dap & phosphoric acid plant improvements

367 Pages·2011·20.47 MB·English

PProgrram
24th AFA Int’l. Technical Fertilizers Conference & Exhibition
22 – 24 November 2011, Amman, Jordan

Since 1975
Best Available Technology in Fertilizer Industry :
Energy / Water Optimization – HSE - Operations and Equipment – R&D

Registration & Help Desk :

Monday: November 21 th, 2011
09 hr:30 - 16 hr:00

Tuesday: November 22 th, 2011
09 hr:30 - 14 hr:30

Wednesday: November 23 th, 2011
09 hr:30 - 12 hr:30

Committees Meetings:
Restricted to members only

Monday: November 21 th, 2011

10 hr:00 AFA Technical Committee Meeting
11 hr:00 AFA Economic Committee Meeting
12 hr:00 AFA HSE Committee Meeting

14 hr:00 - 15hr:30 Lunch
Hosted by: AFA General Secretariat
Sponsors

Jordan Phosphate Mines (JPMC) Indo-Jordan Chemicals Company (IJC) Nippon Jordan Fertilizer Company

The Arab Potash Company
DAY 1: Tuesday: November 22 th, 2011

10:00 Opening Ceremony & Exhibition Inauguration

 Welcome From AFA :
Dr. Shafik Ashkar, AFA Secretary General
 OPENING ADDRESS :
Mr. Mohamed S. BADERKHAN, Representative of Jordanians Fertilizer Industries
Eng. Mohamed El-Mouzi, AFA Chairman

11:00 Networking Coffee / Tea
Sponsored By:

JPMC IJC NJFC
11:30 Session I

Chairperson: Faisal DOUDIN - Managing Director - Indo-Jordan Chemicals co. Ltd

1 DAP & Phosphoric Acid Plant Improvement John Wing, P.E. USA
Mr. John Wing - Phosphate Consultant
2 Phosphate Plant Yield Comparisons
Mr. Richard D. Harrison – Process Supervisor / Fertilizer Consultant PegasusTSI Inc. USA
3 Novel Large Scale Energy Efficient Technology for Urea
Production R&D Institute of Urea Russia
Mr. Rinat Anderzhanov, Deputy Technical Director of Innoviations
4 Guaranteed (Risk Free) Energy Savings in Water and Steam Avanceon Pakistan
Systems through Avanceon's Proprietary "iwater" & “iboiler”
Mr. Armaghan Yusuf – Business Manager
5 Utilization of Satellite Image To Improve Solar Ponds
Production APC Jordan
Mr.: Zaid Halasah - Senior Chemist

14:00 Networking Lunch Sponsored By :

Nippon Jordan Fertilizer Company
Jordan Phosphate Mines (JPMC) Indo-Jordan Chemicals Company
(IJC)
20 :00 GALA Dinner Sponsored By :

Jordan Phosphate Mines (JPMC) The Arab Potash Company
Wednesday: November 23 th, 2011

10:00 Session II
Chairperson: Mr. John Wing - Phosphate Consultant – USA

1 The major research activities of the Research Institutes for JSC “NIUIF” Russia
Fertilizers (JSC “NIUIF”)
Mr. Yuri Chernenko – General Director
2 FSA Neutralization with Calcium Compounds JACOBS USA
Mr. Salah Albustami - Process Engineer
3 Catalysts for Sulphuric Acid and Ammonia Plants Haldor Topsoe Denmark
Mrs. Ayten Y. Wagner – Arae Manager – Catylest Devision
Mr. Henrik Larsen - General Manager , Marketing & Sales
4 IJC Experience on Revamping of Sulfuric Acid and Phosphoric
Acid Plants IJC Jordan
Mr. AWINASH PESHWE, PLANT HEAD
5 Replacement of High Pressure Scrubber in SAFCO-II Urea Plant SAFCO S. Arabia
Mr. Bellary Muhammad Usman – Maintenance Superintendent

12:00 Networking Coffee / Tea
Sponsored By:

APC
12:30 Session III
Chairperson: Saed Bokisha - Plant Manager - Ruwais Fertilizer Industries (Fertil) - UAE

1 Meeting environmental issues facing new and existing urea Fluid – Uhde Fertilizer Netherlands
bed Granulation with Plants Technology B. V.
Mr. Harald Franzrahe – Process Manager
fluid-bed granulation plants
2 Revamping of a Conventional Total Recycle Urea Plant QAFCO Qatar
Mr. Narayansamy Selvaraj – Head of Urea -1 Plant
3 Best-practice on RBI driven Integrity Assurance from GPIC Bahrain
Concept to Implementation
Mr. salah Abdulaziz Zainaldin - Senior Inspection Engineer (Designated).
4 Health, Safety and Environment in Fertilizer Industry
APC Jordan
Story behind APC Success in achieving 4000000 MHW Free of LTI-s
Mr. Sami Amarneh/ QES Manager

