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Project Report

Manufacturing of 1 Ton/hour Phosphoric Acid by IMI Process

Submitted in partial fulfillment of the requirements

of the degree of

Bachelor of Engineering (Chemical Engineering)

By
Name : SAP :
Manthan Gandhi 60011150012
Aman Sharma 60011150056
Pawan Suvarna 60011150059

Department of Chemical Engineering

Dwarkadas J. Sanghvi College of Engineering

2019
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Project Report Approval

This Project report entitled ‘‘Manufacturing of 1 Ton/hour Phosphoric Acid by

IMI Process” by Manthan Gandhi, Aman Sharma, Pawan Suvarna is approved for the
term work .

Teacher In-charge
Dr. Aparna Tamaskar
Professor
Dept. of Chemical Engineering

Date: 27/04/2019

Place: Vile Parle (W), Mumbai.

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Declaration

We declare that this written submission represent our ideas in our own words and where others ideas or
words have been included, we have adequately cited and referenced the original sources. We also declare that we
have adhered to all principles of academic honesty and integrity and have not misrepresented or fabricated or
falsified any idea/data/fact/source in my submission. We understand that any violation of the above will be cause
for disciplinary action by the Institute and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken when needed.

Date: 27/04/2019
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Acknowledgements

We, Manthan Gandhi, Aman Sharma, Pawan Suvarna present before you the Project report entitled
Manufacturing of 1 Ton/hour Phosphoric Acid by IMI Process. This report is the result of constant
inspiration, encouragement and invaluable guidance provided by Dr. Aparna Tamaskar.

We also thank her for her continuous guidance whenever I needed in course of my complete seminar.
Overall, it was a learning experience and I am sure it’ll help me in my future life as Chemical Engineers
when we pass out of the college.
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CERTIFICATE

DWARKADAS J. SANGHVI COLLEGE OF ENGINEERING

(AFFILIATED TO UNIVERSITY OF MUMBAI)
VILE PARLE WEST, MUMBAI-400 056

This is to certify that the Project report entitled ‘‘Manufacturing of 1 Ton/hour Phosphoric Acid by IMI
Process” is submitted to the University of Mumbai in the partial fulfillment of the requirement for the degree
of ‘‘BACHELOR OF ENGINEERING IN CHEMICAL ENGINEERING” for the academic year 2018-2019.
By,
Name Sap id
Manthan Gandhi 60011150012
Aman Sharma 60011150056
Pawan Suvarna 60011150059
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Sr. CONTENT PAGE

No. NO.
1. INTRODUCTION

2. CHEMICAL AND PHYSICAL

PROPERTIES
3. APPLICATION AND USES

4. ECONOMIC SCENARIO

5. MANUFACTURING PROCESSES AND

PROCESS SELECTION
6. MATERIAL BALANCE

7. ENERGY BALANCE

8. SIZING

9. DETAILED DESIGN

10. COSTING
11. HAZOP
12. MSDS

13. BIBLIOGRAPHY
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CHAPTER 1: INTRODUCTION

Phosphoric acid (H3PO4), also known as Ortho-phosphoric acid or Phosphoric(V)

acid, is a mineral (inorganic) acid. Ortho-Phosphoric acid molecules can combine with
themselves to form a variety of compounds which are also referred to as phosphoric acids.

Amongst the mineral acids, phosphoric acid stands an special status as it is used for
specialty application including anticorrosive and food industry out of number of processes
available only the latest are discussed below which includes applications of electric
furnace, blast furnace and process including oxidation and hydration of phosphorous or the
wet process which uses sulfuric acid and rock phosphate.

The continuous process of phosphoric acid production uses liquid white

phosphorous at the boiling condition for 5 to 6hrs so that about 35 - 50 % white
phosphorous is converted to red phosphorous. The hot red phosphorous is taken in a screw
conveyer which along with inert gases gives a solid pure red phosphorous as product. Red
phosphorous finds the application in manufacturing of matchsticks, chlorides of
phosphorous as PCl3, PCl5, phosphorous oxide as P2O5 and phosphor bronze etc. Not to be
confused with Phosphorous acid.

Ortho-phosphoric acid refers to phosphoric acid, which is the IUPAC name for this compound.
The prefix Ortho- is used to distinguish the acid from related phosphoric acids, called poly-phosphoric
acids. Ortho-phosphoric acid is a non-toxic acid, which, when pure, is a solid at room temperature
The conjugate base of phosphoric acid is the dihydrogen phosphate ion, H2PO4, which in turn has a
conjugate base of hydrogen phosphate, HPO2 -4, which has a conjugate base of phosphate. Phosphates
are essential for life.
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CHAPTER 2: Physical and Chemical Properties

 Physical state: Aqueous

 Color and Odor: colorless, odorless
 Melting Point: 42.3°C(anhydrous)
29.3°C (hemihydrate)
 Chemical name: H3PO4
 Molar Mass: 97.99 g·mol−1
 Initial Boiling point: 158 °C (316 °F; 431 K) decomposes
 Flash point: Non-flammable
 Solubility in water: 392.2 g/100 g (−16.3 °C)
369.4 g/100 mL (0.5 °C)
446 g/100 mL (14.95 °C)
 Solubility: Ethanol
 Vapor pressure: 0.03mmHg(200C)
 Viscocity: 2.4–9.4 cP (85% aq. soln.)
147 cP (100%)
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CALCIUM PHOSPHATE:
PROPERTIES

Chemical formula Ca3(PO4)2

Molar mass 310.18

Appearance White amorphous powder

Density 3.14 g/cm3

Melting point Liquefies under high pressure at 1670 K (1391 °C)

Solubility in water 0.002 g/100 g

HYDROCHLORIC ACID:
Properties

Chemical formula HCl(aq)

Appearance Colorless, transparent liquid

Melting point -114.20C

Boiling point 110 °C (383 K), 20.2% solution; 48 °C (321 K), 38% solution.

log P 0.00

Acidity (pKa) −5.9 (HCl gas)

OTHER PROPERTIES:

Physical properties of hydrochloric acid, such as boiling and melting points, density, and pH, depend on
the concentration or molarity of HCl in the aqueous solution. They range from those of water at very low
concentrations approaching s0% HCl to values for fuming hydrochloric acid at over 40% HCl.

Hydrochloric acid as the binary (two-component) mixture of HCl and H2O has a constant-boiling azeotrope at
20.2% HCl and 108.6 °C (227 °F). There are four constant-crystallization eutectic points for hydrochloric acid,
between the crystal form of HCl·H2O (68% HCl), HCl·2H2O (51% HCl), HCl·3H2O (41% HCl), HCl·6H2O (25%
HCl), and ice (0% HCl). There is also a metastable eutectic point at 24.8% between ice and the HCl·3H2O
crystallization.
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CALCIUM CHLORIDE:
PROPERTIES

Chemical formula CaCl2

Molar mass 110.98 g·mol−1

Appearance White powder, hygroscopic

Odor Odorless

Density  2.15 g/cm3

Melting point 772–775 °C (1,422–1,427 °F; 1,045–1,048 K)

Boiling point 1,935 °C (3,515 °F; 2,208 K) anhydrous.

