PHOSPHORIC ACID FROM ROCK PHOSPHATE AND SULPHURIC ACID
[EIRI/EDPR/4531] J.C.: 2748INR, 2748US$
INTRODUCTION
Phosphoric acid (PA) is an important industrial chemical used as an intermediate in the fertilizer industry, for metal surface treatment in the metallurgical industry, and as an additive in the food industry. Wet-process PA (WPA) is produced by the attack of sulfuric acid (H2SO4) on phosphate rock (PR). Other wet processes use HCl and posterior solvent extraction technology. The corrosivity of phosphate ores, during the production of WPA, depends on two main factors: the chloride content and the interaction between HF formed in the WPA reaction slurry with SiO2, Al2O3, and MgO present in the ore. Many forms of corrosion, mainly localized, are encountered in the PA production plants and facilities such as erosion-corrosion (EC), selective corrosion, pitting, stress-corrosion cracking, intergranular corrosion, and corrosion at high temperature. Laboratory and plant corrosion tests were performed to recognize the corrosion types; EC measuring instruments were developed, built, and applied. The PA industry is spread out worldwide in Europe, Asia, Africa and America, including countries that operate PR mines and produces PA, phosphatic fertilizers, and phosphate-based products.
Phosphoric acid also known as other phosphoric acid (H3PO4) is an important acid, being used, vary widely in the 'Fertilizer Industry (Phosphatic Fertilizers). Phosphatic fertilizers, certainly, affect the growth and contents of agricultural products. Thus, this product is of high level significance.
Phosphoric acid can be manufactured from phosphate rock because of following reasons:
a) Low manufacturing cost
b) Growth of synthetic detergent industry
c) Increased a high level demand in phosphatic fertilizers.
Commercial phosphate ores or "phosphate rocks have one property; its phosphatic content is a phosphate fluorine-calcium combination of apatitic structure. The phosphate rock producers express the content of their products as BPL grade, which is an abbreviation for 'bone phosphate of lime' for Ca3 (PO4)2. To convert BPL grades into P2O5 equivalent grade, divide by 2.183. In our country, this rock is found in Udaipur district in Rajasthan.
The manufacturing process of phosphoric acid consists many processes. At the beneficiation stage, different techniques may be used to treat the same ore for removal of the gangue and associated impurities. This gives rise to further varieties in the finished ore concentrate product. It is clear, therefore, that phosphoric acid technology, having to rely on raw materials of great variety and of permanently fluctuating composition, has to readapt itself constantly.
Phosphoric acid can be produced from these raw materials via two major process routes: the wet process, using sulfuric acid attack and the electric furnace process, using electrical energy to product elemental phosphorus as a first stage. Because of current energy prices, the electric furnace process, although it can cope with lower grade phosphate rocks, has been largely abandoned except in cases where elemental phosphorus is needed. The wet process, which is the subject of this book, accounts for 90% of the current phosphoric acid production.
By its nature, wet process technology conserves most of the impurities found in the original phosphate ore, which are then included in the phosphoric acid produced. Consequently, the variety of the phosphage ores influences not only the process used but also the composition and characteristics of the phosphoric acid produced.
COST ESTIMATION
Plant Capacity 5 MT/Day
Land & Building (2000 sq.mt.) Rs. 2.72 Cr
Plant & Machinery Rs. 2.08 Cr
Working Capital for 1 Month Rs. 89 Lac
Total Capital Investment Rs. 5.95 Cr
Rate of Return 60%
Break Even Point 39%
CONTENTS
INTRODUCTION
PROPERTIES
PHOSPHORIC ACID POSSESSES FOLLOWING PROPERTIES:-
USES & APPLICATIONS
MARKET OVERVIEW OF PHOSPHORIC ACID
SPECIFICATION OF ORTHOPHORIC ACID
FOREWORD
1. SCOPE
2. GRADES
3. REQUIREMENTS
4. PACKING AND MARKING
5. SAMPLING
APPENDIX A
METHODS OF TEST FOR ORTHOPHOSPHORIC ACID
A-1 QUALITY OF REAGENTS
A-2 DETERMINATION OF RELATIVE DENSITY
A-3 DETERMINATION OF ORTHOPHOSPHORIC ACID CONTENT
A-3.1 METHOD A
A-3.1.1 REAGENTS
A-3.1.3 CALCULATION
WHERE
A-3.2 METHOD B
A-3.2.1 REAGENTS
A-3.2.3 CALCULATION
WHERE
A-3.3.1 REAGENTS
A-3.3.1.1 REAGENT A
A-3.3.2 PROCEDURE
A-3.3.3 CALCULATION
A-4 TEST FOR IRON
A-4.1 APPARATUS
A-4.3 PROCEDURE
A-4.3.1 FOR ‘TECHNICAL GRADE’
A-5 TEST FOR CHLORIDES
A-5.1 APPARATUS
A-5.2 REAGENTS
A-5.3 PROCEDURE
A-6 TEST FOR SULPHATES
A-7 TEST FOR ARSENIC
A-8 TEST FOR ANTIMONY
A-9 TEST FOR NITRATES
A-10 TEST FOR HEAVY METALS
A-11 TEST FOR SILICA
A-12 TEST FOR CALCIUM AND MAGNESIUM
A-13 TEST FOR OXYGEN ABSORBED
A-14 TEST FOR VOLATILE ACIDS
A-15 TEST FOR MANGANESE
SAMPLING OF ORTHOPHOSPHORIC ACID
B-L GENERAL REQUIREMENTS OF SAMPLING
B-2 SCALE OF SAMPLING
B-3 PREPARATION OF TEST SAMPLES
B-4 NUMBER OF TESTS
B-5 CRITERIA FOR CONFORMITY
MANUFACTURING PROCESS OF PHOSPHORIC ACID USING SULPHURIC ACID
REACTION
PROCESS FLOW DIAGRAM
PROCESS IN DETAILS
DIHYDRATE PROCESS
THE DISADVANTAGES ARE:-
FIGURE: DIHYDRATE PROCESS
GRINDING
REACTION
FILTRATION
CONCENTRATION
FIGURE: PHOSPHORIC ACID CONCENTRATION. FEED CIRCULATION SYSTEM.
HEMIHYDRATE (HH) PROCESS
FIGURE: HEMIHYDRATE PROCESS
CAPITAL SAVINGS
PURER ACID
LOWER ROCK GRINDING REQUIREMENTS
THE DISADVANTAGES OF HH SYSTEMS ARE:-
FILTRATION RATE
PHOSPHATE LOSSES
SCALING
FILTER CAKE IMPURITY
PURITY TEST FOR PHOSPHORIC ACID
GRAVIMETRIC METHOD
VOLUMETRIC METHOD
MANUFACTURERS/SUPPLIERS OF PHOSPHORIC ACID
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ROCK PHOSPHATE
SUPPLIERS OF PHOSPHATE ROCKS
SUPPLIERS OF HYDRATED LIME (CALCIUM HYDROXIDE)
ADDRESSES OF PLANT AND MACHINE SUPPLIERS
SUPPLIERS OF DRYERS
SUPPLIERS OF MIXERS
SUPPLIERS OF AGITATORS
SUPPLIERS OF EVAPORATOR
SUPPLIERS OF PRESSURE VESSEL
SUPPLIERS OF STORAGE VESSELS
SUPPLIERS OF FILTER PRESS
SUPPLIERS OF CENTRIFUGE MACHINE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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