phosphatic
TRANSCRIPT
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Phosphate Rock
• Formula for rock is CaF2.3Ca3 (P04)2 or Ca10F2(P04)6 – Tri calcium phosphate. Its chemical name is’ Fluorapatite’
• This compound is totally insoluble in water. Its trading is done by the name of ‘Bone phosphate of lime’ (BPL)
• Grounded rock is directly applied on acidic soil, but out -put is not good. The rock is made water soluble by treatment of acid.
• Rock is used for manufacture of, i. Fertilizers, ii.Phosphoric acid, iii. Super phosphates, iv. Phosphorus, and phosphorus compounds.
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Phosphatic Fertilizers
• Phosphate Fertilizers The best use of phosphate rock is in the manufacture of single and triple super phosphates and other phosphate derivatives including phosphoric acid.
• The acidulation of phosphate rock to produce super phosphates has been the most important method to make phosphate available for fertilizer purposes
• The phosphate rock formula is CaF2.3Ca3 (P04)2 and overall reaction is as follows,
• Ca F2.3Ca3 (P04)2+7H2S04+3H20 ---
• 3CaH4(P04)2. H2O + 2HF + 7CaS04 (mono calcium phosphate)
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Phosphate Rock
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Grinded Phosphate Rock
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Phosphate rock Reserves
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Transportation of rock
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Phosphorus Rock
• A good phosphate rock must have
following properties,
• 1. P205 content above 33%, 2. less
CaC03 & Gypsum and Silica, 3. Nil toxic
elements, 4. Less other chemical
impurities, 5. must be soft , and 6. less
than 1% moisture and impurities
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Phosphatic Fertilizers
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Single supper phosphate
• The product produced contains 16 to 20% available P205 and it contain 50% active CaSO4, which is good for reclamination of soil.
• The manufacture of SSP involves the following four steps.
• 1. preparation of rock, 2. Mixing rock with acid, 3.Curing and drying of original slurry by completing the reaction,
4.Excavation, milling and bagging of the product.
• All plants, first pulverize rock. The rock is grounded to an average of 70 to 80% through 200 mesh screen, with the
following benefit.
• 1. reaction rate become faster, 2. More efficient use of acid (less use). 3. A higher grade of product is achieved.
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Single super phosphate
The rock is acidulated with acid (H2SO4) to produce SSP.
Insoluble phosphorus is made soluble in water for plant .
The stage wise reactions are;
i. Ca3(PO4)2 +H2SO4 + 4H2O CaH4(PO4)2 +
2(CaSO4 . 2H2O)
ii. CaF2+H2SO4+H2O CaSO4.2H2O + 2HF
iii. 4HF + SiO2 SiF4 + 2H2O
iv. 3Si F4 + 2H2O SiO2 + 2H2SiF6
i. An excess of H2S04 is used by the impurities present in
the phosphate rock like CaC03, Fe203,Al203 and CaF2.&
SiO2
An excess of H2S04 is used by the impurities present in the
phosphate rock likeCaC03, Fe203,Al203 and CaF2. + SiO2
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Super Phosphate
• Following is a more probable expression
of the main reaction.
• CaF2.3Ca3(PO4)2 + 7H2SO4 + 3H2O
(Phosphate rock)
3Ca H4(PO4)2.H2O + 2HF (gas) + 7CaSO4.
(Monocalcium Phosphate)
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Flow sheet for SSP
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SSP plant
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Single supper phosphate plant
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TSP
• Triple Super phosphate. (TSP)
• This fertilizer is three times more
concentrated than SSP, containing 45 to
46% P205, which is available to plant.
• TSP is made by the action of H3P04 on
phosphate rock. No CaS04 (Gypsum) is
formed in this process.
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TSP
• The reaction for the manufacture of TSP is,
• CaF2.3Ca3(P04)2 +14 H3P04 10Ca(H2P04)2 + 2HF
• Process - The pulverized rock is mixed with H3P04 in a reactor. The resultant slurry is sprayed into the granulator along with recycled fines from the process.
• The products from the granulator, is dried, screened, over sizes are crushed and cooled.
• THE FINISHED PRODUCT IS CONVEYED TO THE STORAGE, where the product is cured for 4 to 6 week , before packing and dispatched to market.
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TSP
• During this time, which is four to six weeks in the storage, the reaction between rock and acid is completed and P205 availability is increased
• Exhaust gases from the process are scrubbed with water to remove SiF4.
• Non-granulated TSP is also available, which is prepared by using cone- mixer and conveyer belt only. The setting time for TSP is only 14 to 20 minutes.
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Flow sheet of Non-granulated
TSP
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Powder TSP Production Plant
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TSP Manufacturing Process
• Grounded rock is mixed with H3PO4 acid.
• The resultant slurry is sprayed into granulator along with
recycled fines.
• The product from granulator is dried , screened, the over
sizes crushed and cooled.
• The final product is conveyed to store for curing for 4 to
6 weeks. During this period the reaction is completed.
• The exhaust gases are scrubbed in a scrubber to
remove SiF4.
• TSP is an acidic fertilizer having 46% P2O5
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TSP manufacturing Plant
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Di ammonium phosphate (DAP)
• DAP is a concentrated fertilizer containing 18% N2 and 46% phosphorus in the form of P205.
• Vapors or anhydrous liquid NH3 and H3P04 acid (40 to 50%) are continuously fed to an agitated tank, called preneutralizer vessel.
• The heat of reaction heats up the mass, evaporating app. 100Kg of water per ton of product.
• The reaction ratio is maintained at 1.5 moles of NH3 per mole of H3P04 acid. This ratio is optimum for maintaining fluidity of the slurry.
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DAP Manufacturing Plant.
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DAP Processing Diagram
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Flow sheet for DAP
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DAP
• The slurry formed in the preneutralizer flows into a ammoniator – Granulator at 120c, where it is distributed evenly over the bed of solid materials and is made to react with additional NH3, which is supplied under the bed from a distributor to complete the reaction.
• Dried recycled material from product screening is used to control the moisture.
• The ammomitor combined the function of chemical reactor, mixing and proper size and shape of granular particles.
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DAP
• The dryer reduce the moisture content of
the product to 1.0%.
• After cooling the product, in a counter
current air flow rate, the product is stored
in bulk storage. The exhaust gases are
scrubbed by incoming H3P04 acid
• This complete the process of
manufacturing of a concentrated fertilizer
called DAP. Di ammonium phosphate
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Hammer Crushers
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Hammer Crushers
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Ball Mill
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Rock Crushers
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Roll Mill
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• Moderate Cost
• Easy to Operate
• Hard Granules
• Less Dusty-no
Caking
• Normal Size 2-4mm
• Less Corrosion
Problems
• More Common Now-
a-Days
• Can be Used for
Making NPK
• Graduals Good for
Blending with Other
Fertilizers
• Low Cost
• Easy to Operate
• Hard Graduals
• Less Dusty-no
Caking
• Graduals Sizes 4-
11mm
• Less Pollution
Problems
• Can be Used for
Blending with
Other Fertilizers
• Limited Use
• High Cost
• Expensive to
Operate
• Hollow Prills
• Dusty-More Caking
• Prills 1-2mm
• Big Pollution
Problems
• Not Good for
Blending
• Cannot be Used for
Making NPK
Granulation/prilling