Life Cycle Assessment

of Diammonium Phosphate Production

by

Prof. S. D. Manjare
Dept of Chemical Engg
BITS-Pilani, K.K. BIRLA, Goa Campus
 Introduction

• Food demand is increasing with increase in

population

• Pollution due to fertilizer production is also

increasing

• Different techniques available for the making

environmental decisions
 Life Cycle Assessment (LCA)

Defined as
The life cycle assessment is an objective process to
evaluate the environmental burdens associated with a
product, process or activity by identifying, quantifying and
assessing the impact of energy and material usage and
environmental releases and to implement opportunities to
effect environmental considerations.
Full Life Cycle Assessment (LCA)

Primary
Resources

Extraction & Reuse/

Production Use Disposal
Processing Recycle

Emissions &
Waste
 Life Cycle Assessment (LCA)

• The LCA methodology is standardised by a series of

ISO standards and includes the following phases
– 1. Goal and scope definition (ISO 14041)
– 2. Inventory Analysis (ISO 14041)
– 3. Impact Assessment (ISO 14042)
– 4. Interpretation (ISO 14043)
 Impact Assessment
• The environmental burdens quantified in
“Inventory Analysis” are translated into the
related environmental impacts. This is carried
out within the following steps
– Classification
– Characterisation
– Normalisation
– Valuation
 LCA of DAP Production

Goal and Scope of the study

•The objectives of this particular study were to identify and
quantify the potential environmental impacts associated
with DAP production in the Zuari industry, Goa and IFFCO,
Kandla, Gujarat and to identify the grey areas (i.e. those
are less efficient and with largest environmental impacts) in
which enough scope is there for further improvements.

•Two approaches, viz “gate-to-gate” and “cradle-to-gate”

has been considered for this study. In “gate-to-gate”
approach, only production of DAP is considered whereas in
“cradle-to-gate” approach upstream processes in DAP
production have been considered in addition to DAP
production process.
 Functional Unit
• The system to be assessed is defined in terms of a “functional unit,”
a measure of performance that the system delivers.

• The functional unit is specified as a basis for comparison:

of a product before and after improvement;

a comparison of several design alternatives of new product;
or
a comparison between different products with the same
function.

In this study the functional unit has been defined on the basis of 1 kg
DAP (18-46-0) product manufactured.
 Life Cycle Inventory

• LCI consist of input/output material and energy analysis of

the system under study.

• For this study, plant data is collected from Zuari Industries

Ltd Goa and IFFCO Kandala, Gujarat.
 Flow Diagram

For data-inventory it is appropriate to view the system as a series of

subsystems.

A schematic representation of the DAP process for inventory analysis

is shown in following figure.

Materials required are reactants and energy in the form of electricity,

steam production & hot combustion gas for drying. The output
materials from the system are in the form of DAP product and
emissions to the environment.

Energy requirement for machines like pumps, compressors, fans,

blowers, and electrical motors are taken into account in addition to
energy requirement for processes involved in DAP production.
 Steam Reagent Tank
(Heater)

NH3,
H3PO4
Preneutralizer
H2SO4 Emissions to the
Steam Scrubber environment
NH3, Particulate
Filler Granulator solid, Sox, NOx

Furnace Oil Combustion Dryer Cyclones

Steam Tank Heater Primary Elevator

Air
Screens

Cooler
DAP

Electricity Electrically powered Equipments such as Pumps, Fans, Motors, Agitators, etc

Inventory inputs and outputs for DAP production

 Water 0.371 kg
Particulates 0.00506
Ammonia 1.125E-3 Kg

Ammonia 0.2186 kg
Phosphoric Acid 0.848 kg
Sulphuric Acid 0.0344
Water 0.1 kg Diammonium
Bentonite 0.04 kg DAP PRODUCTION
Phosphate 1 Kg
Furnce oil 282 kJ
Steam 1.5 kg
Electricity 32 Wh
Input/output Amount unit

Raw materials

Ammonia 0.2186 kg

Phosphoric Acid 0.8480 kg

Sulphuric Acid 0.0344 kg

Water 0.1000 kg

Bontonite 0.0400 kg

Enery inputs

Furnace oil 282 kJ

Steam 1.5 kg

Electricity 32 Wh

Emissions

Particulate 0.00506 kg

Phosphoric Acid 0.0324 kg

Ammonia 1.125E-3 kg

Table 1 DAP production plant (Data from Zuari Industries Ltd, Goa)
 Input/output Amount unit

