CHAPTER 4

PROCESS
SIMULATION OF
STIRRED
TANK
REACTOR
 Stirred Tank Reactor
Process Description

The Bubble Column Reactor (stand-alone) model is considering the following reactions.

2 (NH3)g + H2SO4 (1) -----> (NH4)2SO4

Diammonium Sulfate

(NH3)g + H3PO4 (1) ------> (NH4)H2PO4

Monoammonium Phosphate

(NH4)H2PO4 + NH3(g) -------> (NH4)2HPO4

Diammonium Phosphate

5CaO + 3/2 P2O5 + 1/2 H2O ------> Ca5(PO4)3OH

MgO + 1/2P2O5 + NH3 + 1/2H2O -------> Mg(NH4)PO4

Fe2O3 + 2NH3 + 2P2O5 + 3H2O -------> 2Fe(NH4)(HPO4)2

Al2O3 + 2NH3 + 2P2O5 + 3H2O -------> 2Al(NH4)(HPO4)

 The monoammonium phosphate (MAP), is made simply by passing ammonia gas into
around 75% H3PO4. Considerable heat is given off in the reaction, and the mass becomes pasty
and crystallizes to an almost solid mass on cooling. The white crystals are centrifuged free from
the mother liquor and dried for sale. The production of the diammonium phosphate (DAP) is
brought about by conducting ammonia into around 35% acid with agitation. After passing
through a series of agitating tanks, and a blunger, the product is dried, screened and crushed for
size. A more dilute acid, such as the 35 % H3PO4 should be used in the di salt preparation to
prevent operating difficulties. If the acid employed is too concentrated, the rise in temperature
caused by heat of reaction will be so great that the solution will no longer take up any ammonia,
resulting in a mixture of the mono- and diammonium salts. If the mixture is cooled at this point,
the mass solidifies, which also prevents any further absorption of ammonia to convert the
product to diammonium phosphate. The reactions are instantaneous and hence the kinetics is not
important. All these reactions are exothermic and proceed with increase in temperature. This
increase in temperature is controlled by the flow of Ammonia and Phosphoric Acid into the tank.

The reactor is operated at the prevailing pressure of 2KG/CM2 G, in order to elevate

boiling point of the mixture. The solubility of ammonium phosphate in water increases with the
temperature, with corresponding decrease in moisture content in the slurry. The composition of
N moles/ P moles is recommended to be maintained at the ratio 1.4:1.5. Since it is the ratio, the
solubility of MAP and DAP in water is high. It is thus possible to operate the system with the
lowest possible moisture contents.
 Training Exercises
The exercise begin with the program operating at the normal condition, following a “DESIGN
START”. If any difficulties arises in the midst of work, reinitialize the program and continue
without getting bogged down in by manipulation of the control.

Sr
Action Result Discussion
No.
1 Close HIC 204
2 Close HIC 203
3 Close FIC 206
4 Close the valve in water input line