14:00 Networking Lunch Sponsored By :

The Arab Potash Company
DAY 3: Thursday, November 24 th, 2011

10:00 Session IV
Chairperson: To be Advised

1 10 Years of Safurex Experiences in Stamicarbon Urea Plants Stamicarbon Netherlands
Mr. Joost Roes – Acqisition Manager Mechanical Engineer
2 Capacity Increase of Urea Plants Uhde GmbH Germany
Mr. Thomas Krawczyk – Senior Process Engineer
3 M.P. Boiler Super Heater Coil Failure and Replacement FERTIL UAE
Mr. Adel Mohammad Al Wahedi - Mechanical Engineer
4 Carbon Dioxide Recovery Plant at GPIC – A Sustainable Option GPIC Bahrain
Mr. Jamal Ali Al Shawoosh - Methanol Plant Superintendent
5 Latest improvements in Indirect Cooling Technology for Solex Thermal Canada
Granular Fertilizer Science Inc.
Ms. Marietta Mansvelt - Technical Service Manager

12:00 Networking Coffee / Tea
Sponsored By:
12:30 – 14:30 Session V
Chairperson: To be Advised

1 Analysis of Safety Performance of Indian Fertilizers Plants FAI India
Mr. Manish Goswami - Dy. Chief (Technical)
2 Commissioning and Revamping Fertilizer Plants Through an K&T Monaco
Objective Oriented Approach
Mr. Gian Pietro Testa – Consultant for Saipem (Italy) - Business
Development Manager O.V.S (Italy)
3 Environmental friendly way of spent catalyst recycling Nickelhütte Aue GmbH Germany
Mr. Clemens Kuhnert - Area Manager Middle East & Africa
4 A new approach for Urea Plant Optimization using Advanced IPCOS-Stamicarbon Belgium
Process Control
Mr. Christiaan Moons – Sales Director
Mr. Luc Dieltjens - Process Engineer
14:00 Closing Session
14:30 Networking Lunch Sponsored By :
Seessioon I
DAAP & Phhosphorric Acidd Plant Improvvement
Mr. JJohn WWing
Phoosphatte Conssultant - John Wing, PP.E.

USA
DAP & PHOSPHORIC ACID
PLANT IMPROVEMENTS

Proven Winners for Capacity, Profitability,
Quality, By-Products, and Clean Operation

John Wing, P.E.

Arab Fertilizer Association
th
24 International Fertilizer Conference
& Exhibition

Amman, Jordan
22 to 24 November, 2011

8 Content of this paper Copyright by John Wing, P.E.

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DAP & PHOSPHORIC ACID PLANT IMPROVEMENTS

Proven Winners for Capacity, Profitability, Quality,
By-Products, and Clean Operation

by John Wing, P.E.

24th AFA International Technical Fertilizers Conference
& Exhibition

Amman, Jordan 22 to 24 November, 2011

ABSTRACT

A selection of attractive modifications are described, based on successful projects.
DAP innovations include:
Dual Mole Reactor-Granulator Acid Scrubbing
BFL Vaporizer/Scrubber - Vaporizes all ammonia with free heat from air leaving
the reactor-granulator acid scrubber. This unit provides a 3rd stage of
scrubbing – potentially eliminating need for any tail-gas scrubber.
Product Screen Diverter Systems – easy capacity increase
Automated Recycle Control - continuously monitors recycle particle size and
adjusts process to keep size in mid-range.
Dual diameter reactor (pre-neutralizer)
Pipe Reactor
Cooler Air Chiller
Tran-Tech Product Cooler

Phosphoric Acid plant projects to consider include:
Conversion from Dihydrate to Hemi: Makes acid at 42% concentration vs. ~27%
No need for most evaporation. Usually no rock grinding is needed.
Conversion to Hemi-Di – similar benefits plus 98.5% recovery & clean gypsum
Utilize gypsum – many ways to make gypsum an asset rather than liability
Recover uranium – major investment with high profit potential
Recover fluosilicic acid – high-purity grade for AlF3 feed
A variety of profitable uses for phosphogypsum
Advances in dry gypsum stacking
Purify phosphoric acid to technical or food grade

Project management and start-up issues are discussed.

John Wing, P.E., 1121 Waters Edge Drive, Lakeland FL 33801, USA
Phone: [phone] Email: [email protected]

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