Oct 22, 2018 1

FINAL YEAR PROJECT

PRODUCTION OF 1000 MTPD NITROPHOSPHATE
FERTILIZER

Supervised By:
Dr. Saleem Iqbal
Mr. Fazeel Ahmad

Presented By:

Shaharyar Abbasi UW-15-Ch.E-BSc-014

Khawaja Rehan Ahmed UW-15-Ch.E-BSc-016
Muhammad Mansoor UW-15-Ch.E-BSc-030
Abubaker Sufyan Amjad UW-15-Ch.E-BSc-034
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Outline
• Plant Capacity • Energy Balance on Digester (R-02)
• Analysis of Phosphate rock • Energy Balance on Filter Drum (F-04)
• Material Balance on Digester (R-02) • Energy Balance on Heat Exchanger (E-05)
• Material Balance on Drum filter (F-04) • Energy Balance on Crystallizer (CR-08)
• Material Balance on Crystallizer (CR-08) • Energy Balance on Drum Filter (F-10)
• Material Balance on CN Filter (F-10) • Energy Balance on Neutralizer (R-12)
• Material Balance on Neutralizer reactor (R-12) • Energy Balance on Evaporator (E-14)
• Material Balance on Scrubber (S-06) • Energy Balance on Carbonation reactor (R-16)
• Material Balance on Evaporator (E-15) • Energy Balance on Conversion reactor (R-19)
• Material Balance on Carbonation reactor (R-16)
• Material Balance on Conversion reactor (R-19)

Dec 04 2018 3
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Plant Capacity
• 1000 MTPD
• 41,666.66 kg/hr.

Ca3 PO4 2 + 6HNO3 → 3Ca NO3 2 + 2H3 PO4

H3 PO4 + 2NH3 → NH4 H2 PO4

• Conversion = 99%.

Dec 04 2018 Source: Fertilizer processing manual by International Fertilizer Development Centre (IFDC) 4
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer

Dec 04 2018 5
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Analysis of Phosphate rock
Components Flow rate
Component Percentage kg/hr. kmol/hr.
P2O5 34.35% Ca3(PO4)2 17848.24 57.57
CaO 52.65% CaCO3 2163.73 21.64
F 3.98% CaF2 1944.42 24.93
SiO2 468.88 7.81
CO2 4.00%
Inerts 487.92 -
SiO2 1.97%
Water 238.01 13.22
Moisture 1.00% Total 23801.01 125.18
Inerts 2.05%
Major compounds in rock are:
Total 100.00%
CaO + CO2 → CaCO3 Source:
1 “The operating experience of NP Plant”, by
Flow rate = 23801.01 kg/hr. CaO + 2F → CaF2 + O2 Iltifat Hussain
2
3CaO + P2 O5 → Ca3 PO4 2
Dec 04 2018 6
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Digester (R-02)

Ca3 PO4 2 + 6𝐻𝑁𝑂3 → 3Ca NO3 2 + 2H3 PO4 (a)

𝐶𝑎𝐶𝑂3 + 2𝐻𝑁𝑂3 → Ca NO3 2 + 𝐻2 𝑂 + 𝐶𝑂2 (b)
𝐶𝑎𝐹2 + 2𝐻𝑁𝑂3 → Ca NO3 2 + 2𝐻𝐹 (c)
Ca NO3 2 + 𝑆𝑖𝑂2 + 6𝐻𝐹 → 𝐶𝑎𝑆𝑖𝐹6 + 2𝐻𝑁𝑂3 + 2𝐻2 𝑂 (d)
Dec 04 2018 7
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Digester (R-02)
Stream 4 analysis
6 ∗ 63 2 ∗ 63 2 ∗ 63 2 ∗ 63
x 17848.24 + x 2163.73 + 𝑥 1944.42 − 𝑥 (468.88)
310 100 78 60

Theoretical HNO3 = 26645.96 kg/hr. = 422.95 kmol/hr

With 10% excess
26645.96 + (26645.96 x 0.1) = 29310.56 kg/hr. = 465.25 kmol/hr.
Fresh HNO3 required
29310.56
= 48850.93 kg/hr. = 775.41 kmol/hr.
0.6
Water required
48850.93 – 29310.56 = 19540.37 kg/hr. = 310.16 kmol/hr.

