A

PRESENTATION

ON

ANP – FRONT
BY
Mayur Kachhiya
M A Shaikh
ANP – FRONT
NITRO(P)
Content
• Overview of Nitro Complex
• Introduction
• Where ANP – Front stands ???
• Products and Side Products
• Objective of Each Section
• Block Diagram me
• Process
• Safety during AN storage, handling
and dispatch.
Overview of Nitro Complex
WNA

Ammonia NA (61-62%)
Rock
Sec 43
CO2
ANP – F
NP Acid Lime

85% AN Sale
ANP – R AN (94%) CAN
Introduction
– Design Capacity : 475 MTPD of ANP
– Technology Supplier : M/s BASF Germany
– Detail Engineering : UHDE India
– Based on ODDA Process
– Raw Materials : Rock Phosphate

Nitric Acid

Gypsum

Carbon Dioxide

Ammonia
– Product : ANP (20:20:0)
– Side Products : Lime
Where ANP – Front stands???

It's a plant which provides the raw

materials for both ANP-Rear and CAN
plants, Also produce 85% AN for sale -
by processing Rock Phosphate and
60% of Nitric Acid produced in WNA
Plant. Also consumes Ammonia and
Carbon Dioxide from Ammonia Plant.
Products & Side Products

» NP acid
» Ammonium Nitrate ( ~ 60/85/94%
Concentration)
» Calcium Carbonate ( ~ 10-12%
moisture)
» Inert - Sand (Acidic in Nature)
Objective of Each Section
– Unit 31 : Handling and storage of Rock Phosphate
– Unit 32 :Dissolving of Rock Phosphate in NA to
convert insoluble P2O5 into water
soluble.
– Unit 33 :Crystallization and Separation of DDIS

– Unit 34 :Brine Circuit and Refrigeration Unit for

Crystallization Process
– Unit 41 :Conversion of CN and Separation into AN
and CaCO3
– Unit 42 :AN evaporation to make AN concentrated
for the use in CAN/ANP(R) Plant
and for sale.
– Unit 35-36 :Neutralization and Evaporation of NP Acid
and Granulation of slurry to get finalized
product ANP granules
Block Diagram of ANP – F
ROCK HANDLING

UNIT:31 ROCK HNO3 60%

DISSOLVING

UNIT:32

WASH
SAND
ACID SAND
SEPARATION

CN
BORSING
CRYSTALLIZATION
REF. UNIT:34
UNIT:33

WASH NA

ACB AND CN
CN
CN NH3
CONVERSION
FILTERATION
MELT CO2
UNIT:41
LIME TO CAN

NP ACID AN EVAPORATION

NEUTRALISATION UNIT:42

NH3 GAS AND EVAPORATION AN TO ANP AN TO CAN PLANT

UNIT:35
85% TO AN SALE.

GRANULATION
GYPSUM UNIT:36
Dissolving:
• To convert the insoluble Phosphate from Rock into
water soluble form
• Rock Phosphate from Unit- 31 supplied to reactors
arranged in series with Nitric Acid (NA) ~61.5%
supplied from WNA Plant which is cooled in
ANP(F) plant itself in 2 subsequent coolers
• In addition to that Wash Nitric Acid (WNA) and
Effluent to be recycled added.
• Temperature maintained by mean of WNA quantity
• Water maintained by means of Effluent quantity
recycled
 Digestion reaction

 Ca5(PO4)3 F + 10HNO3 ---------> 5Ca(NO3)2 +

3H3PO4 + HF
Inert Removal:
• >100 micron size inert separated in Lamella
Separator (Plate type separator – works under
laminar flow condition).
• Reduce erosion and easy to handle.
• The DIS flows through the inclined plated from the
bottom to the top in a laminar flow pattern.
• By means of gravity acting on the inert particles
heavy inert particles settle down and get separated
from sludge room (the bottom of the separator)
through sluice valve system.
• Inert will be filtered in a belt filter for recovery of
P2O5
 Crystallization & Filtration:
• 2 – parallel trains each having 5 crystallizers in
series
• Agitated tank type crystallizers having paddle blade
agitators
• Contains cooling coils and COB as a cooling media
• Provision of HOB circulation to remove
incrustallation over the coil surface
• DDIS contains NP Acid and Calcium Nitrate.
• CaO/P2O5 ratio which is about 1.5, cooling the
DDIS so that the remaining solution has a much
lower CaO/P2O5 ratio (e.g. < 0.35).
 ACB Synthesis:
2 NH3 (g) + CO2 (g) + H2O (l) = (NH4)2CO3 (l)

