries (GVR, 2020-2027) .
The figure below shows the world share of Phosphoric acid, it can be noticed that Asia pacific countries
has the largest share of phosphoric acid.
Figure 9 : Global Phosphoric acid market share. (GVR, 2020-2027)
30
3.3 LOCAL MARKET (IMPORTS/EXPORTS)
3.3.1 MARKET OF EXPORTS (JORDAN)
The value of the local market of phosphoric acid in Jordan is described in terms of the country’s imports
and exports, Jordan is one of the largest exports of phosphoric acid to the countries in the area and in the
world, the value of the export market in the year of 2019 was valued as $191 million. (TRENDECONOMY,
2019).
The top market of exports from Jordan of phosphoric acid and Polyphosphoric acid in the year 2019 in
percent as:
 India
 Saudi Arabia
 United Arab Emirates
 Egypt
 Bangladesh
 Ukraine
 Sudan
 Syrian Arab Republic
 Free Zones
 Libya
31
The figure below shows the export of Jordan on phosphoric acid and poly-phosphoric acid during the
forecast period of (2008-2019), The figure shows an increasing in the value of market of export during
the last 10 years as the demand on phosphoric acid and poly phosphoric acid increased which impacted
positively the market of export in Jordan.
Figure 10: The value of exports of phosphoric acid and poly phosphoric acid by Jordan market. (TRENDECONOMY, 2019)
32
3.3.2 MARKET OF IMPORTS (JORDAN)
As the total supply/demand balance is affected by the import of phosphoric acid and polyphosphoric acid
the value of imports of polyphosphoric acid and Phosphoric acid to Jordan in the year of 2019 in ($) was
13.5 million, this value is considered low compared to the value of exports. (ECONOMY, 2020)
The directions of import to the Jordan market of polyphosphoric acid and Phosphoric acid in the year of
2019 was as follows:
 Free Zones
 China
 Belgium
 United Kingdom
 Korea
 Germany
33
The figure below shows the annual imports market of Jordan during the forecast period (2008-2019), as
it shows the Jordanian imports of phosphoric acid and Poly phosphoric acid in terms of net weight (Kg).
Figure 11: The value of Imports of phosphoric acid and poly-phosphoric acid by Jordan market. (TRENDECONOMY, 2019)
34
3.4 PRICE TRENDS
In this section the price trends of raw materials and product globally and locally will be viewed.
1. RAW MATERIALS
The key raw material of phosphoric acid production process are phosphate rock and sulfuric acid and
water, as water considered a utility, Phosphate rock and sulfuric acid will be reviewed.
 PHOSPHATE ROCK
Phosphate rock is considered the main raw material in the process of phosphoric acid production, the
prices of phosphate rock is defined globally by the authorized bodies and depending on this price other
countries export and import amount of phosphate rock depending on this price, according to the latest
updates on phosphate rock prices delivered to the plant was: 60-70 Dollar/ ton.
 SULFURIC ACID
In the figure below the prices fluctuations during the forecast period from the (2010 – 2020), It can be
noticed that the prices of sulfuric acid in the US was increasing from 2012 -2013 before the sharp decrease
in the second half of 2013 due to the reduced demand from the phosphate suppliers, at the begging of the
2014 as the importing markets of sulfuric acid flourished due to the changes in supplying policies at which
it results in increasing of the demand of it which results in increasing in its price in the global market (Boyd,
2014)
35
.
Figure 12: Sulfuric acid price trend during (2010-2020). (US Producer Price Index: Chemicals and Allied Products: Sulfuric
Acid, 2020)
In figure below it shows the price fluctuation in Jordan during the period of (2009-2018), as it shows that
the prices of sulfuric acid was fluctuating at 2009 and 2010 before it decreased clearly in the period of
2010-2012 then it started fluctuating in the given time period, In the second half of 2014 the prices of
phosphate rock and fertilizers increased which results in increasing in sulfuric acid prices due to exporting
of fertilizers to other countries and increase in consumption of phosphoric acid. (STATISTICS, 1999-2018).
Figure 13: Sulfuric acid price fluctuation in Jordan during (2009-2018) (CEIC, Jordan Exports: Domestic: SITC:
Chemicals: ow Phosphoric Acid, 2009-2018)
36
2.PHOSPHORIC ACID PRODUCT
Phosphoric acid prices worldwide changes depending on demand and supply balances worldwide and
importing and exporting and the country's needs.
The figure below shows the fluctuations in phosphoric acid prices in the forecast period of (2010-2020).
it can be noticed that in 2010 the prices of phosphoric acid in the US were high due to the increase in
demand as phosphoric acid is considered a raw material of phosphate fertilizers and back at this time the
due to the high prices of Barrel oil results in high prices of phosphoric acid. At the first half of 2014 a
sharp decrease in the prices of phosphoric acid as the demand of it decreased worldwide in the second half
of 2014 the changes in prices of phosphoric acid are obvious depending on demand and supply worldwide.
Figure 14: Phosphoric acid price change % in the US (2010-2020). (YCHARTS, US Producer Price Index: Phosphatic Fertilizer
Manufacturing: Phosphoric Acid, Superphosphates, and Other Materials, 2008-2020)
37
In Jordan, the changes in Phosphoric acid prices depends in country’s demand of the end-user industries
that use phosphoric acid as raw material, and the worldwide demand of phosphoric acid and phosphate
rock, as many countries such as India, Bangladesh and Korea which affects the prices and production of
phosphoric acid.
The figure below, shows the phosphoric acid prices fluctuations during the period between (2009-2018),
at which it shows the changing in the price in the unit of thousand JOD, According to the figure the prices
of phosphoric acid in the year of 2008-the first half of 2009 high due to the Barrel oil high price and the
high demand of phosphoric acid worldwide. In the 2009 a sharp decrease in the prices of phosphoric acid
prices then it increased in slow manner in the following months, In the first half of 2015 the prices
increased and sustained in this manner until the first half of 2016 and it follows fluctuating.
Figure 15: Phosphoric acid price change in Jordan in JOD (2009-2018). (CEIC, Jordan Exports: Domestic: SITC: Chemicals: ow
Phosphoric Acid, 2009-2018)
38
3.5 PRODUCTION CAPACITY
The capacity of production of phosphoric acid is impacted mainly with supply and demand balance. At
which it is affected by the exporting levels and the local demanding. Depending on the previous section
of the imports and exports of the Jordanian market, the suggested capacity of production of phosphoric
acid would be 250,000 ton/annum based on the export amount in kg of 2019 and previous year as an
average and the local market needs of phosphoric acid.
39
4.PLANT LAYOUT
Plant layout can play an important part in determining construction and manufacturing costs, is also known
as facilities design. It constitutes planning of the amount of space required for all kind of activities in an
industry, equipment, machinery, office, etc.
The main factor to choose the distribution of equipment and facilities inside the plant perimeter is the
prevailing wind. In this study, wind direction is considered to be important to prevent bad odors and pre-
vent any fire agitation than might happen.
Wind direction is shown in the following figure which are presents the wind rose chart for Ma’an City.
Figure 16: prevailing wind in Ma’an region
40
Figure 17: predicted plant layout for phosphoric production plant
41
5.PLANT LOCATION
In this section, we will choose many locations in Jordan that fit the plant requirement, discussing these
locations and do a comparison between it, the choose of location, comparing and select one will be in
terms of an important factors to be discussed in this study for sure.
 Raw Material
-There are many important aspects to such an important matter and those might include the following:
Material availability and distance from source of supply. In addition, Transportation and storage are also
considered as crucial factors.
- First of many steps should be researching for a nearby supplier of the raw material needed for the process
in order to save transportation costs as well as saving time and effort.
- Considering the material availability includes raw material prices, distance from source of supply, trans-
portation expenses and storage requirements and therefore is the most important step.
 Labor Supply:
- This aspect deals mainly with the workers. It includes workers’ availability, scholarships, payment
scales, productivity as well as hours worked per week.
- Mostly, skilled workers are picked from areas outside the plantation region and we can train local un-
skilled workers to attend to the plants whereas the skilled workers supervise the process.
- There are many factors to be considered when dealing with this matter such as local labor laws, restric-
tive practices for recruitment and costs of salaries and training.
42
 Utilities:
-This matter is related to the availability of crucial needs of the project such as water supply, electricity
or other sources of energy and the cost of such needs.
As a rule of thumb, cost is the determining factor on choosing withers to purchase energy or generate it.
 Transportation:
-This is a side of great importance as it controls supplies incomes and production outcomes. Railways
and highways are the cheapest and therefore favorable routes. Air routes are the most expensive trans-
portation method but it comes with its benefits. It's the safest of all methods.
Choosing the right transportation method is of great importance as it could save a lot of money, effort
and time. Mostly railroads or ocean transports if available are the most suitable.
 Climate:
-Caution to weather conditions is required because: humidity, hot, or cold extremes may cause the initia-
tion of trigger effect on plant equipment.
 Market:
-Choosing locations near to potential customers prove vital and advantageous because it is less time con-
suming and even more time efficient to them (also depends on whether buyers are local or international).
-It can also be beneficial because the closer the plant to the market the less it costs in exporting.
43
 Taxation and Legal restrictions:
-Legal restrictions are mainly implied on importing and exporting.
-The placement of the plant in the city has different outcomes according taxes, for example placing it in
industrial areas results in lesser taxation in comparison to placing it in unauthorized areas.
-Jordan policy of applying less taxes on plants in industrial cities encourages new projects and invest-
ments.
 Water Supply:
-Rivers, lakes, wells, and sea water act as a great and essential supply for industrial plants which neces-
sary for multiple process and uses in plants such as: cooling, washing, steam generation etc…
 Waste Management:
-Waste disposal techniques and equipment should be put in mind due to certain pollution limitations and
permissible tolerance rates that you have to abide to.
44
 Four main industrial cities were compared; all the four cities are located in Jordan. The criteria used in
this selection are as shown in the table below.
Table 3: site selection criteria
Criterion Weighing Compared industrial zones in Jordan
AL-hasa Al-Abiad Al-Rusaifa Al-Shidyah

(Tafila) (kark) (Zarqa) (maan)
Raw material 10 7 70 7 70 6 60 8 80
Transportation 7 6 42 5 35 4 28 7 49
Water supply 6 5 30 5 30 4 24 6 36
Utilities 8 6 48 6 48 5 40 7 56
Climate 5 4 20 4 20 3 15 5 25
Labor supply 6 4 24 5 30 6 36 4 24
Taxation and le-
16
gal 4 4 16 3 12 4 16 4
Restrictions
Waste disposal 7 6 42 5 35 4 28 7 49
Market 8 6 48 5 40 5 40 8 64
sum 340 320 287 399
According to the table above, at which is ranked the selected locations to construct the plant,
Eshidya which is located about 70 km southeast of maan city and 25 km northeast of Aqaba
port is candidate and it was ranked as the best location to start-up the plant.
Taking in consideration the transportation point of view, EL-shidya is close enough to Aqaba’s port
at which the storage of product takes place. From other view. Jordan’s total phosphate
reserves at the beginning of 1999 were estimated to be 1.7 billion tons, Al-shidya mine alone contain 1.5
billion ton of phosphate ores. (Azhar, 2000)
45
Figure 18: Site location that chosen in Maan,Governorate in Jordan
46
6. PROCESS SELECTION
Process background
There are three basic processes to produce phosphoric acid (H3PO4) namely the wet process, thermal pro-
cess and dry kiln. Each of this method produced phosphoric acid in different grade and each of this method
have a different applications based on the percent of purity of phosphoric acid produced from the process.
6.1 THERMAL PROCESS

The thermal process is known as thermal acid and is more purity than the wet process.
Thermal process can produce phosphoric acid by two steps, which are combustion of phosphorus with
ambient air to form P2O5 and the P2O5 is hydrated to form phosphoric acid.
The phosphorus in liquid phase is oxidized in the presence air by burn it to produce vapor phosphorus
pentoxide at higher temperatures in a combustion chamber, which the flame temperature is in the range
of 1800°C - 2000°C, then hydrated in recycle acid or water to produce thermal phosphoric acid.
Two chemical reaction occur in this process, both are exothermic and these represented in the following
equations:
Equation 3 P4 + 5O2 → 2P2O5 ΔH=-3012 KJ/mol (Gilmour, Phosphoric Acid: Purification, Uses,
Technology, and Economics 1st Edition, 1990)
Equation 4 P2O5 + 3H2O → 2H3PO4 ΔH =-188KJ/mol (Gilmour, Phosphoric Acid: Purification, Uses,
Technology, and Economics 1st Edition, 1990)
This method is not used in fertilizer production but it is used in pharmaceutical, food products and bev-
erages manufacture and that due to high power requirement resulting in high cost of production.
The production of concentrated phosphoric acid from thermal acid is about the range of (70-85%), and
this process is considerably pure but it is expensive.

47
Figure 19: thermal process of phosphoric acid production (epa.gov)
6.2 DRY KILN PROCESS

The dry kiln is an improved and amended process from the thermal acid, the process in general done by
reducing the phosphate ore by silica sand and coal to form phosphorus and slag in a rotary dry kiln at
1500°C then the phosphorus is oxidized to form phosphorus pentoxide that is leaving the kiln as vapor
absorbed in water or recycle H3PO4 to produce phosphoric acid which it is represented in the following
reaction:
Equation 5: Ca10(PO4)6F2 + 34C + 5SiO2 + 10O2 → 3\2 P4 + 5Ca2SiO4 + 34CO + F2
Equation 6: P4 + 5O2 → 2P2O5
Equation 7 : P2O5 + 3H2O → 2H3PO4
48
The research of this method had proved that the dry kiln process had much more saving of energy than
thermal process and it had shown a better effect on the environment, but this process still used in pilot-
scale pant and also it is expensive because needs high temperature and energy.
Figure 20 : dry kiln process of phosphoric acid production
6.3 WET PROCESS

The wet process is the most popular process of producing phosphoric acid and this acid is used in phos-
phate fertilizers production such as Mono-Ammonium phosphate(MAP), Di-Ammonium phos-
phate(DAP), Triple-Superphosphate(TSP) and single superphosphates, which this due to low purity of
phosphoric acid produced as range (P2O5) 32%-52%.
In wet acid process, the concentrated phosphoric acid (H3PO4) and calcium sulfate (CaSO4), which is
known as gypsum, are produced by acidulation the phosphate ore in concentrated sulfuric acid and dilute
phosphoric acid.
The process of production phosphoric acid is the sulfuric acid and phosphate rock are fed to the reactor,
which the reactor temperature range is 70°C - 100°C , which the reaction that presented in the equation
below and done in the reactor is self-limiting because an insoluble layer of calcium sulphate form on the
surface of the particles of the rock so to minimum this problem, the phosphate rock could be in contact
with recirculated phosphoric acid to convert it as much as possible to soluble mono calcium phosphate
49
then precipitating it with sulfuric acid to form concentrated phosphoric acid and gypsum, Then to separate
phosphoric acid from gypsum is send to filtration and recycle the dilute acid to reactor, finally the filtrated
phosphoric acid is sent to evaporator to concentrate the phosphoric acid and then go to storage tank.
Equation 8: Ca10(PO4)6 F2 CaCO3 + 11H2SO4 +11xH2O → 6H3PO4 + 11CaSO4xH2O + 2HF + CO2 + H2O
(Gilmour, Phosphoric Acid: Purification, Uses, Technology, and Economics 1st Edition, 1990) .
The phosphoric acid production from wet process is done by the Di-hydrate(DH) and hemihydrate(HD)
process.
6.3.1 DI-HYDRATE
Di-hydrate is one of the most applied method of wet process that using in phosphoric acid production
(H3PO4) due to low capital and construction cost mainly, the desired product concentration about (P2O5)
(20 – 32 )% the percent determined by the quality of phosphate rock and the interferences present inside
the rock .
The following block flow diagram show the main process of Di-hydrate:
mill reactor filter evaporator
The phosphate rock input to the size reduction unit (miller) with one of two methods wet grinding and dry
grinding the power required in the dry grinding depend on the initial size of rock, hardness, and the size
required.
50
On the other hand, in wet grinding slurry containing (60-70) % of solids input to the digester unit the
advantages of this method is low power requirement and reducing the dust rate, however the equipment
rapidly aging and reducing recycled water these problems considered negatives.
The second main unit is the reactor unit where the reaction of phosphate and sulfuric acid takes place to
recover as much as amount of P2O5 , The reactor designed to achieve high conversion sulfuric acid which
coating phosphate rock and calcium sulphate as by product , these considered as inhibition for the reaction
which sometimes need several days to correct .The effluent from reactor at Temperature range (70-80) ℃
which is low temperature and the gypsum only in solid phase with the composition (30-35)% of slurry ,
the agitation inside the reactor used to ensure the homogeneity also foam braking .
Filtration unit is the third basic unit in di-hydrate method, three types of filters used to separate the gypsum
from the solution, Belt filter, titling pan filer and table filter.
The concentration process gives approximately 30% H3PO4 which is acceptable ratio and this method has
lowest cost in term of operation and energy consuming.
Di-hydrate method need low maintenance cost and employees due to simple design and few number of
equipment and its also start up and shut down more easier.
51
Gases
Figure 21:the DH process of phosphoric acid production (Kellog, 2009)
6.3.2 HEMI-HYDRATE PROCESS
This process Takes place when Phosphate rock is first decomposed with phosphoric acid and sulfuric
acid under this condition of hemihydrate stable range (90-100 °C). Resultant hemihydrate crystals are
filtered as it is obtaining calcium sulfate Hemihydrate (Ca2SO4.1/2 H2O) it is commonly known as gyp-
sum and product phosphoric acid, this phosphoric acid enters the evaporator. The forced circulation
evaporator consists of: a condenser, vapor or flash chamber, heat exchanger, circulating pump, acid cir-
culating pump, and circulation piping. A fluosilicicacid scrubber(absorber) is included in the forced cir-
culation evaporator system. All the evaporators in this service are generally of the single-effect design.
Because of the corrosive nature of phosphoric acid and the very high boiling point elevation, the heat
52
exchangers are fabricated from stainless steel or graphite with the rest of the equipment made from rub-
ber-lined steel. The stages in the hemihydrate process are similar to those of the dihydrate process, but
the grinding stage may be unnecessary.
The main reaction in The Hemihydrate process is:
Equation 9: 3Ca3(PO4)2CaF2 + 10H2SO4 + 5H2O ==> 6H3PO4 + 10CaSO4.1/2H2O +2HF (Yara Belgium SA,
2012)
Moreover, as Hemihydrate process is considered more capital saving than Di-hydrate process, the con-
centration of the produced acid from Hemihydrate process is (40%-52%), which has high strength. Also
The feed requirements of the hemi process are less restrict as phosphate rock feed may be coarser than Di-
hydrate feed. However, despite the mentioned features of hemi it is not widely applied due to its weak-
nesses that present in corrosion, cost, maintenance and simple drawbacks.
Corrosion in Hemihydrate plants is considered a real problem, the Hemihydrate process operates at highly
elevated temperatures, as a result, metals tend to corrode somewhat faster than in the Di-hydrate process.
Additionally, metals in filter, pumps, and agitators wetted parts will be somewhat more expensive in a
Hemi plant, while the entire filter/reactor system for a Di-hydrate process will usually be less expensive
and smaller. In order to achieve successful engineering goal for a robust process, The Hemihydrate process
requires many years of experience in engineering equipment (agitators, reaction tank, filters, cooling
equipment) and operation. Moreover, Hemihydrate process is high in cost, which has difficulty of control
system hence the maintenance cost is also higher than Di-hydrate process, and it is not widely used.
53
Figure 22 : the HH process of phosphoric acid production (Yara Belgium SA, 2012)
6.4 SELECTIVITY COMPARISON

6.4.1 COMPARISON OF PRODUCTION METHODS
Based on the table below, at which it shows comparison criteria between the three common methods of
phosphoric acid production, depending on preferable factors of each process, as the table below shows
weighting of each factor to each method wet, thermal and dry kiln.
As shown below, the highest ranking was for wet process, as it is considered the elevating method nowa-
days. It scores the highest weight for the availability of the raw material, as the feed for the wet process is
the phosphate ore, but for thermal process is the elemental phosphorus (yellow) and for dry kiln is phos-
phate pellets.
As the purity of phosphoric acid produced from wet process is relatively high and can be increased, but
for thermal process it has the highest purity of phosphoric acid and dry kiln has purity of product close to
the wet process. The utilities needed for each method varies depending on the temperature of the reaction
for each process which thermal process needs the highest temperature, and dry kiln method needs blowing
54
air of high temperature which increases its needs of energy. The cost is considered an important factor at
which most of the countries choose its method of production depending on it, the cost for the three methods
depending on the cost of the feed and energy needed for each and the selling price of produced phosphoric
acid, nevertheless, wet process scores the highest rank based on all above-mentioned factors.
Table 4 Comparison of the three production methods of phosphoric acid.
Criteria Weighting Wet process Thermal pro- Dry kiln

cess
Raw material avail- 10 8 7 6

ability
Purity of product 9 6 7 6
Utilities require- 8 6 4 4
ments
Total cost 7 7 5 5
Literature recom- 5 4 3 3
mendation
Total 39 31 26 24
55
6.4.2 COMPARISON OF HEMIHYDRATE AND DI-HYDRATE WET-
PROCESS PRODUCTION METHODS
According to the table below, at which it shows the comparison between the two distinct processes of wet-
process production method of phosphoric acid, as the Di-hydrate scores the highest rate, according to the
preferable factors it has.
As shown in the table below, DH method has the highest rank compared to HH depending on the factors
below which made the DH process the most applicable and easy to apply worldwide (rating with five
being excellent ).
Table 5: Comparison of DH AND HH wet process methods of phosphoric acid production.
Criteria Dihydrate Hemi-hy- Notes

drate
Purity of product 2 4 P2O5% product form DH is (25%-29%) whereas

from HH is (40%-45%)
By-product purity (Gypsum) 2 2 By-product purity for both methods is almost the
same.
Capacity of equipment 5 3 The equipment in DH is smallest
Sulfuric acid consumption 3 3 Both are same
P2O5 recovered from filtration 3 2 DH range is (96%-97%), but HH is 95%
Capital cost of plant (reactor and fil- 5 2 DH has smallest reactor and filter and less than
ter) in HH
Capital cost of other section 3 5 HH process have less evaporation and no need to
grinding the phosphate rock
Energy efficiency 1 5 DH need to enter mills to grinding rock and need

more evaporator, but HH needs higher tempera-
ture for the reaction and one evaporator with
very large scale.
Uranium and Flourosilicic acid recov- 5 1 ..

ery
Total 28 25
56
6.4.3 ADVANTAGES AND DISADVANTAGES FOR HH AND DH
The advantages and disadvantages of both methods are listed in the table below, at which it shows the best
method depending on both advantages and disadvantages for both methods listed in the following table:
Table 6: Advantages and disadvantages of HH and DH processes.
The process The advantages The disadvantages
DH  Simple design and applica-  Product Acid has high levels

tion of Florosilicis, but is low
comparing to HH
 Single stage filtration
 High energy consumption in
 Easy removal of gypsum
the acid concentration stage
slurry as by-product
 Require rock grinding
 Ease of operation
 Low maintenance cost
 Wet rock grinding possible
(simplicity and acceptance to
the feed grade)
HH  Pure acid (40-52%P2O5)  Difficulty in separating the
by-product crystals which
 No need or low need of rock
are hemi-hydrate
grinding
 Corrosion due to higher tem-
 Capital saving
perature which is the real
 Lower heat requirements for problem
concentration stage
 Tight water balance
 High maintenance cost
57
Based on the table above, DH is considered more applicable due to its advantages compared to the HH
method, at which it has good advantages but the HH disadvantages cause a real problem in the plants of
phosphoric acid. DH is considered easier and simpler and the product can be purified easily which make
this process preferable than HH, and more applied worldwide.
58
7. PROCESSES DESCRIPTION
7.1 BLOCK FLOW DIAGRAM (BFD)
Figure 23 : Block Flow Diagram for phosphoric acid production
59
The previous Block Flow Diagram is a brief description of the selected process. In general, the phosphate
rock is introduced to the miller with the dilute Phosphoric acid to reduce the size of the rock, the resulting
phosphate slurry product is then introduced to the reactor with the sulfuric acid solution to give phosphoric
acid and gypsum with other emission gases such as HF, H2SiF6 and air, then the stream which contains
the gases are fed to the absorber to absorb the required gas (H2SiF6) by the water solvent because it found
in high percent. the other stream that contains the phosphoric acid and gypsum and comes out from the
reactor is fed to the filter to separate the phosphoric acid from the Di-hydrated gypsum, then the dilute
phosphoric acid that is produced from the filtration stage, is fed to multi-effect evaporator to concentrate
the acid by use the steam to evaporate water and at the final the concentrated phosphoric acid is produced
with 75 wt%percent.
60
7.2 PROCESS FLOW DIAGRAM (PFD)
2 T-105
T-100
4
1 7
V-101
T-101
T-104
V-100 11
5 14 24
18
20 22
P-34
16 15 P-100 A/B
P-104 A/B
T-103 F-100
R-100 12 17
MIX-100
P-101 A/B
13
Steam
E-103
19 21
E-100 E-101 E-102
23
T-100: Phosphoric Acid Solution Storage Tank V-101: Absorption and Stripping Column T-103: Sulfuric acid Solution storage Tank
V-100: Ball Mill P-101 A/B: Pump E-103: heat exchanger
R-100: CSTR Reactor F-100: Tilting Pan Filter E-100: Evaporator one
P-100 A/B: Pump T-104: Wash Water Storage Tank E-101: Evaporator two
T-105: Water Storage Tank MIX-100: Mixing Tank E-102: Evaporator three
T-101: Phosphate Rock Storage Tank
Figure 24 : Process Flow Diagram for phosphoric acid production
61
Symbol Equipment Use
T-100 Phosphoric Acid Solution To storage acid solution before entering the miller
Storage Tank
T-101 Phosphate Rock Storage Tank To storage phosphate rock before entering the miller
V-100 Ball Mill To reduce the size of phosphate rock
R-100 CSTR Reactor To mix streams (3) and (15) to produce phosphoric acid
and gypsum
T-105 Water Storage Tank To storage water that use in the absorber as a solvent
V-101 Absorption Column To absorber the H2SiF6 acid in the stream (4) by use
water
P-100 Pump To increase the pressure of stream (14) before entering
A/B the filter
F-100 Horizontal vacuum belt filter To separate the phosphoric acid from gypsum
T-103 Wash Water Storage Tank To wash the stream (11) in the Horizontal vacuum belt
filter
MIX-100 Mixing Tank To mix the streams (13) and (16) to produce the stream
(15) that contains sulfuric acid
T-104 Sulfuric acid Solution storage To storage sulfuric acid before entering the mixing tank
Tank
P-101 A/B Pump To increase the pressure of stream (17) before entering
the evaporator
E-100 Reboiler To heat the steam before entering the evaporator to

evaporate the water
E-101 Multi-effect evaporator To evaporate the water in the stream (17) to produce the
concentrated phosphoric acid in the stream (23) with
E-102
percent 75%
E-103
Table 7: The summary of equipment in the PFD
62
7.3 DESCRIPTION OF STAGES IN PROCESS FLOW DIAGRAM
FOR PHOSPHORIC ACID PRODUCTION BY DI-HYDRATE
PROCESS
7.3.1 PHOSPHATE ROCK GRINDING (BALL MILL)
The stream L1 with T=25°C, P=1atm and flowrate=8525Kmol/day (Ca3(PO4)2=75wt%, CaF2=
20wt%, SiO2= 5wt%) which came out from the storage tank(T-101) at which is fed to the ball
mill (V-100), it enters the miller to reduce the size of phosphate rock to (42mm ~ -35 mesh), the
importance of preparation and grinding of phosphate rock is to create adequate large surface
area with pores to complete dissolution of the phosphate rock in a short period of time with
sulfuric acid, also to reduce the power input to the agitators and achieve a uniform suspension.
(becker, 1983) in the figure below, it shows the ball miller (V-100), at which it consists of a hollow
cylindrical shell which is rotating about its horizontal axis, and its other component has feeding,
discharging and driving parts and grinding medium (balls), the work needed to the wet grinding
is about 7.38 kw.
Figure 25: the balls miller (becker, 1983)
63
When the balls in the mill raise at a rotational direction until it reaches a certain height, it falls
back on the rocks creating force called impact and crushing force and this force is done on the
phosphate rock, due to this impaction and crushing dust is formed, in order, to promote and
minimize the dust in the zone stream L2 that contains dilute Phosphoric acid with T=25°C,
P=1atm and flowrate=36047 Kmole/day (85 wt %H2O to 15wt %H3PO4) is added to the mill,
also it contains H3PO4 to help the miller in the process of grinding the phosphate rock, then the
slurry
(streamL3)with
flowrate=44572.21Kmol/day,(Ca3(PO4)2=7161Kmol/day,CaF2=7502Kmol/day,SiO2=2387Kmol
/day,H3PO4= 2265Kmol/day and water =69828Kmol/day) that is made in the miller discharged
by discharging part .
7.3.2 THE REACTOR STAGE

the stream L3 with T=25°C and P=1atm and flowrate 44572.2 Kmol/day that is coming out from
the miller(V-100) containing phosphate slurry, is fed to the reactor(R-100), the range of suitable
temperature is (25°C to 90°C) to control the rate of the chemical reactions that occur in the acid
dulation of the Phosphate Rock and the concentration of the acid. (benjamin valdez sales, 2017)
The stream L15 with T=31°C, P=1atm and flowrate=149326 Kmole/day enters the reactor, at
which is coming from the mixing tank containing sulfuric acid with (94% wt%) concentration
and water, this stream (stream L15) is produced from mixing stream L16 with T=25°C, P=1atm
and flowrate=233455 Kmol/day that contains H2SO4 solution, with the recycle stream L13 with
64
T= 72°C, P=1atm and flowrate=6961 Kmol/day from the filter. The importance of the mixing
tank, is to mix and prepare the sulfuric acid with water in a homogenous form, and to ease the
dispersion process before sulfuric acid is introduced to the reactor, the concertation in the stream
must be in the range of (93% wt% - 98 % wt%) to ensure the production of highly strength
phosphoric acid at which enhances energy saving in the evaporator. However the concentration
of H2SO4 control important to heat regulation inside the reactor and crystallization of gypsum
(VAISALA, 2019).
The figure 2 shows the CSTR single reactor with agitators(R-100), the reaction in the reactor
takes place in two stages at temperature(70°C), which in the first stage (the dispersion of
sulfuric acid and mixing it with slurry), the phosphate slurry (stream L3) is introduced into the
reactor compartment then the stream L15 is also entered and is dispersed within the slurry to
ions of SO4-2 and 2H+ as shows below in equation 1, the dispersion of the sulfuric acid releases
heat and cause to increase the temperature of the reactor and that lead to poor filtration, reduced
capacity and
increased P2O5 loses, (Gilmour, Phosphoric Acid Purification, Uses, Technology, and Economics,
1990),in order to
control the temperature, the recycle stream L15 with T=25°C ,P=1atm and
flowrate=236606 Kmol/day is added to the reactor.
Equation 10 H2SO4 → 2H+ + SO4-2 (becker, 1983)
Then H+ ions attack the particles of phosphate rock to form H3PO4 and to produce the ions of
Ca+2 to form the crystals at presented in equation 2 below