Dec 04 2018 8
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer

Material in Material out

kg/hr.
Stream 3 & 4 Stream 5 & 6
HNO3 48850.93 H3PO4 11184.69 HNO3 12732.19
CaCO3 2163.73 CO2 942.04 HF 59.38
CaF2 1944.42 H20 9651.25 Inerts 487.92
SiO2 468.88 CaSiF6 1422.27
Ca3(PO4)2 17848.24 NOx 492.32
Inerts 487.92 Ca(NO3)2 34682.05
Total 71276.19 71276.19

Dec 04 2018 9
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Drum Filter (F-04)
70,260.37 kg/hr.

1910.19 kg/hr.

68350.18 kg/hr.

Dec 04 2018 10
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Drum Filter (F-04)
Material in Material out
kg/hr.
Stream 10 Stream 11 Stream 12
Ca(NO3)2 34682.05 Ca(NO3)2 34682.05 CaSiF6 1422.27
H3PO4 11284.69 H3PO4 11284.69 Inerts 487.92
HNO3 12732.19 H20 9651.25
CaSiF6 1422.27 HNO3 12732.19
H20 9651.25
Inerts 487.92

Total 68350.18 Total 1910.19

68350.18+1910.19
Total 70,260.37 Total 70,260.37

Dec 04 2018 11
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer

Material Balance on Crystallizer (CR-08)

68350.18 kg/hr.

68350.18 kg/hr.

Dec 04 2018 Source: “Fertilizer processing manual”, by International Fertilizer Development Centre (IFDC) 12
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Crystallizer (CR-08)
Material in Material out
Stream 17 analysis Stream 18 analysis
Component Flow rate Component Flow rate
Ca(NO3)2 34682.05 kg/hr. Ca(NO3)2.4H20 32888.22 kg/hr.
H3PO4 11284.69 kg/hr. Ca(NO3)2 11445.08 kg/hr.
H20 9651.25 kg/hr. H3PO4 11284.69 kg/hr.
HNO3 12732.19 kg/hr. HNO3 12732.19 kg/hr.
Total 68350.18 kg/hr. Total 68350.18 kg/hr.

Dec 04 2018 13
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Drum Filter (F-10)

68350.18 kg/hr. Water

23974.13 kg/hr.

59440.09 kg/hr.
Crystals
32888.22 kg/hr.

Dec 04 2018 14
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Drum Filter (F-10)
Material in Material out
Stream 21 analysis Stream 24 analysis

Component Flow rate Component Flow rate

Ca(NO3)2.4H20 32888.22 kg/hr. Ca(NO3)2.4H20 32888.22 kg/hr.
Ca(NO3)2 11445.08 kg/hr. Total 32888.22 kg/hr.
H3PO4 11284.69 kg/hr. Stream 23 analysis
HNO3 12732.19 kg/hr.
Component Flow rate
Total 68350.18 kg/hr.
Ca(NO3)2 11445.08 kg/hr.
H3PO4 11284.69 kg/hr.
Stream 22 = water = 23974.13 kg/hr.
H2O 23978.13 kg/hr.
HNO3 12732.19 kg/hr.
Total = 92328.31 kg/hr.
Total 59440.09 kg/hr.

Dec 04 2018
Total = 92328.31 kg/hr. 15
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer

Material Balance on Neutralizer (R-03)

Ammonia

HNO3 + NH3 → NH4 NO3 (e)

H3 PO4 + NH3 → NH4 H2 PO4 (f)
Ca NO3 2 + H3 PO4 + 2NH3 → CaHPO4 + 2NH4 NO3 (g)

Dec 04 2018 16
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Neutralizer (R-12)
Stream 20 = Ammonia required = 6591.51 kg/hr.

Material in Material out

Kg/hr.
Stream 23 Stream 25
HNO3 12732.19 CaHPO4 9491.04
Ca(NO3)2 11445.08 NH4NO3 27333.79
H3PO4 11284.69 NH4H2PO4 5216.73
H2O 23978.13 H2O 23978.13
NH3 11.91
Total 66031.60 Total 66031.60

Dec 04 2018 17
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Scrubber (S-06)

Inlet gases

Dec 04 2018 18
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Scrubber (S-06)
Material in
kg/hr.
Gases Liquids
HF 59.38 DMW 770.00
CO2 952.04 Urea solution 560.00
NOx 492.32
NH3 52.91
Total 1556.65 Total 1330.00
Total 2886.65
Material out
kg/hr.
Gases to air Rich liquids
NOx 49.23 DMW 1548.72
CO2 285.61 Urea solution 1003.09
Total 334.84 Total 2551.81
Total 2886.65
Dec 04 2018 19
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Evaporator (E-14)

Water evaporated
23978.13 kg/hr.

