CASE STUDY on Phosphoric Acid Plant process.

The process followed to produce phosphoric acid is Single tank dihydrate process.

Plant capacity 150 MT/day of P2O5 Raw materials: Rock phosphate and Sulphuric acid. Brief process description: Rock phosphate and Sulphuric acid are admitted in a reactor in the presence of Weak Phos. acid. Liquid Phosphoric acid and solid gypsum is getting formed out of the reaction. This slurry is separated in a belt filter, wherein liquid phos.acid and solid gypsum are separated.

Phosphoric acid quality is expressed in terms of % of P2O5. We are producing phos. Acid of 25 to 26% P2O5 concentration.This P2O5 is comes out of the Rock phosphate. The present recovery of P2O5 from the Rock phosphate is about 92% only.

Requisite: Improvement of P2O5 recovery to 93.5%

Problem Statement 2: How to design a condensate coalesced to remove water content from wet condensate Flow rate 8000 BBLSD Pressure 63 Barg Allowable differential P 1 Barg Inlet condensate water content 2000 ppm

Outlet condensate water content 200 ppm Would like to see the coalesced design to improve HC condensate

Ground liquid flares are frequently prone to damage and leads to major shutdown of the Gas Booster station facilities. As Ground flares are needs to be designed by considering the Air Head winds and inward winds. Air velocity consider 20 km/hr and purge gas flow rate is 564 nm3/hr in the 48" Blow down Header, fire ball inside the pipe was not able to push out near to the flare tip. Pipe line length is around 10 KM with expansion loops and stress reliving loops. Purge gas rate splitted in to 3 locations through 1" purge gas ine and purge gas header pressure is 5 Barg at point of entry in to the Liquid blow down Header. Comments and suggestions are welcome on the above problem. 1. what will be the purge rate required to maintain the Fire ball at the tip instead of burning inside the pipe line"?

2. What will be the Optimized size of the pipe line for Liquid blow off of 20,000 BBLS @ 15 mins from 63 Barg to atmospheric pressure?

3. What are all the reasons that causing for frequent failure Ground Liquid flares tips and Flare burn pit retention walls?