65
Equation 11 nH+ + Ca3(PO4) 2 → 2H3PO4 + (n-6) H+ + 3Ca+2 (becker, 1983)
after the ions of Ca+2 and SO4-2 are produced, the crystal of di-hydrated gypsum started to form
as equation 3 below, which is known as crystallization process. Equation 12 3Ca+2 + SO4-2 +
2H2O → CaSO4. 2H2O at the second stage, the resulting slurry leaves the unit after passing
through compartment 1and travels by over- flowing into compartment 2 of the reactor. the
completion of reaction of phosphate slurry being enhanced by an intimate mixing of the
components by means of the agitators distributed throughout the reaction zone, that shows by the
overall and main equation 4 below. (US Patent No. 4205046, 1980) Then the final slurry in liquid
phase (stream L5) is pumped to filtration stage with no ions remains as impurities due to the
highly efficiency of the reactor, which contains 1.5% excess sulphuric acid at which this percent
must not exceed 2.0% because it’s generally affecting the gypsum crystal (UNIDO).
Equation 13 Ca(PO4)2+ 3 H2SO4 + 6 H2O → 2 H3PO4 + 3 (CaSO4.2H2O) (becker, 1983)
Also, in this stage side reactions occur and are determined in the following equations:
Equation 14 CaF2 + H2SO4 → 2HF + CaSO4 (ThomasDahlke, 2016)
Equation 15 6HF + SiO2 → H2SiF6 + H2O (ThomasDahlke, 2016)
Side reactions occur by the reaction of calcium fluoride with H2SO4 during the acidulation to
produce hydrofluoric acid HF and calcium sulphate CaSO4, then the hydrofluoric acid reacts with
all active silica present to form flourosilicic acid and water directly by heat released from acid
66
dilution of sulfuric acid. The reaction and percent of HF and H2SIF6 product depends on the
temperature and sulphric acid concentration. (benjamin valdez sales, 2017)
Also, fluoride presence inside of H3PO4 production makes phosphoric acid highly corrosive and
unsuitable for some uses such as fertilizer applications , high concentration of fluoride causes
precipitation for some chemical compounds . (Rosmalen, 1987)
The stream L4 with T= 70°C, P=1atm and flowrate=9698 Kmol/day, which contains all the
hydrofluoric acid residual after the reaction, flourosilicic acid, air gas and water vapors are
discharged to scrubber(absorber) stage.
the H2SIF6 is a desirable acid and mostly used for drinking water fluorination and for the
production of Aluminum Fluoride (AlF3) or, in most cases, was neutralized or disposed to sea or
ponds. (ThomasDahlke, 2016). the flowrate of H2SIF6 in stream L4 equals=9698Kmol/day,
which its high percent must be recovered by the scrubber(absorber).
67
Figure 26 : the single reactor with two compartments (UNIDO)
7.3.3 FILTRATION STAGE
The stream L5 with T=70°C, P=1atm and flowrate=87036Kmol/day is coming out from the
reactor which is pumped by the pump(P-100) and introduced as the stream L14 with T=70°C,
P=6atm and flowrate=87036Kmol/day, enters the Horizontal vacuum belt filter (F-100) at which
travels over horizontal belt under vacuum pressure, the method of working the Horizontal vacuum
belt filter is to move the horizontal belt that containing the slurry in a continuous cycle. To
produce gypsum (cake) and filtrate that separated from each other (US Patent No. 4,675,107,
1987) .
68
according to the figure below, the slurry (stream L14) is fed to the filter(F-100). Then the slurry is
dewatering by a discharge that the vacuum pressure inside the filter works to withdrawal the slurry
in and passing through the filter medium after the dewatering the cake that is discharge from the
fiter , the wet slurry and set the time needed to remove the liquid from slurry .Then the filter belt
goes to washing step using feed stream L11 with T= 25°C, P=1atm and flowrate=89000 Kmol/day,
which contains water to draw off the recycles liquid, to reduce the solids in the filtered liquid and
control the concentration of acid another stage of filtration and washing added to improve the
product . after the final dewatering stage, the filter belt is inversion to discharge the filter cake.
Which is removed by the blade
Figure 27: the Horizontal vacuum belt filter (US Patent No. 4,675,107, 1987)
In general the range of temperature of the solid-liquid phase in di-hydrate method (55°C -70°C ).
and this elevation in temperature is important to be monitored and controlled to reduce viscosity
69
and increase flow rates and to give the large amounts of calcium sulfate by-product. (US Patent
No. 5,185,135, Feb. 9, 1993)
Then the stream L13 with T=72°C, P=1atm and flowrate=134345Kmol/day that contains
phosphoric acid solution is recycled to mixing tank, and the di-hydrate gypsum (stream L24) with
T= 66.5°C, P=1atm and flowrate=15016Kmol/day is extracted from filtration stage as by product,
finally the phosphoric acid (stream L12) with T=72°C, P=1atm and flowrate= 61748 Kmol/day
(40 wt% H3PO4 concentration) discharge from filtration, is pumped as stream L17 with T=72°C,
P=2atm and flowrate=61748 Kmol/day to the evaporation system to concentrate and purify
phosphoric acid product.
7.3.4 ABSORBER STAGE (SCRUBBER)

the stream L4 with T=70°C, P=1atm and flowrate=9698Kmol/day is entered the packed
absorption tower(V-101), which is the most common absorber used in wet process plant and is
filled with one of many available packing materials. The packing is designed to expose a larger
surface area. When this packing surface is wet by the solvent, it presents a larger area of liquid
film for contacting the solute gas. (Mayer, 1979) the flow through the packed column is
countercurrent, with the pure water liquid as the stream L9 with T=25°C, P=1atm and
flowrate=8000 Kmol/day that enter the absorber at the top to trickle down through the packing
while gas as the stream L4 enters the bottom to pass upward through the packing. This results in
highest possible efficiency while the recovery equals 99% of H2SiF6, as the solute of H2SiF6
concentration in the gas stream L4 decreases as it rises through the tower, there is constantly
fresher solvent available for contact. This gives maximum driving force for the diffusion process
throughout the entire column. (Mayer, 1979)
70
The solvent that have been choose is the water because it is common and not expensive, also the
H2SiF6 acid have higher solubility in water than HF. So as simple as that, when the stream L4
enter the tower with high concentrated of H2SiF6(g) (flowrate=1193Kmol/day) and contact with
water, the H2SiF6 will be dissolved in water and mass transfer of solute will done between the gas
and the liquid.
The outlet water stream L7 with T=53.71°C, P=4atm and flowrate=17246 Kmol/day, contains
H2SiF6 flowrate=16063.6Kmol/day whereas, the outlet air stream L8 with T=53.71°C, P=4atm
and flowrate = 352.7 Kmole/day, contains HF gas flowrate=341 Kmole/day, and H2SiF6 flowrate=
11.7 Kmol/day, this emission is controlled and almost have no effect on environment, humans and
animals. Also, there is a minor loss of convention heat transfer by scrubber wall due to ambient
conditions.
71
Figure 27: the packed absorption tower (Team, 2000)
72
7.3.5 MULTIPLE EFFECT EVAPORATOR
Multi-effect evaporator defined as a unit to increase the concentration of desired product by
evaporate the water from the solution , the energy of evaporator supplied by heated steam .
(Pankaj, 2017)
The stream L12 with T=31°C, P=1atm and flowrate=2499kg/day , containing dilute phosphoric
acid which came from filter is fed to the pump(P-101), the pumped dilute phosphoric acid as
stream L17 with T=31°C, P=2atm and flowrate=2499kg/day is fed to the first effect evaporator(E-
100) (the pressure in first effect= 1.81 bar), the temperature should be close to the temperature of
B.P. of the solution, Also the stream L26 enters the reboiler to raise its temperature from T26=25°C
to T25 =120°C,then the output stream from the reboiler (stream L25 )with T=120°C, P=2atm and
flowrate=2426840 Kg/s, is fed to heat exchanger tubes section then the heat starts to transfer from
steam to the solution, this steam is used only in one effect to provide heat used to evaporate the
water, the solution temperature increases and reaches the B.P. and the rate of condensation
increases so the water in the solution starts to evaporation then the vapor generated is came out
as steam L18 with T=120°C, P=1.81bar and flowrate=10833 kg/day (the vapor flowrate of stream
L18 equal to streams L22 and L20) , which is used in the second effect as the steam to evaporate
the water in the stream L19 that is came from first effect, when the temperature of the solution and
the steam become almost equals, the heat transfer and the evaporation rate are decreased until
almost stopped then the concentrated liquid (stream L19) with T=120 °C which it is similar to
evaporator temperature, P= 1.81bar and flowrate=57833 kg/day ( produces, then it is fed to next
effect evaporator(E-101) to get more evaporation, also the steam goes out as condensate or drips.
73
This stage consumes energy about 9191 (KW) to produce H3PO4 with percent 47% wt%.
After the stream L19 fed to the second effect evaporator with vapor steam L18 from first stage, the
process in first effect will be repeated in second effect but the temperature and pressure will be
decreased to T= 80 °C and P=1.27bar, the amount of water evaporated in the second stage is
10458Kg/day and fed to third effect(E-102) as the steam L20, the second effect consumes
( 6855 kw) of energy to produce H3PO4 with percent 58% wt%.
Finally, the stream L21 with T=80°C, P=1.27bar and Flowrate=47366 kg/day, with stream
L20 with T= 80°C and P=1.27bar and flowrate=10458Kg/day, are fed to third effect evaporator(E-
102), this streams are fed to heat exchanger tubes section to transfer the heat from steam to stream
until reaches the B.P. of the solution which it is similar to evaporator, at which is similar to stream
L23 and steam L22 temperature, the same procedure that done in previous effect will be done in
this effect.
As a result, the concentrated acid is produced with H3PO4 of 37133 kg/day with percent 75 %
wt % of (H3PO4), the final product (stream L23) is delivered to a storage tank with
T= 50°C and P=1atm and flowrate=37133kg/day. and the evaporated water at stream L22 with
T= 50°C, P=1atm and Flow rate =10208 kg/day. The third effect consumes
6374 (KW) of energy .
Conservation of energy is one of major factors that taken in the design of an evaporation unit.
As the evaporation duty increase the conservation of energy increase. the main advantages is the
recovery of heating fluid , and gives more concentrated product with low cost , easier to future
expansion by adding another effect (benjamin valdez sales, 2017) .

74
Figure 28: multi-effect evaporator (nishantarora, nov,2017)
75
8. MATERIAL AND ENERGY BALANCE
8.1 Mill (V-100)
1 3
V-100
Figure 29: material balance on mill
Table 8: material balance on Mill
stream 1 2 3
Flowrate 8525.21 36047 44572.21

Kmole/day
H2 O 0 0.968 0.783
H3PO4 0 0.032 0.025
SiO2 0.140 0 0.027
CaF2 0.439 0 0.084
Ca3(PO4 )2 0.420 0 0.080
76
8.2 REACTOR (R-100)
15
R-100
6
Figure 30: CSTR Reactor R-100
Table 9: Material balance on reactor (R-100)
Stream 3 5 4 15
Flowrate 44572.21 87060.54 9596.80 149325.92

Kmole/day
YCa3(PO4)2 0.080 0.002 0 0
YCaF2 0.084 0 0 0
YSiO2 0.027 0 0 0
YHF 0 0 0.04 0
YH2SiF6 0 0 0.124 0
YCaSO4.2H2O 0 0.117 0 0
YCaSO4 0 0.04 0 0
YH2SO4 0 0 0 .040
YH3PO4 0.025 0.091 0 .009
YH2O 0.783 0.746 0.840 .90
77
Table 10: Energy balance on Reactor (R-100)
Streams ∆ 𝐻 𝐼𝑁(𝐾𝑊) ∆𝐻 𝑂𝑈𝑇(𝐾𝑊)
S1 -368430.4607 0
S2 0 -519464.7668
S3 0 14555.89478
S4 -134175.309 0
S5 0 0
Q(kw) -2303.102321
8.HORIZANTAL VACCUM BELT FILTER (F-100)
11
14 24
F-100
13 12
Figure 31: Titling pan Filter (F-100)
78
Table 11: Material balance on Filter (F-100)
Stream 14 12 24 11 13
Flow rate 177942.14 68986.61 99185.59 89577.05 6961.65

Kg/hr
X wash water 0 0 0 1 0
XCaSO4.2H2O .411 0 .738 0 0
XcaSO4 .120 0 .216 0 0
XH2SO4 0 0 0 0 0
XH3PO4 .182 .4 0.186 0 .4
XCa3(PO4)2 .013 0 0.07 0 0
XH2O .274 .6 0.005 0 .6
Table 12: Energy balance on Filter (F-100)
Streams 14 11 15 13 12
Temperature (𝐂 𝟎 ) 70 25 31 31 31
Pressure (atm) 6 1 1 1 1
79
8.4 COUNTER-CURRENT ABSORBER (V-101)
8 9
V-101
10 7
Figure 32: Absorber (V-100)
Table 13: Material balance on Absorber (V-100)
stream 10 9 8 7
Flowrate 9698 8000 352.7 17246

Kmole/day
YH2O 0.84 1 0 0.93
YHF 0.035 0 0.096 0
YH2SiF6 0.125 0 0.033 0.07
Table 14: Energy balance on Absorber (V-101)
Streams 9 10 7 8
Temperature (𝐂 𝟎 ) 25 70 53.71 53.71
Pressure (atm) 1 1 4 4
80
8.5 BALANCE ON MIXER(MIX-100)
16
13
15
MIX-100
Figure 33: Mixer (MIX-100)
Table 15: Material balance on Mixer (MIX-100)
Streams 16 15 13
Flowrate 233455.72 236606.50 6961.65

Kmole/day
XH2SO4 .98 .984 0
XH2O .02 .004 .6
XH3PO4 0 .012 .4
Table 16: Energy Balance on Mixer (MIX-100)
Streams 13 16 15
Temperature (𝐂 𝟎 ) 31 25 31
0.061 0.41 0.48

Flow rate ( mole /s)
81
8.6 MULTI EFFECT EVAPORATOR
18
20 22
17
25
19 21
E-101 E-102 E-103
23
Figure 34 : Multi Effect Evaporator
Table 17 : Material Balance around Multi Effect Evaporator
Stream 17 18 19 20 21 22 23
Flowrate 2499 10833 57833 10458 47366 10208 37133

Kg/day
XH3PO4 .400 0 .474 0 .58 0 .75
XH2O .599 1 .526 1 .42 1 .25
Table 18: Energy Balance around Multi Effect Evaporator
Items 𝒌𝒋 𝐐(𝐤𝐰) 𝒕𝒐𝒏 𝐩𝐬 (𝒃𝒂𝒓) 𝐓(𝐤)

𝝀𝒔 ( ) 𝐦̇ ( )
𝒌𝒈 𝒅𝒂𝒚
First effect 2202 9191 349 1.81 393

Second effect 2281.8 6855 251 1.27 353
Third effect 2377 6374 245 0.7 323
82
8.7 PUMPS
10
P-100 A/B
Figure 35: Pump (P-100 A/B)
Table 19: Balance on Pump
Streams 4 10
Temperature (𝐂 𝟎 )
70 70
145 145
Flow rate (kmole/day)
Pressure (atm)
1 4
14
P-101 A/B
Figure 36: Pump (P-101 A/B)
83
Table 20: Balance on Pump (P-101 A/B)
Streams 5 14
Temperature (𝐂 𝟎 ) 70 70
Flow rate (kmole/day) 100 100
Pressure (atm) 1 6
17
12
P-102 A/B
Figure 37: Pump (P-102)
Table 21: Balance on Pump(P-102)
Streams 12 17
Temperature (𝐂 𝟎 ) 72 72
Flow rate (kmole/day) 94 94
Pressure (atm) 1 2
84
9. EQUIPMENTS SIZING AND MECHANIC DESIGN
INTRODUCTION
This section involved the sizing of various equipment present in the process flow diagram shown
in figure 24 . equipment sizing is a critical part in the design of this plant, it affects the profitability
of the plant in accordance to the materials chosen and the sizes of units. The results presented in
this section are directly used to estimate the equipment cost , The list of equipment can be seen in
Table (23) in addition to the quantity of each type of equipment.
Table 22: LIST OF EQUIOPMENTS PRESENT IN PROCESS OF PRODUCTION OF
EQUIPMENT ABBREVIATION QUANTITY
STORAGE TANKS TK-10X 9
MILLER V-10X 1
REACTOR R-10X 3
ABSORBER V-10X 1
FILTER F-10X 1
HEX E-10X 1
MIXER MIX-10X 1
MULTI-EFFECT
E-10X 1
EVAPORATOR
PUMPS P-10X 2
*X is the number designated for each equipment present in the process.
The following sections will include the considerations of details taken while designing the various
equipment in this process, additionally, specification sheets which summarize the design results of
each equipment will be presented.
85
9.1 BALL MILL DESIGN(V-100)
9.1.1 INTRODUCTION
Milling technique is used widely in industries process, it is used to grind or mill materials used in
mineral dressing processing, ceramics, paints and certain products processes. it aims to produce
pieces of material free of cutting edges, which in general reduce the size of particles used in the
process in which effect the energy consumed in the process in general.
Ball mill is one of grinding machines used to reduce size of particles based on gravitational and
centrifugal forces at which are produced by the movement of the shell of the miller, this centrifugal
movement of the shell causes the movement of the balls at which it is the grinding material of the
miller. The main principle at which ball mills works on is the critical speed, at which it’s the speed
after which the steel balls that are responsible for the grinding of particles start rotating along the
direction of the cylindrical device, thus causing no further grinding.
Ball mill is a grinding device at which it consists of cylindrical hallow, it rotates around its axis
which cause the movement of the grinding media which with the cascading effects produce fine
powder of the material.
The grinding material inside the mill are made of different materials like rubber, steel an example
of product produced using rubber balls are the grinding of explosive material. Also, the diameter
and amount of the grinding material differs based on the type of the material to be crushed and the
product size. Also, the size of the shell of the mill is affected by the material to be crushed and the
product size and the capacity of the designed mill.
Ball mill differs than other millers by the grinding material at which it produces different product
size depend on the desired size to be used in the process. The grinding process using ball mill can
be wet or dry based on the specification of the desired product, and the feed material to the mill.
Specifications of the grinding media in ball mills:
1. Size: The smaller the desired product particles the smaller the grinding media.
86
2. Hardness: The grinding media must be hard enough to grind the material, but at the same
time not that tough that will wear down the machine.
3. Taking in consideration the color of the final product, so the grinding media color will
affect the product.
4. The contamination is considered where low contamination must occur to separate the
grinding media from the product easily.
The Ball mall has many advantages in industries in which the cost of installation and grinding
medium is low, the flexibility of adjusting the shell diameter based on the capacity, the fineness
of the product is adjusted based on the diameter of the ball, the suitability of both batch and
continuous processes, open and closed grinding circuits and it is applicable for materials with
all degree of hardness.
In the figure below, it shows the (1) ball miller and (2) cross-sectional view for the mill show-
ing the grinding media inside the shell, the first figure shows the ball mill, it shows how the
charge enters the mill, and the discharge point, it also shows the direction of movement of the
miller shell as it moves in rotational movement.
87
Figure 38 below shows the cross-sectional view of the miller, including the movement of the grinding media along with the move-
ment of the shell of the mill.
figure 39: cross sectional veiw of ball mill
88
9.1.2 LIST OF ASSUMPTIONS
1. Assuming efficiency of ball mill grinding is 1%

2. Assuming ball mill runs at 70% of the critical speed
3. Central distance of mill to effective diameter ratio (h/D) equals to 0.045, to set values of specific
charge and bulk density
9.1.3 DESIGN EQUATIONS
1. Energy required, Bond’s equation:
𝑃 1 1
W= =0.316*Wi * ( − ) (bond’s equation) (Peter harriott, Julian smith)
𝑚 √𝐷𝑝 √𝐷𝑓
Where:
P: power in (KW)
m: feed flow rate (ton/hr.)
W: work in (KW/ton)
Wi: work index for raw material, (KW.h/ton)
Dp: Diameter of final product (mm)
Df: Feed diameter (mm)
2. Grinding media,Ball’s diameter:
𝐹 𝑊𝐼 𝑆
d=√ √ (cementequipment.org, n.d.)
𝐶𝑆 𝐾 √𝐷
Where:
d: ball diameter (m)
F: Feed size 80% mesh of new product (m)
Wi: Work index of feed
Cs: percentage of critical speed
89
K: equals 200 for balls as grinding media
S: specific gravity of feed
D: diameter of mill (m)
3. Effective Diameter:
𝑛
N=F.g.D.a . sinσ. π. (cementequipment.org, n.d.)
60
𝜋
Substitute g.60=0.51417
At which (Sin σ) =µ, Torque factor
N=0. 5417.F.n.D.µ
Where:
N: Power consumption by mill (KW)
F: feed charge (ton)* assumption
n: Mill speed (rpm)
D: diameter of mill (m)
σ: angle of displacement ( ֯ )
µ: torque factor from figure A-4
4. Critical Speed
1 𝑔
N= √ (rps) (Peter harriott, Julian smith)
2𝜋 (𝑅−𝑟)
Where:
N: critical speed (rps)
g: gravitational acceleration (m/s2)
R: mill radius (m)
r: balls radius (grinding media) (m)
90
5. Effective length is calculated from charge feed to mill equation:
𝑞
F= . 𝜔. 𝑉 (ton) (cementequipment.org, n.d.)
100
Where:
F: charge to the mill (ton)
q: specific charge from figure A-5
ω: bulk density (ton/m3) from figure A-5
V: volume of mill (m3)
6. Volume of mill (cylindrical shell):

𝜋
V= . 𝐷2 . 𝐿 (m3)
4
Where:
V: volume of mill (m3)
D: effective diameter of mill (m)
L: effective length (m)
7. Effective length to diameter ratio:

𝐿
𝐷
Where:
L: effective length (m)

D: effective diameter (m)
91
9.2.4 BALL MILL DESIGN EQUATION SUMMARY
Table 23: BALL MILLER V-100 DESIGN DATASHEET.
IDENTIFICATION
Name of equipment Miller
Item No. V-100
Equipment Type Ball miller

Material of construction (MOC) Carbon steel
Grinding media MOC Carbon steel
Function To reduce size of feed phosphate rock
Temperature 25 C֯
Grinding type Wet
OPERATING CONDITIONS
PARAMETER VALUE UNIT
Work index 9.92 -
Specific gravity 2.73 -
F 0.05 mm
P 70 µm
Charge flowrate 61.23 Ton/hr
Mill efficiency 1 %
Percentage of mill critical
70 %
speed
DESIGN PARAMETERS OF MILLER
Work consumed 7.5 Kw.hr/ton
Actual work consumed by
0.075 Kw.hr/ton
crushing
Ball Mill Power 454.6 KW
Effective diameter 2 m
Effective length 10.2 m
L/D ratio 5
Mill Volume 32.2 m3
Mill rotational speed 30.4 rpm
Critical speed 21.3 rpm
Ball diameter 22 mm
92
9.3 REACTOR DESIGN(R-100)
9.3.1 INTRODUCTION
This reaction was carried out in a continuous stirred tank reactor. A chemical process's heart is
the reactor. Reactor design is a key phase in the overall design of the operation since it is the
only area where raw materials are turned into products. (Land, 2011)
The characteristics listed below are used to categorize reactor designs.: (Land, 2011)
1.Phases present: homogeneous or heterogeneous.
2.Mode of operation: batch or continuous
3.Reactor geometry: flow pattern and manner of contacting the phases.
A. Tubular reactor.
B. Stirred tank reactor.
C. fluidized bed.
D. packed bed, fixed and moving;
Batch or continuous processing
Batch process
Continuous process
In a batch process, all of the reagents are
added at the start; the reaction occurs, The reactants are continually fed into the
with the compositions changing over reactor and the products are continually
time; the reaction is stopped, and the extracted in continuous processes; the
product is extracted when the desired reactor runs in steady-state conditions.
conversion is achieved. Batch procedures Continuous manufacturing has lower
are ideal for small-scale production and manufacturing costs than batch
procedures that need the manufacture of a production, but it lacks batch production's
variety of various products or grades in flexibility. For large-scale production,
the same equipment; for example, continuous reactors are frequently
pigments, polymers and dyestuffs. chosen. (Sinnott R. K., 1996)
(Sinnott R. K., 1996)
93
The continuous process was chosen due to the large-scale production, and lower production costs
than batch production.
• Homogeneous and Heterogeneous Reactions

Homogeneous reactions are those in which the products, reactants, and any catalyst used to form
one continuous phase: Liquid or gaseous, but in a heterogeneous reaction, two or more phases
exist. (Land, 2011)
In this equipment, there is a heterogeneous reaction, liquid-solid phase: with one, or more, liquid
phases (H2O, H2SO4 , H3PO4 ) in contact with a solid, which is a reactant material (phosphate rock),
as a result, it is finely suspended solids.
• Reactor Geometry (Type)

The essential chemical reactor is the stirred tank (agitated) reactor, which was chosen for the
following reasons: Tank sizes range from a few liters to several thousand liters, and it is
employed for reactions involving finely suspended materials that are held in suspension by the
agitation. Also Stirred tank reactors are appropriate for reactions requiring efficient heat or mass
transfer. (Land, 2011)
Figure 40:CSTR mixing patterns
94
9.2.2 REACTOR DESIGN EQUATION
The design of this reactor dimensions was provided according to these equations:
1-volume of the reactor
𝐹𝐴◦
V= 𝑥 (Fogler, 1986)
−𝑟𝐴
Where:
Rate of Reaction: -ra = k CA (Caecilia Pujiastuti, 2020)
−𝐸𝑎 −3742.4
Reaction rate constant : k = A exp [ 𝑅𝑇 ]  k =1.1627 exp [ ] (Caecilia Pujiastuti, 2020)
𝑇
Nonisothermal Reaction: (Fogler, 1986)

∑𝜃𝑖 𝐶𝑝𝑖 (𝑇 − 𝑇𝑖)
𝑋𝐸𝐵 = −
∆𝐻𝑟𝑥𝑛 + ∆𝐶𝑝(𝑇 − 𝑇𝑖)
2-Diameter of the reactor

as the volume of the cylinder, so that VR = 𝐷2
4
x H x π then,
4 𝑥 VR
D2= ×H
πxH
3-The height can be assumed

H=1.5 D
4-Reactor thickness:
𝑃 𝑟𝑖
t = 𝑆𝐸 + 𝐶𝑐 (Peters M. S., Plant Design and Economics, 2003)
𝑗 − .6𝑃
95
9.2.3 SPECIFICATION SHEET FOR 3 REACTORS IN PARALLEL
Table 24:Design results summary for Reactor (R-100)
CSTR Reactor Datasheet
Equipment CSTR Reactor