Raw materials

Ammonia 0.1785 kg

Phosphoric Acid 0.3478 kg

Sulphuric Acid 0.0173 kg

Urea 0.0269 kg

Bontonite 0.0210 kg

Enery inputs

Furnace oil 0.0095 kg

Steam 0.25 kg

Electricity 53 Wh

Emissions

Particulate 0.0004941 kg

Ammonia 6.6962E-3 kg

Table 2 DAP production plant (Data from IFFCO Kandla,Gujarat)

Name of Equipment Power supplied
Preneutralizer agitator 25 HP
Phosphoric Acid Day tank Agitator 20 HP
Granulator Motor 200 HP
Cooler feed conveyor 3 HP
Filler conveyor 10 HP
Product Conveyor 5 HP
Fines Conveyor 50 HP
Screen drag feeder 40 HP
Filler Feeder 1.5 HP
Urea Feeder 2 HP
Potash Feeder 2 HP
Primary elevator 75 HP
Secondary Elevator 50 HP
Electric Hoist 8 HP
Name of Equipment Power supplied
Product elevator 20 HP
Filler elevator 10 HP
Urea Bin vibrator 2 HP
Filler bin Vibrator 1.5 HP
Potash Bin vibrators 2 HP
Dryer Motor 350 HP
Product cooler 50 HP
Pulveriser 3 X 60 HP X 3
Lump crusher 25 HP
Vibrating screen 0.75 X 3
Magnetic separator 150 W X 3
Coating Drum motor 40 HP
Polishing screen 0.75 HP
Name of Pumps Power supplied
Phosphoric acid Supply Pumps 30 HP
Slurry Pumps 30 HP
Sump Pumps 40.5 HP
Scrubber effluent Pump 75 HP
Cooler and Tail gas scrubber pump 60 HP
Scrubber liquor Pump 125 HP
Phosphoric acid pump for DPR 50 HP
Scrubber effluent Pump for DPR 50 HP
Sulfuric acid Pump for DPR 7.5 kW
Reagent Pump O.5 HP
Fuel oil supply pump 5 HP
Name of Fans & Blowers Power supplied
Fumes Fan 200 HP
Dryer fan 500 HP
Dust fan 200 HP
Cooler Fan 125 HP
Quench Air fan 125 HP
Primary Air Blower 60 HP
Name of Equipment Power supplied
Combustion chamber 5.29 million kCal/hr
Fuel oil supply 0.3 kL/hr of API 12 and 10000 kCal/kg
5.29E6 kCal/hr
Fuel oil in-line heater 74 kg/hr @ 133 C steam, 2 Kg /cm2 g
49488 kCal/hr
Fuel oil suction Heater 95 kg/hr @210 C steam 3 kg/cm2 g
54802 kCal/hr
Reagent Tank Heater 0.75 kg/hr@ 133 C steam 2 kg/cm2 g
501 Kcal/hr
 Impact Assessment: 1

Gate to gate approach

Fig 2 Characterization of emissions from DAP production in gate-to-gate approach
(Zuari Industry Goa)
Fig 3 Normalization of impact categories identified in DAP production ingateto-
gate (Zuari Industry Goa)
Fig 4: Single Score analysis for DAP production in gate-to-gate approach (Zuari
Industry Goa)
Impact Assessment: cradle-to-gate
Fig 5 Characterization of emissions from DAP production in cradle -to-gate
approach (Zuari Industry Goa)
Fig 6 Normalization of impact categories identified in DAP production in cradle -to-gate
approach (Zuari Industry Goa)
Fig 7 Single Score analysis for DAP production in cradle -to-gate approach (Zuari
Industry Goa)
Impact Assessment: 3 gate-gate (kandla)

Gate to gate approach

Characterization
Normalization
Single Score
 Impact Assessment: cradle-to-gate

Cradle to gate approach

Characterization
Normalization
Single Score
 Conclusion

• This work has provided valuable insights into the DAP production at
both the plants, identifying the main sources of impact.

• The major processes which affect the environment are phosphoric

acid, ammonia, MAP and DAP production processes along with
steam production.

• The pollutants emitted from these processes are ammonia,

phosphoric acid, DAP dust, SO2, CH4, CO2, CO and NOX.

• These pollutants are categorized into three major impact categories

viz. respiratory inorganics, global warming and non renewable.
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Thank You