DiAmmoniumPhos_technology selection.pptx

DAP

1. Technology selection for 1 MMTPA Integrated Di-Ammonium Phosphates and other NPK Grades(12:32:16,14:35:14,20:20:00 and 10:26;26)

2. AGENDA CAPITAL PROPOSAL PROPOSED PROJECT GLOBALLY RENOWNED TECHNOLOGY SUPLLIER FOR DAP/NPK PLANT BEDP SCOPE OF WORK BASIC COMPARISON BETWEEN TWO TECHNOLOGY BASIC PARAMETERS FOR PN & PR PLANT SIZE & PRODUCT QUALITY COMARISON SPECIFIC CONSUMPTION NORM EMISSION NORM MAJOR EQUIPMENTS COMPARISON RECOMMENDATION

3. Business Fertilizer Originating Plant Zuari Ferilisers and Chemicals ltd. Plant/place Di-Ammonium Phosphates/ Ras Al Khaimah CAPITAL PROPOSAL

4. PROPOSED PROJECT 1.0 Million MTPA Green Field Integrated phosphate Fertilizer complex at RAK Maritimecity , Ras Al Khaimah . Project will consist of following units: Unit Installed capacity Sulphuric Acid Unit 4500 MTPD Phosphoric Acid Unit 1500 MTPD Granulation unit to produce DAP/NPK fertilizer 3000 MTPD Power plant based on excess Steam 50 MW Captive Desalination Unit 15 MLD Seawater intake system & seawater cooling (once through) 720 MLD Raw material & Product Storages and handling facilities As per the requirement Gypsum storage As per the requirement

5. GLOBALLY RENOWNED TECHNOLOGY SUPPLIER FOR DAP/NPK PLANT M/S JACOBS Lakeland –USA. M/S INCRO s.a – Spain. Bids have been invited for supply of Basic Engineering and Design Package (BEDP) ,License and Technical Know how for Di ammonium Phosphate Plant . Enquiries were floated to both the technology supplier and Techno-Commercial proposal were received from both.

6. BEDP, SCOPE OF WORK Process License /Know How. Basic Engineering and Design Package (BEDP). Supply Proprietary equipment (If Any). Design of Critical equipment apart from Proprietary item ( If any). Services after completion Basic Engineering . Assistance during tendering of EPC contract. Coordination and Supervision of Contractor’s Document.  

7. Participation for Inspection of Critical Equipment Stage wise inspection during Construction (Erection & Installation) phase (if required).   Pre commissioning, Commissioning and Start-Up Assistance.   Performance test run. Operator training. BEDP, SCOPE OF WORK

8. JACOBS Technology INCRO Technology Based on mixed PN+PR Mode in series configuration . Based on mixed PN+PR Mode in parallel configuration. Generally operates at 100% PN mode where slurry from PN is pumped to PR and PR acts as simple pipe for feeding slurry to Granulator. Can run on 100 % PR mode where PR operated inside the granulator directly producing ammonium phosphates slurry in this mode need for pumping of slurry is eliminated. For mixed PN+PR mode 20% reaction takes place in PR. For mixed PN+PR mode 25-20% slurry produced in PR remaining 75-50% produced in PN. Suitable for large size plant ( 100%PN mode) 100% PR mode not suitable for large size plant as steam evacuation problem is there which causes over granulation and excess ammonia loss. Plant can run on using 70 % strong acid (52%) and 30 % weak acid (27%) used in scrubbing system Only used 100% strong acid (48%) in PN, PR as well as in scrubbing system. BASIC COMARISON B/W TWO TECHNOLOGY

9. BASIC PROCESS PARAMETERS FOR PN & PR REACTORS Process condition Preneutalizer Pipe Reactor Temperature 120-125 Deg C 125-145 Deg C Moisture content in the slurry 16-18% 4-8% Mole ratio ( N:P) 1.4-1.5 1.45-1.55 Density 1550 (Kg/m3) 1520(Kg/m3) P2O5 concentration by wt 40-42 % 45%

10.   JACOBS INCRO Product DAP 20:20:00 DAP 20:20:00 Design capacity (TPH) 120 98 120 95 Guaranteed Capacity (TPH) 110 98 110 90 Plant Availability 24x315 24x315 22x330 22x330 Product Quality   Total Nitrogen,wt % 18 20 18 20 NH4- Nitrogen,min.wt % 15.5 18     Urea- Nitrogen,max wt% 2.5 2     NH3 Nitrogen,wt %     18 18.5 P2O5,APA,min.wt% 46 20 46 20 P2O5,WS,min.wt% 41 17     K2O,min.wt% … …     Moisture,max.wt % 1.5 1.5 1 1.5 Temperature, deg C 40-45 C 45 C or max.7 + Ambiant Temp. Particle Size   > 4 mm,max. wt% 5 5 5 5 2 mm-4mm,min. wt% 90 90 90 90 <1 mm,max.wt% 1 1 1 1 PLANT SIZE & PRODUCT QUALITY COMPARISON

11.   JACOBS INCRO Specific consumption DAP 20:20:00 DAP 20:20:00 NH3 (kg/T) 223 240 223 240 P2O5 (kg/T) 465 203 465 203 H2SO4 (kg/T) 70 450 0-40 432 Urea(kg/T) NA 12 NA 10-40 Filler(kg/T) 70   0-30 … KCl(kg/T) NA … NA … Process Water (m3/T) 0.1   0.25 0.60 Steam(kg/T)   MP 35 45 5 5 LP 40 45 Fuel (kcal/T) 74,000 78,000 60,000 70,000 Coating Oil(kg/T) 4   1.5 1.5-2.5 Defoamer (kg/T)     0.1 0.1 Power (kWH/T) 40 45 45 45 SPECIFIC CONSUMPTION NORM