Equipment No. R-100
No.Required 3 reactors in parallel
Function To mix streams (3)(phosphate rock ) and
(15) to produce phosphoric acid and gyp-
sum
Temperature (in) (k) 298.15 Pressure (bar) 1
Temperature out 347.15
Material of construction Carbon steel lined with rubber
Main Reaction Ca3(PO4)2+3H2SO4 → 3CaSO4+2H3PO4
Rate of main reaction -rA= K [Ca3(PO4)2]1
6HF+SiO2 → H2SiF6+2H2O
Two Side of Reactions 3SiF4+2H2O → 2H2SiF6+SiO2
Description Unit Value
Design specification of one reactor

Wall thickness m .0046
Resistance Time Min 150
Diameter m 5
Length m 8
Volume m 150
Orientation Vertical
Cost of three reactor $ 1080000
96
9.2.4 REACTORS AGITATOR DESIGN
9.2.4.1 INTRODUCTION
Mixing is the random distribution into and through one another, of two or more initially separate
phases, in this reactor solid-liquid mixing. The type of agitator is chosen first, based on the
viscosity of the liquid, the volume of the tank, and the rate of the reaction. When it comes to
competitive fast reactions, when swift blending is crucial, the feed stream was supplied to the
Impeller at a high velocity using a six-blade disk impeller. The feed is forced outward along the
disk and into the high shear zones near the impeller blade tips, where local blending is particularly
rapid, and the turbine agitator is utilized because it is the most often employed agitator in the
process industries. (Hurst, 1961)
Figure 41: The 6-blade disk impeller.
97
9.2.4.2 ASSUMPTIONS FOR AGITATOR DESIGN
Table 25: The geometric proportions (shape factors) of the mixing system which are considered typically "standard" design.
S1=Da/Dt S2 =E/Dt S3 =H/Dt S4 = W/Da S5 =J/Dt S6 =L/Da

1/3 1/3 1 1/5 1/12 ¼
Where,
Dt = (0.1-10) m.
2- Number of baffles =4
3- Number of impeller blade = 4-16
4-
Table 26: the geometry for mixing system
Dt Internal diameter of the vessel

H Liquid height
J Baffle width
Da Impeller diameter
E Height of impeller above vessel floor
W Width of impeller blades
L Length of impeller blade
5- n = 90 rpm (since turbine speed typically range from 55 to 125 rpm)
6- Efficiency of transfer of motor power to water power based on =80%
98
9.2.4.3 DESIGN EQUATION
In the agitator design, there are many parameters must be considered which are:
1- Impeller tip speed vtip:
𝑣 𝑡𝑖𝑝 (𝑚/𝑠) = 𝛱 ∗ 𝑛 ∗ 𝐷𝑎 (J.Hickey, 2001)
Where,
Da: impeller diameter (m)
n: impeller rotational speed (rps)
Π =3.14
2- Impeller Reynolds number Re:

n Da2 ρ
𝑅𝑒 =
μ
Where,
n: rotational speed (rps)
ρ: density (kg/m3)
μ: viscosity (Pa. s)
3- Power dissipation by an impeller:
P (watt) = KT n3 Da5 ρ (J.Hickey, 2001)
Where,
KT: Proportionately constant depend on type of impeller and geometry ratio for the system.
99
KT from Table 67 for Fan turbine six blades = 1.65
n: rotational speed (rps)
ρ: density of water (kg/m3)
4- Velocity gradient G:
G(s-1) = √𝑃/𝑉𝜇 (J.Hickey, 2001)
Where,
P: Power dissipated by an impeller (watt)
V: volume of (m3)
μ: viscosity (Pa. s)
9.2.4.5 MIXER AGITATOR SIZING

Table 27: Design results summary for agitator design in Reactor (R-100)
Identification
Equipment Impeller
Function Gentle agitation to encourage the particles formed to
agglomerate
MOC Carbon steel lined rubber
No. required 1
Type Top Entry, Fan six blades turbine with agitator shaft
Location In CSTR Reactor
Design specifications
Number of blades 6
Impeller diameter m 1.66
Height of impeller above vessel m 1.66
floor E
Length of impeller blade L m .415
Width of impeller W m .332
Baffle width m .416
Speed of impeller rpm 90
Power required Kw 136.8
100
9.3 HORIZONTAL VACUUM BELT FILTER DESIGN(F-100)
9.3.1 INTRODUCTION
Vacuum filtration is used in industries to separate solids from liquid this technique, vacuum filter
is A category of filter that uses vacuum induced driving forces and semipermeable
media to facilitate the separation of solids from suspension. While pressure differences across the
filter are limited to less than 85 kPa (usually _75 kPa), most units are capable of processing a wide
range of feed materials in a continuous manner. Many types employ a rotary valve arrangement to
set different vacuum levels over sequential phases in a filter cycle thus facilitating more control
over cake formation, de-liquoring and washing. Several vacuum filters have countercurrent wash-
ing capability.
Although it is possible to enclose some types to conserve heat and/or vapors the processing of
more volatile constituents at higher altitudes can cause significant problems. Woven filter cloths
or specially developed coated media are used almost exclusively on continuous machines, despite
the inherent difficulties of achieving clear filtrate.
-Horizontal Belt Filter:

The feed suspension is introduced at one end of the filter and deliquored to produce a cake. The
length of the filter, which can be in excess of 60 m, is arranged to allow adequate cake formation
as well as the Due to the ease with which wash liquors can be segregated, it is relatively simple
to perform countercurrent washing to exacting requirements provided wash liquor carry-over
into the next suction box is avoided. The final cake is naturally discharged as it passes over the
second roller and separation of the
belt and cloth beneath the filter allow the exposed cloth to be cleaned by sprays as it returns.
Horizontal belt filters are best suited to the larger scale filtration of medium and faster settling
slurries. Although they occupy a large floor space and the cost of installation per unit filter area is
101
relatively high, these disadvantages are generally offset by full automation, flexibility, high capac-
ity and relatively.
Figure 42: Horizontal belt filter HBVF.
- Filter Media:
The filter medium is that critical component which determines whether or not a filter will perform
adequately, the principal role of a filter medium is to cause a clear separation of particulates (which
may be solid particles, liquid droplets, colloidal material, or molecular or ionic species) from the
liquid with the minimum consumption of energy.
The most used filter medium is the traditional filter medium clothes.
102
Figure 43: Filter medium of filter (cloth).
9.3.2 LIST OF ASSUMPTIONS:
1. Assumed Cake thickness equals to 0.035 m
9.3.3 DETAILED DESIGN EQUATIONS OF HVBF FILTER:
1. Area of filter:
Using bed voidage equation to calculate the area of filter, which it relates the cross-sec-
tional area to the voids in the cake and mass of removed solids,
Bed voidge equation,
𝑚
ɛ = 1 − 𝐻∗𝐴∗𝜌𝑐 (F. T. Campbell, R. Pfefferkorn und J. F. Rounsaville)
In terms of Area:
𝑚 1
A=(1−ɛ) ∗ 𝐻∗𝜌
Where:
A: Filter cross-sectional area in m2 needed to remove kg of solids / min
103
m: solid mass flow rate in feed (Kg/min),
ɛ: Cake porosity
H: Cake thickness (m)
ρ: Solid density (kg.m-3)
 As the area of the belt is rectangular then

A= L * W
Where:
L: length of belt (m)
W: width of belt (m)
2. Vacuum pressure applied across filter:

Calculations of pressure drop across filter from equation ( (F. T. Campbell, R.
Pfefferkorn und J. F. Rounsaville)):
𝑞 µ∗𝐻
ΔP=𝐴 ∗ *10-3
𝐾
Where:
ΔP: Vacuum pressure applied across filter (KPa)
q/A:Flow rate of filtrate per unit area (specific flow rate) (m/s)
µ: Viscosity of filtrate and wash (Pa.s)
K: cake permeability
A: area of filtration used to filter kg of slurry/ min
3. Permeability of Cake:
As permeability of cake is related to specific cake resistance and cake porosity and cake
porosity, according to Kozeny-carman equation, which relates cake porosity and thick-
ness to the permeability of the cake:
104
1
K=𝐻∗𝜌𝑐∗(1−ɛ) (Steve Tarleton, Richard wakeman, 2006)
Where:
K: permeability of cake
H: cake thickness (m)
α: Cake resistance (m.kg-1)
ɛ: porosity of cake
ρ: solid density (kg.m-3)
4. Solid mass fraction in feed:

The mass of solids in slurry entering the filter divided to the total amount of slurry enter-
ing the filter:
𝑚(𝑠𝑜𝑙𝑖𝑑)
S=𝑚 (𝑠𝑙𝑢𝑟𝑟𝑦)*100%
Where:
m(solids): mass flowrate of solid (gypsum) in the feed (Kg/day)
m(slurry): mass flowrate of slurry feed to the filter (kg/day)
5. Mass fraction of dry/wet cake:

According to reference (Steve Tarleton, Richard wakeman, 2006), which indicates the
mass of dry/wet cake can be obtained from equation below:
𝜌𝑙 1−𝐶𝑎𝑣
mav=1+ 𝜌𝑠 ∗ ( )
𝐶𝑎𝑣
Where:
mav: mass fraction of wet/ dry cake
ρl: liquid density (filtrate) in (kg.m-3)
105
ρs: solid density (gypsum) in (kg.m-3)
Cav: solidosity, volume fraction of solids in filter cake
6. Solidosity, volume fraction of solids in filter cake:
Cav = 1-ɛ (Steve Tarleton, Richard wakeman, 2006)
Where:
Cav: Solidosity
ɛ: Porosity of cake
106
9.3.4 DETAILED HVBF DESIGN SUMMARY:
Table 28: DETAILD FILTER DESIGN DATASHEET
IDENTIFICATION
Name of Equipment Filter
Item No. F-100
Equipment Type Horizontal Vacuum Belt Filter
Material of Construction (MOC) Stainless steel
Function To separate solids from slurry feed.
Temperature 25 C
Number of Equipment 1
OOERATING CONDITIONS
Parameter value unit
Barometric Pressure 101.3 Kpa
Solid Mass Fraction in Feed 41.1 %W/W
(S)
Solid Mass Fraction in cake 73.9 %W/W
Cake resistance* 4*109 m-1
Wash Water Flowrate 5 Kg/hr
1.2*10
Slurry load 1.8*105 Kg/hr
DESIGN PARAMETERS OF FILTER
Belt Width 3.2 m
Belt length 13.4 m
Filtration Area 42.74 m2
Applied Vacuum 41 Kpa
BY-PRODUCTS CHARACTRISTICS
Effective feed concentration 3566.8 Kg. m-3
Ratio mass wet/dry cake 2.063
Cake sludge flowrate 9.9*104 Kg/hr
Filtrate flowrate 6.9*10104 Kg/hr
Cake (gypsum) porosity 0.65
Cake Solidity 0.35
Density of Solids(cake) 2330 Kg/m3
Density of filtrate 1334 Kg/m3
* Cake resistance for cake produced (gypsum) from ref (Steve Tarleton, Richard wakeman, 2006)
107
9.4 PUMPS DESIGN
9.4.1 INTRODUCTION
Pumps can be divided into two categories: (Land, 2011)
1. Positive displacement pumps, such as reciprocating and diaphragm pumps.
1. Dynamic pumps, such as centrifugal pumps.
Centrifugal pumps are the most commonly used type and have several good qualities: (Sinnott R.
K., 1996)
1. They are simple in construction, are inexpensive, are available in a large variety of materials,
and have a low maintenance cost.
2. They operate at high speeds so that they can be driven directly by electrical motors.
This section shows the detailed design results for the pumps used for this specific plant. the
pump (P-101) selected were centrifugal pumps with efficiencies of (60-80)%. Since this kind of
pump is characterized by its low purchased and maintenance costs.
Figure 44:Centrifugal pump
The type of pump (P-100) was selected to be a reciprocating pump since centrifugal pumps are not
adequate for transferring thickened sludge for the pumps used for transporting sludge the frictional
losses calculated were multiplied by 3 ,since the frictional losses resulting from sludge are higher
than that resulting from water.
108
9.4.2 DESIGN EQUATION
1-work needed
𝑊0 = ∆𝑧𝑔 + ∆𝑃/ 𝜌 + ∆𝑉 2 / 2𝛼 + 𝛴 F
- ∆z.g = the elevation multiplied by the acceleration due to gravity

-∆𝑉 2 /2 𝛼 = which is velocity term needed for the pump
- ∑F = is the friction calculated of pipe, expansion, compression and valves/elbows
2-Power
-Theoretical power = W• * Mass flow rate

𝒕𝒉𝒆𝒐𝒓𝒊𝒕𝒊𝒄𝒂𝒍 𝒑𝒐𝒘𝒆𝒓
-Actual power =
𝒆𝒇𝒇𝒆𝒄𝒊𝒆𝒏𝒄𝒚
109
9.4.3 DESIGN RESULTS SUMMARY
Table 29: Design results summary for Pump P-101
Identification
Name of Equipment Pump
Item No. P-101
Equipment Type Centrifugal Pump
Drive Electrical
Material of Construction (MOC) SS902
Temperature 30 C◦
Function Pumping Dilute Phosphoric acid from Filter

(F-100) to Multi-effect evaporator
Number of Unit Required 1
3
Flow Rate m /s .017
Density Kg/m3 1424
Viscosity cP 2.1
Pump Efficiency % 66
Work Needed J/Kg 41.84
Power hp 3
Cost $ 11520
110
Table 30: Design results for pump P-100
Identification
Item No. P-100
Equipment Type Reciprocating pump
Drive Electrical
Temperature 74 C◦
Function Pumping Slurry from Reactor (R-100) to

Filter (F-100)
Flow Rate m3/s .0209
Density Kg/m3 1560
Viscosity cP 22
Pump Efficiency % 66
Work Needed J/Kg 41.84 J/Kg
Power hp 15
Cost $ 12510
111
9.5 THE ABSORBER( V-101)
9.5.1 INTRODUCTION
absorption is a mass transfer of one or more components from the mixture of gases by a suitable
solvent, the principle of gas absorption is that when a soluble gas contacts with a solvent,
molecules of the gas will enter the liquid to form a solution.
The gas absorption is used for:
 Separate the component that have economic value from a gases mixture
 Removing the undesired gases from the desired components (pollution)
The absorber column is used in phosphoric acid production plant to separate the
Hexafluorosilicic acid gas(H2SiF6) from gases mixtures by pure water solvent.
The Hexafluorosilicic acid is corrosive and toxic, it is used in water fluoridation, electroplating
and in manufacturing enamels and cement. Also, it is used to treat industrial process and potable
raw water. So, when it is produced in huge amount from the reactor, it is must entered to the
absorber to recovery by water and to isn`t released to the environment.
112
Figure 45: the gas absorber column
There is two type of absorber which are used for absorption purposes:
 Packed
 Plate
Comparison between the two types above:
1. The plate absorber brings the liquid and gas phase on stage wise basis to contact while
the packed absorber provides a continuous contact between two phases
2. The pressure drop in the plate more than in the packed, because there is additional fric-
tion in plate column
3. For tower with small diameter, the packed requires materials costs and fabrication lower
than the plate.
113
So in our design, the counter current packed absorber selected to recovery the Hexafluorosilicic
acid.
The packed bed absorber is a common absorber used in gas absorption operation, it is a hollow
pipe or vessel that is filled with a ceramic, metal or plastic packing material. The absorber
consists of a cylindrical column with a liquid inlet and distributor at the top; random or
structured packing; gas inlet and distributing space at the bottom; liquid and gas outlets at the
bottom and top, respectively; and packing support plate.
The packing material is divided into two types: those that stacked by hand and made up from a
wire mesh or perforated metal sheet that are arranged with regular and uniform geometry to give
a large surface area, which it is known as structured packing. And those that dumped into a
column at a random shape to give high surface area and low pressure drop, which it is known as
random packing the packing. The random packing is selected in our design because it is widely
used in absorption and distillation column to increase the surface area between the vapor and
liquid in the column and is less expensive than structured packing.
Figure 46: the packed bed absorber column
114
The random packing type is used in most industrial packed columns because it’s the main
influence on the efficiency of the column. The random packing has more than 50 different types
presented in the marked, includes the rasching rings, ball rings, berl saddles and INTAL lox
saddles.
Figure 47: the types of random packing
115
9.4.2 ASSUMPTIONS
 The packing type is ceramic intalox saddles and the size of it =51 mm due to table 11.3
in (Coulson Richardson s Chemical Engineering vol_6)
 The pressure drop per length of packing equal 21mmH2O/m
9.4.3 DETAILED DESIGN OF ABSORBER V-101

The type of random packing that was chosen in our design is INTALOX Saddle packing because:
 The ceramic resists the corrosion
 It provides a larger contact area per unit volume.
 It has an open structure and high bed porosity.
 It is most popular choice and most effective
 It is economical and its cost is not high
Figure 48: the ceramic INTALOX saddles packing
116
And in this report, the material of construction of the absorber that is selected the rubber lined
with carbon steel because the materials that enter the packed bed absorber are very corrosive so,
we need to corrosion-resistant alloys. And the rubber lined with carbon steel protect it and resist
the corrosion
Also, the cost of this alloy isn’t expensive .
9.4.4 DESIGN EQUATION

In the design of the packed bed absorber, many critical factors must be considered, such as:
 The size of packing material
 The number of transfer units NOG
 The diameter of the column
 The Liquid-film transfer unit height HL
 The Gas-film transfer unit height HG
 The height of transfer units HOG
 The height of the column Z
 The operating velocity
 The flooding velocity
 The wetting rate
 The pressure drop at flooding
 The total pressure drop
 To calculate number of streams for liquid distribution at top of the packing

117
1. The size of packing material
76mm size
2. The number of transfer units NOG
From graph 11.40 in (Coulson Richardson s Chemical Engineering vol_6) book
3. The diameter of the column
diameter of the column = [4A] ½

[3.14] ½
A: area of the column= G/ V*W

Where:
G: gas mass flowrate (Kg/s)
V*W: gas mass flowrate per unit column cross-sectional area (Kg/m2.s)
V*W = [k4× ρg × (ρL-ρg) / 13.1×Fp× (µL /ρL) 0.1] ½
Where:
FP : packing factor
K4:factor
o
ρL: Density of liquid solvent at C
ρg: Density of gas mixture= PM /RTg

µL: Viscosity of liquid solvent at oC
4. The Liquid-film transfer unit height HL
Where:
118
HL= Liquid-film transfer unit height
Ct = Concentration of solvent
KL = liquid film coefficient m/s
dp = packing size
DL = diffusivity of liquid
aw = effective interfacial area of packing per unit volume, m2/m3
5. The Gas-film transfer unit height HG
HG : Gas-film transfer unit height

KG = Gas film coefficient, kmol/m2s.bar
Where:
Vw : gas mass flowrate per unit column cross-sectional area
K5 = 5.23 for packing sizes above 15 mm, and 2.00 for sizes below 15 mm,
Dg ;Diffusivity of gas
ρg: Density of gas mixture= PM /RTg
o
µg :Viscosity of Gaseous mixture at C
6. The height of transfer units HOG

119
7. The height of the column Z
Z= NOG × HOG
8. The wetting rate
Wetting rate = Liquid volumetric flow rate per unit cross-sectional area
Specific area of packing per unit volume (a)
Liquid volumetric flow rate/Unit cross-sectional area=

[mass liquid flowrate / (area*3600*𝜌L)]
9. The pressure drop at flooding
ΔPflooding =0.115Fp 0.7
10. The total pressure drop
150𝜇𝜈𝑠 𝐿 (1−𝜀)2 1.75𝜌𝜈𝑠 2 𝐿 (1−𝜀)

𝛥𝑃 = +
𝐷𝑝2 𝜀3 𝐷𝑝 𝜀3
Where:
𝜇: the viscosity of the gas (kg/m.s)
𝜈𝑠 : the velocity (m/s)
𝐿: length of the packing (m)
𝜀: the void fraction of the packing
120
𝐷𝑝 : particle diameter = (6*(1- 𝜀))/a (m)
𝜌: the density of the gas (kg/m3 )
11. To calculate number of streams for liquid distribution at top of the packing
Ns= (D/6)2
D = Diameter of the absorption column in inches
12. To calculate the thickness of the column:
e = (Pi Di/ 2f-Pi) + C
where :
e : thickness of column mm
Pi: design pressure N/mm2
Di : internal diameter mm
F : design stress N/mm2
C : corrosion allowance mm
121
9.4.5 PACKED BED ABSORBER V-101
Table 31: specification sheet of absorber V-101
Identification
Item Name Absorber
separate the Hexafluorosilicic acid gas(H2SiF6) from
Objective gases mixtures by pure water and recovery it.
Item No. V-101
Number required 1
Absorber type Packed Bed
Absorber position Vertical
Material of Construction rubber lined with carbon steel
Cost ($) 180,000 $
Process Data
o
Operating Temperature C 47
Operating Pressure atm 1
Entering Gas Kg/hr 13497
Entering liquid Kg/hr 11135

o
Feed gas temp. C 70
o
Feed liquid temp. C 25
Feed pressure atm 1
Design Data
No. of transfer units - 11
Height of transfer units m 1.2
Gas Film Coefficient kmol/m2s.bar .0003
Liquid Film Coefficient m/s .0001
Height of packing section m 13
Total height of column m 15
122
Diameter of column m 2
Thickness mm 5.1
Operating velocity m/s .9
Pressure drop Kpa 2.1
Internals
Type of packing INTA lox saddles
Size of packing (mm) 51
Material of packing Ceramic
Packing arrangement Dumped
Type of packing support Simple grid and perforated support
123
9.5 DESIGN OF MULTIEFFECT EVAPORATOR(E-100,101,102) .
9.5.1 INTRODUCTION :
The main aim from multi effect evaporator is to increase the concentration of phosphoric acid –
water solution by usind saturated steam heated by reboilar the input steam will exchange the heat
between the acid solution and steam then an amount of water in the solution will evaporated and
this vapor input to the second effect at temperature and pressure less than temperature and pressure
of the first effect which makes on increase the concentration of H3PO4 , the final effect works on
vaccume pressure and higher concentration of phophoric acid achieved . Since it is often the
cheapest per unit of capacity, this is another of the most commonly used natural circulation
evaporators. A shell secures the long vertical tube bundle, which extends into a larger diameter
vapor chamber at the tip. One pass shell and tube heat exchanger make up the long-tube vertical
(LTV) evaporator. The liquid flows as a thin film on the walls of a long (from 12 to 30 feet in
length) and vertical heated tube in this form of evaporator. Both rising and dropping film forms
are employed. The length of the tube is normally between 20 and 65 feet. This form of evaporator
has a higher heat transfer rate as its main benefit. The feed enters at the bottom of the vent, and the
liquid begins to boil at the bottom. In the paper and pulp industries, LTV evaporators are widely
used to concentrate black liquors.
Figure 49: VERTICAL FORCED CERCULATION EVAPORATOR
124
9.5.2 EQUATIONS
The design done by Badger mccabe method .

1. Balance equation of first effect :
𝐹 ℎ𝑓 + 𝑄 = 𝑉1 𝐻1 + 𝐿1 ℎ1
𝐹ℎ𝑓 + 𝑣° 𝜆° = (𝐹 − 𝐿1 )𝐻1 + 𝐿1 ℎ1
𝐹(ℎ𝑓 − ℎ1 ) + 𝑣° 𝜆° − (𝐹 − 𝐿1 )𝜆1 = 0
After rearrange .
𝐹𝐶𝑝 (𝑇𝑓 − 𝑇1 ) + 𝑣° 𝜆° − (𝐹 − 𝐿1 )𝜆1 = 0
Rate equation :
𝑈1 𝐴(𝑇∘ − 𝑇1 ) = 𝑣° 𝜆°
Balance equation around SECOND effect :

𝐿1 𝐶𝑝 (𝑇1 − 𝑇2 ) + (𝐹 − 𝐿1 )𝜆1 − (𝐿1 − 𝐿2 )𝜆2 = 0
Rate equation :
𝑈2 𝐴(𝑇1 − 𝑇2 ) = (𝐹 − 𝐿1 )𝜆1
Balance equation around THIRD effect :

𝐿2 𝐶𝑝 (𝑇2 − 𝑇3 ) + (𝐿1 − 𝐿2 )𝜆2 − (𝐿2 − 𝐿3 )𝜆3 = 0
Rate equation :
𝑈3 𝐴(𝑇2 − 𝑇3 ) = (𝐿1 − 𝐿2 )𝜆2
2. The driving force for the system And calculate
∆𝑇𝑠𝑦𝑠 = ∆𝑇1 + ∆𝑇2 + ∆𝑇3

125
3. Get L1 and L2 from these equations :
𝐿1 𝐶𝑝 (𝑇1 − 𝑇2 ) + (𝐹 − 𝐿1 )𝜆1 − (𝐿1 − 𝐿2 )𝜆2 = 0
𝐿2 𝐶𝑝 (𝑇2 − 𝑇3 ) + (𝐿1 − 𝐿2 )𝜆2 − (𝐿2 − 𝐿3 )𝜆3 = 0
4. Calculate the area for each effect and the average area from the following
equation :
𝑣° 𝜆° (𝐹−𝐿1 )𝜆° (𝐿1 −𝐿2 )𝜆2 ∆𝑇1 ∗𝐴1 +𝐴2 ∆𝑇2 +∆𝑇3 𝐴3
𝐴1 = 𝑈 𝐴2 = 𝐴3 = 𝐴𝑎𝑣𝑒𝑟 =
1 ∆𝑇1 𝑈2 ∆𝑇2 𝑈3 ∆𝑇3 ∆𝑇𝑠𝑦𝑠
5. Tube pitch ∆Pt = 1.25 × do
6. Surface area of each tube a = doL

7. Number of tubes required Nt = A /a
8. Evaporator drum diameter D =√3∗𝐴

𝜋
9. v=π*(D^2/4)*1.5D
0.866∗𝑁𝑇 ∗𝑑2
10. area occupied by tube sheet = , 𝛽 = 0.9
𝛽
𝜋
11. Downcomer area = 0.5 ∗ (𝑁𝑇 ∗ ( ) ∗ 𝑑 2
4
4
12. Downcomer diameter =√
𝜋∗𝐴
13. Calculate tube pitch and the bundle diameter 𝑝𝑡 = 1.25 ∗ 𝑑.
𝑁𝑡 1
𝐷 = 𝑑.∗ ( )𝑁
𝐾
𝐿𝑒𝑛𝑔ℎ𝑡 𝑜𝑓 𝑡𝑢𝑏𝑒 1
14. Number of buffles = 𝐵 = 5 ∗ (𝐷)0.75
𝐵−1
15. The thickness calculations :

𝐷∗𝑃
𝑡𝑠 =
2∗𝑆𝑒+𝑃
𝑣
𝐴
16. The drum diameter 𝑅𝑑 = 𝜌𝐿−𝜌 , Rd =1.3
𝑉
0.0172∗√
𝜌𝑉
126
9.5.3 ASSUMPTIONS
The type of evaporator used is long –tube vertical –forced circulation the overall heat transfer
coefficient assumed to be .
𝑊
U1 = 1140 𝑚2 .𝑘
𝑊
U2=1160 𝑚2 .𝑘
𝑊
U3=930 𝑚2 .𝑘
 The three evaporators has the same area .