Solubility in water Anhydrous:

74.5 g/100 mL (20 °C)
Viscosity  3.34 cP (787 °C)

Solubility Soluble: CH3COOH, alcohols

Insoluble: liquid NH3, DMSO, CH3COOC2H5

OTHER PROPERTIES:

Calcium chloride dissolves in water, producing chloride and the aquo complex [Ca(H2O)6]2+. In this way, these
solutions are sources of "free" calcium and free chloride ions. This description is illustrated by the fact that these
solutions react with phosphate sources to give a solid precipitate of calcium phosphate:

3CaCl2 + 2PO43- → Ca3(PO4)2 + 6 Cl−

Calcium chloride has a very high enthalpy change of solution, indicated by considerable temperature rise
accompanying dissolution of the anhydrous salt in water. This property is the basis for its largest-scale application.

Molten calcium chloride can be electrolysed to give calcium metal and chlorine gas:

CaCl2 → Ca + Cl2

CALCIUM FLUOIRDE:
PROPERTIES

Chemical formula CaF2

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Molar mass 78.07 g·mol−1

Appearance White crystalline solid (single crystals are

transparent)
Density 3.18 g/cm3

Melting point 1,418 °C (2,584 °F; 1,691 K)

Boiling point 2,533 °C (4,591 °F; 2,806 K)

Solubility in water 0.015g/L(18°C)

0.016 g/L (20 °C)
Solubility Insoluble: Acetone
slightly soluble in acid
Magnetic susceptibility (χ) -28.0·10−6 cm3/mol

Refractive index(nD) 1.4338

1-BUTANOL:
PROPERTIES

Chemical formula C4H10O

Molar mass 74.12 g·mol−1

Appearance Colourless, refractive liquid

Odor banana-like, harsh, alcoholic and sweet

Density 0.81 g cm−3

Melting point −89.8 °C (−129.6 °F; 183.3 K)

Boiling point 117.7 °C (243.9 °F; 390.8 K)

Solubility very soluble in acetone

miscible with ethanol, ethyl ether

Viscosity 2.573 mPa×s (at 25 °C)

Vapor pressure 6 mmHg (20 °C)

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CHAPTER 3: USES AND APPLICATIONS

Application Demand Main phosphate derivatives

in
thousands
of tons
Soaps and detergents 1836 STPP
STPP (Na5P3O10), SHMP, TSP, SAPP, SAlP, MCP,
Food industry 309
DSP (Na2HPO4), H3PO4
Water treatment 164 SHMP, STPP, TSPP, MSP (NaH2PO4), DSP
Toothpastes 68 DCP (CaHPO4), IMP, SMFP
STPP (Na3P3O9), TCP, APP, DAP, zinc
Other applications 287 phosphate (Zn3(PO4)2), Aluminium
phosphate (AlPO4, H3PO4)

Food-grade phosphoric acid (additive E338) is used to acidify foods and beverages such as various
colas and jams. It provides a tangy or sour taste. Phosphoric acid in soft drinks has the potential to
cause dental erosion. Phosphoric acid also has the potential to contribute to the formation of kidney
stones, especially in those who have had kidney stones previously.
Specific applications of phosphoric acid include:
 In anti-rust treatment by phosphate conversion coating
 As an external standard for phosphorus-31 nuclear magnetic resonance.
 In phosphoric acid fuel cells.
 In activated carbon production.
 In compound semiconductor processing, to etch Indium gallium arsenide selectively with
respect to indium phosphide.
 In microfabrication to etch silicon nitride selectively with respect to silicon dioxide.
 As a pH adjuster in cosmetics and skin-care products.
 As a sanitizing agent in the dairy, food, and brewing industries.
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CHAPTER 4: MANUFACTURING PROCESSES

AND
PROCESS SELECTION

The modern manufacturing methods of phosphoric acid are following:

1. Using phosphate rock and blast furnace

2. Using phosphate rock and electric furnace
3. Oxidation and hydration of phosphorous
4. Wet process or from sulfuric acid and phosphate rock

1. Using Phosphate Rock and Blast Furnace:

The blast furnace process was widely used in the first three decades of 20th century.
Resulting phosphoric acid can be used in manufacturing of insecticide, pesticides,
detergents etc. but not for fertilizers.

Chemical Reactions :

Ca3(PO4)2 +3SiO2 +5C 2P+5CO+3CaSiO3

2P+ 5CO+ 5O2 P2O5 + 5CO2
P2O5+ 3H2O 2 H3PO4 ( 85-90% yield )

Phosphate rock is pulverized and mixed with coke powder and binder is
compressed to 5000 psi resulting into the briquettes. Briquettes are dried and charged along
with sand and additional coke powder from top of the blast furnace. The preheated air (1000
– 1100◦C) is charged from bottom of the blast furnace via tuyere. A tuyere is cooled copper
conical pipe numbering 12 in small furnace and up to 42 in large furnace through which hot
air is blown in to the furnace. Preheated air leadstoburningofbriquettes givingtemperature
riseupto1370◦C. Thecokeacts as reducing agent as well as fuels.
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About 760kgof coke is consumed in reduction of phosphate rock to phosphorous and

remaining generates heat by combustion with air. Reaction is completed in the furnace itself
producing P2O5and calcium silicates as slag. The product gases also contain carbon
monoxide and nitrogen alongwith dust particles. For purification, it is passed through
cyclone separator and phosphorous condenser. Thus, P2O5 and elemental phosphorous are
separated out. Hot P2O5 gases are cooled in the heat exchanger. Therefore, superheated
steam is produced and a part of gas is taken into regenerative blast furnace. As a result the
entire phosphorous and phosphorous pentoxide is cooled and purified before taken into
hydrating towers. Purification of phosphoric acid includes removal of arsenic by hydrogen
sulfide treatment followed by filtration.

Engineering Aspects:

Blast Furnace
Blast furnace is made of high temperature resistant refractories brick. Blast furnace have
accessories of hot blast stove for supply of compressed preheated air having temperature
1000 – 1100◦C, briquette press for preparation of briquettes of Phosphate rock and coke,
dust collector (cyclone separator) for removal of dust particles from product stream.
Also, two outlets for removal of slag and ferro-phosphorous are provided at the bottom
of the furnace.

