FACUALITY OF ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING

REPORT ON REACTOR

PRODUCTION OF PHOSPHORIC
ACID BY DRY KILN PROCESS
MJNKIIBJM ,NJHKBVHCTFYUJM

PREPARED BY:

Aram Nasih

REVISED BY

Arkan Jasim Hadi

Contents
WHAT IS CHEMICAL REACTOR.................................................................................. 3
TYPES OF REACTOR................................................................................................ 3
DRY KILN PROCESS FOR PHOSPHORIC ACID PRODUCTION....................................4
A ROTARY KILN REACTOR......................................................................................... 5
DESIGN STEPS TO DESUIGN KILN.......................................................................... 7
REFRENCES................................................................................................................ 8
WHAT IS CHEMICAL REACTOR
A chemical reactor is an enclosed volume in which a chemical reaction takes place.
In chemical engineering, it is generally understood to be a process vessel used
to carry out a chemical reaction, which is one of the classic unit operations
in chemical process analysis. The design of a chemical reactor deals with
multiple aspects of chemical engineering. Chemical engineers design reactors
to maximize net present value for the given reaction. Designers ensure that the
reaction proceeds with the highest efficiency towards the desired output
product, producing the highest yield of product while requiring the least amount
of money to purchase and operate. Normal operating expenses include energy
input, energy removal, raw material costs, labor, etc. Energy changes can come
in the form of heating or cooling, pumping to increase pressure, frictional
pressure loss or agitation.

TYPES OF REACTOR
The most common basic types of chemical reactors are tanks (where the
reactants mix in the whole volume) and pipes or tubes (for laminar flow reactors
and plug flow reactors)Both types can be used as continuous reactors or batch
reactors, and either may accommodate one or more solids (reagents, catalysts,
or inert materials), but the reagents and products are typically fluids (liquids
or gases). Reactors in continuous processes are typically run at steady-state,
whereas reactors in batch processes are necessarily operated in a transient
state. When a reactor is brought into operation, either for the first time or after
a shutdown, it is in a transient state, and key process variables change with
time.There are three idealised models used to estimate the most important
process variables of different chemical reactors:

Batch reactor model,

Continuous stirred-tank reactor model (CSTR),
Plug flow reactor model (PFR).
DRY KILN PROCESS FOR PHOSPHORIC ACID
PRODUCTION
For dry kiln process, it is an improved process from thermal process. For
thermal process, it used electrical arc furnace to burn the phosphorus. But for
the improved method, it used rotary kiln which also known as dry kiln to
burn the phosphorus using direct-fired to the reactor (Shaw, 2002). The burning
of phosphorus will further be produced carbon monoxide as co-product and
will continued to be burnt out throughout the process continuously. This reaction
will generate heat of combustion which most of it will be used to replace the
electrical energy that usually used in conventional method. By using heat of
combustion to generate energy, this method had proved that it would be much
energy saving than the conventional thermal process. Although this process
had shown much improvement and better impacts to the environment, but this
process currently conducted in pilot plant scale (Shaw, 2002). Research for
this method is still on going to be expand to industrial scale, which could
affect the energy, cost saving and reducing its carbon footprint itself to the
environment.
A ROTARY KILN REACTOR.
A rotary kiln for reducing phosphate ore in kiln phosphoric acid process,
comprising a kiln body (3), a kiln box (1) and a kiln tail box (6), at the kiln tail
box (6) is provided an outlet flue (7), an upper portion of the kiln body is not
provided with a wind tube, wherein, the outlet flue (7) is disposed in a way that
the fume exiting the kiln at the tail of the rotary kiln does not deviate much in a
movement direction upon entering the outlet flue.

A rotary kiln for reducing phosphate ore in kiln phosphoric acid process
wherein, the rotary kiln further comprising a driving device (5) for driving the
rotation of the kiln body.

A rotary kiln for reducing phosphate ore in kiln phosphoric acid process ,
wherein, at the kiln head of the kiln body is provided a fuel burner (15), at the
kiln tail box (6) are provided a feed pipe (8) and an outlet flue (7) connected
to an external hydration tower.