 The heat capacity values (CP) are equal( 1) for all liquid streams
So :
Q1=Q2 =Q3
A1=A2 =A3
𝜆1 = 𝜆2 = 𝜆3 = 𝜆
U1 A ∆𝑇1= U2 A ∆𝑇2
∆𝑇2 U1
=
∆𝑇1 U2
∆𝑇2 = 1.21∆𝑇1
127
9.5.4 DESIGN SUMMERY PF MULTI EFFECT EVAPORATOR
Table 32: DESIGN SUMMERY OF MULTI EFFECT EVAPORATOR
SPECIFICATION SHEET
IDENTIFICATIONS
Name of equipment Evaporator
Type Long – tube vertical evaporator
Function To concentrate the H3PO4 to 0.74 wt%
Number of units Three units
Evaporation capacity 200000 ton/year
Operation Continuous
Material handled Phosphoric acid solution
BASIC DESIGN DATA
Pressure 1 atm
Temperature range 31 ℃ – 120℃
Heat transfer area 255 m2
Density (kg/m3) 1424
HEATING SYSTEM DESIGN
Tube side design Shell side design
Fluid handled Seam Fluid handled H3PO4 solution
Mass flow rate (ton/day) 349 Mass flow rate (ton/day ) 1648
Boundle diameter (mm) 874 Pressure 1 atm

Temperature (℃) 120 Shell diameter(m) 6
Pressure (bar ) 1.84 Shell height (m) 9
Number of tubes 191 Shell thickness(mm) 10
Length of tube (m) 8.53 Head and bottom thicknes(mm) 10
Outside diameter (mm) 50 Buffle spacing(m) 1.2
Inside diameter (mm) 42 Number of buffles 11
Pitch (mm) 52.7 Drum diameter 2.39 m
Material of construction Grafite Stainless steel
Material of construction
128
9.6 STORAGE TANKS
9.6.1 INTRODUCTION
Storage tanks are necessary to store the required raw materials and products in the plant. Three
tanks were used. The raw material tanks are sulfuric acid and dilute phosphoric acid, and
phosphoric Storage tanks should be in a suitable environment with adequate containment provided.
9.6.2 DESIGN EQUATIONS
1. Total volume of tank

VTotal = (3.14 / (24*tanθ)) * (D3 – B3) +( 3.14 / 4) *D2 * H
Where:
Ө: Response angle in ֯
D3: Diameter of tank (m)
B3: Diameter of cone (m)
H: Hight of tank (m)
2. Dimensions of cone
Figure 50:Dimensions of the bottom cone.
1. h0 = (D/2)/ (tanθ)
where:
h0: Cone hight (m)
129
2. hB = (B/2)/(tanθ)
Where:
hB: bottom cone hight (m)
3. h = h0 – hB
3. Bulk density
ρb=ρp*(1-ɛ)
Where:
ρp: Particle density (kg/m3)
ɛ: Voidage
9.6.2 LIST OF ASSUMPTIONS
1. The angle of response of the cylindrical tank is 32֯

2. Hight of tank is 3 times dimension (H= 3D)
3. The tank is 90% filled of the total volume
4. Residence time of materials inside the tank is 3 days
130
9.6.3 DESIGN SUMMERY OF TANK (T-101)
IDENTIFICATION
Name of equipment Storage Tank
Item No. T-101
Equipment type Storage tank
Material of construction (MOC) Concrete
Function Storage of phosphate rock
Material Handled Phosphate rock
CONDITIONS
Temperature 25 c
Pressure 101.3 Kpa
Density of phosphate rock 1762 Kg/m3
Bulk density ρb 969.9 Kg/m3
Residence time 3 days
voidage 0.45
Mass Flow rate 1.48*106 Kg/day
DESIGN PARAMETERS
Volumetric capacity 5086.3 m3
Diameter 12.5 m
Height 37.5 m
Bottom cone diameter 0.35 m
Angle of response 32֯
Height of cone 10 m
Head type
131
9.7 TANK DESIGN (T-103)
Table 33: Design results summary for Tank Tk-103
H2SO4 Tank Data sheet
item Storage tank
Item.no T-103
No.required 4
Function Storage of Sulfuric acid at ambient conditions
MOC Carbon steel
type Storage tank
Material handled Sulfuric acid
Temperature 25 c Pressure(Kpa) 101.325
density 1830 kg/m3
3.4 * 105 kg/day

Flowrate
Density 1830 kg/m3
Resistance time 2 days
Volumetric capacity 186 m3/day
Material of construction Carbon steel
Diameter (m) 5
Length (m) 15
Wall thickness (mm) 5
Corrosion allowance (mm) 2
Head type Tori spherical head
Head thickness (mm) 4.7
Cost ($) 295680
132
9.8 TANK DESIGN (T-100)
9.8.1 PHOSPHORIC ACID STORAGE TANKS SPECIFICATION SHEET (T-100)

Identification
Item number T-100

Number required 4
Function Storage of phosphoric acid solution at ambient
temperature and 1 atm.
Type Cylindrical
Process Data
Material handled Dilute phosphoric acid
Molecular Weight (g/mol) 20
Operating temperature (℃) 25
Operating pressure (atm) 1

Density (kg/m3) 1200
Flow rate (kg/hr.) 30061
Residence time (day) 1
Volumetric capacity per tank 167
(m3)
Material of construction Carbon steel
Diameter (m) 6.5
Length (m) 19.5
Orientation Vertically mounted on concrete foundation
thickness (mm) 10
head Type Tori spherical
head thickness (mm) 9.5
133
9.9 MIXER DETAILED DESIGN(MX-100)
9.9.1 Design Equations
In the design of the mixer tank, many critical factors must be taken into account, which are:
1- The diameter of the tank (Dt).
2- The length of the tank (H).
3- The retention time (t).
4- Number of the baffles (N).
1-The diameter of the tank Dt

4𝑉
Dt (m) = (𝛱𝐻 )1/2
Where,
V: volume of the tank (m3)
H: length of the tank (m)
Π =3.14
2-The length of the tank H

4𝑉
H (m) =
𝛱𝐷𝑡 2
Where,
Dt: diameter of the tank (m)
Π= 3.14
134
3- The retention time
𝑉
t (s) = 𝑣
Where,
v: volumetric flow rate (m3/s).
9.9.2 ASSUMPTIONS FOR MIXER TANK DESIGN
1- Composition and temperature are uniform everywhere in the tank.
2- The effluent composition is the same as that in the tank.
3- The tank operates at steady state.
4- Detention time of chemical precipitation of chromium = 5 min (USACE)
5- The liquid depth equal the tank diameter H=Dt
135
9.9.3 AGITATOR DESIGN .
9.9.4 Assumptions :

1/3 1/3 1 1/5 1/12 ¼
Dt Diameter of vessel
H liquid height
J baffle width
E height of impeller above the vessel floor
W width of impeller blades
L length of impeller blades
136
9.9.5 SPECIFICATION SHEET OF MIXER WITH AGITATOR (MX-100)
Table 34: DESIGN SUMMERY OF MIXER (MX-100)
Identification
Item Mixer
Item no. MX-100
No. required 1
Function Mixing the acids with water
Type Cylindrical
Process data
Material handled H3PO4 , H2SO4 , H2O
Temperature (°C) 31
Pressure (atm) 1
Flow rate
Mass flow rate Kg/day 4307476.8
Volumetric flow rate m3/min 2.17
Size data
Retention time Min 3
3
Volumetric capacity m 6.51
Design specification
Material of --- ss-304
construction
Position --- Vertical tank
Tank volume m3 6.51
Diameter m 2.02
Liquid depth in the m 2.02
tank
Number of baffles --- 4
137
Identification
Equipment Impeller
Function Mixing reactants
No. required 1
Type Top Entry, turbine 6 Pitched Blades 45° with agitator
shaft
Location Mixer tank MX-100
Number of blades 6
Impeller diameter m 0.67
Height of impeller above vessel m 0.67
floor E
Length of impeller blade L m 0.167
Width of impeller W m 0.134
Baffle width m 0.16
Speed of impeller rpm 90
Gradient velocity s-1 366.8
Power required Watt 3014
9.10 PIPELINE SYSTEM:

9.10.1 INTRODUCTION:
In the phosphoric acid production plant, the pipeline system used to hold and transfer the flow
from equipment to another.
The material of construction of the pipes (MOC):
The cost, corrosion, capacity and type of flow are the main aspects of choosing the material of
construction of pipes in the phosphoric acid plant, to maintain the long life of these pipes and
provide more efficiency of the plant with less repairing cost.
Pipes such as PVC and PP are highlight recommended for using at phosphoric acid plant, since
they have a high reliability strength, smooth operation and maintenance process (Michael Schorr
Wiener, 2015).
So, the PVC type has chosen because it has high corrosion resistance to the raw material and
product that are found in our phosphoric acid plant, easy to clean, effective in phosphoric acid
plant and has lower cost. (Chemical Performance of PVC)
138
9.10.2 DETAILED EQUATION:
In the design of the pipeline system, many critical factors must be considered, such as:
(The procedures below are taken from (Plant Design and Economics) book section 12)
 the optimum diameter
- For turbulent flow:

Di = .363 (mv)^.45 (𝜌)^.13
- For viscous flow:
Di = .133 (mv)^.40 (𝜇).20
Where :
mv: volumetric flow rate of the fluid (m3/s)
𝜌 : the density of the fluid (Kg/m3)
𝜇 : the viscosity of the fluid (Kg/m.s)
 The Reynold number Re

Re= (1280 𝜌 mv)/( Di 𝜇)
 The area
A= 4 (Di)^2 /𝜋
 The velocity
v = mv/A
 Now, from table D-13 in (Plant Design and Economics), we found the thickness, NPS,
the OD and the ID
139
 From the figure below at sch. 40 and the different NPS , we found the safe working pres-
sure .
Figure 51 : Safe Working Pressure for PVC Pipes (the engineering toolbox, n.d.)
 Then the safe working stress is :
1000𝑃𝑠
Ss = (Peters M. S., Plant Design and Economics, 2003)
𝑆𝑐ℎ.
Where :
Ss: safe working stress (psi)

Ps : Safe working pressure (psi)
Sch. : schedule Number = 40
140
9.10.3 SPECIFICATION SHEET FOR PIPELINES:
Table 35: Design Results Summary for Pipe (L1).
Identification
Item No. L1
Equipment Type Pipeline
Material of Construction (MOC) PVC
Temperature 25 ˚C
Function Transport Flow from T-101 to V-100
Flow Rate m3/day 2795
Density Kg/m3 3257
Viscosity cP 7.5
Optimum Diameter (Di, opt) m 0.144

Optimum Diameter (Di) in. 5.661
Length m 8
Flow Area m2 .038
Velocity m/s .89
Reynolds Number 81059
NPS in. 6
Inner Diameter based on NPS (IN) in. 6.065
Outer Diameter based on NPS (OD) in. 6.625
Schedule Number 40
Thickness in. 0.313
Safe Working Stress Kpa 29303
Safe Working Pressure Kpa 1172
141
Identification
Item No. L2
Temperature 25 ˚C
Density Kg/m3 1132
Viscosity cP 1.17

Length m 8
Flow Area m2 0.042
Velocity m/s 1.16
NPS in. 8
Schedule Number 40
Thickness in. 0.358
142
Identification
Item No. L3
Temperature 25 ˚C
Function Transport Flow from V-100 to R-100
Flow Rate m3/day 1158.8
Density Kg/m3 1921.9
Viscosity cP 12.5

Length m 15
Flow Area m2 0.015
Velocity m/s .88
NPS in. 6
Schedule Number 40
Thickness in. 0.313
143
Identification
Item No. L4
Temperature 70˚C
Function Transport Flow from R-100 to V-101
Density Kg/m3 1.21
Viscosity cP .751

Length m 20
Flow Area m2 0.15
Velocity m/s 2.58
Reynolds Number 2300.1
NPS in. 6
Schedule Number 40
Thickness in. 0.313
144
Identification
Item No. L5
Temperature 70˚C
Function Transport Flow from R-100 to P-100
Viscosity cP 22

Length m 10
Flow Area m2 0.022
Velocity m/s .58
NPS in. 6
Schedule Number 40
Thickness in. 0.313
145
Identification
Item No. L9
Temperature 25˚C
Density Kg/m3 997
Viscosity cP .89

Length m 8
Flow Area m2 0.008
Velocity m/s .95
NPS in. 4
Schedule Number 40
Thickness in. 0.264
146
Identification
Item No. L11
Temperature 25˚C
Function Transport Flow from T-104 to F-100
Density Kg/m3 997
Viscosity cP .89

Length m 8
Flow Area m2 0.12
Velocity m/s 1.14
NPS in. 8
Schedule Number 40
Thickness in. 0.358
147
Identification
Item No. L12
Temperature 31˚C
Function Transport Flow from F-100 to P-101
Density Kg/m3 1424
Viscosity cP 2.1

Length m 12
Flow Area m2 0.015
Velocity m/s .96
NPS in. 6
Schedule Number 40
Thickness in. 0.313
148
Table 43:Design Results Summary for Pipe (L13).
Identification
Item No. L13
Temperature 31˚C
Function Transport Flow from F-100 to M-100
Density Kg/m3 1023
Viscosity cP 1.91

Length m 10
Flow Area m2 0.0023
Velocity m/s .85
NPS in. 2
Schedule Number 40
Thickness in. 0.173
149
Identification
Item No. L14
Temperature 70˚C
Function Transport Flow from P-100 to F-100
Viscosity cP 22

Length m 10
Flow Area m2 0.022
Velocity m/s .58
NPS in. 6
Schedule Number 40
Thickness in. 0.313
150
Identification
Item No. L15
Temperature 31˚C
Function Transport Flow from M-100 to R-100
Density Kg/m3 1894
Viscosity cP 50

Length m 10
Flow Area m2 .014
Velocity m/s .85
NPS in. 4
Schedule Number 40
Thickness in. 0.264
151
Identification
Item No. L16
Temperature 25˚C
Function Transport Flow from T-103 to M-100
Density Kg/m3 1852
Viscosity cP 15

Length m 8
Flow Area m2 .011
Velocity m/s .85
NPS in. 6
Schedule Number 40
Thickness in. 0.313
152
Identification
Item No. L17
Temperature 31˚C
Function Transport Flow from P-101 to E-100
Density Kg/m3 1424
Viscosity cP 2.1

Length m 12
Flow Area m2 0.015
Velocity m/s .96
NPS in. 6
Schedule Number 40
Thickness in. 0.313
153
Identification
Item No. L18
Temperature 108˚C
Function Transport Flow from E-100 to E-101
Density Kg/m3 941.1
Viscosity cP .36

Length m 4
Flow Area m2 .004
Velocity m/s .91
NPS in. 2
Schedule Number 40
Thickness in. 0.173
154
Identification
Item No. L19
Temperature 108˚C
Density Kg/m3 1678
Viscosity cP 11.16

Length m 4
Flow Area m2 .01
Velocity m/s .86
NPS in. 4
Schedule Number 40
Thickness in. 0.264
155
Identification
Item No. L20
Temperature 80˚C
Density Kg/m3 964.4
Viscosity cP .35

Length m 4
Flow Area m2 .003
Velocity m/s .9
NPS in. 2
Schedule Number 40
Thickness in. 0.173
156
Table 51:Design Results Summary for Pipe (L21).
Identification
Item No. L21
Temperature 80˚C
Density Kg/m3 2143
Viscosity cP 44

Length m 4
Flow Area m2 .006
Velocity m/s .77
NPS in. 3
Schedule Number 40
Thickness in. 0.242
157
Identification
Item No. L22
Temperature 50˚C
Function Transport Flow from E-102 to vacuum pump
Density Kg/m3 988.4
Viscosity cP .53

Length M 6
Flow Area m2 .003
Velocity m/s .9
NPS in. 2
Schedule Number 40
Thickness in. 0.173
158
10. ECONOMIC ANALYSIS AND EVALUATION
10.1 COST OF EQUIPMENT
Table 53: Summary of The Equipment cost in Dollars,$.
Identification
Name of Equipment Miler
Item No. V-100
Equipment Type Ball miller
Material of Construction (MOC) Carbon steel
Function To reduce size of feed phosphate rock
Cost = 206200$
Identification
Name of Equipment Reactor
Item No. R-100
Equipment Type CSTR
Material of Construction (MOC) Carbon steel with rubber
Function To mix streams (3)phosphate rock and

(15)sulfuric acid to produce phosphoric acid and
gypsum
Cost = 1080000$
Identification
Name of Equipment Filter
159
Item No. F-100
Equipment Type Horizontal vacuum belt
Function To separate solids from slurry feed.
Cost = 358788$
Identification
Name of Equipment Evaporator
Item No. E-100, E-101, E-102
Equipment Type Vertical forced circulation
Function Concentration unit
Cost = 4810000$
Identification
Name of Equipment Mixer tank
Item No. MX-100
Equipment Type VESSEL
Function To mix sulfuric acid with water and dilute

phosphoric acid
Cost = 16500$
160
Identification
Name of Equipment Absorber
Item No. V-101
Equipment Type Packed bed vertical column
Material of Construction (MOC) Carbon steel with rubber line
Function To recovery H2SiF6 gas with water
Cost = $180,000
Identification
Name of Equipment Dilute phosphoric acid storage tank
Item No. T-100
Equipment Type Vertical cylindrical tank
Function To storage phosphoric acid solution
Cost = $268,800
Identification
Name of Equipment Phosphate rock storage tank
Item No. T-101
Equipment Type Storage tank
Material of Construction (MOC) Concrete
Function To storage phosphate rock
161
Cost = 87550$
Identification
Item No. P-100
Equipment Type Reciprocating pump
Function To pump the flow from reactor to filter
Cost = $12510
Identification
Name of Equipment Sulfuric acid storage Tank
Item No. T-103
Equipment Type Vertical storage tank
Function To storage sulfuric acid
Cost = $ 295680
Identification
Item No. P-101
Equipment Type Centrifugal pump
162
Function To pump the flow from filter to evaporator
Cost = $ 11530
Total purchased equipment costs sum up to about $7,356843; this value will be used in the
successive sections to estimate the total investment cost of the plant.
163
10.2 ESTIMATION OF CAPITAL INVESTMENT BY PERCENTAGE OF
DELIVERED EQUIPMENT METHOD
Estimating by percentage of delivered-equipment cost is commonly used for preliminary and

study estimates. This method provides an accuracy in the ±20 to 30 percent range. The
estimation procedure is presented in table below. (Max S. Peters, 2003)
Table 54: Ratio factors and calculations for estimating capital investment items based
Fraction of delivered equipment

Solid fluid fluid Calculated
Solid- processing Fluid
Project Identifier: processing values,
processing plant processing
plant million $
plant plant
Direct Costs
Purchased equipment, E' 7.4
Delivery, fraction of E' 0.10 0.10 0.10 0.10 0.74
Subtotal: delivered equipment
8.14
Purchased equipment 0.45 0.39 0.47 0.39
3.17
installation
Instrumentation 0.18 0.26 0.36 0.26
2.11
&Controls(installed)
Piping (installed) 0.16 0.31 0.68 0.31 2.52
Electrical systems (installed) 0.10 0.10 0.11 0.10 0.81
Buildings (including services) 0.25 0.29 0.18 0.29 2.36
Yard improvements 0.15 0.12 0.10 0.12 0.97
Service facilities (installed) 0.40 0.55 0.70 0.55 4.47
Total direct costs 1.69 2.02 2.60 2.02 24.5
Indirect Costs
Engineering and supervision 0.33 0.32 0.33 0.32 2.60
Construction expenses 0.39 0.34 0.41 0.34 2.76
Legal expenses 0.04 0.04 0.04 0.04 0.32
Contractor's fee 0.17 0.19 0.22 0.19 1.54
Contingency 0.35 0.37 0.44 0.37 3.01
Total indirect costs 1.28 1.26 1.44 1.26 10.2
Fixed capital investment (FCI) 34.8

Working capital (WC) 0.70 0.75 0.89 0.75 6.10
Total capital investment (TCI) 40.1
164
1. Estimation of Annual Total Product Cost
Table 55: Annual cost of raw material in million$/yr.
Raw Materials
Name of Material Price, Annual Amount, Annual raw materi-

$/kg million kg/y als cost, million
$/y
Phosphate Rock 0.082 442.5 36.2

Sulfuric Acid industrial& fertilizer
grade 0.083 410.62 34.7
Total annual cost of raw materials = 70.63
Table 56: Annual operating labor cost.
Operating Labor
Number of operators per shift Shifts per day Operator rate, Annual operat-
$/h # ing labor cost,
million $/y
4.65 3 3 0.122
To obtain current, local value of the annual operating cost:

ENR skilled labor index for the value in the table is 6067
ENR skilled labor index for 2021 is 10786.7
Cost Index = ENR CCI In 2021/ ENR CCI In table = 10786.7/6067 = 1.78
Current local value of annual operating cost = 0.101 M$/yr * 1.78 = 0.179 M$/yr
165
Table 57: Calculations of total utilities cost.
Default unit
Annual utility Default Annual
Default
requirement, units of util- utility
cost
Utility cost
in appropriate ity require- cost, mil-
units
units ment lion $/y
Air, compressed
Process air 0.45 $/100m3 # 100 m3#/y
Instrument air 0.90 $/100m3 # 100 m3#/y
Electricity
Purchased, U.S. aver- 4.704
1.400 $/kWh kWh/y
age 3360000
Self-generated 0.05 $/kWh kWh/y
Fuel
Coal 1.66 $/GJ GJ/y
Fuel oil 3.30 $/GJ 370000 GJ/y 1.221
Natural gas 3.00 $/GJ GJ/y
Manufactured gas 12.00 $/GJ GJ/y
Waste water
Disposal 0.53 $/m3 m3/y
Treatment 0.53 $/m 3
m3/y
Water
Cooling 0.08 $/ m3 m3/y
Process
General 0.53 $/m3 520000 m3/y 0.276
Distilled 0.90 $/m 3 3
m /y
166
Table 58: Annual Total Product Cost.
Capacity 200 106 kg per year

Fixed Capital Investment, FCI 35.790 million $
Item Default factor, user may Basis Basis Cost, million

change cost, $/y
million
$/y
Raw materials 70.365

Operating labor 0.101
Operating supervision 0.15 of operating labor 0.101 0.015
Utilities 6.201
Maintenance and repairs 0.06 of FCI 35.790 2.147
Operating supplies 0.15 of maintenance & repair 2.147 0.322
Laboratory charges 0.15 of operating labor 0.101 0.015
Royalties (if not on lump-sum ba- 0.01 of co 91.168 0.912
sis)
Catalysts and solvents 0 -- 0.000
Variable cost = 80.078
Taxes (property) 0.02 of FCI 35.790 0.716
Financing (interest) 0 of FCI 35.790 0.000
Insurance 0.01 of FCI 35.790 0.358
Rent 0 of FCI 35.790 0.000
Depreciation Calculated
separately
Fixed Charges = 1.074
Plant overhead, general 0.6 of labor, supervision and 2.264 1.358
maintenance
Plant Overhead = 1.358
Manufacturing cost = 82.510
167
Administration 0.2 of labor, supervision and 2.264 0.453
maintenance
Distribution & selling 0.05 of co 91.168 4.558
Research & Development 0.04 of co 91.168 3.647
General Expense = 8.658
TOTAL PRODUCT COST WITHOUT DEPRECIATION = co = 91.168
Products, Coproducts and Byproducts

Name of Price, Annual Annual value of product, million $/y
Material $/kg Amount,
million
kg/y
phosphoric 0.7 200 320.00

acid
Total annual value of products = 320.00
 The depreciation constants depend on MACRS method :

Recovery period YEAR
1 2 3 4 5 6 7 8 9 10
3-year 0.33 0.44 0.15 0.07
6- year 0.2 0.32 0.19 0.12 0.12 0.06
7-year 0.14 0.24 0.17 0.12 0.09 0.09 0.09 0.04
10-year 0.1 0.18 0.14 0.12 0.09 0.07 0.07 0.07 0.07 0.07
15-year 0.05 0.1 0.09 0.08 0.07 0.06 0.06 0.06 0.06 0.06
20-year 0.04 0.07 0.07 0.06 0.06 0.05 0.05 0.05 0.04 0.04
168
10.3 EVALUATION REVENUE
 the following factors took in accounts

Construction inflation rate, fraction/y = 0.02
Product price inflation rate, fraction/y = 0
TPC inflation rate, fraction/y = 0.02
Annual-compounding discount rate, fraction/y = 0.15

minimum acceptable rate of return, mar =
Continuous-compounding discount rate, 0.14

fraction/y = minimum acceptable rate of return,
rma=
169
Table 59: evaluation summery
Factors Results
Total Capital Investment, 106$ -43.06
Fixed Capital Investment, 106$ -35.79
Annual sales, 106$ 1222
Annual Total Product Cost, depreciation

-997.9
not included,106$
Annual depreciation, 106 $/y 35.79
Annual Gross Profit, 106$ 184
Annual operating cash flow,106$ -155

-112
Total annual cash flow, 106$
27.9
.Return on investment, ave. %/y
Payback period, y 2.3

Net return, 106$ 5.5
Net present worth, 106$ 34.09
 this study done by taking study period from -3 to 10 years .
170
11. HAZARD AND OPERABILITY STUDY (HAZOP)
11.1 Introduction
HAZOP study is the study of hazard and operability in a systematic technique for identifying
all plant or equipment hazards and operability problems that may represent risks to
personnel or equipment, that each segment (pipeline, piece of equipment, instrument, etc)
is carefully examined, and all possible deviations from normal operating conditions are
identified.
A standard list of seven guide words is used: No, More, Less, As Well As, Part Of,
Reverse, and Other Than. Some practitioners add Early, Late, Before and After,
although other practitioners consider these as variants of Other Than. The HAZOP
study team chooses appropriate parameters for each node, for example, flow, pressure,
temperature, composition, level, addition, cooling, etc. The use of guide words with
parameters provides the opportunity, at least in principle, to explore deviations from
design intent in every conceivable way, thus helping to ensure completeness of
scenario identification.
For processes plant, each of meaningful design intent can be specified and they are
commonly indicated on piping and instrumentation diagram (P&IDs) and process flow
diagram (PFD).
It is necessary to use proper guidewords in HAZOP for each line and each node. The following is
an example of some guide words that are commonly used:
171
Table 60:HAZOP guide word
GUIDE WORD MEANING
NO OR NOT Complete negation of the design intent
MORE Quantitative increase
LESS Quantitative decrease
AS WELL AS Qualitative modification/increase
PART OF Qualitative modification/decrease
REVERSE Logical opposite of the design intent
OTHER THAN/ Complete substitution
INSTEAD
EARLY Relative to the clock time
LATE Relative to the clock time
BEFORE Relating to order or sequence
AFTER Relating to order or sequence
172
11.2 PIPING & INSTRUMENTATION DIAGRAM FOR REACTOR R-100
PT PC
FT FC
FCV-8
FCV-5
Sulfuric acid
FT FC
LT LC
FCV-6
phosphate FC FT
FCV-7
FC FT Fcv-9
TC TT
Figure 52: PID diagram for Reactor (R-100)
173
Table 61: Hazop study for the reactor
Deviation
Process s (Guide Possible causes Possible consequences Action Required
Parameters
Words )
• Feed flowrate is too

high in recycle stream
due to problems with  Increase viscosity of
FCV-7 or product
corresponding control • Instruct operators and update
low
valves  low conversion, low procedures
of
• Controller fails and product production.
Temperature open valve
• Pressure buildup inside

reactor,
•Controller fails and 0product quality affected. • Install high temperature alarm
High recycle stream valve to alert operator.
closed  Reaction rate af-
fected
• Overpressure in reactor,
would lead to an explosion.
• Inlet v-4 valve

partially closed or
blocked • Low conversion
• Undesired products
low • Install level control
 Rupture in  No reaction takes
Inlet rate line place inside the reac-
 H2SO4 valve tor
Flow FCV-5
closed
• Inlet valve fully •Change in product quality •Install level control
opened
High • Excess Phosphoric acid • Emergency relief valve
degrades product. No Hazard
• Control valve failure to work area
•relief valve FCV-8

close or broken • Use pressure indicator with
High • Explosion
alarming system.
•PC failure
Pressure
•relief valve FCV-8

open or broken • Use pressure indicator with
Low •No reaction
alarming system.
•PC failure
174
12.CONCLUSIOS
 By conducting a preliminary design for the manufacturing of Phosphoric acid was con-
cluded that the importance of a H3PO4 plant was related mainly to the phosphate rock .
 were the key factor that controlled the equipment design parameters.
 Teamwork was an important factor; we would have not finished the project in a time without
a group effort.
 This project presents the design of Phosphoric acid plant where located in ma'an city.
 This project done through several mass and energy balances as well as mechanical design
for the capacity required produce 200,000 ton/year of H3PO4
 The output product concentration about 0.74 H3PO4 and the rest water .
 HAZOP study makes demonstration of the controller system and hazard around the reactor
unit .
 Phosphoric acid mainly used in the fertilizer , food , cosmetics and many other industries .
 The total capital investment about 43 million dollars , and 2.3 years payback period .
 For the manufacturing of phosphoric acid, the wet process was chosen.
175
13.RECOMMENDATIONS
 Keeping the number of incidences and accidents zero.
 Having a robust and dynamic safety program.
 Major Hazard is Fire and it want development detection sensors.
 Regular training and drill of the employees and workers.
176
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181
APPENDIX A: PHYSICAL AND CHEMICAL PROPERTIES OF
MATERIALS
Table 62: Properties of the materials

Components 𝑲𝑱 Density 𝑲𝑱 𝒈 𝑻𝑩𝒐𝒊𝒍𝒊𝒏𝒈 (℃)
𝑪𝑷 ( ) 𝒈 ∆𝑯𝒇(𝟐𝟗𝟖𝒌) ( ) 𝑴𝑾(𝒎𝒐𝒍𝒆 )
𝒎𝒐𝒍𝒆. 𝒌 ( 𝟑 ) 𝒎𝒐𝒍𝒆
𝒄𝒎
Ca3(PO)2 0.18197 3.36 -4138 310.18 -------
CaF2 0.0666 3.18 -1225.91 78.7 2533
SiO2 0.0447 2.65 -851 60.08 2230
H2 O 0.0754 0.997 -285 18.015 100
H3PO4 0.14065 1.88 -1281.1 97.994 158
N2 0.0291 0.00125 0 28.013 -195.8
H2SO4 0.2542 1.83 -811.32 98.079 337
CaSO4 0.0993 2.32 -1432.7 136.14 --------
CaSO4.2H2O 0.0993822 2.96 -2021 172.17 163
HF 2.2*10-5 0.99 -272.55 20.01 19.5
(NIST Chemistry
WebBook, 2018)
H2SiF6 0.036749 1.22 -262.96 144.091 163

