• Mono-Ammonium Phosphate (MAP) shut down in year 2014.
• Plant capacity for MAP is 200,000 tons/year. Plant was revamped throughout years; most recent revamp was performed in 2011.
• Plant has a DCS control system, manufactured by Honeywell in years 2000.
• Comprehensive documentation is available
• All instrumentation has been covered with polyethylene sheets to preserve them.
• Plant was operated with 5 persons per shift.
• Extensive spare parts inventory is available at plant warehouse.
Process to obtain mono-ammonium phosphate (MAP) is commonly made by neutralizing orthophosphoric acid (H3PO4) with ammonia at an N/P mole ratio of 1.0 as follows:
NH3 + H3PO4 → NH4H2PO4 (∆ H) = -32 kcal/mol
The reaction is generally carried out in the presence of sufficient water to make a mobile fluid of the reaction medium. Since more heat is evolved than necessary to raise the resultant mixture to its boiling point, excess heat is utilized to drive off some of the water. Where concentrated acid feedstock is used, water must be added if formation of polyphosphates is to be avoided. The reaction of ammonia and phosphoric acid to monoammonium phosphate is exothermic with a heat of reaction of -120 kJ/mol. Even though some of the heat is used to evaporate water, 11 cooling is required to keep the temperature at a constant level. Since the reaction can be regarded as instantaneous and complete, the pressure and temperature does not affect the formation of product. However, depending on temperature and pressure the physical state of the product from the reactor varies. Apart from water, the slurry consists of a mixture of solid crystals and MAP dissolved in a solution.
The slurry process is generally made from wet process merchant grade acid (54% P2O5), water and ammonia. Reaction is affected by the solubility of MAP at different N to P ratios. Operation of the process is generally as follows:
Phosphoric acid is pumped from the storage tank through a flowmeter to the lower end of the reaction leg of the Pre-Neutralizer. Water is introduced to the Pre-Neutralizer concurrently which prevents solidification of the reactor charge. Simultaneously liquid ammonia from the storage tank is passed through the Vaporizer at autogenous pressure of the ammonia storage vessel. The ammonia flow is regulated to the Pre-Neutralizer at a rate proportional to the acid flow. A reaction primarily takes place in the reaction leg and a slurry collects in the Pre-Neutralizer. The heat of reaction raises the temperature of the mixture to boiling, and part of the water is evaporated.
The neutralized ammonia phosphate slurry from the Pre-Neutralizer is discharged to the Surge Vessel. It is then pumped to the Pipeline Reactors. A slurry sits in the Surge Tank and mixed with ammonia and steam in the Pipeline Reactors. The superheated slurry is then discharged through the Pipeline Reactors to impinge on a moving belt. A foam slurry readily solidifys on the belt conveyor. The light flaky product separates readily from the belt as the product reaches the turn roller. Crushing and Grinding of the material is accomplished easily due to the cellular nature of the product.
531213 A-14 PHOSPHORIC ACID TO THE REACTOR 531355 BG-1 LUBRICATION PUMP (PUMP)531365 P-1A ??SOUND PUMP (PUMP)531368 P-1B NORTH PUMP (PUMP)531382 P-2 WATER CYLONE RECIRCULATION PUMP531386 P-3 SCRUBBER PUMP Nº1 WASHER MAP 531390 P-4 SCRUBBER RECIRCULATION PUMP NO. FANS, BLOWERS531359 VE-1 SLEEVE FILTER FAN 531378 V-1 MAP GAS WASHING MACHINE
531229 A-3 EXTRACTOR PLATE (ARMS). TAPES531232 A-4 BELT UNDER EXTRACTOR PLATE 531233 A-4 BELT UNDER EXTRACTOR PLATE 531309 A-5 REVERSIBLE BELT SINFINES, ALVEOLARES531343 SF-1 SINFIN Nº 1 (COUPLED) (SINFIN)531346 SF-2 SINFIN Nº 2 (COUPLED) (SINFIN531349 SF-3 SINFIN Nº 3 (COUPLED) (SINFIN531362 AV-1 ALVEOLAR (STRUCTURE) OTHERS (SPECIAL MACHINES)531371 RA-1 ROTATING SCRAPER OF C-2 (ESTR.
SPECIAL (DRYERS, CENTRIF.)