12.   JACOBS INCRO Emissions DAP 20:20:00 DAP 20:20:00 Dust(mg/Nm3) 50 50 50 50 Flourine(mg/Nm3) 5 5 5 5 NH3 fume (mg/Nm3) 50 50 50 50 Effluent (liquid) EMISSION NORM

13. Rotary Drum JACOBS INCRO Capacity,TPH Dia,m Length,m Capacity,TPH Dia,m Length , m Granulator 695 4.5 9 750 4.6 10 Dryer 680 4.5 33.7 750 5.1 32 Cooler Drum 200     175 4.4 23 Coating Drum 200 2.2 6.6 150 2.8 9 Bucket Elevator JACOBS INCRO Capacity, T PH Height, m Capacity,TPH Height,m Dryer 680 40.1 750 53 Recycle 680 29 750 33 Product Screen 400 38.7     Polishing Screen 200 37.5 175 53 Reclaim Intake 100 29.1     MAJOR EQUIPMENTS COMPARISON

14. Screens JACOBS INCRO Deck Capacity,TPH Surface,m2 Deck Capacity,TPH Surface,m2 Oversize Double 170 9.3 Double 225 19.5 Under Size/product Single 100 9.3 Single 175 13.2 Polishing Double 100 9.3 Double 175 13.2 Fans JACOBS INCRO Capacity , Am3/h Capacity , Am3/h Dryer 250,000 210,000 Dust & fume 284,000 175,000 Cooler 201,000 155,000 Cooler and dedusting Exhaust 263,00 280,000 De-Dusting Heater 34,000 18,000 MAJOR EQUIPMENTS COMPARISON

15. RECOMMENDATION Jacobs offer is considered to be technically superior based on the following features Overall Equipment cost of Incro may be more than Jacobs because Compare to Incro , Jacob’s Rotatory equipment’s ( Granulator, Bucket Elevator , Drier and Cooler ) are smaller in size for same capacity of plant 110 TPH. The Proprietary equipment’s has to be purchased from Incro to get the process guarantee whereas Jacobs has agreed to provide the process Guarantee even the proprietary equipment’s can be purchase from any of the globally renowned supplier Incro Indicated that the price of Proprietary equipment are 2.23 million USD. In case of Jacobs as the equipment can be purchased from any renowned supplier so price of the equipment definitely will be lower than Incro Specific power consumption per ton Final product provided by I ncro is 45 kwh /T which is higher than Jacobs by 5 kwh /T which has annual saving of 5Million Kwh

16. Over all Plant availability provided by Jacobs 7560 hrs vis-à-vis 7250 hrs by incro in a year. Till today Largest plant build by Incro is 102 TPH ( Maaden phase -1). Jacobs has wide experience to build more number of plants of capacity more than 110 TPH.PCS-7(USA) and WMC(Australia) plants were designed at 135 TPH but both the plants are now operated more than 150 TPH. IFFCO Paradeep was designed at @ 95TPH but now it is running at above 135 TPH without any operational issue. In case of PR route ( Recommended by Incro ) the large amount of heat and steam generate inside the granulator and evacuation of gas from the system(Granulator ) is critical .Poor evacuation system lead to more ammonia loss from the granulator and also there is tendency for over granulation which leads to poor product quality. All the bigger capacity plant like WMC , IMC and IFFCO (Paradeep ) they have gone through PN route where all the gasses can be easily evacuated from the PN resulting in to good granulation . Incro has indicated the combined phos acid strength is 48 % where as Jacobs recommended the use of weak phos acid at the scrubber and overall acid strength is 38 -40 %. Use of weak acid to the extent of 30 % in the scrubber is a unique advantage for Jacobs and it will save low pressure steam to the extent of 150 -160 ton per day in PAP plant. RECOMMENDATION

17. Both the technology suppliers provide the Dual Mole scrubbing and it helps to remove the Max Ammonia and fluorine from the system. In addition that , Incro provide the separate scrubbing system for Cooler whereas Jacobs recommended to use the Tail Gas scrubber for cooler and De dusting. Packed bed in the Tail gas scrubber provided by Incro may require frequent cleaning which may affect the plant availability.Jacobs provide the more flexible operating window for scrubber operation compare to Incro which may lead to more plant availability. RECOMMENDATION

18. RECOMMENDATION Recently Incro has commissioned the CIL (India ) plant and if we compare the Performance Guarantee test report with WMC supplied by Jacobs the major advantages for Jacobs process technology are : Product size of 2-4 mm is more (97 % vis-à-vis 83 %) Crushing strength is more ( 5.4-7.3 vis-à-vis 4). Dust and Fluorine emission are less . Sp Power consumption is less ( 28 kwh vis-à-vis 38 kwh ) Sp Ammonia is less ( 0.2 vis-à-vis 0.223 T/T

19. RECOMMENDATION Tabular form of CIL (INCRO) & WMC (JACOBS) plants test result:

20. RECOMMENDATION Apart from all the above advantages Jacobs has excellent team of people at Mumbai office who are experience in phosphate industry and EPCM work can be continue from Mumbai under guidance of Lakeland office which not only reduce the execution time but also very easy to follow up.