(Nutrien,
2015)
O2 0.0259 0.001429 0 15.99 -183
Table 63: Properties of Phosphoric acid
Chemical and Physical Properties

Molecular weight 97.994 g/mole
Chemical name Ortho-phosphoric acid
Molecular Formula H3PO4
Common name Phosphoric acid
Vapor pressure (20C) 2.2 mm Hg
Boling point 158C
Critical Temperature 623K
Density (25C) 1.885 g/ml(liquid)
Appearance Clear,color less ,odorless, liquid
Oxidation state +5
182
Table 64: Conditions of streams
Temperature Pressure
Streams number
°C (atm)
L1 25 1
L2 25 1
L3 25 1
L4 70 1
L5 70 1
L6 25 1
L7 53.71 4
L8 53.71 4
L9 25 1
L10 70 4
L11 25 1
L12 72 1
L13 72 1
L14 70 6
L15 31 1
L16 25 1
L17 72 2
L18 106 1.81(bar)
L19 106 1.81(bar)
L20 90 1.27(bar)
L21 90 1.27(bar)
L22 80 0.7(bar)
L23 80 0.7(bar)
L24 66.5 1
L25 120 2
L26 25 1
183
APPENDIX B: MATERIAL BALANCE
Sample of calculations
1.material balance
The general material balance used in all following calculations is:
Input + generation - output – consumption = accumulation


*Basis of mass balance : production of H3PO4 = 2 * 10^5 tonne /year= 666666.6 kg

666666.6𝑘𝑔 𝑘𝑚𝑜𝑙𝑒
/day = ∗ = 6803.13 kmole/day
𝑑𝑎𝑦 97.994𝑘𝑔
Assumptions:
>>Yield of the desired product H3PO4 = 95%
>>Excess of Sulfuric Acid ( H2SO4 ) = 15 %
>> 1.5% of Sulfuric acid go with gypsum to make it easily filterable
>> steady state, accumulation =0
>> Concentration of H2SO4 = 94%
Ground rock wt% mole%
Ca3(PO4)2 ===> 75 42
CaF2 ===> 20 44
SiO2 ===> 5 14
from yield:
𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 (𝐻3𝑃𝑂4)
Yield( based on feed) = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑙𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑓𝑒𝑒𝑑 (𝑖𝑛𝑝𝑢𝑡 )(𝐶𝑎3𝑃𝑂4)
6803.13
 0.95 =𝑓𝑒𝑒𝑑(𝐶𝑎3𝑃𝑂4)  feed Ca3PO4 (input) steam (1) = 7161.19kg mole /day = 92498.79
kg/hr
184
7161.19(𝑓𝑒𝑒𝑑 𝑐𝑎3𝑝𝑜4)
To find molar flowrate of feed stream (1): =17050.46
.42 (𝑚𝑜𝑙𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛(𝐶𝑎3(𝑃𝑂4)2)
kgmole/day
Feed stream (1) in kg /hr = 123331.72kg/hr
1.Material balance on mill
1 3
V-100
stream 2
Dilute H3PO4
contains :
15 wt % 3 mol % H3PO4
85 wt % 97 mol % H2O
50 𝑘𝑔 𝐻3𝑝𝑜4
 dilute H3PO4 stream (2) = 100 𝑘𝑔 𝑝ℎ𝑜𝑠𝑝ℎ𝑎𝑡𝑒 𝑟𝑜𝑐𝑘 * 123331.72(mass flowrate of stream (1)
= 61665.86 kg/hr
H2O in stream (2) = wt % * feed stream (2) = .85 * 61665.86= 52415.981 kg/hr=
69828.69 kmole/day
 H3PO4 in stream (2) = wt % * feed stream (2) = .15 * 61665.86 = 9249.879 kg/hr
=2265.41 kmole day
Stream 1
185
Phosphate Rock
 CaF2(input) in stream ((1)= mole fraction of (CaF2)* molar flowrate of feed stream (1) =
.44 * 17050.46 = 7502.2024 kmole / day
SiO2(input) in stream (1) =mole fraction of (SiO2)* molar flowrate of feed stream (1) =
.14 * 17050.46 =2387.0644 kmole /day
*stream (1)
input Ca3(PO4)2: 7161.19kmole/day
Input CaF2: 7502.2024 kmole / day
Input SiO2: 2387.0644 kmole /day
Stream 3
Ca3(PO4)2
Input +generation-output-consumption=accumulation
: 7161.19kmole/day (in stream 1) + 0 – output – 0 = 0
Output Ca3(PO4)2 = 7161.19kmole/day

CaF2
Input+ generation- output- consumption=accumulation
7502.2024 kmole / day (in stream 1) + 0 – output – 0=0
Output CaF2 = 7502.2024 kmole / day
SiO2
2387.0644 kmole /day (in stream 1) + 0 –output -0 = 0
Output SiO2 =2387.0644 kmole /dayy
H3PO4

186
2265.41 kmole day (in stream 2) + 0 – output – 0=0
Output H3PO4 = 2265.41 kmole day
H2 O

69828.69 kmole/day (in stream 2) + 0 –output -0 = 0
Output H2O = 69828.69 kmole/day
2.Material balance on R-100 (Reactor)
15
R-100
6
Main reaction:
Ca3PO4 + 3H2SO4 + 6H2O --------> 2H3PO4 + 3(CaSO4.2H2O) ……. (1)
Side reactions: we choose these side reactions because we assume Ground rock contains only
three main impurities (Ca3(PO4)2, CaF2, SiO2)
CaF2 + H2SO4 --------> 2HF + CaSO4 ……. (2)
187
6HF + SiO2 --------> H2SiF6 + 2H2O ……... (3)
From reaction (1):

 Ca3(PO4)2 6803.13 kmole/day
6803.13 𝑘𝑚𝑜𝑙𝑒 (𝐻3𝑃𝑂4) 1 𝑘𝑚𝑜𝑙𝑒 𝐶𝑎3𝑃𝑂4
Ca3(PO4)2 reacted( consumption) = ∗ = 3401.565 kmole /day
𝑑𝑎𝑦 2 𝑘𝑚𝑜𝑙𝑒 𝐻3𝑃𝑂4
H2SO4
6803.13 (𝐻3𝑝𝑜4 ) 3 𝑘𝑚𝑜𝑙𝑒 𝐻2𝑠𝑜4
H2SO4 reacted = ∗ 2𝑘𝑚𝑜𝑙𝑒 𝐻3𝑝𝑜4 = 10204.695 kmole /day
𝑑𝑎𝑦
H2 O
6803.13 (𝐻3𝑝𝑜4 ) 6 𝑘𝑚𝑜𝑙𝑒 𝐻2𝑜
Reacted( consumption ) of H2O = ∗ 2𝑘𝑚𝑜𝑙𝑒 𝐻3𝑝𝑜4 =20409.39 kmole/day
𝑑𝑎𝑦
CaSO4.2H2O
10.20 (𝐻3𝑝𝑜4 ) 3 𝑘𝑚𝑜𝑙𝑒 CaSO4.2H2O
CaSO4.2H2O reacted = ∗ = 10204.695kmole/day
𝑑𝑎𝑦 2𝑘𝑚𝑜𝑙𝑒 𝐻3𝑝𝑜4
From reaction 2
CaF2:
Input + generation = output + consumption
7502.2024kgmole / day(in stream 1) + 0 = 0 + consumption

Input = reacted( consumption )
188
Reacted CaF2 = 7502.2024kgmole/day
H2SO4
7502.2024 𝑘𝑚𝑜𝑙𝑒(𝐶𝑎𝑓2 ) 1 𝑘𝑚𝑜𝑙𝑒 ℎ2𝑠𝑜4
Reacted H2SO4 = ∗ = 7502.2024 kmole/day
𝑑𝑎𝑦 1 𝑘𝑚𝑜𝑙𝑒 𝐶𝑎𝑓2
HF
7502.2024 𝑘𝑚𝑜𝑙𝑒(𝐶𝑎𝑓2 ) 2 𝑘𝑚𝑜𝑙𝑒 𝐻𝐹
Generation HF = ∗ 1 𝑘𝑚𝑜𝑙𝑒 𝐶𝑎𝑓2 = 15004.4048 kmole/day
𝑑𝑎𝑦
CaSO4
7502.2024𝑘𝑚𝑜𝑙𝑒(𝐶𝑎𝑓2 ) 1𝑘𝑚𝑜𝑙𝑒 𝐶𝑎𝑆𝑂4
 Generation CaSO4 = = ∗ = 7502.2024 kmole/day
𝑑𝑎𝑦 1 𝑘𝑚𝑜𝑙𝑒 𝐶𝑎𝑓2
From Reaction (3)

SiO2
2387.0644 kmole /dayy + 0 = 0 + consumption
Consumption SiO2 =2387.0644 kmole /day

HF
2387.0644𝑘𝑚𝑜𝑙𝑒(𝑠𝑖𝑜2 ) 6𝑘𝑚𝑜𝑙𝑒 𝐻𝐹
Reacted HF == ∗ 1 𝑘𝑚𝑜𝑙𝑒 =14322.3864 kmole/day
𝑑𝑎𝑦 𝑠𝑖𝑜2
H2SiF6
2387.0644 𝑘𝑚𝑜𝑙𝑒(𝑠𝑖𝑜2 ) 1𝑘𝑚𝑜𝑙𝑒 𝐻2𝑆𝐼𝐹6
Generation H2SiF6 = ∗ = 2387.0644 kmole/day
𝑑𝑎𝑦 1 𝑘𝑚𝑜𝑙𝑒 𝑠𝑖𝑜2
H2 O
189
2387.0644 𝑘𝑚𝑜𝑙𝑒(𝑠𝑖𝑜2 ) 2𝑘𝑚𝑜𝑙𝑒 𝐻2𝑜
Generation H2O = ∗ 1 𝑘𝑚𝑜𝑙𝑒 = 4774.1288 kmole/day
𝑑𝑎𝑦 𝑠𝑖𝑜2
*stream (15)(Recycle stream )

𝑖𝑛𝑝𝑢𝑡−𝑡ℎ𝑒𝑟𝑜𝑖𝑡𝑖𝑐𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑖𝑛𝑝𝑢𝑡−𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛
Excess H2SO4 = 15% , excess = =
𝑡ℎ𝑒𝑟𝑜𝑖𝑡𝑖𝑐𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛
Consumption(reacted) H2SO4 =reacted H2SO4 from reaction (1) + reacted H2SO4 from reaction (2)
= 10204.695 kmole/day + 7502.2024 kmole /day = 17706.8974 kmole /day
𝑖𝑛𝑝𝑢𝑡−17706.8974
15%= , input H2SO4 in stream (15) = 20362.93201 kmole/day = 83215.667 kg/hr
17706.8974
𝐻2𝑠𝑜4 𝑖𝑛 𝑠𝑡𝑟𝑒𝑎𝑚 15 83215.667

mass flowrate of stream (15) = 𝑐𝑜𝑛𝑐𝑒𝑛𝑟𝑡𝑎𝑡𝑖𝑜𝑛 𝐻3𝑃𝑂4 = = 88527.30 kg/hr= 151129 kmole/day
.94
Input H2O is stream 15 = 151129 * .06 = 7.964 kg/hr = 3096.559067.79 kmole/day

*Stream (5)
Ca3(PO4)2

7161.19kmole/day(in stream 3) + 0 = output + 3401.565 kmole/day
Output(Ca3(PO4)2 = 3759.625 kmole/day
H2SO4

20362.93201 kmole/day ( in stream 15 ) + 0 = output + 17706.8974
Output of H2SO4 in stream 5 = 2655.395801 kmole/day
H2 O
190
Input in stream (15) +generation in reaction (3) = output in stream (5) + consumption in reaction (1)
(9067.79+ 69828.69 kmole/day) + 4774.1288 kmole/day = output H2O in stream (5) + 20409.39
kmole/day
output H2O in = 63261.2188 kmole/day ,

Assume .45% From H2O is vaporized
output H2O in stream 15 = 63261.2188 kmole/day – (.45 *63261.2188)= 34793.67 kmole/day
CaSO2.2H2O
0 + 10204.695 kmole/day = output + 0
output CaSO2.2H2O = 10204.695
CaSO4
0 + 7502.2024 kmole/day = output + 0
output CaSO4 = 7502.2024 kmole/day
H3PO4
2265.41 kmole/day (stream 3) + 6803.13 kmole/day = 9068.54 kmole /day (output H3PO4)
*Stream 4
H2[SiF6]
0 + 2387.0644 kmole/day = output + 0
Output H2[SiF6] =2387.0644 kmole/day
191
HF
0 + 15004.4048 kmole/day = output + 14322.3864

Output HF = 682.0184 kmole/day
H2 O
.45 *63261.2188)= = 28467.54 kmole/day
14
P-101 A/B
Input = output
Mole flowrate of stream (5)= Mole flowrate of stream (14)
Note stream 5 ( output from Reactor ) = stream 14( is pumped output of reactor )
3-Material balance on F-100 (filter)
192
11
14 24
F-100
13 12
*Stream (14)
Ca3(PO4)2

10.74 kmole/day(in stream 3) + 0 = output + 5.1 kmole/day
Output(Ca3(PO4)2 = 10.74 – 5.1 = 5.64 kmole/day
H2SO4

30.5325(in stream 14 ) + 0 = output + 26.55
Output of H2SO4 in stream 2 = 3.9825 kmole/day
H2 O
Input in stream (14) +generation in reaction (3) = output in stream (5) + consumption in reaction (1)
193
(104.3+10.609 kmole/day) + 7.1596 kmole/day = output H2O in stream (5) + 30.6 kmole/day
output H2O in = 91.4686 kmole/day ,

Assume .45% From H2O is vaporized
output H2O in stream 5 = 91.4686 kmole/day – (.45 *91.4686)= 50.30773 kmole/day
CaSO2.2H2O
0 + 15.3 kmole/day = output + 0
output CaSO2.2H2O = 15.3
CaSO4
0 + 11.25 kmole/day = output + 0
output CaSO4 = 11.25 kmole/day
H3PO4
3.39 kmole/day( stream 3) + 10.20 kmole/day = 13.59 kmole /day (output H3PO4)
In stream (12)
Note :The concentration of H3PO4 40%(wt%) , H2O 60% (wt%)
H3PO4
Flowrate H3PO4 in stream 12 = 10.20 kmole/day= 41.64 kg/hr
41.64
Stream 12 = = 104.1 kg/hr =94 kmole/day
.4
H2 O
flow rate of H2O in stream 12= 104.1-41.64= 62.46 kg/hr = 83.209 kmole/day
194
Stream (13) recycle stream from filter
Note :excess sulfuric acid 1.5%
H2SO4
𝟏.𝟓
= * 3.9825(H2SO4in stream 14) kmole/day = .05973kmole/day (H2SO4 in stream 24 )
𝟏𝟎𝟎
H2SO4 in stream (13) = 3.9825(in stream 14) - .05973(in stream 24) = 3.9227 kmole/day= 16.03
kg/hr
𝐻2𝑆𝑂4 𝑖𝑛 𝑠𝑡𝑟𝑒𝑎𝑚 (13) 16.03
Flowrate stream 13 = = =17.05 kg/hr =5 kmole/day
𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑎𝑟𝑡𝑖𝑜𝑛 𝑜𝑓 𝐻2𝑠𝑜4 .94
H2 O
H2O in stream 13 = flowrate in stream 13 - H2SO4 in stream (13) = 17.05 – 16.03 = 1.02 kg/hr =
1.358 kmole/day
Stream 24
H2SO4
1.5
= 100 * 3.9825(H2SO4in stream 14) kmole/day = .05973kmole/day
H2 O
𝟏.𝟓
=𝟏𝟎𝟎 * 50.30773 (H2O in stream 14) kmole/day = .7546 kmole/day
Ca3(PO4)2
Input+generation-output-consumption=accumulation
5.64 kmole/day (in stream 14) + 0 – output – 0=0
Output = 5.64 kmole/day
195
CaSO4.2H2O
15.3 kmole/day (in stream 14 ) + 0 – output – 0 =0
Output in stream 24 = 15.3 kmole/day
CaSO4
Output in stream 24= 11.25 kmole/day
H3PO4
Output in stream 24 = 3.39 kmole/day
Stream 11
wash water = H2O in stream (13)+ In stream (12) + in stream (24) –in stream 14
= 1.358 kmole/day + 83.209 kmole/day + .7546 kmole/day–50.30773 kmole/day=35
kmole/day
10
P-100 A/B
Input = output
196
Note stream 4( output from Reactor ) = stream 10( is pumped output of reactor )
4-Material balance on absorber
8 9
V-101
10 7
(yn+1) −𝑦1
RecoveryH2SIF6 = 99% , Recovery = (𝑦𝑛+1
y1 (H2SIF6)(in stream 8)= yn+1 (in stream10) (1-Recovery)

yn+1 = 0.024663634 = .025
y1= .025 (1-.99 ) =
Y1= .00025
Input = output
197
Lx+ vn+1yn+1 = Lnxn + v1y1
Assumption ( L = Ln ) , (v1 = vn+1 )

R=L/V
𝑃𝑣 𝑃𝑣
X1= 0 , Rault law  yH2SIF6 = * xH2SIF6 , m = , pv= 418 mmHg , PT = 760 mmHg
𝑃 𝑃
418
m= = .55
760
𝑦(𝑛+1)−𝑦1 𝑦𝑛+1 .025
L(x – xn ) = v( y1 – yn+1)  L/V = , x n= = = .045
𝑥𝑛 𝑚 .55
.025−.00025
L/V(min) = = .55
.045
R = 1.5 R(min)
R= .825
V (stream 10 ) = 145.14487 kmole /day , L(H2O in stream 9 ) = R * V = 118.547073 kmole/day
Stream 7
H2 O
= H2O in stream (9 ) + H2O in stream ( 10 )
= 118.547073 + 41.16087
= 159.707943 kmol/day
H2SiF6
= Recovery * H2sSiF6 (in stream 10 )
= .99 * 3.5798
= 3.544002 kmole/day
Stream 8
198
H2SiF6
= H2SiF6 (in stream 10 ) – H2SiF6 in stream ( 7 )

= 3.5798 - 3.544002 = 0.035798 kmole /day
HF
Input = output
1.2242 ( stream 10 ) = output in stream 8
HF in stream 8 = 1.2242 kmole/day
O2
Input = output
31.5 ( stream 10) = output in stream 8
O2 in stream 8= 31.5 kmole/day
N2
Input = output
67.68 ( stream 10 ) = output in stream 8
N2 in stream 8 = 67.68 kmole/day
199
4-material balance on Mixer (V-101 )
16
13
15
MIX-100
Stream 16:
H2 O
= H2O (in stream 15) – H2O (in stream 13)

= 10.609 kmole/day - 1.358 kmole/day = 9.251 kmole/day
H2SO4
= H2SO4(in stream 15 ) – H2SO4 (in stream 13)

= 30.5325 kmole/day - 3.9227 kmole/day
= 26.6098 kmole/day
200
17
12
P-102 A/B
Input = output
Note stream 12( output from Filter ) = stream 17 ( is pumped output of Filter)
5. material balance on three evaporators
18
20 22
17
25
19 21
E-101 E-102 E-103
23
In stream 17H3PO4= 40%(wt%) , H2O = 60% (wt%)
In stream 23 (H3PO4 = 75% wt% )
V1= stream 18, V2= stream 20 , V3= stream 22
L1= stream 19 , L2= stream 21 , L3= stream 23
201
F(Feed stream 17 ) = 93.4093645 kmole/day = 2498.5788 kg/day
Assuming V1=V2=V3(equal amount vaporized )
Making overall and H3po4 balance to calculate the total amount of vaporized (V1 +V2 +V3)
and L3
H3PO4 balance
XH3PO4 in stream 23 = 75wt%
XH3PO4 in stream 17 = 40 wt%
F* XH3PO4=L3*XH3PO4+(V1+V2+V3)* XH3PO4
2498.5788 kg/day * (.4) = L3 *(.75 ) + 0
L3 (stream 23 ) = 1332.57536kg/day
Overall balance
F = L3 + (V1+V2+V3)
2498.5788 kg/day = 1332.57536kg/day+(V1+V2+V3)

(V1+V2+V3)= 1166.0034 kg/day
𝟏𝟏𝟔𝟔.𝟎𝟎𝟑𝟒𝟒
V1= = 388.6678133 kg/day =V1=V2
𝟑
Stream 18 (V1)
H2O = 388.6678133kg/day
Stream 19 (L1 )
202
F= V1 + L1
2498.5788 kg/day = 388.6678133 kg/day + L1
L1 (stream 19)= 2109.910987 kg/day

To find concentration of H3po4 in stream 19 :
Balance on H3PO4
F * XH3PO4 = L1 * XH3PO4 + V1* XH3PO4

2498.5788 * .4 = 2109.910987* XH3PO4 + 0
XH3PO4(concentration in stream 19 ) = .474
Concentration of H3PO4 in stream 19(output of evaporator 1) = 47 % wt%
H3PO4
=Flowrate of stream 19 * XH3PO4
= 2109.910987* .474 = 1000.09 kg/day
H2 O
=Flowrate of stream (19) * XH2O
= 2109.910987* (1-.474 ) = 1109.813 kg/day
Stream 20 (V2)
H2O = 388.6678133 kg/day
Stream 21 (L2)
L1= V2+L2
2109.910987= 388.6678133 + L2
L2=1721.243174 kg/day
To find concentration of H3PO4 in stream 21:
Balance on H3PO4
L1 * XH3PO4 = L2 * XH3PO4 + V2 * XH3PO4
* .47 = 1721.243174 * XH3PO4 + 0

XH3PO4 = .576
203
XH3PO4 concentration of H3PO4 in stream 21 (output of evaporator 2 ) = 58 % wt%
H3PO4
=Flowrate of stream 21 * XH3PO4
=1721.243174* .58 = 988.32kg/day
H2 O
=Flowrate of stream (21) * XH2O
= 1721.243174*(1-.58 )= 722.922 kg/day
Stream 22 (V3)
H2O = 388.6678133 kg/day
Stream 23 (L3)
Flowrate stream 23 =1332.57536 kg/day

H3PO4
999.5 kg/day = 1 tonne/day
= stream 23 * .75 = 1332.57536kg *.75 = 999.5 kg/day = 1 tonne/day
H2 O
= stream 2 * .25 = 333.1425 kg/day .
204
APPENDIX C: ENERGY BALANCE
Sample of calculations :
General energy balance equation :
𝑄 − 𝑊 = ∆𝐻 + ∆𝐸𝐾 + ∆𝐸𝑃
ASSUMPTIONS :
 NO MOVING PARTS W=0.
 No potential energy ∆𝐸𝑝 = 0 .
 No kinetics energy ∆𝐸𝐾 = 0.
The energy balance done by using heat of formation method .

1. ENERGY BALANCE AROUND MILL
1 3
V-100
 The work index of phosphate rock in wet grinding ( 𝑤𝑖 )= 12.74

 Assume the feed rock is very large in size (D𝑓𝑒𝑒𝑑 ) = ∞
 The Ca3(PO4)2 Feed flow rate = 10.92 kmole/day
 The product particle size (D𝑜𝑢𝑡 ) =42 mm .
1 1
 From the following equation ṗ = 𝑚 ∗ 𝑤 = 0.3162 ∗ 𝑤𝑖 *( − )
√D𝑜𝑢𝑡 √D𝑓𝑒𝑒𝑑
𝑘𝑔 1
 =0.3162 ∗ 1.88 * 12.74**( ) =7.38 kw
𝑠 √42
205
2. Energy balance Around reactor .
15
R-100
6
 Stream (S3 ) , the reference for elements ref T=25c , P=1atm , Ca(s) ,O(g ) , H(g) ,si (s)
,N(g) , S(s) P(s) .
The following table show the input mole flowrate of each component in the stream with the mole fraction for
each one and the standard enthalpy of formation at T=298 K.
ref T=25c , 1atm , Ca(s) ,O(g) , H(g) ,si (s) ,N(g) , S(s)P(s)
S3 T=298 K
component mole flowrate (kmole/day) mole fraction delta Hf (KJ/mole) flowrate (mole/s) ∆H(kw)
Ca3(po4)2 11 0.08 -4138.00 0.12 -514.38
CaF2 11 0.08 -1225.91 0.13 -159.62
Sio2 4 0.03 -851.00 0.04 -35.26
H2o 105 0.78 -285.00 1.21 -345.46
H3po4 3 0.03 -1281.10 0.04 -50.27
134 in -1104.99
206
1000𝑚𝑜𝑙𝑒 1 𝐷𝑎𝑦
 the conversion factor of flowrate is * 86400 𝑠 .
1𝑘𝑚𝑜𝑙𝑒
10.74∗1000 𝑚𝑜𝑙𝑒
 for 𝐶𝑎3 (𝑃𝑂4 )2 = = 0.124305556 .
86400 𝑠
 ∆𝐻𝑓298𝑘 𝑖𝑠 𝑡𝑎𝑏𝑢𝑙𝑎𝑡𝑒𝑑 .
 ∆𝐻 𝑜𝑓 𝑠𝑡𝑟𝑒𝑎𝑚 = ∆𝐻𝑓298𝑘 ∗ (𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒) for each component .
 ∆𝐻 𝑜𝑓 𝐶𝑎3 (𝑃𝑂4 )2 =
-4138 *0.124305556 = -514.3763889 KW apply it to all compo-
nents in the stream .
 summation of values of H for each component = -1104.988 KW input from (s1)
 energy balance on stream (S5) at same reference conditions of stream (S3) .
The following table showing the energy balance for stream( S5) .
S5 T=343 K
COMPONENT MOLE FRACTION molar flowrate (kmole/day ) Capacity (kj/mol.k) Hf (KJ/mole) Cp*(T-T ref) ∆𝐻 flowrate(mole/s) H (KW)
ca3(po4)2 0.06 6 0.18 -4138.00 8.19 -4129.81 0.07 -269.58
H3po4 0.14 14 0.14 -1281.10 6.33 -1274.77 0.16 -200.51
H2so4 0.04 4 0.13 -811.32 5.91 -805.41 0.05 -37.12
H2o 0.50 50 0.08 -285.00 3.39 -281.61 0.58 -163.97
caso4 0.11 11 0.10 -1432.70 4.47 -1428.23 0.13 -185.97
caso42h2o 0.15 15 0.10 -2021.00 4.47 -2016.53 0.18 -357.09
100.07 Q (OUT) -1214.25
 heat capacity (Cp) values tabulated or found from the following equation :
 𝑐𝑝 = 𝑎 ∗ 10−3 + 𝑏 ∗ 10−5 ∗ 𝑇 + 𝑐 ∗ 10−8 ∗ 𝑇 2 (kj /mole.k) . which (a,b and c) are

constants.
 Cp for water (L) = 75.4 ∗ 10−3 =0.0754 (kj/mole.k)
 ∆𝐻𝑓298𝑘 are constant and tabulated for all components in stream S2 .
𝑇
 sensible heat equation ∫𝑇𝑟𝑒𝑓 𝐶𝑝 𝑑𝑇 .
343 𝐾𝐽
 Sensible heat for 𝐻2 𝑆𝑂4 = ∫298 0.13132 𝑑𝑇 = 5.9094 .
𝑚𝑜𝑙𝑒.𝑘
1𝑘𝑚𝑜𝑙𝑒 1 𝐷𝑎𝑦
 flowrate conversion factor = 1000𝑚𝑜𝑙𝑒 𝑎𝑛𝑑 to convert the flowrate to this unit
86400 𝑠
(mole/s) as shown in the calculations of stream (S1).
207
𝑇
∆𝐻 = ∆𝐻𝑓298 + ∫ 𝑐𝑝 𝑑𝑇
𝑇𝑟𝑒𝑓
 ∆𝐻 For 𝐶𝑎𝑠𝑜4 = −1432.7 + 4.4685 = −1428.23 KJ/mole the same of each compo-
nent in S2 .
 convert the unit of 𝐻 To KW by (𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 ∗ ∆𝐻) .
 Summation of H(Kw) for stream (S2) = -1214.25 kw output .
 Energy balance on stream (S4) at same standard conditions used in stream (S3) .
The following table showing the energy balance on stream (S4) .
S4 T= 343 k
Component mole fraction MOLAR FLOWRATE(MOL/DAY) Cp(kj/mole.K) ∆Hf(kj/mole) ∆H (kj/mole) CP*(T-Tref) flowrate(mole/s) H(kw)
N2 0.47 68 0.03 0.00 1.31 1.31 0.78 1.03
HF 0.01 1 0.00 -272.55 -272.55 0.00 0.01 -3.86
H2siF6 0.02 4 0.24 -262.96 -4102.96 10.62 0.04 -170.00
H2o 0.28 41 0.04 -241.83 -240.18 1.65 0.48 -114.42
O2 0.22 32 0.03 0.00 0.00 0.00 0.36 0.00
Q(out) -287.25
 The heat capacity calculated from the same equation mentioned in the stream (S2):
 𝑐𝑝 = 𝑎 ∗ 10−3 + 𝑏 ∗ 10−5 ∗ 𝑇 + 𝑐 ∗ 10−8 ∗ 𝑇 2 (kJ/mole.k ) .
 Cp for (H2O g ) = 33.46 ∗ 10−3 + 0.6880 ∗ 10−5 ∗ 343 + 0.706 ∗ 10−8*3432 =0.036749
Apply this relation for all component in the stream .
 Cp for (H2SiF6) by the following equation = 2𝑐𝑝𝐻 + 𝑐𝑝𝑠𝑖 + 6𝑐𝑝𝐹 .
343
∆𝐻343𝐾 = ∆𝐻298𝐾 + ∫ 𝐶𝑃 𝑑𝑇 .
298
 Cp For HF = -272.55+9.9∗ 10−4 = -2.46 ∗ 10−5 kj/mole.k .
 flowrate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert the

flowrate to this unit (mole/s) as shown in the calculations of stream (S1).
 H for the stream =(∆𝐻343𝐾 ∗ 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒) to convert it to (kw) .

