Detailed Project Report (DPR) on food grade phosphoric acid by thermal process

FOOD GRADE PHOSPHORIC ACID
BY THERMAL PROCESS
[CODE NO.3303]  


Phosphoric acid is an important intermediate chemical product. It is used mainly by the fertilizer industry. In 1980 the worldwide production capacity for phosphoric acid yielded about 33 million tons of P2O5 equivalents.

Pure 100% phosphoric acid is a white crystalline solid (monoclinic) that melts at 38.85oC to a syrupy liquid which has a strong tendency to super cool.
 
In dilute solutions, phosphoric acid has a pleasingly sour taste which is similar to but distinguishable from that citric, tartaric, lactic and acetic acids Rock phosphate is the major and essential raw material required for production as phosphoric acid by any route. Usually, when considering a phosphate rock as a potential raw material, the first approach is to analyze its chemical composition, i.e. the P2O5 content and its impurities.

Phosphoric acid (H3PO4) is produced by 2 commercial methods: wet process and thermal process. Wet process phosphoric acid is used in fertilizer production. Thermal process phosphoric acid is of a much higher purity and is used in the manufacture of high grade chemicals, pharmaceuticals, detergents, food products, beverages, and other nonfertilizer products.

There are two basic methods in commercial use for the production of phosphoric acid - the wet process and the furnace process. In the electric furnace process elemental phosphorous is produced by the electrothermic reduction of phosphate rock with carbon (coke). The silica added to the furnace charge behaves as a strong acid at the high temperatures (about 1500°C) employed in furnace operations and combines with the calcium constituent of the phosphate rock to form calcium silicate. The overall reaction, neglecting carbonates, fluorides, and other non-phosphatic constituents, may be expressed as follows:
 
In the manufacture of furnace phosphoric acid, the condensed elemental phosphorus is burned in air. The phosphorus oxide vapor (P.01o) formed reacts with water to produce phosphoric acid.

 
The phosphoric acid thus produced has very small amounts of impurities and the major industrial markets for this acid are in the manufacture of sodium phosphates and tetra potassium pyrophosphate for use in detergents and calcium phosphates for use as an animal feed supplement and in dentifrices, medicinal, glass, food, and plaster stabilizers.

COST ESTIMATION

Plant  Capacity                                                :       5.00 Ton/day
land & Building (3000 Sq.Mtrs)                    :       Rs. 3.97 Cr
Plant & Machinery                                           :       Rs. 3.00 Cr
Working Capital for 2 Months                       :       Rs. 1.16 Cr
Total Capital Investment                                :       Rs. 8.33 Cr
Rate of Return                                                 :       17%
Break Even Point                                            :       68%

INTRODUCTION    
PHOSPHORIC ACID FROM ROCK PHOSPHATE    
PHOSPHORIC ACID (ORTHO) FOOD GRADE (75%)    
PRODUCT SPECIFICATIONS    
PROPERTIES & SPECIFICATION OF PHOSPHORIC ACID    
PURE PHOSPHORIC ACID:-    
TYPICAL ANALYSIS OF PHOSPHORIC ACID    
PROPERTIES    
PHOSPHORIC ACID POSSESSES FOLLOWING PROPERTIES:-    
USES & APPLICATIONS    
PHOSPHORIC ACID IS USED IN A NUMBER OF AREAS, FEW OF ITS
USES ARE GIVEN BELOW:-    
GRADES OF PHOSPHORIC ACID    
REQUIREMENTS FOR ORTHOPHOSPHORIC ACID    
B.I.S. SPECIFICATION    
MARKET SURVEY    
ANNUAL PRODUCTION OF PHOSPHORIC ACID    
DETAILED IMPORT DATA OF PHOSPHORIC ACID    
85 FOOD GRADE    
EXPORT DATA FOOD GRADE PHOSPHORIC ACID    
PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS OF PHOSPHORIC ACID    
TECHNOLOGY OVERVIEW OF PHOSPHORIC ACID    
WET ACID PROCESS    
THERMAL PROCESSES    
ELECTRIC FURNACE PROCESS    
THE HARD PROCESS    
THE IMPROVED HARD PROCESS    
IHP PROCESS DESCRIPTION    
MANUFACTURING PROCESS OF PHOSPHORIC ACID (FOOD GRADE)
BY THERMAL PROCESS    
RAW MATERIAL REQUIREMENTS    
PROCESS FLOW DIAGRAM    
PURIFICATION OF PHOSPHORIC ACIDE    
PROCESS IN DETAILS    
TABLE (METRIC AND ENGLISH UNITS). CONTROLLED EMISSION
FACTORS FOR THERMAL PHOSPHORIC ACID PRODUCTION    
EMISSIONS AND CONTROLS    
DIFFERENT PRODUCTION PROCESSES    
OF PHOSPHORIC ACID    
IN EUROPE THE MORE CURRENT PROCESSES ARE THE FOLLOWING:-    
TABLE: SHOWS THE VARIATION IN CHEMICAL ANALYSIS
OF VARIOUS PHOSPHATE ROCKS.    
PRINCIPLES OF THE PROCESS    
DIHYDRATE PROCESS    
THE DISADVANTAGES ARE:-    
DIHYDRATE PROCESS.    
GRINDING    
REACTION    
FILTRATION    
CONCENTRATION    
HEMIHYDRATE (HH) PROCESS    
CAPITAL SAVINGS.    
PURER ACID.    
LOWER ROCK GRINDING REQUIREMENTS.    
FILTRATION RATE.    
PHOSPHATE LOSSES.    
SCALING.    
FILTER CAKE IMPURITY.    
CORROSION.    
RECRYSTALLISATION PROCESSES    
SEVERAL PROCESSES HAVE BEEN DEVELOPED BUT THERE ARE
ONLY THREE BASIC ROUTES:-    
PURIFICATION OF GREEN PHOSPHORIC ACID    
TO FOOD GRADE PHOSPHORIC ACID    
STORAGE AND HANDLING OF PHOSPHORIC ACID    
STORAGE CONSIDERATIONS    
CONSTRUCTION MATERIALS    
STORAGE TANK    
• STAINLESS STEEL    
• RUBBER-LINED CARBON STEEL    
• FIBERGLASS REINFORCED POLYESTER (FRP)    
HEALTH AND SAFETY INFORMATION    
FIRE, EXPLOSION AND HEALTH HAZARD DATA    
TOXICOLOGICAL INFORMATION    
PERSONAL PROTECTIVE EQUIPMENT    
TECHNOLOGY SUPPLIERS FOR PHOSPHORIC ACID    
SUPPLIERS OF RAW MATERIALS    
PHOSPHATE ROCK    
SILICA SAND    
LABORATORY CHEMICALS    
SODIUM HYDRAUXIDE    
CALCIUM HYDROXIDE    
SULPHURIC ACID    
PACKAGING MATERIALS (HDPE WOVEN LAMINATED BAGS)    
SUPPLIERS OF PLANT AND MACHINERY    
JAW CRUSHER    
ELECTRIC ARC FURNACE    
EVAPORATORS    
FLUIDIZED BED DRYER    
AIR COMPRESSORS    
LABORATORY EQUIPMENTS    
PACKAGING MACHINE    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
MATERIAL HANDLING EQUIPMENTS    
STORAGE VESSEL    
D.G. SETS    
            
        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET