Department of Chemical Engineering

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

666, Upper Indira Nagar, Bibwewadi, Pune 411037

A Presentation on

CHEMICAL PROCESS TECHNOLOGY

Presented by ,

Prof. Amruta Mokashi

Lecture 31,32 & 33: 13th & 15th Dec 2021

 Phosphoric acid
• Properties of Orthophosphoric Acid (H3PO4)

 Molecular weight: 98 g/mol; forms (H3PO4)2∙H2O in water solution

 Melting Point: 42.4°C

 Boling Point: 158°C [Loses of water of hydration from (H 3PO4)2∙H2O at 213°C]

 Density: 1.83 gm/cc

 Solubility: Completely miscible with water

Indian Phosphoric acid Market
 Methods of Production
1. Wet Process- (accounts for 2/3 of production in USA)
a) Strong sulfuric acid leaching
b) Hydrochloric acid leaching (IMI process)

2. Electric Furnace Processes

a) Direct conversion at plant site
b) Oxidation and hydration of phosphorus near consumers market

3. Blast Furnace- no longer competitive

 Wet process (Strong Sulfuric Acid)
Chemical Reactions:

Raw Materials :
● Phosphate rock (crushed) ● Strong Sulfuric Acid

Quantitative requirements :
a) Basis : 1 ton of 100% H3PO4, (90% yield) 2.7 tons of gypsum
Phosphate rock (32% P2O5) 2.5 tons
Sulfuric acid (93-98%) 2.0 tons

b) Plant Capacities : 100-150 tons/day of 100% H 3PO4

 Major Engineering Problems

1. Process Design
a. Fineness of grind
b. Temperature
c. Control of sulfuric acid

2. Materials of construction
Wet process (Hydrochloric Acid Leaching) (IMI Process)
Chemical Reactions:

Raw Materials :
● Phosphate rock (high P2O5) ● HCl ● Organic C4 or C5 alcohol solvents

Quantitative requirements :
a) Basis : 1 ton of 100% H3PO4, (in 98% yield)
Phosphate rock (32% P2O5) 2.3 tons
HCl (100%) 1.4 tons
Solvent make-up (Butanol or Amyl Alcohol) 3.0 kg
Flocculating agent 0.4 kg

b) Plant Capacities : 15-150 tons/day of 100% H 3PO4

 Major Engineering Problems

1. Solvent recovery

2. Materials of construction

3. Waste disposal
Electric Furnace Process (Direct Conversion at Plant Site)
Chemical Reactions:

Raw Materials :
● Phosphate rock (crushed) ● Coke (reductant) ● Sand (flux)

Quantitative requirements :
a) Basis : 1 ton of 100% H3PO4 in 90% yield; 2.3 tons of by-product slag
Phosphate rock (28% P2O5) 2.9 tons
Sand 0.85 tons
Coke breeze 0.5 tons
Carbon electrode consumption 8 kg
Electricity 4800 KWH
Air 3600Nm3

b) Plant Capacities : 60-200 tons/day of 100% H 3PO4 per furnace, 1-4 furnaces per plant
 Major Engineering Problems
1. Complete removal of acid mist
2. Materials of construction
Electric Furnace Process (Oxidation and Hydration of Elemental Phosphorus)

Chemical Reactions:

Raw Materials :
● Elemental Phosphorus ● Air ● Steam

Quantitative requirements :
a) Basis : 1 ton of 100% H3PO4 in 96 % yield
Phosphorus 0.33 tons
Air 3600Nm3
Water and steam Not defined
Major Engineering Problems

1. Materials of construction
2. Waste disposal
3. Chamber design
Economic Evaluation of Phosphoric Acid
1. Capital Investment Comparison for Acid Versus Electric Furnace Processes
2. H2SO4 Versus HCl Acid Processes
3. Plant Location Comparison
4. By-product Usage
 Superphosphate
Chemical Reactions:

Raw Materials :
● Phosphate rock (high grade; 30-35 % P2O5) ● Dilute Sulfuric Acid (62-70 % H2SO4)

Quantitative requirements :
a) Basis : 1 ton of superphosphate
Phosphate rock (30-35 % P2O5) 0.5-0.6 tons
Sulfuric acid (62-70 % H2SO4) 0.3-0.4 tons

b) Plant Capacities : 100-1400 tons/day

 Triple Superphosphate
Chemical Reactions:

Raw Materials :
● Phosphate rock (32 %, P2O5) ● Phosphoric Acid (56 %, P2O5)

Quantitative requirements :
Basis : 1 ton of superphosphate
Phosphate rock (32 %, P2O5) 0.45 tons
Phosphoric acid (56 % H2SO4) 0.62 tons