• Exothermic Reaction temp maintained ~50-55 deg C

• For this purpose continuous circulation of ACB material with

~450 m3/hr and cooling done with the help of Cooling
Water

• Ammonium nitrate solution (AN) with a concentration of 60% is

fed to the top of the packed carbonation tower

• CO2 concentration of 85% by volume

• NH3 from evaporator 34 E002

 CN Conversion:
(NH4)2CO3 + Ca(NO3)2 = CaCO3 + 2 NH4NO3

• KAN solution preheated to maintain approx. 51 dec.C in the CN

reactors

• The reactors operate with a slight ACB (approx 0.3% by wt).

• The size distribution of the precipitated lime depends not only on the

KAN/ACB ration but also on the parameters indicated below:

Type of rock phosphate

Residence time in reactors

Conversion temperature
Lime Filtration

• Includes Thickener, Lime filter

• To Separate 60% AN and Lime

• Moisture content in the lime is 8 -12 %.

• Lime for CAN Plant and Sale.

• 60% AN feed into Evaporation Unit.

AN Filtration & Neutralisation :

• AN filtration from pressure filter ( contains >150 micron)

• pH correction with AN dosing ( 5.5 to 6.5 pH)

(NH4)2CO3 + 2HNO3 = 2NH4NO3 + CO2 + H2O

• AN Storage
 Off Gas Scrubbing :
• Gases from all equipments from section
41 and 42 containing mainly unreacted
NH3
CO2
CO
AN vapour
• Density and pH monitoring.
• VPC and NA dosing.
 AN Evaporation:
• 3-stage evaporation (Mixed Feed)
• MP steam
• Falling film type evaporator
• Concentrate AN from 60% to about 94% .
• Evaporators arranged in series with
separators 42D004/42D006/42D007.
• An optimum energy recovery is ensured
by integration of several heat exchangers
42E002/42 E006/42E007.
Refrigeration Unit (BORSIG):
• Absorption refrigeration plant
• Brine flows in close loop. It flows
through:
Chilling NOx circulating water.
WNA Plant for chilling water.
In Crystallizer coils
For cooling NA.
 cont...

Kind of plant : Single-stage

absorption
refrigeration plant
Purpose :
Brine chilling
Solvent :
Water(H2O)
Refrigerant :
Ammonia(NH3)
Refrigerating capacity : 2.8 MW (796 TR)
Cooling water I/l temp : 33 deg C
Refrigerant :
Ammonia/Water
 AN Handling:
• What are AN safety
Detailed study on AN summaries that :
Low pH (Below 4.0)
Confined Space
Presence of organic materials
High temperature
• Any of above two conditions when co-
exist at a time possibility of AN explosion
persists.
 Safety Design During
Storage of Ammonium Nitrate
• Storing AN at 135-140 deg C
• Insulated, atmospheric, ventilated
• Steam coil at bottom of tank
• Ammonia dosing facility with continuous pH
monitoring by analyzer as well regular sampling by
laboratory
• Overhead tank filled with DM water having
automatic control valve which will open if high
temperature initiate in any of tank 42
T005/T006/F001Same arrangement at other AN
storage tanks
 Safety Design During
Storage of Ammonium Nitrate
• In case of fire/explosion use of plenty of water
is the best option.
• To be kept far of transformer, switches, fuses,
motor etc
• In silo, bin storage galvanized sheet should
not used in case of solid storage
• High density AN is more safe than low density
pallets
• Vent should be provided
 Safety Design During
Storage of Ammonium Nitrate
• Alkaline status
• Stored well below 175 deg C
• Contaminations are kept to a minimum
• Confinement to be avoided
• Inventory is kept to a minimum
• No any hot work allowed near storage tank
without precaution like asbestoses clothing
wall or water curtain provision
 Test during inspection
• Gaskets • TREM Card
• Flanges • PH
• Foreign material • MOC
• Odor • Explosive Test
• Water free • Hammer Test
• Drain valve • Mirror Test
• Mud guards • Vent Valve
• M seal if found on • No of holes on baffle
body • No of compartments
• Washing duration
• Dedicated status
 AN safety
• Storage tanks & filling area is separated with
one anti-blast wall.
• Filling capacity is 400 mts/day on two shift
basis.
• Overhead tank is always ensured for filled
condition in which in any condition if temp rise
observed into 42F002/F004/Bay17/Bay18 this
water is used to dilute AN content.