Thetopoftheblastfurnaceisclosed as itoperates at hightoppressure. There are two

different systems are used for charging of briquettes, coke and silica. One is having double bell
system which is often equipped with movable throat armour and other is bell less top as shown in
figure.
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One utilized lintel or support ring at the bottom of the shaft upon which the higher
level of the furnace rests. The other is free standing constructionrequiring and independent
support for the blast furnace top and gas system. The required expansion both thermal as
well as pressure for the installation is below for the lintel i.e., in bosh/belly area in lintel type
furnace, while compensator for expansion in the free standing furnace is at the top.

2. Using Phosphate Rock and Electric Furnace:

Chemical Reactions :

Ca3(PO4)2 +3SiO2 +5C 2P+ 5CO+ 3CaSiO3 ΔH =- 364.8 kcals

2P+ 5CO+ 5O2 P2O5 + 5CO2
P2O5 + 3H2O 2H3PO4 ( 87-92%yield) ΔH = - 44.9 kcals

The phosphate rock is reduced to elemental phosphorous by the action of coke

and heat in the presence of sand in electric arc furnace subsequent oxidation of
phosphorous gives phosphorous pentoxide which on hydration gives the product
phosphoric acid.

Phosphate rock after proper grinding and primary purification is taken into sintering oven where it is
nodulized and granulized so that fast oxidation of the separatedphosphoroustakesplace. Temperature
of 1095˚Cismaintainedinelectric furnace so that maximum amount of elemental phosphorous
extracted out and oxidation takes place. Since fluoride of phosphorous and calcium are the
common impuritywhich reacts with sand giving flourosilicates as the slag.
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3. Oxidation and Hydration of Phosphorous:

Chemical Reactions :
2P+2½O2 P2O5
P2O5 + 3H2O 2H3PO4 (94 – 97%yield)

Manufacture :

At the locations away from phosphate rocks mines from purified elemental
phosphorous is oxidized and hydrated to give phosphoric acid. In the manufacturing process
molten phosphorous is sprayed into combustion chamber along with preheated air and
superheated steam. Combustion of phosphorous increases the temperature up to 1980˚C.
Furnace design depends on the requirement with respect to quantity and quality. They are
made of acid proof structural bricks, graphite, carbon and stainless steel.

The gases from furnace which mainly contains P2O5, steam, N2 and small quantityof oxygen is
takeninto a hydrationcolumnwherecounter current mixingof dilute phosphoric acid and the gases
gives the product concentrated H3PO4 of 75% to 85%. concentration. Remaining acid is
trapped into packed column or electrostatic precipitator

4. Wet process or from Sulfuric Acid and Phosphate Rock:

The wet process is according to the acids (sulfuric acid, nitric acid or hydrochloric acid) used to
decompose the phosphate rock. The process using sulfuric acidisthemost commonamongall
particularlyforproducingfertilizergrade phosphoric acid.
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The wet process phosphoric acid, also called as green acid. Depending upon the hydrate forms of
calcium sulfate produced during the wet process, it is classified as anhydrate, hemi hydrate and
dihydrate. The hydrate form is controlled mainlyby temperature and acidconcentration.

Chemical Reactions :

Ca10F2(PO4)6 +10H2SO4 + 20H2O 10CaSO4.2H2O + 2HF + 6 H3PO4

Manufacture :

There are two processes i.e. dihydrate and hemihydrates

(CaSO4.2H2O and CaSO4.1/2 H2O) are used for production of phosphoric acid.
Sulfuric acid on reaction with phosphate rock along with precipitation of calcium sulfate
results into the formation of phosphoric acid. The process is simple and requires grinding of
phosphate rock reacting with dilute phosphoric acid so that melt is produced which in a
reactor as mixed with concentrated sulfuric acid for 4 to 8hrs in the temperature range of
75-80˚C. Lot of air is required to control the temperature. Resulting gases includes HF and
P2O5 which in the absorption tower is separated and finally treated to give fluorosilicates
and dilute phosphoric acid. The main product in the liquid form which is phosphoric acid
and calcium sulfate is filtered and washed. Thus, gypsum and phosphoric acid are
separated and after minor purification the phosphoric acid is concentrated into the evaporator.
Throughout the plant, corrosion resistant materials of construction must be used. The most
common ones are structural carbon or nickel alloy for evaporator heat exchangers; rubber or
carbon-brick for reactor linings; polyester-fiber glass in pipes, ducts, and small vessels.
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Process Selection

Sr. Parameter Blast Electric Oxidation and Using H2SO4 Using HCL
No. Furnace Furnace Hydration
1 Raw P. Rock, P.Rock, Elemental P.Rock and P.Rock, HCL Acid
Material Coke, Air, Sand, Phosphorous,Air, Sulphuric and Solvent
Silica, Coke Steam and Water Acid
Birquette Breeze,
Binder Carbon
Electrod,
Electricity
2 Cost High High High Low Low
3 Quality and H3PO4 H3PO4 H3PO4 H3PO4 H3PO4
Purity of (70%) (85%) (75%) (75%) (80%)
Product
4 Equipments Outdated Electric Combustion Modern Modern Technology
Used Technology Furnace- Chamber of Technology and Consumes
Expensive Small Capacity and Power Economically
Consumes
Power
Economically
5 Yield of 85% 90% 96% 90% 98%
Process
6 Plant Phosphate Phosphate Consumer Phosphate Phosphate Rock
Location Rock Rock Market Rock Region Region
Region Region
7 M.O.C High Temp. High Acid -Proof Reaction All Section of Plant
Resistant Temp Structural Tank are HCL-Resistant
Refractories Acid Bricks, Graphite, constructed i.e., RUBBER or
Brick Brick is Carbon and S.S. of Steel and PVC Lined
used in Lined with
Furnace Acid -Proof
and Brick
Chamber
Area
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5. Wet Process or from Hydrochloric Acid Leaching and Phosphate Rock:

Raw Materials:

Basis:1 ton of 100% H3PO4 98% yield

Phosphate rock = 2.3tons

HCl = 1.4tons
Solvent make-up = 3kg
Floculating agent = 0.4kg

Chemical Reactions :

Ca3(PO4)2 + HCl + 6 H2O 2H3PO4+ 3CaCl2

Side Reactions:
CaF2 + 2HCL 2HF + CaCl2
6HF + SiO2 H2SiF6 + 2 H2O

Manufacture :

Phosphate rock is ground to pass a 20 mesh screen and fed to a dissolver where
An acid stream of conc. HCl plus make-up wash water from the counter-current
decantation system is added. Fumes of CO2, HCl and HF are scrubbed for acid recovery.
The mixture is fed to a series of decantation units with overflow from first settler
moving to the counter-current extraction process. The solids under flows goes to 2-3
washing thickeners.
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Extraction of H3PO4plus some free HCl is done in a battery of mixer settlers (a)
With CaCl2 +CaF2 retained in aq. Phase. The extract is again passed through several
more mixer settler (b) for removal of trace impurities of Ca2+ which are co-extracted.
The extractant is aq. Reflux from next unit transfer extractor (c) where water extracts
H3PO4 and HCl from solvent phase.