65630.19 kg/hr.

41652.06 kg/hr.

Dec 04 2018 20
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Evaporator (E-15)
Material in Material out
Stream 27 analysis Stream 27 analysis
Component Flow rate Component Flow rate
CaHPO4 9491.04 kg/hr. CaHPO4 9491.04 kg/hr.
NH4NO3 27333.79 kg/hr. NH4NO3 27333.79 kg/hr.
NH4H2PO4 5216.73 kg/hr. NH4H2PO4 kg/hr.
5216.73
H2O 23978.13 kg/hr. Total 41652.06 kg/hr.
Total 65630.19 kg/hr.

Stream 30 = water evaporated = 23978.13 kg/hr.

Dec 04 2018 21
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Carbonation Reactor (R-16)
Ammonia
7121.26 kg/hr.
-4 deg. C

50 deg. C Ammonium carbonate

19302.80 kg/hr.
50 deg. C
Carbon dioxide
9215.75 kg/hr.
40 deg. C

𝐶𝑂2 + 2𝑁𝐻3 + 𝐻2 𝑂 → NH4 NO3 aq

Dec 04 2018 22
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Carbonation Reactor (R-16)
Stream 33 = Amount of carbon dioxide = 9215.75 kg/hr.
Stream 34 = Amount of ammonia required = 7121.26 kg/hr.

CO2 9215.75
Inputs kg/hr. H20 3770.08 20107.085
NH3 7121.26
Generation kg/hr. (NH4)2CO3 19302.80 19302.80
CO2 8847.12
Consumption
H20 3619.28 19302.80
kg/hr.
NH3 6836.41
Output kg/hr. generation + unreacted 20107.085

Dec 04 2018 23
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Conversion Reactor (R-19)
Calcium nitrate
32888.22 kg/hr.
100 deg. C
70 deg. C

Ammonium carbonate
19302.80 kg/hr.
50 deg. C

Ammonium nitrate +
calcium carbonate
49683.49 kg/hr.
70 deg. C
NH4 NO3 aq + Ca NO3 2 → 2NH4 NO3 + 𝐶𝑎𝐶𝑂3

Dec 04 2018 24
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Material Balance on Conversion Reactor (R-19)
Stream 34 = Ammonium carbonate = 19302.80 kg/hr.
Stream 30 = calcium nitrate melt = 32754.74 kg/hr.

Ca(NO3)2 32888.22
Inputs kg/hr. 51947.40
(NH4)2CO3 19302.80
NH4NO3 32086.07
Generation kg/hr. 30574.46
CaCO3 20053.79
Consumption Ca(NO3)2 32888.22
49683.49
kg/hr. (NH4)2CO3 19302.80
Output kg/hr. generation + unreacted 51947.40

Dec 04 2018 25
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance

Ambient Temp. 25⁰C

Time of Operation 1 hr
Basis
Ambient Pressure 1 atm

State of H20 at 25⁰C Liquid

Dec 04 2018 26
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance on Digester (R-02)
25 deg. C
0 kcal/hr. 60-70 deg. C
0.89 bar
68 deg. C
-19339.19 kcal/hr.
25 deg. C
0 kcal/hr.
68 deg. C
-1816065.293 kcal/hr.
Total heat of reactions = ∆H = -13361343.14 kJ/hr. = -3196493.57 kcal/hr.

Source: Basic Principles and

Calculations in Chemical Ca3 PO4 2 + 6𝐻𝑁𝑂3 → 3Ca NO3 2 + 2H3 PO4 (a)
Engineering by David M. 𝐶𝑎𝐶𝑂3 + 2𝐻𝑁𝑂3 → Ca NO3 2 + 𝐻2 𝑂 + 𝐶𝑂2 (b)
Himmelblau 𝐶𝑎𝐹2 + 2𝐻𝑁𝑂3 → Ca NO3 + 2𝐻𝐹 (c)
2

Dec 04 2018 Ca NO3 2 + 𝑆𝑖𝑂2 + 6𝐻𝐹 → 𝐶𝑎𝑆𝑖𝐹6 + 2𝐻𝑁𝑂3 + 2𝐻2 𝑂 (d) 27

 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance on Filter Drum (F-04)

68 deg. C
1816065.29 kcal/hr.