531352 EN-1 ROTARY COOLER (COOLER)
531228 A-3 EXTRACTOR PLATE (REDUCER).531234 A-4 BELT UNDER EXTRACTOR PLATE 531310 A-5 REVERSIBLE BELT (REDUCER)531344 SF-1 SINFIN Nº 1 (COUPLED) 531347 SF-2 SINFIN Nº 2 (COUPLED) 531350 SF-3 SINFIN Nº 3 (COUPLED)
OTHERS (STATIC EQUIPMENT)
531320 SHOWER AND WASHERS REACHER LOW531321 SHOWER AND WASHERS HIGH REACTOR531322 SHOWERS AND WASHERS MIXING TANK MAP ATMOSPHERIC TANKS AND TANKS531208 A-15 MIXING TANK (TANK C531225 A-2 DUST COLLECTOR (EMBUDO, PA TOWERS AND REACTORS531217 A-1 TUBULAR REACTOR531223 SPRAY TOWER TOWER (ESTR531226 STEAM CHIMNEY(CHIME531227 A-3 EXTRACTOR PLATE (PLATE, CABLE
531357 FM-1 SLEEVE FILTER (STRUCTURE) ACCUMULATORS, EJECTORS, SILENCERS531377 GASES WASHER MAP (WASHER)531381 CYCLONE WASHER MAP (CYCLONE)531385 SCRUBBER Nº1 WASHER MAP (SCRUBBER)531389 SCRUBBER Nº2 WASHER MAP (SCRUBBER
531201 T-200 PIPES PHOSPHORIC ACID 54%.531202 T-300 PIPES GASES AND POWDER.531203 T-400 PIPES PROCESSING WATER (RE531204 T-600 STEAM PIPES.531205 T-700 AIR PIPES.531206 T-810 PIPES PAPILLA M.A.P.531207 T-910 AMMONIA GAS PIPES (AU)531301 T-320 PIPE WATER PIPES (DIS531302 T-400 PIPE AND POT WATER531303 T-600 STEAM PIPING.531304 T-700 AIR PIPE (AIR ROOM D531305 T-910 AMMONIUM LIQUID PIPING (VA531358 FM-1 SLEEVE FILTER (VALVES)
531209 A-15 MIXING TANK (REDU ENGINE531214 A-14 PHOSPHORIC ACID TO THE REACTOR 531230 A-3 EXTRACTOR PLATE (ENGINE).531235 A-4 BELT UNDER EXTRACTOR PLATE 531311 A-5 REVERSIBLE BELT (ENGINE)531353 EN-1 ROTARY COOLER (ENGINE)531360 VE-1 FAN SLEEVE FILTER (M531363 AV-1 ALVEOLAR (ENGINE)531366 P-1A ??SOUND PUMP (ENGINE)531369 P-1B NORTH PUMP (ENGINE)531372 RA-1 ROTATING SCRAPER OF C-2 531379 V-1 MAP GAS WASHING MACHINE531383 P-2 WATER CYLONE RECIRCULATION PUMP531387 P-3 SCRUBBER RECIRCULATION PUMP Nº531391 P-4 SRUBBER RECIRCULATION PUMP Nº2
PICTURES, TABLES DISTRIBUTION
531210 A-15 MIXING TANK (FEED531215 A-14 PHOSPHORIC ACID TO THE REACTOR 531221 A-1 REACTOR (ELECTRIC POWER SUPPLY531231 A-3 EXTRACTOR PLATE (FEED531236 A-4 BELT UNDER EXTRACTOR PLATE 531249 SUBESTAC. ELECTRIC SUBSTATION 531307 SALA SPI SALA SPI 531312 A-5 REVERSIBLE BELT (ELECTRIC POWER SUPPLY531345 SF-1 SINFIN Nº 1 (COUPLED) (FEED531348 SF-2 SINFIN Nº 2 (COUPLED) (FEED531351 SF-3 SINFIN Nº 3 (COUPLED) (FEED531354 EN-1 ROTARY COOLER (E531356 BG-1 BULB PUMP (FEED ELE531361 VE-1 SLEEVE FILTER FAN (A531364 AV-1 ALVEOLAR (POWER SUPPLY531367 P-1A ??SOUTH PUMP (ELECTRIC POWER SUPPLY531370 P-1B NORTH PUMP (ELEC POWER SUPPLY531373 RA-1 ROTATING SCRAPER OF C-2 (ALIM531380 V-1 MAP GAS WASHING MACHINE531384 P-2 WATER CYLONE RECIRCULATION PUMP531388 P-3 SCRUBBER RECIRCULATION PUMP Nº531392 P-4 SCRUBBER RECIRCULATION PUMP NO.
531253 FLOOR LIGHTING FLOOR, RED 2 CONTROL HALLS, DISTRIBUTED CONTROL531316 DISTRIBUTED CONTROL PANEL
531211 A-15 MIXING TANK (AUTOMATIC531216 A-14 PHOSPHORIC ACID TO THE REACTOR 531222 A-1 REACTOR (CONTROL LRCV-3, TR-1531224 TOWER SPRAY TOWER
LOGICAL SYSTEMS, PLC, CABINETS
531374 PIC-2000 CONTROL LOOP FILTER SLEEVES531375 LIC-2000 TANK LEVEL CONTROL TANK LINES, PIPES, CABLES, TRAYS531252 TRAYS ELECTRICAL TRAYS AND INST
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