The washed solvent is recycled to a final series of mixer settlers (d) where the
balance of HCl is extracted from raffinate phase of extractor (a). The acid free brine is
sent to steam stripping for solvent recovery.The aq. acid raffinate from (c) is separated and
concentrated in triple effect.

Evaporator to give three different overhead streams:

(1) Alcohol-water over head flash from the first effect which is condensed
and returned to extractor(a)
(2) Dilute HCl from the second effect
(3) Conc. HCl from the third effect.
The HCl is returned to acid make-up. The bottoms from the third effect is product
phosphoric acid (80% H3PO4).

Major Engineering Problem:

1. Solvent Recovery: The use of relatively expensive solvent in producing low Cost acid means
careful attention to design and operation of solvent handling equipment.
2. Material of Construction: All sections of plant must be HCl resistant which requires rubber lined or
PVC lined mild steel or rigid PVC equipment .The latter is recommended.
3. Waste Disposal: Problems of disposing CaCl2aq. Effluent and siliceous rock Residue become acute
where lagooning is not allowable.
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CHAPTER 5: THE ECONOMIC SCENARIO

Phosphoric acid (H3PO4) is the leading inorganic acid produced and consumed in terms of
production value and it is the second largest in terms of volume—after sulfuric acid. By far
its greatest use is in the manufacture of phosphate chemicals consumed primarily as carriers
of phosphorus values in fertilizers. Use in the production of animal feeds is of secondary
importance. Phosphoric acid is also used in the manufacture of phosphate chemicals for
use in water treatment and detergent builders, dentifrices, fire control chemicals, and a host
of smaller markets. Consumption of phosphoric acid for its acid properties is relatively small
(e.g., treatment of metal surfaces, beverage acidulation). Phosphoric acid is the leading
intermediate product or processing step between phosphate rock and the end markets for
phosphorus in phosphate form.

Overall and on a global level, the phosphoric acid market is expected to grow annually by
about 2% per year. The supply/demand balance is demand driven. If all the announced projects
materialize—especially the large ones by OPC in Morocco and Ma’aden in Saudi Arabia,
as well as those by Vale in Brazil and by Sunkar in Kazakhstan—incremental capacity
additions will be slightly in excess of additional demand. This will lead to an overcapacity
y situation, which is expected to depress operating rates. Global trade currently accounts for
about 11% of demand. This is expected to decline slightly as emerging regions are heavily
investing in downstream phosphate fertilizer production units. As a result, it is expected
that older phosphoric acid production units in regions without indigenous phosphate rock
reserves will come under additional pressure and will eventually be forced to close.
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The following pie chart shows world consumption of phosphoric acid:

The primary market for phosphoric acid is the production of the phosphate fertilizer products
ammonium phosphates and triple superphosphate. Fertilizer production accounts for an estimated
84% of the global market for phosphoric acid and animal feed for about 6%. The remainder is
consumed in a variety of industrial applications.

Fueled by the rapid growth in the Chinese economy and the growing need for phosphate fertilizers
, China has become the world’s largest producer and consumer of phosphoric acid. In 2015,
production and consumption in China accounted for about 39% of the world total. From 2005 to
2015, phosphoric acid capacity in China grew at an average annual rate of almost 8%. Phosphoric
acid production and consumption grew at an average annual rate of 8.5% during the same period.
 `

Indian production of phosphoric acid is estimated to correspond to around 3.6% of global production,
with Indian imports accounting for around 44% of global trade in 2015. Southwest Asian consumption
will increase by about 2.4% per year during the next five years.

In Southeast and Northeast Asia, Indonesia is the major producer of the region, accounting for about
36% of phosphoric acid production in 2015. Indonesia has significantly increased its capacity in the
past five years and imports have been increasing since 2011.
Since 2011, Japanese production and consumption of phosphoric acid has been decreasing as a result
of the declining agrichemical market, while the industrial phosphoric acid market remains unchanged.

In Latin America, the first half of 2015 saw a reduction in demand for phosphate fertilizers as a
result of lower food prices. In the second half, demand is expected to rise following increases in
soybean prices.

The phosphoric acid market is driven by industrial applications, which are expected to grow by almost
5% per year through the forecast period, followed by animal feed and fertilizers at 3.4% and 1.7% per
year, respectively. On a volume basis, production of DAP (diammonium phosphate) has the largest
influence on global phosphoric acid growth rates, accounting for 35% of global consumption, and is
projected to grow at about 2% per year through 2020.

The global phosphoric acid market was valued at US$ 13,399.62 Mn in 2017 and is anticipated to
register a stable CAGR of 3.0% from 2018 to 2026, according to a new report published by
Transparency
Market Research (TMR) titled “Phosphoric Acid Market: Global Industry Analysis, Size, Share,
Growth, Trends, and Forecast, 2018–2026.” The global phosphoric acid market is driven by rise in the
demand for phosphate fertilizers. Asia Pacific accounts for a major share of the global phosphoric acid
market, due to increased usage of Diammonium Phosphate (DAP) in agricultural activities in the region.
 `

Rise in Demand for Di-Ammonium Phosphate (DAP) projected to Drive Market

Diammonium Phosphate (DAP) is a water-soluble ammonium phosphate salt, which is produced when
ammonia reacts with phosphoric acid. DAP is widely used as a fertilizer. The use of fertilizers in the soil
increases the soil fertility and thereby, the crop yield. DAP improves the quality of fruit and vegetable
crops. Developing countries and regions are using fertilizers increasingly, so as to raise the crop yield.
Fertilizers are employed to compensate phosphorus deficiencies in the soil. High demand for food led
by growing population and increasing spending power of consumers is likely to promote growth of the
phosphoric acid market during the forecast period.
 `

Asia Pacific dominates Global Phosphoric Acid Market Among regions, Asia Pacific accounted for a
major (58%) share of the global phosphoric acid market in 2017. Presence of a large number of
phosphate rock reserves in the region is attracting a large number of customers of phosphoric acid
toward the market in Asia Pacific. Rise in the use of phosphate fertilizers is anticipated to provide
lucrative growth opportunities to manufacturers of phosphoric acid in Asia Pacific in the next few
years. In Asia Pacific, China is the key exporter, while India is the leading importer of phosphoric
acid. In terms of volume, China is the major consumer of phosphoric acid, followed by India. High
demand for phosphoric acid in Asia Pacific can be ascribed to increase in agricultural activities in
countries across the region. Manufacturers in Asia Pacific are engaged in the production of phosphate
fertilizers such as diammonium phosphate (DAP), monoammonium phosphate (MAP), and trisodium
phosphate (TSP). The phosphoric acid markets in both Western and Central Europe are fairly mature.
The market in Eastern Europe is expected to expand at a significant pace during the forecast period
. Phosphate reserves have been explored in Kazakhstan and Turkmenistan. With this, new phosphoric
acid plants are expected to be established in these countries in the near future. Several phosphoric acid
plants have also been explored in Russia.