A rotary kiln for reducing phosphate ore in kiln phosphoric acid process
wherein, the outlet flue (7) is provided in the radius range of the kiln body
with the axis of the rotary kiln as a center, and the fume conveying
direction in the outlet flue (7) is substantially parallel to the axis direction of
the rotary kiln or has an included angle of less than 45° thereto.
A rotary kiln for reducing phosphate ore in kiln phosphoric acid process
wherein, the kiln body (3) compromises an external cylinder casing (12) and
a kiln liner (11) disposed inside the cylinder casing (12), and the kiln body
(3) is divided into a reduction zone and preheating zone in a lengthwise
direction of the rotary kiln, and the reduction zone is located near kiln head
box (1) and the preheating zone is located near kiln tail box (6).

A rotary kiln for reducing phosphate ore in kiln phosphoric acid process
wherein, the length of reduction zone is ⅓ to ⅗ of the length of the kiln body
(3) and the length of preheating zone is ⅖ to ⅔ of the length of the kiln
body (3).

A rotary kiln for reducing phosphate ore in kiln phosphoric acid process ,
wherein, the kiln liner (11) mainly comprises a refractory brick or a
refractory pouring material.

A rotary kiln for reducing phosphate ore in kiln phosphoric acid p wherein, the
kiln liner (11) located in reduction zone comprises a clay material layer (17)
close to cylinder casing (12) and a high-aluminous material layer (18) close to
the inner cavity of kiln; and the kiln liner (11) located in preheating zone
comprises a clay material layer close to the cylinder casing (12) and a silicon
carbide material layer (16) close to the inner cavity of kiln.

The method , wherein, the raw material is fed into the cavity of the rotary
kiln through a feed pipe at the kiln tail of the rotary kiln, a fuel burner is ignited
to heat a reduction zone in the rotary kiln to 1300-1450, the phosphate ore raw
material in the rotary kiln is reduced by the reductant at a high temperature to
generate kiln fume, the outlet flue is arranged in a way that the fume exiting
the kiln at the tail of the rotary kiln does not deviate much in a movement
direction upon entering the outlet flue, thereby preventing metaphosphoric
acid in the fume exiting the kiln from generating centrifugal physical
settlement at the tail of the rotary kiln so that the metaphosphoric acid in the
kiln gas directly enters a subsequent hydration tower along with the fume
exiting the kiln and is converted to be orthophosphoric acid after meeting
water.

The method , wherein, an axis of the rotary kiln forms an angle in a range of
1.2°-2.9° with a horizontal plane; a length-diameter ratio of the kiln body is 10-
25:1; a filling rate of the rotary kiln is 7%-25%, and a rotation speed of the rotary
kiln is controlled in a range of 0.6 r/min-3 r/min; a thickness of the refractory
material of the rotary kiln is 200 mm-280 mm.
DESIGN STEPS TO DESUIGN KILN

RESIDENCE TIME IN KILN “T” = 1.77 (PHY)^1/2 L /ALPHA* D*N

Phy =Angle of repose for lime stone ~ 36

Degree L = length of Kiln in meter

Alpha = Kiln inclination in %

D = Effective diameter of Kiln in

meter N = Rotation per minute

rpm

W = PI X (L) X (D) X THK (MM) X 7.85 METRIC

TONS ROTARY KILN CAPACITY

C = 2.826( v/Vg)X D^3

C = Kiln Capacity Ton / Hr

V = Gas Velocity in gas discharge end , m /
sec Vg = specific gas volume , m^3 / kg
clinker
D = Kiln Diameter on Bricks, m

VOLUME OF KILN

V=πr2h
REFRENCES
R K Sinnott , “Chemical Engineering Design,” 4th ed., Elsevier Butterworth-
Heinemann (2005)

J P Holman, “Heat Transfer”, 6 th ed., McGraw Hill Book Company (1986)

Donald Q Kern, “Process Heat Transfer,” McGraw Hill Book Company (1988)

Robert H. Perry, “Perry's Chemical Engineers' Handbook,” 8 th ed., McGraw

Hill (1934)