-5726.68 kcal/hr.
68 deg. C

68 deg. C
-1079311.29 kcal/hr.

Dec 04 2018 Source: “Perry's Chemical Engineers Handbook”, 7th ed. 28

 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance on Heat Exchanger (E-05)
1079311.29 kcal/hr.
68 deg. C

-387498.23 kcal/hr
CW CW
40 deg. C 25 deg. C
25818.84 kg/hr. 25818.84 kg/hr.

35 deg. C
Dec 04 2018 Source: “Process Heat Transfer”, by D. Q. Kern -691813.03 kcal/hr. 29
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance on Crystallizer (CR-08)
35 deg. C
691813.03 kcal/hr.
-5 deg. C

-100487.24 kcal/hr.
Heat of crystallization = -1019148.09 kcal/hr.

0 deg. C
-427822.70 kcal/hr.
Dec 04 2018 Source: “Perry's Chemical Engineers Handbook”, 7th ed. 30
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer

Energy Balance on Neutralizer (R-02)

-6 deg. C

120 deg. C

0 deg. C
119 deg. C
-1935109.08 kcal/hr.
∆H = -4442831.74 kcal/hr.
HNO3 + NH3 → NH4 NO3 (e)
H3 PO4 + NH3 → NH4 H2 PO4 (f)
Ca NO3 2 + H3 PO4 + 2NH3 → CaHPO4 + 2NH4 NO3 (g)
Dec 04 2018 Source: “Basic Principles and Calculations in Chemical Engineering”, by David M. Himmelblau. 31
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance on Evaporator (E-14)
Latent heat of steam = 8311.32 kcal/kmol

239.46 kmol/hr. 201 deg. C

118 deg. C
1935109.08 kcal/hr.
175⁰C
-1943355.48 kcal/hr.
-8246.41 kcal/hr.
175 deg. C
Dec 04 2018 Source: “Perry's Chemical Engineers Handbook”, 7th ed. 32
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance on Carbonation Reactor (R-19)
Ammonia
-4 deg. C
3.7 bar
1913981.05 kcal/hr.

50 deg. C

0 kcal/hr

Carbon dioxide
40 deg. C
3.7 bar R-19 Ammonium carbonate
50 deg. C
∆H = -230.31 x 209448.86 = -48238167.78 kcal/hr 2 bar
-35351.50 kcal/hr.
𝐶𝑂2 + 2𝑁𝐻3 + 𝐻2 𝑂 → NH4 NO3 aq

Dec 04 2018 Source: “Basic Principles and Calculations in Chemical Engineering”, by David M. Himmelblau. 33
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer
Energy Balance on Conversion Reactor (R-22)

Ammonium carbonate
35351.50 kcal/hr.

Calcium Nitrate
673483.68 kcal/hr

Calcium Carbonate +
∆H = 496.29 x 199724.02 = 99121036.06 kcal/hr. 70 deg. C Ammonium nitrate
-471573.59 kcal/hr.
NH4 NO3 aq + Ca NO3 2 → 2NH4 NO3 + 𝐶𝑎𝐶𝑂3

Dec 04 2018 Source: “Basic Principles and Calculations in Chemical Engineering”, by David M. Himmelblau. 34
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer

References
1. “Fertilizer processing manual”, by International Fertilizer Development Centre
(IFDC).
2. “Fertilizer processing manual”, by Francis T. Nielsson.
3. “Process Heat Transfer”, by D. Q. Kern.
4. “Perry's Chemical Engineers Handbook”, 7th ed.
5. “Basic Principles and Calculations in Chemical Engineering”, by David M.
Himmelblau.
6. Production Plant, "Fatima Fertilizer Company Limited (FFCL)”.
7. “The operating experience of NP Plant”, by Iltifat Hussain.

Dec 04 2018 35
 Final Year Project
Production of 1,000 MTPD Nitro-phosphate Fertilizer

Dec 04 2018 36