High Degree of Competition among Established Players

Key players profiled in the report on the global phosphoric acid market are The Mosaic Company,
Nutrien Ltd., Israel Chemicals Ltd., OCP Group, Yara International, Maaden, Eurochem Group AG,
WengFu Group, Prayon S.A., J.R. Simplot Company, Solvay, and CECA (Arkema Group). These
players account for almost 50% share of the global phosphoric acid production capacity and are
forward integrated. Manufacturers of phosphoric acid are mostly concentrated in countries/regions
where phosphate rock reserves are found in abundance; for example, China, Russia, North Africa,
and North America.
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Global Phosphoric Acid Market, by Application

 Fertilizers
o Diammonium Phosphate (DAP)
o Monoammonium Phosphate (MAP)
o Trisodium Phosphate (TSP)
o Others
 Food Additives
 Animal Feed
 Others

Global Phosphoric Acid Market, by Region

 North America
o U.S.
o Canada
 Latin America
o Brazil
o Mexico
o Rest of Latin America

 Europe
o Germany
o France
o U.K.
o Italy
o Spain
o Russia & CIS
o Rest of Europe

 Asia Pacific
o China
o Japan
o India
o ASEAN
o South Korea
o Rest of Asia Pacific

 Middle East & Africa

o South Africa
o Egypt
o Rest of Middle East & Africa
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IMPORT
(October – November 2016)
DATE DESCRIPTION ORIGINAL PORT OF UNIT VALUE PER
COUNTRY DISCHARGE QUANTITY (INR) UNIT
(INR)
22 PHOSPHORIC MOROCCO GOA 5,864,111 232,29, 40
NOV ACID PORT KGS 592
16 (Analysis
53.19%)
(For
manufacture of
FERTILIZER)
22 PHOSPHORIC VIETNAM NHAVA 23,520 1,202, 64
NOV ACID (85%) SHEVA KGS 477
16 PORT
22 PHOSPHORIC TAIWAN NHAVA 23,800 120,247 51
NOV ACID (85%) SHEVA KGS
16 (For Industrial PORT
use)

22 PHOSPHORIC MOROCCO COCHIN 5,571,084 220,64, 40

NOV ACID (85%) PORT KGS 360
16 (For
FERTILISER )

22 PHOSPHORIC VIETNAM NHAVA 47,040 2,996, 64

NOV ACID (85%) SHEVA KGS 519
16 PORT
22 PHOSPHORIC TAIWAN NHAVA 13,020 488,556 38
NOV ACID (85%) SHEVA KGS
16 PORT
22 PHOSPHORIC SOUTH CHENNAI 21,000 1,104, 53
NOV ACID (85%) KOREA PORT KGS 023
16
22 PHOSPHORIC TAIWAN NHAVA 24,010 975,388 41
NOV ACID (85%) SHEVA KGS
16 PORT
22 PHOSPHORIC TAIWAN NHAVA 11,780 442,027 38
NOV ACID (85%) SHEVA KGS
16 PORT
`

EXPORT

(October – November 2016)

DATE DESCRIPTION DESTINATION PORT OF QUANTITY VALUE PER

LOADING (INR) UNIT
(INR)
11 PHOPHORIC CONGO NHAVA 8 KGS 621 83
NOV ACID SHEVA
16 PORT
01 PHOPHORIC VIETNAM DELHI 1 KGS 178,464 178,
NOV ACID AIR 464
16 CARGO
28 PHOPHORIC UNITED BOMBAY 6 KGS 130, 21,664
OCT ACID STATES AIR 417
16 CARGO
28 PHOPHORIC UNITED BOMBAY 4 KGS 130, 30,904
OCT ACID STATES AIR 417
16 CARGO
28 PHOPHORIC UNITED BOMBAY 40 KGS 129, 3,246
OCT ACID STATES AIR 838
16 CARGO
28 PHOPHORIC UNITED NHAVA 120 KGS 2,008, 16,739
OCT ACID ARAB SHEVA 632
16 EMIRATES PORT
27 PHOPHORIC UNITED NHAVA 7,500 KGS 11,551, 1,540
OCT ACID STATES SHEVA 106
16 PORT
27 PHOPHORIC ETHIOPIA NHAVA 9 PCS 452 50
OCT ACID SHEVA
16 PORT
21 PHOPHORIC TANZANIA NHAVA 5,040 KGS 1,028, 204
OCT ACID SHEVA 298
16 PORT
18 PHOPHORIC TAIWAN NHAVA 3,240 KGS 502,054 155
OCT ACID SHEVA
16 PORT
06 PHOPHORIC GERMANY BOMBAY 10 KGS 74 740
OCT ACID AIR
16 CARGO
`

Total Value & Volume of Imports in India

Total Value $4,768,130,994

Total Quantity 6,482,744,820
Average price per unit $0.74
Average value per shipment $664,641

Top Suppliers

Morocco $2,194,001,101
United States $678,965,912
Senegal $631,037,634

Top Ports of Discharge

Kandla $1,839,461,286
Kakinada $1,007,383,015
Goa Sea $450,610,640

Kandla $1,839,461,286
Kakinada $1,007,383,015
Goa Sea $450,610,640
`
`
 `

Potential Phosphoric Acid fertilizer supply worldwide from 2014 to 2019 (in million metric tons)

This statistic depicts the potential global supply of phosphoric acid fertilizer from 2014 to 2019.
In 2014, the potential supply of phosphoric acid fertilizers has reached some 46.71 million metric tons.
`

Chapter 6 : Material Balance

Chemical Reactions :

Ca3(PO4)2 + HCl + 6 H2O 2H3PO4+ 3CaCL2

Side Reactions:

CaF2 + 2HCL 2HF + CaCl2

6HF + SiO2 H2SiF6 + 2 H2O

Component Molecular Weight

Ca3(PO4)2 310
HCl 36.5
H3PO4 98
CaCl2 111
H2SiF6 144
H2 O 18
SiO2 60
HF 20
CaF2 78
 `

Phosphate Rock Composition (Wt %, Dry Basis) :

Component Wt %

P2O5 32

CaO 49

SiO3 2

SiO2 3

F 3.6

Al2O3 0.7

Fe2O3 0.7

MgO 0.5

Moisture Content 1.5

CO2 3.52

Inerts 3.48
`

Basis: 1ton/day of 100% Phosphoric acid in 98% yield.

The product contains 80% H3PO4, 20% H2O, Fe<100ppm and Al<10ppm.So, the product
contains1000Kg of H3PO4 and 250 Kg of H2O.