 H IN (KW) For N2 = 0.78333333*1.3095 =1.025775 KW .
 Summation of H(343k) in stream (S3) = -287.25 kw output .
208
 Energy balance on stream (S15) with same conditions of stream (S1) .
The following table showing the energy balance on (S15) .

S 15 T=304 K T ref=298 k , T-Tref= 6
component fraction flowrate(kmol/day) Hf(kj/mol) CP cp(T-Tref) ∆H(kj/mole ) flowrate(mole/s) ∆H (kw )

H2so4 0.74 31 -811.32 0.25 1.53 -809.79 0.35 -285.87
H2o 0.26 11 -285.00 0.08 0.45 -284.55 0.12 -34.94
Q(in ) -320.80
 Cp has a constant value tabulated or from the previous equation :

 𝑐𝑝 = 𝑎 ∗ 10−3 + 𝑏 ∗ 10−5 ∗ 𝑇 + 𝑐 ∗ 10−8 ∗ 𝑇 2 (kj /mole.k) ---- a,b, c is constants .
 For H2SO4 cp= 193 ∗ 10−3 + 15.59 ∗ 10−5 ∗ 393 = 0.2542687 KJ/mole.k .
393
∆𝐻393𝑘 = ∆𝐻298𝐾 + ∫ 𝐶𝑃 𝑑𝑇
298
 For H2SO4 ∆H (304k ) = -811.32 +1.5252= -809.7948 kj/mole.k

 convert ∆H (304 k) to KW by ( flowrate *∆H (304k )) .
 summation of ∆H (393k ) in stream (S5) = -320.8044779 input .
 Energy balance on stream (S6) with same conditions of stream (S3) .
The following table showing the energy balance on stream (S6).
S6 T=298 K
component FRACTIONS FLOW RATE (KMOL/DAY) (kj/mol)
O2 0.32 32 0.00
N2 0.68 68 0.00
99 Q (in ) = 0
There is no energy input with this stream because it has an element at reference temperature .
The final of reactor Q (kw) from the following equation Q (kw) = Σ 𝐻𝑜𝑢𝑡−Σ𝐻𝑖𝑛 = -75.71148943 kw
209
3. Energy Balance Around Pump :
10
P-100 A/B
Assumptions :
 no heat generation .
 mass in =mass out .
 pressure before the absorber =4 atm .
𝐻 = 𝜐 ∗ Δ𝑃
1 1 1 1 1 = 2.14 𝑚3
𝜐𝑎𝑣𝑒𝑟𝑎𝑔𝑒 = 1.2 + 1.65 + 1000 + 1150 + 1.42 =0.428 .
5 𝑘𝑔
 ΜW𝐴𝑣𝑒𝑟𝑎𝑔𝑒 = 0.46*28.013+0.008*20+0.02*144.09+0.8*18+0.2*15.9 = 24.31 g/mole .

24.31𝑔
𝑘𝑔

𝑚𝑜𝑒
= 0.024310 * 𝜐 = 0.0104 m3/mole .
1000 𝑚𝑜𝑙𝑒
1𝑗
𝑚3 1𝑘𝑗 𝐾𝐽
 𝜐 *Δ𝑃 =(4-1) =( 3 atm )* (101352 pascal/1 atm) * *103 𝑗 *0.01040=0.032877𝑚𝑜𝑙𝑒 .
1 𝑝𝑎𝑠𝑐𝑎𝑙
𝐻 = 0.032877 ∗ 𝑀𝑂𝐿𝐸 𝐹𝐿𝑂𝑊 𝑅𝐴𝑇𝐸 .
𝑲𝑱
 𝑯 =0.05523 .
𝑺
210
4.Energy balance Around pump :
14
P-101 A/B
Assumptions :
 pressure before the filter = 6 atm .
(2.7+5.39+5.39+4.31+3.37+10−3 )∗10−4
 𝜐𝑎𝑣𝑒𝑟𝑎𝑔𝑒 = = 3.5*10-4 m3/kg .
6
 ΜW𝐴𝑣𝑒𝑟𝑎𝑔𝑒 =0.05*310+0.13*97+0.039*98+0.5*18+0.11*136.14+0.15*172.17 =81.732

𝑔 𝑚3
=0.0817329kg/mole *𝜐𝑎𝑣𝑒𝑟𝑎𝑔𝑒 = 2.86*10-5 𝑚𝑜𝑙𝑒 .
𝑚𝑜𝑙𝑒
1𝑗
𝑚3 1𝑘𝑗 𝑚3
 𝜐 *Δ𝑃 =(6-1 atm )* (101352 pascal/1 atm) * *103 𝑗 = 2.86*10-5 𝑚𝑜𝑙𝑒 = 0.014489
𝐾𝐽
.
𝑚𝑜𝑙𝑒
 𝐻 = 3.16134 ∗ 𝑀𝑂𝐿𝐸 𝐹𝐿𝑂𝑊 𝑅𝐴𝑇𝐸 .

𝒌𝒋
=0.01678 𝒔 .
211
5.Energy balance Around filter :
11
14 24
F-100
13 12
General energy balance equation :
𝑄 − 𝑊 = ∆𝐻 + ∆𝐸𝐾 + ∆𝐸𝑃
 Heat (in) = heat(out)
 Energy balance on stream (S14) the reference for elements ref T=25c , P=1atm , Ca(s) ,O(g )
, H(g) ,si (s) ,N(g) , S(s) P(s) .
The following table show the energy balance on filter :
212
ref T=25c , 1atm , Ca(s) ,O(g), H(g) ,si (s) ,N(g) , S(s)
P(s)
S14
T=343 K T-Tref= 45
COMPONENT mole fraction flowrate(kmol/day) CP(KJ/MOLE.K) H=Cp*(T-T ref) flowrate(mol/s) H(KW)

ca3(po4)2 0.06 6 0.18 8.19 0.07 0.53
H3po4 0.14 14 0.14 6.33 0.16 1.00
H2so4 0.04 4 0.13 5.91 0.05 0.27
H2o 0.50 50 0.08 3.39 0.58 1.98
caso4 0.11 11 0.10 4.47 0.13 0.58
caso42h2o 0.15 15 0.10 4.47 0.18 0.79
Q(in) 5.15
 Temperature difference on this stream = T-𝑇𝑟𝑒𝑓 = 343 -298 = 45 k.

𝑘𝑗
 heat capacity value for each element in the stream in (𝑚𝑜𝑙.𝑘) is constant value and tabu-
lated .
flowrate to this unit (mole/s) as shown in the calculations of stream and apply this conversion
for all component flow rate.
1000 𝑚𝑜𝑙
 For 𝐶𝑎3 (𝑝𝑜4 )2 = 5.65* =0.06527777 .
86400 𝑠
 the energy for this stream is due to sensible heat type and calculated by the following equation .
343
∆𝐻343 𝑘 = ∫ 𝑐𝑝 𝑑𝑡
298
343
 ∆𝐻343𝐾 For (𝐻2 𝑆𝑂4 ) = ∫298 0.13132 𝑑𝑡 =5.9094 (kj/mol) .
 The same calculation for all component in the stream .
 To convert the energy to (KW) multiply by the molar flow rate .
 For water = 3.393*0.582265394=1.97562648 (KW) .
 Total energy for this stream = 5.151875886 (KW) .
213
 Energy balance on stream ( S15) at same condition of stream (S14) .
the following table show the energy balance on ( s15) :

s15 T=339.5 K
T-Tref= 41.5
component mole fraction flowrate(kmol/day) CP(KJ/MOLE.K) H=Cp*(T-T ref) flowrate(mol/s) H(KW)
H2so4 0.002 0.06 0.13 5.45 0.00 0.00
H2o 0.021 0.75 0.08 3.13 0.01 0.03
ca3(po4 )2 0.155 5.64 0.18 7.55 0.07 0.49
CaSO4.2H2O 0.420 15.30 0.10 4.12 0.18 0.73
caso4 0.309 11.25 0.10 4.12 0.13 0.54
H3po4 0.093 3.39 0.14 5.84 0.04 0.23
Q(out) 2.020017174
 The temperature difference = T-𝑇𝑟𝑒𝑓 =339.5-298 =41.5k .

𝑘𝑗
lated .
1000 𝑚𝑜𝑙
 for H2O = 0.7546595 *86400 = 0.008733981 .
𝑠
339.5
∆𝐻339.5𝑘 = ∫ 𝑐𝑝 𝑑𝑡
298
339.5
 ∆𝐻339.5𝐾 For (𝐻2 𝑆𝑂4) = ∫298 0.13132 𝑑𝑡 =5.44978 4(kj/mol) .
 The same calculation for all component in the stream .
 For H2O =3.1291*0.008733981 =0.0273295 (kw) .
 Total energy for this stream = 2.020017174 (kw)
214
 The energy balance on stream (S12) with same condition assumed in (S14) .
the following table show the energy balance on ( S12) .

s12 T=345K T-Tref= 47
component mole fraction flowrate(kmol/day) CP(KJ/MOLE.K)H=Cp*(T-T ref) flowrate(mol/s) H(KW)
H3po4 0.11 10 0.14 6.61 0.12 0.78

H2o 0.89 83 0.08 3.54 0.96 3.41
Q (out) 4.19
 The temperature difference = T-𝑇𝑟𝑒𝑓 =345-298 =47 k .

𝑘𝑗
lated .
 the energy for this stream is due to sensible heat type and calculated by the following equation
.
345
∆𝐻345𝑘 = ∫298 𝑐𝑝 dt .
345
 ∆𝐻345𝐾 For (𝐻2𝑂) = ∫298 0.0754 𝑑𝑡 =3.5438 (kj/mol) .
 For H2O =3.5438*0.963071348=3.4129 (kw)
 Total energy for this stream = 4.193344(kw) .

s11 T-Tref=0 T= 298 K

wash water 1.00 35.02 0.08 0.00 0.41 0.00
Q 0
 The temperature of this stream is same as the temperature assumed to be reference tem-
perature .
 So there is no energy in this stream .
215
s13 T=345 K T-Tref= 47
H2so4 0.74 4 0.13 6.17 0.05 0.28

H2o 0.26 1 0.08 3.54 0.02 0.06
Q(out) 0.34
 The temperature difference = T-𝑇𝑟𝑒𝑓 =345-298 =47 k

𝑘𝑗
lated .
345
∆𝐻345𝑘 = ∫298 𝑐𝑝 dt .
345
 ∆𝐻345𝐾 For (𝐻2𝑂) = ∫298 0.0754 𝑑𝑡 =3.5438 (kj/mol) .
 For H2O =3.5438*0.01577445=3.4129 (kw) .
 Total energy for this stream = 0.336137 (kw) .

 By trial and error the temperature for streams S24 ,S12 , S13= 339.5k , 345k , 345k re-
spectively .
216
6.Energy balance Around Absorber :
8 9
V-101
10 7
 Heat (in) = heat (out) ( to get the temperature of stream S7 AND S8) .
For stream S9 (INPUT) :
The following table show the energy balance on stream S9 :
s9 T=298 k T-Tref=0
componnt mole fraction flowrate(kmol/day) CP(KJ/MOLE.K) H=Cp*(T-T ref) flowrate(mol/s) H(KW)

H2O 1.000 118.547 0.075 0.000 1.372 0.000
 flowrate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert

the flowrate to this unit (mole/s) as shown in the calculations of stream and apply this
conversion for all component flow rate.
298
 ∆𝐻298 𝑘 = ∫298 𝑐𝑝 𝑓𝑜𝑟 𝑤𝑎𝑡𝑒𝑟 dt = zero
217
For stream (10) :
 The following table show the energy balance on stream S10 :
s10 ref T=25c , 1atm , Ca(s) ,O(g), H(g) ,si (s) ,N(g) , S(s),P(s)
T= 343 K T-Tref = 45
Component mole fraction flowrate(kmol/day) CP(KJ/MOLE.K) H=Cp*(T-T ref) flowrate(mol/s) H(KW)

N2 0.47 68 0.03 1.31 0.78 1.03
HF 0.01 1 0.00 0.00 0.01 0.00
H2siF6 0.02 4 0.24 10.62 0.04 0.44
H2o 0.28 41 0.04 1.65 0.48 0.79
O2 0.22 32 0.03 1.17 0.36 0.42
Q(in) 2.68
• flowrate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert

the flowrate to this unit (mole/s) as shown in the calculations of stream and apply this
conversion for all component flow rate.
343 𝑇
Σ ∫298 𝑚 𝐶𝑃 𝑑𝑇 in = Σ ∫298 𝑚 𝐶𝑃 𝑑𝑇 out
For stream S10 (INPUT ) :
343
 ∆𝐻343 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝑁2 𝑑𝑇 = 0.0291 *45*0.78333 = 1.3109
343
 ∆𝐻 343 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻𝐹 𝑑𝑇 = 0.01 *0000022 *45 = 1.4027*10-5
343
 ∆𝐻343 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑆𝑖𝐹6 𝑑𝑇 =0.2361 *0.0414132 *45 =0.4402035
343
 ∆𝐻343 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 =0.036749 *0.47639*45 = 0.78782
343
 ∆𝐻343 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝑂2 𝑑𝑇 =0.0259 *0.3645*45 =0.4249
218
For stream S7(OUTPUT) :
 The following table show the energy balance on stream S7 :
S7
component mole fraction molar flowrate CP(KJ/MOLE.K)H=Cp*(T-T ref) flowrate(mol/s) H(KW)
H2SIF6 0.02 3.54 0.24 5.19 0.04 0.21
H2O 0.98 159.71 0.08 1.66 1.85 3.07
163.2519446
• flowrate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert the

flowrate to this unit (mole/s) as shown in the calculations of stream and apply this conver-
sion for all component flow rate.
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑠𝑖𝐹6 𝑑𝑇 =0.0410185*0.2361*(T-298)
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 =1.84847155*0.0754*(T-298)
For stream S8 (OUTPUT) :

 The following table show the energy balance on stream S8.
S8
componant mole fraction flowrate(kmol/day) CP(KJ/MOLE.K)H=Cp*(T-T ref) flowrate(mol/s) H(KW)
HF 0.01 1.22 0.00 0.00 0.01 0.00
O2 0.31 31.50 0.03 0.57 0.36 0.21
N2 0.67 67.68 0.03 0.64 0.78 0.50
H2SIF6 0.00 0.04 0.24 5.19 0.00 0.00
100.44
• flowrate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert the flowrate
to this unit (mole/s) as shown in the calculations of stream and apply this conversion for all compo-
nent flow rate .
219
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻𝐹 𝑑𝑇 = 2.2*10-5*0.014168981*(T-298)
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝑂2 𝑑𝑇 = 0.0259*0.3645833*(T-298)
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝑁2 𝑑𝑇 =0.0291*0.78333*(T-298)
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑆𝐼𝐹6 𝑑𝑇 =0.2361*0.000414329*(T-298)
 Now by apply the following equation then trial and error .
343 𝑇
 the temperature for streams S7 AND S8 = 53.71 ℃
7.Energy balance Around mixer :
16
13
15
MIX-100
 Heat (in) = heat (out) ( to get the temperature of stream S15 :
220
For stream S15 (OUTPUT) :
 The following table show the energy balance on stream S15:
S15 T =304 k
COMPONANTS mol fraction mol flowrate (kmol/day) CP(kj/mol.k) flow rate (mol/s) H(KW)
H2O 0.26 10.61 0.08 0.12 0.06
H2SO4 0.74 30.50 0.13 0.35 0.28
0.28
• flowrate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert the flowrate
to this unit (mole/s) as shown in the calculations of stream and apply this conversion for all component
flow rate .
 For H2O =30.5*1000/86400=0.12 mole /s
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 =0.1227895*0.0754*(T-298)
𝑇
 ∆𝐻 𝑇 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑆𝑂4 𝑑𝑇 = 0.353009259*0.13132*(T-298)

 The following table show the energy balance on stream S16:
S16 T ref=298
T = 298 K T-Tref = 0
componant mol fraction flow rate (kmol/day ) CP(kj/mol.k) flow rate (mol/s) H(KW)
H2o 0.258097078 9.24582873 0.0754 0.107011907 0
H2SO4 0.741902922 26.5772375 0.13132 0.307606916 0
298
 ∆𝐻 298 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 = 0
298
 ∆𝐻 298 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 = 0
 This stream has no energy because the stream input at reference temperature .
221
The following table show the energy balance on stream S13 :
s13 T=345 K T-Tref=47
compnant mol fraction mol flow rate CP(kj/mol.k) flow rate (mol/s) H(KW)
H2O 0.257886559 1.36317127 0.0754 0.015777445 0.055912111
H2SO4 0.742113441 3.9227625 0.13132 0.045402344 0.280225082
0.336137192
• flow rate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert the flow rate
flow rate .
 For H2SO4 =3.22625*1000/86400= 0.045402344 mole/s .
345
 ∆𝐻 345 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 = 0.0754*47*0.015777445= 0.05512111
(kw)
345
 ∆𝐻 345 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑆𝑂54 𝑑𝑇=0.13132*0.045402344*47 =0.280225082
(kw) .
 Now by apply the following equation then trial and error .
343 𝑇
 the temperature for streams S15 = 31 ℃
222
8.Energy balance on pump :
17
12
P-102 A/B
Assumptions :
 pressure before the filter = 2 atm .
10−3 +5.31∗10−4 𝑚3
 𝜐𝑎𝑣𝑒𝑟𝑎𝑔𝑒 = = 7.65*10-4 .
2 𝑚𝑜𝑙𝑒
𝑔 𝑘𝑔
 𝑀𝑊𝑎𝑛𝑒𝑟𝑎𝑔𝑒 =0.1*(97.99)+0.89*(18) = (25.81𝑚𝑜𝑙𝑒 )/10000 = 0.02581𝑚𝑜𝑙𝑒 .
𝑚3
 𝜐𝑎𝑣𝑒𝑟𝑎𝑔𝑒 ∗ 𝑀𝑊𝑎𝑛𝑒𝑟𝑎𝑔𝑒 =1.95123*10-5 .
𝑚𝑜𝑙𝑒
1𝑗
𝑚3 1𝑘𝑗
 𝜐 ∗ Δ𝑃 = (2-1) atm * (101352 pascal/1 atm) * *103 𝑗 * 1.95123*10-5
𝑘𝑗
=1.97708 𝑚𝑜𝑙𝑒 .
 𝐻 = 1.97708 ∗ 𝑀𝑂𝐿𝐸 𝐹𝐿𝑂𝑊 𝑅𝐴𝑇𝐸 .
𝒌𝒋
 1.97708*1.08112 =2.1374 𝒔
9.Energy Balance Around Multi Effect Evaporator :
223
18
20 22
17
25
19 21
E-101 E-102 E-103
23
Energy balance Around First Effect :
The energy balance on the evaporator by the following equation:

𝑸𝑰𝑵 = 𝑸𝑶𝑼𝑻 − 𝑸𝒈𝒆𝒏𝒆𝒓𝒂𝒕𝒊𝒐𝒏
 The Temperature of the first evaporator approximately = 106 c
 The reference temperature is 379 k.
 The following table show the balance on stream S17(input) . at reference temperature (379k)
 Energy balance on stream S17 :

T=345 K -34
S17 T- Tref
mole flow rate (kmol/day CP(kj/mol.k) flow rate (mol/s) H(kw)
H2O 83.2093645 0.0754 0.963071348 -2.468929709
H3PO4 10.2 0.14065 0.118055556 -0.564553472
93.4093645 0 1.081126904 -3.033483181
345
 ∆𝐻 345 𝑘 = ∫379 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻3𝑃𝑂4 𝑑𝑇= -0.56
345
 ∆𝐻 345 𝑘 = ∫379 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇=-2.41428
224
 Energy balance on stream S18 :
The following table shoe the energy balance on stream S18 :
Tref=345 k 34
S18 T=379 K
component mol flow rate (kmol/day ) CP(kj/mol.k) flow rate (mol/s) Hvap(kj/mol) H(kw)
H2O 21.57434208 0.0754 0.249703033 40.65 10.790567
• flow rate conversion factor = 1kmole/(1000mole ) and (1 Day )/(86400 s) to convert the flow rate
flow rate .
 For H2O = 21.574*(1000/86400) =0.249703033 (KJ/s) .

 ∆𝐻𝑣𝑎𝑝 for H2O = 40.56 (KJ/mole).
 The energy out of this stream given by the following equation :
𝑇
∆𝐻 𝑘 = ∫𝑇𝑟𝑒𝑓 𝑚 𝑐𝑝 𝑑𝑇 + ∆𝐻𝑣𝑎𝑝
For water = 40.65*0.249703033 =10.150567 (KW).
 Energy balance on stream S19
The following table shoe the energy balance on stream S19:
Tref=379 k
S19 T=379 K
components mol flow rate (kmol/day ) CP(kj/mol.k) flow rate (mol/s) H(KW)
H2o 61.64097736 0.0754 0.713437238 0
H3PO4 10.19890524 0.14065 0.118042885 0
0
 For water =10.19890524*(1000*86400) = 0.713437238(mol/s) .
379
 ∆𝐻 373 𝑘 = ∫379 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇=0.
379
 ∆𝐻 373 𝑘 = ∫379 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻3𝑃𝑂4 𝑑𝑇= 0
the energy balance equation on evaporator :
ΣΔ𝐻𝐼𝑁𝑃𝑈𝑇 + 𝑄 = ΣΔ𝐻𝑂𝑈𝑇𝑃𝑈𝑇
Where Q =𝜆𝑠 * 𝑚
225
𝜆𝑠 (𝑓𝑜𝑟 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑒𝑎𝑚 𝑡𝑎𝑏𝑙𝑒 ) =2202 (kj/kg ) .
ΣΔ𝐻𝐼𝑁𝑃𝑈𝑇 =0…. Because the input stream at reference temperature .
Q = 12.564 (KW) .
ms =492.97 kg/day
Energy balance Around second effect :
 the changing in pressure equal=0.57.
 𝜆𝑠 (𝑓𝑟𝑜𝑚 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑒𝑎𝑚 𝑡𝑎𝑏𝑙𝑒 ) =2281.8 (kj/kg ).
 The Temperature of the second evaporator approximately = 90 c .
Energy balance equation :

𝑸𝑶𝑼𝑻 = 𝟎 ( 𝒃𝒆𝒄𝒖𝒔𝒆 𝒕𝒉𝒆 𝒕𝒘𝒐 𝒔𝒕𝒓𝒆𝒂𝒎𝒔 𝒂𝒕 𝒓𝒆𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒕𝒆𝒎𝒑𝒆𝒓𝒂𝒕𝒖𝒓𝒆 ).
𝑄𝑖𝑛𝑝𝑢𝑡 𝑠(19) ( 𝑎𝑡 𝑇𝑟𝑒𝑓 = 363 𝑘):

379
 ∆𝐻 379 𝑘 = ∫363 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻3𝑃𝑂4 𝑑𝑇 = 0.2656
379
 ∆𝐻 379 𝑘 = ∫363 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 = 0.8606 .
𝑄𝑜𝑢𝑡𝑝𝑢𝑡 𝑠 (20) ( 𝑎𝑡 𝑇𝑟𝑒𝑓 = 363𝑘):
363
 ∆𝐻 363 𝑘 = ∫379 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 + ∆𝐻𝑣𝑎𝑝 = 10.13 kj/mole .
226
𝑄𝑜𝑢𝑡𝑝𝑢𝑡 𝑠 (21) ( 𝑎𝑡 𝑇𝑟𝑒𝑓 = 363 𝑘):
363
 ∆𝐻 363 𝑘 = ∫363 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇=0
363
 ∆𝐻 363 𝑘 = ∫379 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻3𝑃𝑂4 𝑑𝑇 =0
𝑸𝒈𝒆𝒏𝒆𝒓𝒂𝒕𝒊𝒐𝒏 = 𝟏𝟏. 𝟐𝟓𝟒 kj/s .
Q =𝝀𝒔 * 𝒎
𝐦𝒔 =389 kg/s
Energy Balance Around Third Effect :
 the changing in pressure equal=0.57.
 𝜆𝑠 (𝑓𝑟𝑜𝑚 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑒𝑎𝑚 𝑡𝑎𝑏𝑙𝑒 ) =2377 (kj/kg ).
 The Temperature of the third evaporator approximately = 80 c .
𝑄𝑖𝑛𝑝𝑢𝑡 𝑠(21) ( 𝑎𝑡 𝑇𝑟𝑒𝑓 = 353 𝑘):

363
 ∆𝐻 363 𝑘 = ∫353 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻3𝑃𝑂4 𝑑𝑇 = 0.166 (kw)
363
 ∆𝐻 363 𝑘 = ∫353 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 = 0.74 (kw)
𝑄𝑜𝑢𝑡𝑝𝑢𝑡 𝑠 (22) ( 𝑎𝑡 𝑇𝑟𝑒𝑓 = 353𝑘):
363
 ∆𝐻 353 𝑘 = ∫353 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 + ∆𝐻𝑣𝑎𝑝 = 10.127 kj/mole .
227
𝑄𝑜𝑢𝑡𝑝𝑢𝑡 𝑠 (21) ( 𝑎𝑡 𝑇𝑟𝑒𝑓 = 353 𝑘):
353
 ∆𝐻 363 𝑘 = ∫353 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇=0
353
 ∆𝐻 363 𝑘 = ∫353 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻3𝑃𝑂4 𝑑𝑇 =0
 𝑸𝒈𝒆𝒏𝒆𝒓𝒂𝒕𝒊𝒐𝒏 = 𝟏𝟎. 𝟏𝟐𝟓𝟒 kj/s .
 𝐦𝒔 =389 kg/day
1. Energy balance Around Reboiler :
P-1
26 25
E-100
 The reference temperature = 298 k .
 Flow rate = 0.005987 kg/s = 28.736 kmole/day .
 ∆𝐻𝑣𝑎𝑝 for H2O = 2260(kj/kg).
 Component ( H2O) .
𝑸𝑰𝑵 −𝑸𝑶𝑼𝑻 = 𝑸
298
 𝑸𝑰𝑵 = ∆𝐻 363 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 = 0
393
 𝑸𝑶𝑼𝑻 =∆𝐻 363 𝑘 = ∫298 𝑚 𝑐𝑝 𝑓𝑜𝑟 𝐻2𝑂 𝑑𝑇 + ∆𝐻𝑣𝑎𝑝 for H2O .
= ( 0.005987 )*(4.182)*(95)+(2260) *(0.005987) =15.90919 kj .
228
APPENDIX D : COST ESTIMATION
Ball mill V-100 purchase cost:
Figure 53: Purchase cost of Ball and Rod miller, for wet grinding.
Purchase Cost of equipment from figure above at grinding capacity of 61.2 t/hr. is 160,000$,
but the purchase cost must be multiplied with the pre-cost factor of wet grinding which
equals to 1.25
 Purchase cost of filter in 2012 =160,000 $ * 1.25 = 200,000$
Cost of equipment in 2021:

CEPCI (2012) = 584.6
CEPCI (2021) = 602.8
229
𝐶𝐸𝑃𝐶𝐼 (2021) 602.8
Index ratio = = = 1.03
𝐶𝐸𝑃𝐶𝐼 (2012) 584.6
𝐶𝐸𝑃𝐶𝐼 2021
Cost of equipment in 2021 = Cost of miller in 2012 * ( )
𝐶𝐸𝑃𝐶𝐼 2012
602.8
Purchase Cost of equipment in 2021= 200,000$ *( ) =206,200$
584.6
Cost of reactor
Volume of of each reactor in parallel =150 m3