Material Balance Across Disslover:

The dissolver has two inlet streams, One coming from crusher and the other being make-up
HCl and it also consist of two outlet stream, one being final product and the other containg HF gas fed
to the scrubber.

Stream No. Component Mass(Kgs)

Inlet 1 Phosphate Rock 2300
Inlet 2 HCl 1400
H2O 2842.424
Outlet1 H3PO4 1000
CaCl2 1724.1
H2SiF6 4.176
H2O 2877.968
SiO2 67.26
HCl 265.052
CaF2 151.242
Ca3(PO4)2 32.116
CaO 134.786
`

SiO3 46
Al2O3 16.1
Fe2O3 16.1
MgO 11.5
Inerts 80.04
Outlet2 HF 6.14
HCl 5.408
CO2 80.96

Here, all components in Outlet 1, 2 stream are tie components. So, the quantities of these components
will remain same in Inlet and Outlet stream.

Ca3(PO4)2 + HCl 2H3PO4+ 3CaCl2

t=0 5.18 31.08 0 0
t=t 0.1036 0.6216 10.1528 15.2292
Mass (kg) 32.116 22.6884 1000 16972.412

In above reaction Ca3(PO4)2 will be coming from immediate reaction written below and we know
H3PO4 will be 1000 Kg so using yield concept we will get to know how much Ca3(PO4)2 will react.
We even know that 2.3 ton of Ca3(PO4)2 will be required as raw material. So, we know how much
Ca3(PO4)2 will remain and using stoichiometry we even get how much ever other component in
reaction will reaming.
`

3CaO + P2O5 Ca3(PO4)2

t=0 20.125 5.18 0
t=t 4.585 0 5.18
Mass (kg) 256.76 0 1605.2
Above reaction will help us know how much Ca3(PO4)2 will be present in phosphate rock. Here P2O5
is limiting reagent.

2CaO + 4F 2CaF2 + O2
t=0 4.585 4.358 0 0
t=t 2.406 0 2.179 1.0895
Mass (kg) 134.786 0 169.960 34.864
Above reaction will help us know how much CaF2 will be formed to react in side reaction. Here
fluorine is limiting reagent.

CaF2 + 2HCL 2HF + CaCl2

t=0 2.179 4.358 0 0
t=t 1.939 3.878 0.480 0.240
Mass (kg) 151.242 141.547 9.6 26.64
Above reaction is side reaction taking place in dissolver. Here CaF2 is limiting reagent and HCl in
excess. Using data from literature we found that conversion of this reaction is about 11%

6HF + SiO2 H2SiF6 + 2 H2O

t=0 0.48 0.575 0 0
t=t 0.307 0.546 0.029 0.058
Mass(kg) 6.14 32.76 4.176 1.044
Above reaction is final side reaction taking place is dissolver and its conversion is 5%
 `

Mass Balance across the Decantation Equipments:

It has two inlet stream amongst which one is stream that contains flocculating agent and other stream
is coming from exit of Dissolver. It also has two outlet stream one comes out as solid residue and other overflow
stream from first washing thickener goes to first battery settler.

Stream No. Component Mass(Kg)

Inlet1 H3PO4 1000
CaCl2 1724.1
H2SiF6 4.176
H2O 2877.968
SiO2 67.26
HCl 265.012
CaF2 151.242
Ca3(PO4)2 32.116
CaO 134.786
SiO3 46
Al2O3 16.1
Fe2O3 16.1

We assumed that liquid which is coming from inlet 1 here is getting divided into two stream that is 5% is going
into outlet 1 and 95% is going into outlet 2. Only 5% is assumed because only liquid that will be going with solids
is into its pores and cavities and that is too less.
`

MgO 11.5
Inerts 80.04
Inlet 2 Flocculating Agent 0.4
Outlet1 H2SiF6 4.176
H2O 143.898
SiO2 67.26
SiO3 46
Inerts 80.04
CaO 134.786
Ca3(PO4)2 32.116
Al2O3 16.1
Fe2O3 16.1
MgO 11.5
H3PO4 50
CaCl2 86.205
HCl 13.251
CaF2 7.562
Flocculating Agent 0.4
Outlet 2 H3PO4 950
CaCl2 1637.895
HCl 251.761
CaF2 143.679
H2O 2734.069
 `

Mass Balance across the Mixer-Settlers and Stripper:

It has one inlet stream which is coming from overflow of first decantation unit. This
system has two more inlet streams, which are make-up solvent and water. It has two outlet
streams, one amongst which contains CaCl2 and CaF2 and the other one contains HCl,
solvent, H3PO4 and H2O.

Stream No. Component Mass(Kg)

Inlet 1 H3PO4 950
CaCl2 1637.895
HCl 251.761
CaF2 143.679
H2O 2734.069
Inlet 2 Make-up 3
Solvent
Inlet 3 Water 5520
Outlet 1 CaCl2 1637.895
CaF2 143.679
Outlet 2 HCl 163.645
H3PO4 617.5
H2O 552
Solvent 0.3
 `

Here, 10% of H2O and solvent in outlet 2 stream has been recycled. We have assumed
O:A = 1:1 and its corresponding extraction efficiency is 65%. Therefore solvent required for
extraction is 3313.882 kg. From Reference, we know that, for 3000 g of Phosphate Rock,
5cm3/min Water is required for Stripping H3PO4 and HCl from Organic Phase. Therefore, for
2300000 g (2.3 tons) of Phosphate Rock will require 5520kg/day of H2O is required for
Stripping H3PO4 and HCl from Organic Phase.

Mass Balance across Triple Effect Evaporator:

The aq. acid raffinate from (c) is separated and concentrated in triple effect.
Evaporator to give three different overhead streams:
(1) Alcohol-water over head flash from the first effect which is condensed
and returned to extractor (a)
(2) Dilute HCl from the second effect
(3) Conc. HCl from the third effect.
The HCl is returned to acid make-up. The bottoms from the third effect is product
phosphoric acid (80% H3PO4).

1st Effect Evaporator:

Stream No. Component Mass(Kg)

Inlet 1 HCl 163.645
H3PO4 617.5
H2O 552
Solvent 0.3
`

Inlet 2 Weak 5.075

HCl(10%)
H2O 45.675
Outlet 1 H2O 30
Solvent 0.3
Outlet 2 Weak 5.075
HCl(10%)
H2O 45.675
Outlet 3 HCl 163.645
H3PO4 617.5
H2O 522

Here we have assumed that 30 Kg of water is being evaporated with solvent in 1st effect
evaporator.

2nd Effect Evaporator:

Stream No. Component Mass(Kg)

Inlet 1 HCl 163.645
H3PO4 617.5
H2O 522
Inlet 2 Conc. HCl(33%) 158.56
H2O 321.944
`

Outlet 1 Weak 5.075

HCl(10%)
H2O 45.675
Outlet 2 HCl 158.56
H3PO4 617.5
H2O 476.325
Outlet 3 Conc. HCl(33%) 158.56
H2O 321.944

3rd Effect Evaporator:

Stream No. Component Mass(Kg)

Inlet 1 HCl 158.57
H3PO4 617.5
H2O 470.325
Inlet 2 Steam 333.808
Outlet 1 Condensate 333.808
Outlet 2 Conc. HCl(33%) 158.56
H2O 321.944
Outlet 3 H3PO4 617.5
H2O 154.375
`

CHAPTER 7: ENERGY
BALANCE
COMPOUND HEAT CAPACITY (J/MOL K) ENTHALPY (KJ/MOL)

Ca3(PO4)2 227.8 -4121

HCl 29.1 -167.2

CaCl2 72.9 -795.8

CaF2 67 -1219.6

H2O 75.3 -285.8

H3PO4 145 -1271.7

HF 29.085 -273.3

SiO2 43.655 -910.7

H2SiF6 98.9 -811.7

CaO 35

SiO3 84.5

Al2O3 89.72

Fe2O3 104.2

MgO 3.585

DISSOLVER:

INLET TEMPERATURE = 303K

OUTLET TEMPERATURE = 325K

HEAT OF REACTION 1: ΔHr= 981775.76 KJ

ΔH1= mCpΔT

=(25-30)*(0.00518*227.8+0.031*29.1+0.031*75.3)

=-22123.78 KJ
`

ΔH2= mCpΔT

=(52-25)*(0.010153*145+0.01523*72.9+0.0311*75.3+0.000103*227.8+0.623*29.1)

=134038.1876 KJ

(ΔH)reactor1 = -22123.78 +981775.76 +134038.1876

= 1093690.168 KJ

HEAT OF REACTION 2: ΔHr= 50784 KJ

ΔH1= mCpΔT

=(25-30)*(0.00217*67+0.004358*29.1)

=-1364.054 KJ

ΔH2= mCpΔT

=(52-25)*(0.480*103*29.085+0.00024*72.9+0.001939*67+0.003878*29.1)

=7403.9292 KJ

(ΔH)reactor2 = -1364.054 +50784 +7403.9292

= 56823.8752 KJ

HEAT OF REACTION 3: ΔHr= 33575.5 KJ

ΔH1= mCpΔT

=0.00048*29.085*(25-52)+0.000575*43.656*(25-30)

=-502.4526 KJ

ΔH2= mCpΔT

=(52-25)*(0.029*103*98.9+0.058*103*75.3+0.307*103*29.085+0.546*103*43.656)

=1080.0208 KJ

(ΔH)reactor3 = -1364.054 +50784 +7403.9292

= 34153.0682 KJ

∴(ΔH)reactor=1059281.622 KJ
`

But, (ΔH)reactor= mλ

∴m=1059281.622/2257

∴m=469.331689 kg/hr

Decantation:

INLET TEMPERATURE = 325K

OUTLET TEMPERATURE = 320K

(ΔH)inlet1= mCpΔT

=(52-25)* (1000*1.4796+1724.4*0.6567+4.176*0.6868+2877.968*4.18+
265.012*0.7973+67.26*0.7276+151.242*0.8589+134.786*0.6259)

=408215.3636 KJ

(ΔH)inlet2= m*4.18*(30-25)

=m*20.9

(ΔH)outlet1= mCpΔT

=(47-25)* (143.898*4.18+0.05*m*4.18+67.26*0.7276+46*0.72844+
134.786*0.6259+32.116*0.7348+16.1*0.88+16.1*0.62884+11.5*0.955+50*1.47
86+13.25*0.7973+7.562*0.8589+86.205*0.6567+80.04*1.104)

(ΔH)outlet2= mCpΔT

=(47-25)* (950*1.4796+143.679*0.8589+251.761*0.7973

+1637.895*0.6567+2734.069*4.18+0.95*m*4.18)

∴m=824.314 kg/hr
`

Evaporator:
INLET TEMPERATURE = 320K

OUTLET TEMPERATURE = 364.955K

T1=60oC

Tsteam=100oC

U1=1225 W/m2 K

U2=1150 W/m2 K

U3=1050 W/m2 K
1/U1
∴ΔT1= 1 1 1 =15.47
𝑈1+ 𝑈2+ 𝑈3

1/U2
ΔT2= 111 =16.48
++
𝑈1 𝑈2 𝑈3

1/U3
ΔT3= 111 =18.045
++
𝑈1 𝑈2 𝑈3

Now by dew point calculation,

∴P1=19.916 KPa

P2=40.637 KPa

P3=83.589 KPa

ƛ1=2358.89 KJ/Kg

ƛ2=2075.3 KJ/Kg

ƛ3=1650.32 KJ/Kg

Tbase=25oC
`

1st effect:

ΔHfeed = mCpΔT

=(47-25)*(163.645*797.3+617.5*1479.6+552*4180+0.3*2610.7)

=73749.95 KJ

ΔHcoil= mλ

=5.075*412.5424+45.675*2260

=1053149.1527 KJ

ΔHvapour=30*2260+0.3*664.6

=67999 KJ

ΔHliquid=(60-25)*(163.645*797.3+617.5*1479.6+522*4180)

= 11293 KJ

Q1=U1A1ΔT1

∴ A1=5.55 m2

2nd effect:

ΔHfeed = mCpΔT

=112913 KJ

ΔHcoil= mλ

=123006.1629 KJ

ΔHvapour=105319.1527 KJ

ΔHliquid=(75.475-25)*(158.57*797.3+617.5*1479.6+476*4180)

= 152995.7497 KJ

Q2=U2A2ΔT2

∴ A2=6.49 m2
`

3rd effect:

ΔHfeed = mCpΔT

=152995.7497 KJ

ΔHcoil= msteam* λsteam

ΔHvapour=123006.1629 KJ

ΔHliquid=(91.955-25)*(617.5*1479.6+154.375*4180)

= 104381.765 KJ

msteam=333.808 Kg

Q3=U3A3ΔT3

∴ A3=8.64 m2
`

CHAPTER 8: EQUIPMENT SIZING

Reacter:
 Residence Time – 60 min

 Kilogram of liquid handled – 4242.42 kg

 Density of liquid handled – 1.066 kg/ m³

 Volume of liquid handled – 3.9798 m³

 Vapour space= 40%

 Volume of reactor =6m3

 Assuming L:D=3:1, we get

Di=1.3656m

L=4.0967m

Evaporator:
 Kilogram of liquid handled – 1333.44 kg

 Density of liquid handled – 1432.02 kg/ m³

 Volume of liquid handled – 0.93 m³

 Vapour space= 40%

 Coil inside diameter=25mm

 Area of evaporator =5.55m2

 Assuming L:D=4:1, we get

Di=0.667m

L=2.66m
`

Decanter:
𝑄𝑜 (𝑌 − 𝑈) 𝐶 𝜌𝑠
𝐴1 =
𝑈𝑡 𝜌𝑓

U=mass ratio liquid to solid in underflow

Y=mass ratio of liquid to solid in feed

Ut=Terminal velocity
2∗𝑟2∗(𝜌𝑝−𝜌𝑓)
=
µ

=5.5666*103 m3/sec

Y=10.5

U=8.5

C=particle volume fraction=0.0944

∴A=121.71 m2

D=12.45m

Extractor:
 Length=1.103m
 Diameter=3.312m
 RPM=100
 Mass of liquid handled=9031.286 Kg
 Volume of liquid handled = 9.31 m³