Cost for carbon steel at 1( atm ) ( 14.6 psia ) at volume 20 m3 = 30000 $
So the cost of volume 150 m3 = ( 30000 * 7.5 ) = 225000 $
Then Total Cost of three reactors in parallel = 225000 * 3 = 675000 $
CEPCI in (2002) =395.6
230
CEPCI in (2021) =643
Index Ratio = ( 607/643) = 1.6
Cost of pump in 2020 = 675000 * 1.6 =1080000$
Filter F-100 equipment cost estimation:
The cost of filter is calculated from figure below, which related filter capacity vs. purchase cost:
Figure 54: Purchased cost for Filters vs. area in m2 in US dollars in 1987.
 Purchase cost for horizontal vacuum belt filter of area of 42.74 m2 in 1987 from fig-
ure above:
 Area of filter = 42.74 m2= 460.049 ft2
 Discharge factor of horizontal vacuum belt filter = 1.2
231
From the above figure the purchase cost of HVBF filter with area = 42.74 m2
=460.049 ft2, equals to 290,000$, but the purchase cost value must be multiplied by
the pre-cost discharge factor of HVBF filter.
Total filter cost = 290,000$ * 1.2 = 348,000$
**As this cost include all auxiliaries (Vacuum pumps.), which equals to 50% of total
filter cost.
CEPCI for equipment: (2019CEPCIindex, n.d.)
CEPCI (2012) = 390

CEPCI (2021) = 402.2
𝐶𝐸𝑃𝐶𝐼 2021 602.8
Index ratio = ( )=( ) = 1.03
𝐶𝐸𝑃𝐶𝐼 2012 584.6
Cost of equipment in 2021 = Purchase cost in 2012 * Index ratio

 348,000$ *1.03 = 358,788$
Cost of packed bed column
The cost of the column :
232
Figure 55: Purchased cost of packed columns including installation and auxiliaries (Peters M. S., Plant Design and Economics for
Chemical Engineers)
The cost of the absorber column = 120000$

CEPCI for the equipment: (chemical engineering essentials for the CPI professional, n.d.)
CEPCI (2002) = 395

CEPCI (2021) = 643
Index ratio = ( 643/397 ) = 1.5
Cost in 2021 = 120,000$ *1.5 = 180,000 $
233
COST ESTIMATION OF RVAPORATOR
Low carbon
steel has
0.04–
0.3% carbon content and is the most common grade of carbon steel. Mild steel is
also considered low carbon steel as it is defined as having a low carbon content
of 0.05–0.25%
 Area =255 m2 = 2744.8 ft2

 From the figure the cost for on evaporator = 1600000
 Then multiply by the factor of mild steel 0.44 and 0.7
 The total cost for one effect is 492800 $
 Total cost for three effects = 4450000 $

 Cost index in (2012) =570
234
 Cost index in (2021) = 616
 Ratio = 616/570 =1.08 * 445000 = 4810000 $
COST OF PHOSPHORIC ACID SOLUTION STORAGE TANK ( T-101):
Figure 56:the purchased cost of storage tank
The cost = 30,000 $

For thickness
The total cost = 1.4 * 30,000 = 42,000$
The cost for 5 tanks = 4 * 42,000 = 168,000$
CEPCI for the equipment: (chemical engineering essentials for the CPI professional, n.d.)
CEPCI (2002) = 395

235
CEPCI (2021) = 643
Index ratio = ( 643/395 ) = 1.6
The cost in 2021 = 210,000$ * 1.6 = 268,800$
MIXER COST ESTIMATION (MX-100)

Cost estimation :
 the material of construction is carbon steel

 The total cost of mixer with driver is = 11000 $
 Index ratio = ( 616 / 395 ) = 1.031
 Total cost = 16500 $
236
PIPELINE COST RESULT :
Figure 57: : Purchased cost of specialty pipe per length
ENR CCI in (Jan-2002) =6462
ENR CCI in (2020) =11990

2021 11990
Cost Index ratio = ENR CCI in 2002 = = 1.9
6462
Cost of manufacturing pipeline in 2021 = 1.9 * cost of manufacturing in 2002
= 1.8* 1541$ = 2928$
237
Table 65: Results summary of the pipeline system cost
Piping cost estimation
Item number Nominal diameter Length (m) Cost ($/m) Cost ($)
(inch)
L1 6 8 9 72
L2 8 8 25 200
L3 6 15 10 150
L4 6 20 11 210
L5 6 10 11 110
L9 4 8 4 32
L11 8 8 20 160
L12 6 12 8 96
L13 2 10 3 30
L14 6 10 11 110
L15 4 10 7.5 75
L16 6 10 8.5 85
L17 6 12 9 108
L18 2 4 4 8
L19 4 4 6.5 26
L20 2 4 5 9
L21 3 4 6.5 26
L22 2 6 4 24
Total piping cost in 2002 ($) = 1541 $
Total piping cost in 2021 ($) = 2928$
COST OF RAW MATERIAL:
In phosphoric acid production, two raw materials are used in the process:
1) Cost of phosphate rock
Phosphate rock price = 0.082 $/kg (indexmundi, n.d.)

Mass flow rate of phosphate rock = 61,466 kg/hr
$ 𝑘𝑔 ℎ𝑟 𝑑𝑎𝑦
Annual cost of raw material= 0.082𝑘𝑔*61,466 ℎ𝑟 * 24 𝑑𝑎𝑦 * 300 =
𝑦𝑟
3.43 * 107 $/yr = 34.3 M$/yr
2) Cost of Sulfuric acid
238
Sulfuric acid price = 0.083 $/kg (echemi, n.d.)
Mass flow rate of sulfuric acid = 57031.7 kg/hr
$ 𝑘𝑔 ℎ𝑟 𝑑𝑎𝑦
Annual cost of Sulfuric acid = 0.083 𝑘𝑔 * 57031.7 ℎ𝑟 *24 𝑑𝑎𝑦 *300 =
𝑦𝑟
36,186,000 kg/yr = 36.2 M$/yr
Annual cost of raw materials =34.3 M$/yr + 36.2 M$/yr = 70.63 M$/yr
OPERATING LABOR COST:
As the operating labor cost form 10-20% of the total product cost according to “Pant Design
and Economic for Chemical Engineering”, The value of the operating labor cost can be
evaluated by a professional experience or by using published Information, the following
table shows the typical labor requirements for process equipment. (Peters T. a.)
Table 66:Operating labor requirements.
Equipment Type Number of equip- Operators/Unit/Shift Total Number of Op-
ment used in the erators per shift
plant
Reactor 1 0.5 0.5
Evaporator 3 0.25 0.75
Pumps 3 0 0
Heat Exchanger 1 0.1 0.1
Vessels 13 0.2 2.6
Tower 1 0.5 0.5
Vacuum Filter 1 0.25 0.2
Total Number of worker/ Shift 4.65
*Storage vessel of
As the number of shifts in the plant are 3, and the minimum salary of operator per shift,
according to the “Jordan Engineering society”, the engineer minimum salary is 565$.
𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
-Total Number of operators = 3.85 Operators * 3 shifts = 11.55 = 12 operator
𝑠ℎ𝑖𝑓𝑡
$ ℎ𝑟 𝑠ℎ𝑖𝑓𝑡 𝑑𝑎𝑦
-Cost of operating labor =3 ℎ𝑟.𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟* 8 𝑠ℎ𝑖𝑓𝑡* 3 * 365 𝑦𝑒𝑎𝑟 * 12 operator= 315,360
𝑑𝑎𝑦
$/yr
COST OF UTILITIES:
1) Cost of utilities:
Electricity used in the plant from energy consumed by each equipment is summarized in the
table below:
239
Table 67: Equipment electricity consumption.
Equipment type Utility Used Annual utility Unit of Annual
requirement utility
requrment
V-100 Electricity 454 Kwh
P-100 Electricity 2.2 Kwh
P-101 Electricity 11.2 Kwh
V-101 Water 45,000 M3/yr
F-100 Wash Water 475,000 M3/yr
E-100 Fuel 370,000 GJ/yr
Total electricity used to operate the equipment = 14 Kwh, this value was obtained per hour time
period
Kwh 24 ℎ𝑟 300 𝑑𝑎𝑦
Annual Utility requirements = 467 * * = 3360000 Kwh/ yr
ℎ𝑟 𝑑𝑎𝑦 1 𝑦𝑟
Cost of electricity in Kwh according to Purchased, U.S. average = 1.4 Kw/h
𝐾𝑤ℎ $ 1
Annual utility cost = Annual utility requirement ( )* Utility cost ( )*
𝑦𝑟 𝐾𝑤ℎ 1000000
1
=3,360,000 * 1.4* = 4.7 million $/ Kwh
1000000
- Cost of fuel in (M$/GJ)
Daily requirement of energy for multi effect evaporator = 14,200.7 Kwh
𝐾𝑗
Amount of fuel used to generate superheated steam used (𝐾𝑊)= heat of combustion ( ) * Energy required for
𝐾𝑔
multi-effect evaporator (KW)
𝑀𝐽
14,200.7 =42 ( ) * Q = 0.338 kg/s In GJ:
𝐾𝐺
The energy generated by amount of fuel oil is 41868 KJ/KG (world-nuclear.org, n.d.)
𝐾𝑔 𝑠 24 ℎ𝑟 300 𝑑𝑎𝑦
0.338( )* 3600 * * = 8,760,960 kg/yr
𝑠 ℎ𝑟 𝑑𝑎𝑦 1 𝑦𝑟
𝐾𝑔 𝐾𝐽
= 8,760,960 𝑦𝑟
* 41868 𝐾𝑔= 366,803,873,280 KJ/yr = 370,000 GJ/yr
240
APPENDIX E : DESIGN CALCULATIONS
. DETAILED BALL MILL SIZING CALCULATIONS:
Based on material balance and required size of product produced from miller:
62.1 ton/hr of phosphate rock
As product size of phosphate rock is medium (0.05-50mm), bond’s law is used to calculate energy
requirements of the miller, the required produced size is (70 µm):
Figure 58:Table of size produced vs. energy equation().
WI DPf DPi
9.92 0.07 mm 0.5 mm
Based on the table above which relates the required size produced, the energy consumed by
the grinding equipment is calculated using Bond’s equation:
𝑃 1 1
W= =Kb*( − ) in Kw.ton/hr (Peter harriott, Julian smith)
𝑚 √𝐷𝑝𝑓 √𝐷𝑝𝑖
241
Where the product is assumed to pass 80% of mesh size 100 µm
𝐾𝑏
Wi= , Wi for feed= 9.92, Kb=0.31622*Wi
√0.1
𝑃 1 1
W= = 0.31622*Wi*( − )
𝑚 √𝐷𝑝𝑓 √𝐷𝑝𝑖
Final product diameter (Dpf)=70 µm

Initial product diameter (Dpi)= 500 µm
Mass flow of phosphate rock feed in ton/hr= 61.272 ton/hr
Substituting in Bond’s law:
1 1
 W= 0.31622*9.92*( − )=7.42 kw.ton/hr
√0.07 √0.5
 P= W*m = 7.42*61.272 = 454.6382 KW
-Actual energy consumed by unit mass of material in crushing is:
𝑤
W= , Where w is actual energy consumed during crushing
Ƞ
W= 7.42 kw.ton/hr
Ƞ= Crushing efficiency of ball mill = 1%
7.42*0.01 = 0.0742 Kw.ton/hr
Ball Mill Power is calculated using equation:

𝑛
P= F* g* D* a* sin(α)* π*
60
Where (g*π)/60 = 0.514, substituting in the previous equation:

 P=0.514*F*D*a*n*µ
And power
P= 454.63 KW
The charge to the miller is, F= 61.272 ton
1 2𝑔 2∗9.812 0.704965 42.294

ncritical= ∗√ = 0.15915*√ = rps  rpm
2𝜋 𝐷−𝑑 𝐷−𝑑 √𝐷−𝑑 √𝐷−𝑑
Rotational speed of mill (n)= 70%* ncritical

Torque factor (µ) is found from table below, which relates the product size and feed type:
From table A-4 (cementequipment.org, n.d.):
242
Figure 59:The torque factor and media bulk density if grounded material.
 From table above, torque=0.73, Bulk density= 4.3 (t/m3)
To find the value of a and specific charge (q), from table A-5 (cementequipment.org, n.d.):
Assuming h/D =0.045:
Figure 60: The specific charge and arm of gravity of ball mill.
 At assumed h/D, then q=44.3, and a=0.473
Grinding media (Balls) diameter (d) from empirical equation in terms of Shell diameter (D):
𝐷𝑝𝑖∗𝑊𝑖 𝑆.𝐺
d=√ ∗√
𝐾∗𝐶𝑠 √𝐷
K for ball mills =200 from reference (cementequipment.org, n.d.)
243
0.5∗9.92 2.73
d=√ √
200∗.70 √𝐷
0.2418
d= 8
√𝐷
substitute in mill power equation:

42.294
454.63= 0.514*61.272*0.7* 0.0765
*D*0.473*0.73
√𝐷− 4
√𝐷
Solving the equation, D= 2 m, shell diameter

After calculating shell diameter of mill, the grinding ball diameter can be calculated from e-
equation stated above:
0.2418
 d= 8
√𝐷
From ball diameter equation, diameter of grinding balls, d= 0.22 m= 22 mm

Mill rotational speed:
42.294 42.294
N= = = 30.399 rpm
√𝐷−𝑑 √2−0.0643
Mill Critical speed:
ncritical= 70%* n = 0.7*30.399 = 21.27932 rpm
Volume of mill (m3):
From feed charge to mill equation

𝑞 44.3
F= ∗ 𝑤 ∗ 𝑣 = 61.23= ∗ 4.3 ∗ 𝑣 = 32.143
100 100
244
D L
Figure 61: Ball miller configuration.
Length of mill (m):

𝜋 𝜋
V= ∗ 𝐷2 ∗ 𝐿 = 32.143= ∗ 22 ∗ 𝐿
4 4
L= 10.236 m
Effective length to diameter ratio:

𝐿 10.223
= = 5.112
𝐷 2
245
REACTOR DESIGN:
15
R-100
Calculate X → Calculate T → calculate K → Calculate -rA
Ca3(PO4)2 + 3 H2SO4+6H2O → 2 (H3PO4) +3(CaSO4.2H2O)
*Limiting reactant in main reaction is: Ca3(PO4)2
● volume of reactor (nonisothermal) , Liquid Phase
This procedure from (Fogler, 1986) in chapter 8 (non-isothermal )
The rate of reaction is first order
-ra = K CA = k CA◦ (1-X) (given )
The rate of constant

−3742.4
- K = 1.1627 𝑒 𝑇 (given )
246
The design equation of CSTR reactor is
𝐹𝐴◦
-V = 𝑥
−𝑟𝐴
→FA◦ = CA◦ * V◦ = 2486.45 mole/min
−3742.2
→Substituting to get K = 1.1627 𝑒 74+273 = 2.19 x 10-5 (1/min)
→FA◦ = 2486 mole/min
𝐹𝐴◦ 2486
→CA◦ = = = 801.9 mol/ m3
𝑉◦ 3.1
→CA = CA◦ (1-X) = 801.9 (1-.85) = 120.2 mole / m3
When substituting in the equation by trial From excel sheet , the XEB = .8 that is equal X MB when
T = 74 c
∑𝜽𝒊 𝑪𝒑𝒊 (𝑻𝒊−𝑻)

𝑿𝑬𝑩 = − ∆𝑯𝒓𝒙𝒏+∆𝑪𝒑(𝑻𝒊−𝑻) (Fogler, 1986)
-Ti: Inlet temperature = 25 ℃ = 298 K

-Tout = 74 C
-∆𝐻𝑟𝑥𝑛 = −289 𝑘𝑗/𝑚𝑜𝑙 ,
-∑θi Cpi =∑θCa3(Po4)2 Cpi +∑ΘH2So4 Cpi + ∑ΘH2O Cpi = 211115.7918 j/mol.k
-∆Cp = ∑ CP ( Product ) - ∑ CP ( reactant ) = -473 j/mol.k
-(T-Ti) = 347.15– 298.15 = 49 k
Then when substituting in volume’s equation :
247
𝐹𝐴◦
V= 𝑥
−𝑟𝐴
801.9∗3.1∗.8
= 1 1
−3742.4( − )
801.9∗(1−.8 )∗1.1627∗𝑒 298 347
Volume = 424 m3
This volume is high comparing of industrial CSTRs, we choose to divide the flowrate to three
parallel CSTRs.
The volume of each reactor = 150 m3
Π
●𝑉 = D2 H
4
Diameter of Reactor
●D= 5 m,
Height of Reactor
●H = 5 * 1.5 = 8 m
Resistance Time:
𝑣 150 𝑚3
Ʈ = 𝑣 =3 = 150 min = 3ℎ𝑟
◦ 𝑚3 /𝑚𝑖𝑛
3
Reactor thickness:
𝑃 𝑟𝑖
t = 𝑆𝐸 + 𝐶𝑐 (Peters M. S., 1958)
𝑗 − .6𝑃
𝐷
, P = 101.325 Kpa , ri= ,
2
S= 94500 Kpa , EJ= .85 , 𝐶𝑐 = .0015𝑚
248
5
101.325∗
t = 94500∗ .85− .6∗101.325 + .0015 = .0046 m
2
Diameter of each reactor = .0046 +5 = 5.0046 m
Impeller Design:
Figure 62:Disk Turbine Agitator Parameter.
Detailed design calculation for the agitator CSTR:
Table 68: The geometric proportions (shape factors) of the mixing system which are considered as typical "standard" design
1/3 1/3 1 1/5 1/12 1/4
Whereas Dt = (0.1-10) m
Number of baffles =4
Number of impeller blade = 4-16
249
Table 69: parameters identification
Dt Internal diameter of the vessel

H Liquid height
J Baffle width
E Height of impeller above vessel floor
W Width of impeller blades
L Length of impeller blade
5
Impeller diameter Da = = 5/3= 1.66 m
3
5
Height of impeller above vessel floor E = 3 =1.66 m
Da
Width of impeller blades W = = 1.66/5 = .332 m.
5
Dt
Baffle width J = 12 = 5/12 = .416 m
1.66
Length of impeller blade L = = 1.66/4==.415
4
n = 90 rpm (since turbine speed ranges from55 to 125 rpm)

5- Impeller tip speed vtip:
Impeller blade tip speed vtip = Π*n*Da (J.Hickey, 2001)= 469.3 m/min = 7.8 m/s
n Da2 ρ
Impeller Re number = =1.5 *1.662*1560/.022=293095
μ
 Re = 562663> 10000 ,So it is turbulent flow
2-Power dissipation by an impeller

The power dissipated by an impeller in the turbulent flow region is given by:
Equation 10 power dissipated by an impeller in the turbulent flow region

P =KT n3 Da5 ρ (J.Hickey, 2001)
250
KT from the table 67 below for Fan turbine six blades= 1.65.
Table 70:Values of KL and KT for various types of impellers

Type of impeller KL KT
Propeller (square pitch ,three blades ) 41 0.32
Propeller (pitch 2:1,three blades) 43.5 1.00
Turbine (six flat blades ) 71 6.3
Turbine ( six curved blades) 70 4.8
Turbine (six arrowhead blades) 71 4.00
Fan turbine (six blade) 70 1.65
Flat paddle ( two blades ) 36.5 1.7
Shrouded turbine (six blades ) 97.5 1.08
P (W) = 1.65 *1.53 *1.665 *1560 =109502.17W= 109 KW
Efficiency of motor power= 80%
Actual Power = 109 /0.8 = 136.8kw
3-Velocity Gradient
Equation 11: velocity gradiant calculation equation
559141.2
G = √𝑃/𝑉𝜇 (J.Hickey, 2001)=√450∗0.022 =182 s-1
4-Mixing time
𝑫𝒂 𝑫𝒕
n .tT x ( )𝟐 𝒙 ( ) (J.Hickey, 2001) = 4.3 (constant ) ( for turbulent flow )
𝑫𝒕 𝑯
251
 For standard turbine with Da/Dt = 1/3 and Dt/H = 1:
𝟑𝟖.𝟕
n. tT = 38.7 , = 25.8
𝟏.𝟓
DETAILED FILTER DESIGN CALCULATION:
DESIGN PARAMETERS CALCULATIONS ON HORIZONTAL VACUUM BELT FILTER:

Based on material balance on horizontal vacuum belt filter:
𝑘𝑔
4.27*106 𝑑𝑎𝑦 𝑜𝑓 𝑠𝑙𝑢𝑟𝑟𝑦 1.7569*106 Kg/day of
ca2so4.2H2o
1.65*106 Kg/day of filtrate
1.Area calculation of filter:

Using bed voidage equation, which relates cake thickness and voidage of cake to the cross-
sectional area of the filter.
Substituting in equation, where:
ɛ: cake voidage (porosity) =0.65
m: mass flow rate of removed solid, where the gypsum has the largest mass, it was assumed
it’s the main solid exists in exits cake, it equals to = 1220.08 kg (as the batch takes place
each 60 minute)
A: filter area (m2)
ρc: Solid cake density (kg/m3) = 2330 kg/m3
H: cake thickness(m)=0.035m
252
Then:
1220 1
A= ∗ = 42.74 m2
(1−0.65) 0.035∗2330
From calculated area of the filter which equals to =42.74 m2, From table below, which
shows the belt width related to area of horizontal vacuum belt filter width, A= 42.47 m2
which ranges between (26 -88) m2, belt width = 3.2 m, which is the standard value of belt
width for horizontal vacuum belt filter.
Figure 63:Figure 4: belt width vs. Effective belt filter area in m2.
As area of belt filter = L* W, A=42.74 m2, and W=3.2 m

 Effective length of filter L = A / W = 42.74 / 3.2 = 13.35 m
The figure below shows the dimensions of horizontal vacuum belt filter, length and width of
the belt, and area of the belt.
Figure 64: Horizontal vacuum belt filter edges.

253
4.Permeability of cake(gypsum) K:
αav, cake resistance = 4*109
ρs=2330 kg.m-3
H, cake thickness = 0.035 m
Cake porosity, ɛ = 0.65
1
 K= =3.0656*10-13
4∗109 ∗2330∗0.35
7.Vacuum pressure applied across filter (ΔP):
𝑘𝑔 1 ℎ𝑟 𝑚3
Volumetric flow rate of cake to be removed (m3/s) = 73205.249 ∗ ∗ =
ℎ𝑟 3600 𝑠 1334 𝑘𝑔
𝑚3
0.01524
𝑠
Viscosity of filtrate µ= 0.00132 pa.s

Cake thickness (H) = 0.035 m
Cake permeability (B) = 3.065 * 10-13
Area of filtration = 42.74 m2
Substituting in filtration pressure drop applied:
0.01524∗0.001∗0.035
 ΔP= =40747.955 pa = 40.747 kpa
3.065∗10−13 ∗42.74
Calculation of parameters related to filter design of slurry and cake produced:
254
Solid mass fraction in feed, In S14:
Solid’s flowrate in feed = 73205.249 kg/hr
Slurry feed flowrate = 199683.231 kg/hr
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠 𝑖𝑛 𝑓𝑒𝑒𝑑 73205.249

S= = *100% = 41.1 % W/W
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑓𝑒𝑒𝑑 177683.231
Mass fraction of wet/dry cake:

ρl=1334 kg.m-3
ρs=2330 kg.m-3
Cav=0.35
Substituting above values in:
𝜌𝑙 1−𝐶𝑎𝑣
 mav = 1 + ∗( )
𝜌𝑠 𝐶𝑎𝑣
1334 1−0.65
 =1 + ∗( ) = 2.0632
2330 0.65
Feed effective concentration in cake (Cs):

S, solid fraction in feed = 41.1%
ρL=1334 kg.m-3
mav= 2.063
𝑆𝜌𝐿 0.41∗1334
Cs= = =3566.84 kg.m-3
1−𝑚𝑎𝑣𝑆 1−2.06∗0.41
Detailed Design Calculations of Pumps
Pump (P- 103 A/B)
Type: Centrifugal radial pump (Most common for high flow rate)
Material of construction: SS902
Inlet stream component: H2O , H3PO4
255
μ of water at 30°C= 0.0007978 Pa.s.
μ of water at 30°C = .0032 Pa.s
𝛍 𝒎𝒊𝒙 =.0021 Pa.s
Density mixture = 1424 Kg/ m3
Inlet mass flow rate = 1648916 Kg/day = 19.08 kg/s.

ṁ 19,08
Volumetric flow rate = = = .0133 m3/s = 48 m3/hr
ρ 1424
First, assume turbulent flow:
Di, opt. =0.363 * Q*0.45 * ρ*0.13
= 0.363 * (0.0133)0.45 *(1424)0.13

= 0.133 m
Now, check for Re #:

𝑄 𝑄 π
Velocity (V) = =π = 0.0133 /( ∗ 𝐷𝑖, 𝑜𝑝𝑡 2 )= 1.0191 m/s
𝐴𝑟𝑒𝑎 ∗𝐷𝑖,𝑜𝑝𝑡 2 4
4
ρ∗V∗D 1424∗1.0191 ∗ 0.133

Re = = = 86805
μ .0021
Re > 2100 (So, the flow is turbulent) means that our assumption is true
Assume nominal pipe size (NPS) = 6 inch and Schedule # = 40, then from appendix D according to
(Peters, 2004) :
ID = 6.065inch = 0.154 m
OD = 6.625 inch = 0.168 m
Now repeat velocity and Re# calculations using the correct value for ID=0.1022 m
𝑄 π
New velocity =π = 0.0133 /( 4 ∗. 1542 ) = = .71 m/s
∗𝐼𝐷 2
4
ρ∗V∗D 1424∗.71 ∗ 0.154

New Re # = = = 74142
μ .0021
Pump Design Equation:
256
Equation 12: mechanical design equation
𝜟𝑷 𝚫 𝐕𝟐
W• = g Δz + + + Σ F (Peters M. S., 1958)
𝝆 𝟐𝛂
g Δz = 9.81 * 4 = 39.24 J/Kg
𝜟𝑷
=0
𝝆
𝚫 𝐕𝟐
𝟐𝛂
= 0 (assume no change in inlet and outlet velocities of the pump).
Σ F = F St. Pipe + F elbow + valves + F contraction + F expansion

2 f V2 L
F St. Pipe = 𝐷
L = 24 m
Roughness for Stainless steel ꜫ = 0.000046

ꜫ
𝐷
= 0.000298
From moody diagram at Re # = 74142 and ꜫ/D = 0.000298 find Friction factor:
257
f = 0.0075
2∗.0075 ∗.712 ∗24
F St. Pipe = = 1.178 J/Kg
.154
2 𝑓 𝑉2 𝐿𝑒
F elbow + valves = 𝐷
Assume there is four elbows (90 std. radius) and two gate valves
Le/D =(4∗32 )+( 2∗7 )= 142

2∗ .025∗2.132
F elbow + valves = *142=1.073 J/Kg
1
𝐾𝑐 𝑣2 2
F contraction = 2𝛼
𝐴2
Kc = 0.4 (1.25 – ), because A1 larger than A2, the term 𝐴2/𝐴1=𝑧𝑒𝑟𝑜
𝐴1
Kc = 0.4 * 1.25 = 0.56000
𝛼 for turbulent flow = 1
258
F contraction = 0.56* .712 /2*1 = .14 J/Kg
𝑣1 2
F expansion = = .25 J/Kg
2𝛼
Σ F = 1.178 + 1.073 + .14 + .25 = 2.64 J/Kg
W• = 39.2+ 0 + 0 + 2.641 = 41.84 J/Kg
Theoretical power = W• * Mass flow rate
= 41.84 * 68704 Kg/hr
= 2874575/hr = .798 KW = 2 hp
Motor size = 𝒆𝒇𝒇𝒆𝒄𝒊𝒆𝒏𝒄𝒚
Efficiency for centrifugal pump; figure (12-17) according to (Peters, 2004) = (55 – 77) %
Avg. = 0.66
Motor size = 2/0.66 = 3.03 hp
The power range for centrifugal pump between (0.125 – 5000) hp, and our power is equal to 63.63
hp which is in the range of centrifugal pum
PUMP-102
Type: Centrifugal radial pump (Most common for high flow rate)
Material of construction: SS902
Inlet stream component: slurry
259
Density pf slurry = 1560 Kg/ m3
Inlet mass flow rate = 1812.8 m3/day = .0209 m3/s.
The below information from a Pipe
 Di,opt = .17 m
 And Re = 13854.7
 Velocity = .58 m/s
 ID = 6.065 in =.1540 m
 OD= 6.625 = .1682 m
 Roughness for SS ꜫ = 0.000046
ꜫ
 = 0.000298
𝐷
 L=20
Pump Design Equation:
𝜟𝑷 𝚫 𝐕𝟐
W• = g Δz + + + Σ F (Peters M. S., 1958)
𝝆 𝟐𝛂
g Δz = 9.81 * 4 = 39.24 J/Kg

260
𝜟𝑷
=0
𝝆
𝚫 𝐕𝟐
= 0 (assume no change in inlet and outlet velocities of the pump).
𝟐𝛂
Σ F = F St. Pipe + F elbow + valves + F contraction + F expansion
2 f V2 L
F St. Pipe = 𝐷
L = 20 m
Roughness for SS ꜫ = 0.000046
ꜫ
= 0.000298
𝐷
From moody diagram at Re # = 13854.7 and ꜫ/D = 0.000298 find Friction factor:
261
From moody chart f = 0.003
2∗.003 ∗.582 ∗24
F St. Pipe = = .2621 J/Kg
.154
2 𝑓 𝑉2 𝐿𝑒
F elbow + valves = 𝐷
Assume there is four elbows (90 std. radius) and two gate valves
Le/D =(4∗32 )+( 2∗7 )= 142

2∗ .003∗.582
F elbow + valves = *142=.286 J/Kg
1
𝐾𝑐 𝑣2 2
F contraction = 2𝛼
𝐴2
Kc = 0.4 (1.25 – ), because A1 larger than A2, the term 𝐴2/𝐴1=𝑧𝑒𝑟𝑜
𝐴1
Kc = 0.4 * 1.25 = 0.56000
262
𝛼 for turbulent flow = 1
F contraction = 0.56* .712 /2*1 = .14 J/Kg
𝑣1 2
F expansion = = .25 J/Kg
2𝛼
Σ F = 1.178 + 1.073 + .14 + .25 = 2.64 J/Kg
W• = 39.2+ 0 + 0 + 2.641 = 41.84 J/Kg
Theoretical power = W• * Mass flow rate
= 41.84 * 117832 Kg/hr
= 24930090J/hr = 7 KW = 10 hp
Motor size = 𝒆𝒇𝒇𝒆𝒄𝒊𝒆𝒏𝒄𝒚
Efficiency for centrifugal pump; figure (12-17) according to (Peters, 2004) = (55 – 77) %
Avg. = 0.66
Motor size = 10/0.66 = 15 hp
ABSORBER V-101 DESIGN CALCULATION

selection the type of packing material
ceramic INTA lox saddle is selected
determination size of the packing
263
The selected size is 51 mm (2inch), because the recommended size ranges of packing for the ,
diameter larger than .9 m are (50mm-76mm). (J R Backhurst, 1999)
And data design for ceramic intalox saddles for 51 mm are taken From table 11.3
in . ( (Coulson Richardsons Chemical Engineering vol6) book)
Table
71: type size Surface area Packing factor Void fraction
(mm) (Inch)
(m2/m3) m-1 -
INTA lox 51 2 108 130 .7
saddle
(ceramic)
design data for ceramic INTA lox saddles packing
Calculation of the number of transfer unit:

Material balance equation:
Gm (Y1 – Yn+1) = Lm(X° – Xn)
Where:
Yn+1 : Mole fraction of H2SIF6 in entering gas stream S4 = .1233
Y1 : Mole fraction of H2SIF6 in leaving gas stream S8 =.0053
Gm: the inlet gas flow rate (Kgmole /hr)
= 36251.1 Kg/hr
Lm: the inlet solvent flowrate (Kgmole/hr)

= 29907.3 Kg/hr
And
Yn+1=m *Xn
m: the slope of the equilibrium line =.55
Now:
m Gm/ Lm= .667, Y1/Yn+1= 100.18
264
And from
graph 11.40 in ( (Coulson Richardsons Chemical Engineering vol6))book that
is used to find the NOG:
Figure 65: number of transfer unit NOG as a function of Y1/Y2 with mGm/Lm as parameter
NOG: the number of transfer unit =~ 11
 Calculation of diameter of column
265
Table: the property of liquid and gas entering the absorber V-101
Properties Units Gas entering (G) Liquid entering(L)
Flowrate Kg/hr 13497.12 11135.1
Temperature (T) K 343 298
Pressure (P) atm 1 1
Density (𝝆) Kg/m3 PM/RT = 1.13 997

( at inlet temp.)
Avg. MW Kg/Kmol 33.8 18

( at inlet temp.)
Viscosity (𝝁) Kg/m.s .00075 .00089

( at inlet temp.)
The assumed pressure drop is 21 mm of H2O /m of packing because From section 11.14.4 in
(Coulson Richardsons Chemical Engineering vol6) book, the recommended pressure drop is
between 15 to 50 mm H2O per meter of packing height.
Now:
The Abscissa of figure 11.44 in (Coulson Richardsons Chemical Engineering vol6) :
= FLV
266
=(11135.1/13497.1)*(1.13 /997)^.5
FLV = .028
SO :
the figure 11.44 (J R Backhurst, 1999) and FLV are used to Find K4:
Figure 66:Generalized pressure drop correlation
K4= 1
And
at flooding K4 = 5.8
percentage flooding= (K4 at design pressure drop / K4 at flooding).5 *100
267
= 41.8 %
Figure 67: the generalized pressure drop and flooding correlation
Then from correlation 11.118 from (Coulson Richardsons Chemical Engineering vol6) book:
V*W = [k4× ρg × (ρL-ρg) / 13.1×Fp× (µL /ρL) 0.1] ½
Where:
V*
W: gas mass flowrate per unit column cross-sectional area (Kg/m2.s)
FP : packing factor = 130 m-1
K4: factor = 1
ρL: Density of liquid solvent at 25 oC = 997 Kg/m3
ρg: Density of gas mixture= PM /RTg= 1.13 Kg/m3
µL: Viscosity of liquid solvent at 25 oC = .00089 (from appendix -9 in (McCabe W.L., 1993) book)
µg: Viscosity of Gaseous mixture at 70 oC = .00075
V*W = [(1*1.13*(997-1.13)/(13.1*72*(.00089/997)^.1)] .5
=1.55 Kg/m2.s
G = (13497.1Kg/h)/3600 = 3.78Kg/s
268
The column area = G/ V*W
= 3.78 / 1.55 = 2.34 m2
And the diameter of the column = [4A] ½

[3.14] ½
D = 1.98 m
Now to calculate the height of transfer unit HOG, the Onda’s rule is used :
 Calculation of Liquid Film Coefficient :
where :
aw: effective interfacial area of packing per unit volume, m2/m3
LW: liquid mass flow rate per unit cross-sectional area
= (L/Area of column) = 1.82 kg/m2s
a: actual area of packing per unit volume = 108 m²/m3
σc: critical surface tension for particular packing material = .061N/m for ceramic (from Coulson-
Richardson chemical engineering vol.6 (J R Backhurst, 1999),
σL = liquid surface tension= .070 N/m
aw= 45.1 m2/m3
SO, the aw is found to calculate the liquid film coefficient by the correlation below:
Where:
KL : liquid film coefficient m/s
dp : packing size =(6*(1- 𝜀))/a = 20 x 10-3 m
DL : diffusivity of liquid = 1.7 x 10-9 m2/sec
KL= .0001 m/s
269
 Calculation of Gas Film Coefficient :
Where:
Vw : gas mass flowrate per unit column cross-sectional area=1.55Kg/m2.s
K5 = 5.23 for packing sizes above 15 mm, and 2.00 for sizes below 15 mm,
Dg :Diffusivity of gas =.04*10^ -4 m2/s (from appendix or from correlation (21.25) in (unit Operations in
Chemical Engineering) book)
KG: Gas Film Coefficient = .0003 kmol/m2s.bar
 Calculation of Gas-film transfer unit height:
Where:
HG : Gas-film transfer unit height (m)
Gm= Vw/ Mw = 2.085/27.6 = .048 Kmol/m2.s
SO:
HG = .065/(.00044*43.74*4) = .89m
 Calculation of Liquid-film transfer unit height:
Where:
HL= Liquid-film transfer unit height (m)
270
Lm= Lw/ Mw = 1.68/18 = .096 Kmol/m2.sec
Ct = Concentration of solvent = 𝜌L/Mw= 55.39 Kmol/m3
HL= .096/(.000124*43.74 *55.39) = .4145 m
 Calculation Of Height Of Transfer Units:

Then the final step on Onda’s method is to find the height transfer unit HOG by the correlation
below:
= 1.18 m
 To calculate Height Of Tower:

The height of the packing:
Z= NOG × HOG
=10.4*1.18= 13 m
Allowances for liquid distribution = 1m

Allowances for liquid Re-distribution =1m
Total height of tower = 11 + 1 + 1= 15 m
 To calculate Operating Velocity:

Now, to find the operating velocity we use the abscissa of fig. 9.21F in (Applied Process Design for
Chemical and Petrochemical Plants, vol. 2) book:
= .028
271
Then from the figure below (figure 9.21) and the value of the abscissa of the figure we can
calculate the operating velocity :
`
Figure 68: strigles latest generalized pressure drop correlation diagram
G2 ×Fp×µL0.1 / ρg (ρL - ρg)gc = .042
SO:
G=.93 kg/m2 .s
u0 =G/𝜌g = .88 m/s
 To calculate Flooding Velocity:

the correlation below in (the abscissa of fig. 22.6 in (McCabe W.L., 1993) book)
272
= .028
Now from the figure below (figure 22.6) and the value of the abscissa of the figure we can calculate
the flooding velocity :
Figure 69: generalized correlation for flooding and pressure drop in packed columns
G2 ×Fp×µL0.1 / ρg (ρL - ρg)gc = .17
So:
The velocity of flooding = 1.7 m/s
273
Operating velocity as percent % of flooding velocity = (.88/1.7)*100 = 60 %
 To calculate wetting rate:
Wetting rate (W) = Liquid volumetric flow rate per unit cross-sectional area
Specific area of packing per unit volume (a)
Liquid volumetric flow rate/Unit cross-sectional area = [mass liquid flowrate(L) /area*3600*𝜌L)]
= 11135.3/(3600*997*1.8) = .00179
W = .00179/108 = 2*10^-5 m3sec-1/m2
 To calculate Pressure Drop at Flooding:

From (unit Operations in Chemical Engineering) in Eq.22.1, Pressure drop at flooding is given by relation:
ΔPflooding =0.115Fp 0.7
= .98kPa/m of packing
 To calculate Total Pressure Drop:
By Ergun Equation (4.42) in (Industrial Separation Processes - Fundamentals) book
Equation 13: ergun equation

𝛥𝑃𝐷𝑝 𝜀
𝑓𝑝 =
𝐿𝜌𝜈𝑠 (1 − 𝜀)
150
𝑓𝑝 = + 1.75
𝑅𝑒𝑝
𝜌𝜈𝑠 𝐷𝑝
𝑅𝑒𝑝 =
𝜇(1 − 𝜀)
Then:
274
Equation 14: pressure calculation equation for filter
150𝜇𝜈𝑠 𝐿 (1 − 𝜀)2 1.75𝜌𝜈𝑠 2 𝐿 (1 − 𝜀)

𝛥𝑃 = +
𝐷𝑝2 𝜀3 𝐷𝑝 𝜀3
Where:
𝜇: the viscosity of the gas = .00075 kg/m.s
𝜈𝑠 : the velocity = .88 m/s
𝐿: length of the packing = 13 m
𝜀: the void fraction of the packing = .7
𝐷𝑝 : particle diameter = (6*(1- 𝜀))/a = .0155 m
𝜌: the density of the gas = 1.13 kg/m3
So:
ΔP = 2175 pa = 222 mmH2O
= 2.17Kpa
 To calculate number of streams for liquid distribution at top of the packing:

Ns= (D/6)2
D = Diameter of the absorption column in inches =59.1 inch
= 97.02
 To calculate the thickness of the column:
e = (Pi Di/ 2f-Pi) + C
where :
e : thickness of column = (mm)
Pi : design pressure = .10*operating pressure
= (.10 *. 101)+.101 = .1111 N/mm2
Di : internal diameter = 2000mm
F : design stress = 130 N/mm2 ( (Carbon Steel Handbook)
C : corrosion allowance = 2 mm
So:
e= 5.1 mm
 To design the domed end:
Max. thickness(t) = PD/(2SE - .2P)
So
The max. pressure = 2SEt /(D+.2t)
Where :
P: internal pressure N/mm2
275
D: internal diameter = 2000mm
E: joint factor =.8
S: design stress of material 130 N/mm2
Max. pressure =.7 N/mm2
Then :
The nozzles diameter for:

Gas feed=
D= 226 (m).5 *(𝜌).35
= 226* 3.75.5 *1.13-.35
=420 mm
Liquid feed :
D= 226 (m).5 *(𝜌).35
35.5mm
EVAPORATOR DESIGN CACULATIONS :
From mass and energy balance :
𝐾𝐺
F = 1648916.4 𝐷𝐴𝑌
Xf= 0.4 wt%

X3= 0.74 wt%
TF =31 ℃
T3 =50 ℃ the temperature for the third evaporator .
T* = 120 ℃ the temperature for the input steam .
The driving force for the system = ( 120 – 50) = 70℃
∆𝑇𝑠𝑦𝑠 = ∆𝑇1 + ∆𝑇2 + ∆𝑇3
 ∆𝑇1 = 17.6℃ = 𝑇∘ − 𝑇1 ⟶ 𝑇1 = 102℃

 ∆𝑇2 = 21.3℃ = 𝑇1 − 𝑇2 ⟶ 𝑇2 = 80 ℃
 ∆𝑇3 = 𝑇2 − 𝑇3 = 50℃ ⟶T3 = 50 ℃
𝐹 ∗ 𝑋𝐹
𝐿3 =
𝑋3
1648916.44 ∗ 0.4 𝐾𝑔
𝐿3 = = 891306.18 .
0.74 𝑑𝑎𝑦
276
𝐿1 𝐶𝑝 (𝑇1 − 𝑇2 ) + (𝐹 − 𝐿1 )𝜆1 − (𝐿1 − 𝐿2 )𝜆2 = 0
𝐿2 𝐶𝑝 (𝑇2 − 𝑇3 ) + (𝐿1 − 𝐿2 )𝜆2 − (𝐿2 − 𝐿3 )𝜆3 = 0
from solving the previous equations simultaneously .

𝑡𝑜𝑛
𝐿1 = 1388 .
𝑑𝑎𝑦
𝑡𝑜𝑛
𝐿2 = 1336 .
𝑑𝑎𝑦
And from the equation of the first effect .
𝐹𝐶𝑝 (𝑇𝑓 − 𝑇1 ) + 𝑣° 𝜆° − (𝐹 − 𝐿1 )𝜆1 = 0
𝑡𝑜𝑛
𝑣° = 349.6 .
𝑑𝑎𝑦
𝑘𝑔 𝑘𝑗
𝑣° 𝜆° 349 ∗ 2243
𝑑𝑎𝑦 𝑘𝑔
𝐴1 = = = 332 𝑚2
𝑈1 ∆𝑇1 𝑘𝑗
1140 ∗ 17.6𝑘 ∗ 0.001 ∗ 24 ∗ 3600
𝑑𝑎𝑦
Equation 15: design equation of evaporator .

(𝐹 − 𝐿1 )𝜆°
𝐴2 = = 251 𝑚2
𝑈2 ∆𝑇2
(𝐿1 − 𝐿2 )𝜆2
𝐴3 = = 212 𝑚2
𝑈3 ∆𝑇3
∆𝑇1 ∗ 𝐴1 + 𝐴2 ∆𝑇2 + ∆𝑇3 𝐴3

𝐴𝑎𝑣𝑒𝑟 = = 254 𝑚2
∆𝑇𝑠𝑦𝑠
The second iteration :

𝐴1 (∆𝑇1 ) 𝐴2 (∆𝑇2 ) 𝐴3 (∆𝑇3 )
∆𝑇1 = ∆𝑇2 = ∆𝑇3 =
𝐴 𝐴 𝐴
∆𝑇1 = 23.74 ∆𝑇2 =21 ∆𝑇3 = 25
 𝑇1 = 96.2 ℃
 𝑇2 = 78.19 ℃
 T3 = 50 ℃
𝐴1 = 254 𝑚2 . 𝐴2 = 254 𝑚2 𝐴𝑎𝑣𝑒𝑟 = 255 𝑚2
𝑡𝑜𝑛
𝑣° = 349 . 𝐴3 = 254 𝑚2
𝑑𝑎𝑦
277
𝑡𝑜𝑛
 The amount of steam needed 𝑣° = 349 𝑑𝑎𝑦 .
 Area for each effect = 255 𝑚2
𝒗 +𝒗 +𝒗
 Steam economy = 𝟏 𝑣𝟐 𝟑
°
𝑡𝑜𝑛
V2= L1-L2 = 251.6 𝑑𝑎𝑦
𝑡𝑜𝑛
V1 =F-L1=260.8 𝑑𝑎𝑦
𝑡𝑜𝑛
V3 = 245.5 𝑑𝑎𝑦
𝑡𝑜𝑛
 𝑣° = 349 𝑑𝑎𝑦
𝒗𝟏 +𝒗𝟐 +𝒗𝟑
 Steam economy = = 2.16
𝑣°
 Tube pitch calculations( triangular).
Most generally used diameters today ranges from 1.25 to 2.00 in. outer diameter and most
generally used lengths of tubes ranges from 4 to 15 ft.
Let us choose 5/4-in. nominal diameter, 80 schedule, brass tubes of 10-ft length. Therefore
Outer diameter do = 42.164 mm
Inner diameter di = 32.46 mm Length L = 8.53 m
 Tube pitch PT = 1.25 × do

= 1.25 × 42.164
= 52.705 mm
 Surface area of each tube a = 𝜋doL
= 𝜋× 52.705×10-3× 3.048
= 1.337 m2
 Number of tubes required Nt = A /a
= 191
 Evaporator drum diameter D = 6 𝑚
 D for long tube = 6m h=1.5D rule of thum
 v=𝜋*(D^2/4)*1.5D
 volume of evaporator = 254.3 m3
278
0.866∗𝑁𝑇 ∗𝑑2
 area occupied by tube sheet = , 𝛽 = 0.9
𝛽
= 0.459 m2
𝜋
 Downcomer area = 0.5 ∗ (𝑁𝑇 ∗ (4 ) ∗ 𝑑 2
= 0.287 m2
4
 Downcomer diameter =√𝜋∗𝐴 =2.132 m
 Total area of tube sheet = 0.28 +0.459 = 0.75 m2

4
Tube sheet dimeter = √𝜋∗𝐴 = 1.302 m2
Working pressure = 5% of maximum pressure = 1.03*1.05=1.103 kgf/cm2 .

Ts=10mm
Equation 16: drum calculation equation

𝐸𝑡 ∗ 𝑡𝑠 ∗ (𝑑 − 𝑡𝑡 )
𝑘=
𝐸𝑇 ∗ 𝑁𝑇 ∗ 𝑇𝑇 (𝑑 − 𝑇𝑇 )
 Buffle spacing = 0.2 * D = 0.2* 6*0.2= 1.2 m

 Calculate tube pitch and the bundle diameter
𝑝𝑡 = 1.25 ∗ 𝑑.
𝑁𝑡 1
𝐷 = 𝑑.∗ ( )𝑁
𝐾
From the figure assume triangular pitch k = 0.49 , n = 2.207

279
Then the bundle diameter D = 874 mm
𝐿𝑒𝑛𝑔ℎ𝑡 𝑜𝑓 𝑡𝑢𝑏𝑒 1
 Number of buffles = −1 , 𝐵 = 5 ∗ (𝐷)0.75
𝑏
=1/5*(6)^0.75 = 0.7
=(8.53/0.7)-1 = 28
 The thickness calculations :
Equation 17: thikness calculation relashinship

𝐷∗𝑃
𝑡𝑠 =
2∗𝑆𝑒+𝑃
maximum allowable working stress:

Design equations and data for pressure vessels based on the ASME Boiler and Pressure Vessel Code
Carbon steel ( SA-285. Gr. C ) is chosen as a material of construction
And the suitable working stress = 94500 KPa = 13706.066 psig
16.7 ∗ 6
= = 0.045
2 ∗ 0.85 ∗ 13706 − 16.7
The minimum corrosion allowance tc frequently selected is 3.18 mm
= 0.125 in for acidic solutions.
ts (wall thickness) = αs D + tc = (0.045)*(236 in) + (0.125 in) =10 mm
 The same design for each three effects evaporator .

𝑣
 The drum diameter 𝑅𝑑 = 𝐴
𝜌𝐿−𝜌 , Rd =1.3
𝑉
0.0172∗√
𝜌𝑉
𝑘𝑔 𝑘𝑔 𝑚3
 𝜌𝐿 = 1440 𝑚3 𝜌𝑉 = 1.12 𝑚3 𝑣 = 3.6 𝑠
4∗𝐴
 𝐴 = 4.49 𝑚3 D=√ D= 2.39 m
𝜋
280
DETAILED DESIGN OF STORAGE TANK T-100 CALCULATIONS:
Tank T-100, which stores phosphate rock, before entering the miller to be grounded:
1.48 *106 kg/day of phosphate rock
T-100
-Input feed to tank (kg/day) for tank, of phosphate rock = 1.48*106 kg/day of phosphate rock
-Volumetric flow rate of feed (m3/day) =
Density of raw material (phosphate rock) = 1762 kg/m3
-Assume voidage: ɛ= 0.45
-bulk density ρb= ρp*(1-ɛ)
=1762*(1-0.45) = 969.1 kg/m3
The angle of response between (30֯-83֯), because of free flowing
Assumed angle to be 32֯
Mass flow of phosphate rock =1.48*106 kg/day

1.48∗106
 V= = 1525.95 m3/day
969.1
-Residence time= 3 days
-Assume 90% filling
Then:
𝑚3
 1525.95 𝑑𝑎𝑦* 3days =4577.75 m3
 4577.75 m3 /0.9 =5086.38 m3
If two hoppers are needed, the volume for one hopper is 180 m3, from the equation we can calculate
the diameter and height of the tank:
 Vtotal = (3.14/(24*tanӨ)) *(D3-B3) +(3.14*4) * D2*H
- Assume H=3D
- Assume minimum outer diameter B (m)= 0.35 m
 Diameter of the bin = 12.5 m
281
 Height of bin= 37.7 m
Figure 70: Design of storage tank

-DESIGN OF BOTTOM CONE:
h0 = (D/2)/ (tanθ) = 10 m
hB = (B/2)/(tanθ) = 0.28 m
h = h0 – hB = 9.73 m
Figure 71: Dimension of bottom cone.

Cost Estimation of tank T-100:
From figure below which shows purchase cost of concrete tank vs. tank diameter
282
Figure 72: Purchase cost of concrete tanks vs. diameter
From figure above, the purchase cost of concrete tank of diameter 12.4 m which is 40.7 ft equals to
85,000 $ and this is according to year 2012
CEPCI value (2012) = 584.6

CEPCI (2021) = 602.8
𝐶𝐸𝑃𝐶𝐼 2021 602.8
Index ratio = 𝐶𝐸𝑃𝐶𝐼 2012 = 584.6 = 1.03
 Purchase cost of concrete tank in 2021 = Purchase cost 2012 * Index ratio = 85,000$ * 1.03
= 87,550 $
 As the capacity of single tank is 4670 m3 and it’s required to keep 10,000 m3 of phosphate
rock in plant as stored amount, then 3 phosphate rock tanks in the plant:
283
 3*87,550 $ = 262,650 $
MIXER DESIGN (MX-100)
Main Design parameters:

𝑉
 Detention time: volume divided by the inlet volumetric flow rate 𝜈
 Volume of the tank
 The gradient velocity
 Detention time of chemical precipitation of chromium = 3 min

 Volumetric flow rate = 2.17 m3/min
 Volume of tank =2.17 m3/min *3 min = 6.51 m3
 Assume the mixer tank is vertical cylindrical tank
 Volume = Π/4 Dt2*H
 Assume the liquid depth equal the tank diameter H=Dt
4
 Diameter of tank =( 𝛱 V )1/3 =(1.2 *6.51)1/3
 Dt = 2.02 m
 Liquid depth in the tank = Dt
 H = 2.02 m.
AGITATOR DESIGN
 Dt = (2.02) m.
 Number of baffles =4
 Number of impeller blade = 4-16
 Efficiency of motor = 80%.
 n = 90 rpm =1.5 rps
 four baffels
then
284
 Da=0.67 m
 W =0.134 m
 E = 0.67 m
 L=0.167 m
Dt
 J = 12 = 0.16 m
 Impeller blade tip speed vtip = Π*n*Da = 3.15 m/s
(𝐷𝑎 )2 ∗𝜌∗𝑛 1440∗1.5∗2.662

 𝑅𝑒 = = = 281867.4 > 10000 , 𝑆𝑜 𝑖𝑡 𝑖𝑠 𝑡𝑢𝑟𝑏𝑢𝑙𝑒𝑛𝑡 𝑓𝑙𝑜𝑤
𝜇 3.44∗10−3
The power dissipated by an impeller in the turbulent flow region is given by:
P =KT n3 Da5 ρ
 KT from table for Fan turbine six blades= 1.65.

 P (W) = 1.65 *1.53 *0.675 *1440 =2411.8 W.
 Efficiency of transfer of motor power to waterpower = 80%
 Actual Power = 2411.8/0.8 = 3014 W

 3014
G = √𝑃/𝑉𝜇 =√6.51∗3.44∗10−3 =366.86 s-1
 Since mixer must be designing to develop maximum velocity gradient (G value) not less
than 300 s -1), so our assumptions are true
285

Grauation Project 2 Group 2 Phosphoric Acid

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Grauation Project 2 Group 2 Phosphoric Acid

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Jordan University of Science & Technology

Chemical Engineering Department

Submitted in partial fulfillment of the graduation project (ChE 592) course

Submission Date 2/ 6 / 2021

Figure 1: Phosphoric acid and its esters (lardbucket, 2012) . .................................................................. 11

Table 1: Requirement of phosphate rock feed. ...........................................................................................14

1.1 DEFINTION AND CHEMICAL PROPERTIES

42.35°C and 1.834 g / cm3 respectively.

Figure 1: Phosphoric acid and its esters (lardbucket, 2012) .

1.2 PHYSICAL PROPERTIES

acid is reacted with tricalcium phosphate rock.

separate process to obtain phosphoric acid (BYJU'S, 2020) .

tizing agent (SOFTSCHOOLS, 2005-2020) .

1.5 REQURIEMT OF FEED PHOSPHATE ROCK

Component Effect on the wet process Acceptable percent

Cl High amounts of chlorine cause corrosion The acceptable range is (0 - .5)

Equation 2: Ca3(PO4)2 + 2H2SO4 Ca(H2PO4)2 + 2CaSO4.

The chemical formula of Super-phosphates is Ca(H2PO4)2. Super-phosphates is monobasic calcium

2.2 HEALTH AND SAFETY HAZARD:

Diamond Hazard Value Description

Health 3 Can cause serious and permanent injury.

Flammability 0 Will not burn under typical fire conditions.

Instability 0 Normally stable, even under fire conditions.

2.3 PROCESS OF MANUFACTURE

2.3.1 DRY-KILN PHOSHPORIC ACID PRODUCTION

2.3.3 WET PROCESS ACID PRODUCTION (WPAP)

is produced using wet-process (Dorozhkin, 1997).

technique and is normally referred to as “wet process” (Tariq F Al-Fariss, 1991).

(Tariq F Al-Fariss, 1991) .

the crystal type of produced calcium sulfate and they are:

1. HEMI-HYDRATE WET PROCESS ACID PRODUCTION (HH)

2. DI-HYDRATE WET PROCESS ACID PRODUCTION (DH)

major advantage of this process is its flexibility and reliability.

so critical (Abu-Eihah, 2001) .

phosphoric acid production (Dekker, 1989).

2.4 USES AND APPLICATIONS OF PHOSPHORIC ACID:

Di-Ammonium hydrogen Phosphate (DAP) and Mono-Ammonium Dihydrogen Phosphate (MAP)

the dominate segment is fertilizers as it has the highest market share.

Figure4 : Uses of phosphoric acid, Fertilizers. (INTELLIGENCE, 2019)

Figure 3: Phosphoric acid volume (%), by End-user industry.

detergents). In household chores detergents, phosphate-based formulations of detergents also offer

as complexing (softening), emulsifying, dispersing and buffering agents (PRAYON).

 Heavy duty alkaline cleaning products

stone surfaces (PRAYON)

• Other uses of Phosphoric acid, which makes 4% of total uses:

◦ Water based lubricants

◦ Soft drinks (coca cola)

◦ Metal working fluids

Figure 5: Uses of Phosphoric acid. (PUBLICTION, 2016)

upcoming 7 years (GVR, 2020-2027).

from USA of export value of $ 104 million. (TRENDECONOMY, 2019)

value in $US dollars as follows:

 Canada with a share of 40% (104 million US$)

 India with a share of 31% (80 million US$)

 Mexico with a share of 21% (55 million US$)

 Germany with a share of 1.42% (3.65 million US$)

 Colombia with a share of 1.03% (2.67 million US$)

 Singapore - 1.18 million US$

 Korea - 1.09 million US$

 Netherlands - 1.03 million US$

 Ireland - 773 thousand US$

 Brazil - 474 thousand US$

phosphoric acid and poly-phosphoric acid (ECONOMY, 2020).

 Belgium with a share of 28% (60 million US$)