 Density of liquid =948.98 kg/ m³

 No. of baffels in mixer =4
 Blade width =4mm
 Type of agitator= 45o itch blade turbine
 Hold-up time,Ɵ=10-15 min.
`

CHAPTER 9: DETAILED DESIGN

Reactor Design

Jacket I.D = 692.3 mm Shell

I.D = 1365.6 mm

Corrosion allowance:
Shell = 1.5 mm Jacket
= 2 mm

Stainless steel alloy:

Stress = 120 N/mm2
Modulus of Elasticity = 1.7* 105 N/mm2 Poisson’s Ratio
= 0.3

Jacket IS: 2062

Allowable stress = 95 N/mm2

Shell thickness for Internal Pressure

pDi
t= +C
2fJ−p

t = 2.28 mm ~ 6 mm Do =
1377.6 mm
`

DESIGN OF SHELL
THICKNESS FOR
EXTERNAL JACKET
PRESSURE

CRTICAL EXTERNAL PRESSURE

5
t 2
2.42E ( )
Do
P
(1−µ2)3/4
∗ L t
1
2
c

=
(Do)−0.45(Do)

Pc = 0.19 N/mm2
Pa = 0.0475 N/mm2

Allowable external working pressure

L
( )=3
Do
D0
( 𝑡 ) = 229.6
Pa = 0.089 N/mm2
Since, both the allowable pressures is less than the jacket pressure, hence we use stiffening
rings

Let us provide two stiffening rings i.e. 3 spacings

L= 4096.7/3 = 1365.57 mm
Pc = 441553.41 * 1.31 * 10-6
= 0.5784 N/mm2
Pa = 0.145 N/mm2

Since, allowable pressure is greater than jacket pressure, the design is acceptable.
`

MOMENT OF INERTIA

Pc (Do3) L
I=
24E

Pc = 0.14 * 4 = 0.56
I = 490017.1 mm4

The value of I is derated by 30% to accommodate resistance offered by shell.

Desired I = 0.7 * 490017.1
= 343011.97 mm4
The angle ISA 100*100*10 has I =393280.814mm4, which is more than required
I = 343011.97 mm4
Therefore, this angle is adequate for stiffening ring.

TOP AND BOTTOM TORISPHERICAL HEAD

DESIGN

PRcW
th = +c
2fJ
0.11∗1365.6∗1.77
th = + 1.5
2∗120∗1

th = 2.6 mm

Use 6 mm thickness
`

DESIGN OF JACKET

Shell diameter = 1365.6 mm

Jacket diameter = 1365.6 + 6 + 2(stiffening ring)
= 1365.6 + 6 + 40
= 1491.6 mm

Pj Dij
trj = +c
2fJ−Pj
0.14∗1491.6
trj = +2
2∗95∗0.85−0.14

trj = 3.3 mm

Use 6 mm thickness for Jacket shell

Jacket for closer thickness

√𝑃𝑖
trc = 0.866 * wj *
√𝑓

trc = 0.866 * 1491.6−1365.6 * √0.14

2 √95

trc = 2.09 mm

Use jacket closer thickness of 12 mm

`

FLANGE
DESIGN OF GASKET
Do = 1377.6 + 2(6)
= 1384.6 mm
= 1390 mm
Inner Diameter of Gasket Gi = 1400 mm

𝐺𝑜 𝑦 − 𝑝𝑚
=√
𝐺𝑖 𝑦 − 𝑝(𝑚 + 1)

62 − (0.14 ∗ 3.25)
=√
62 − (0.14 ∗ 2.75)

=1.001 mm
Go = 1401.6 mm
Go = 1402 mm

Width of Jacket = N = 𝐺𝑜−𝐺𝑖 = 1mm

2

But minimum width of Gasket = 10 mm

Go = Gi +2N
= 1400 + 2(10)
= 1420 mm
𝑁
bo = = 5 mm
2

bo < 6.33 mm
bo = b = 5 mm
`

DESIGN OF BOLT

Bolt load under atmospheric conditions

Wm1 = πGby = π*1410*5*62
= 1373190.2 N
Bolt load under operating conditions
𝜋
Wm2 = πG(2b)mp + (4 )G2p

= 23255.64 + 218603.07
= 241858.65 N
Wm1 > Wm2
Area of Bolt required
𝑊𝑚1 1373190.2
Am = =
𝑓𝑏𝑜𝑙𝑡 138

Am = 9950.665 mm2
1410
n=𝐺 = = 56.4 ≈ 60
25 25

Diameter of Bolt
4 𝐴𝑚
db = √ +
𝜋 𝑛

4 9950.665
√ +
𝜋 60

db = 14.53 mm ≈ 15 𝑚𝑚

Bolt Circle diameter

B = Go + 2db + 12
= 1410 + 2(15) + 12
= 1452 mm
Actual Bolt spacing required
𝜋𝐵 𝜋∗1452
bs = =
𝑛 60

bs = 76.02 mm ≈ 80 𝑚𝑚
`

DESIGN OF FLANGE

k= 1
1.5𝑊𝑚ℎ𝐺
(0.3+ )
𝐻𝐺

= 1373190.2 N
𝐵−𝐺
hG = = 21 mm
2

H = 𝜋G2b = 218603 N
4

k= 1
1.5∗1373190.2∗21
(0.3+
1410+218603 )

= 2.27

Thickness of Flange
𝑝 0.14
tf = G √ = 1410√
𝑘𝑓 2.27∗140

= 29.59 mm
tf = 30 mm

Outside diameter of flange

Dfo = B + 2db + 12
= 1452 + 2(15) + 12
= 1494 mm
Dfo = 1500 mm

𝐷𝑓𝑖−𝐷𝑓𝑜 1500−1365.6
Width of Flange = = = 67.2 𝑚𝑚
2 2

= 70 mm
`

NOZZLE

Thickness of Shell = 6 mm
𝑝𝐷𝑖 0.14∗1365.6
trn = =
2𝑓𝐽−𝑝 (2∗140∗0.85)−0,14

trn = 0.8 mm
Nozzle I.D = 182 mm
d = di + 2c
= 182 + 3
= 185 mm

Now,
𝑑𝑖
X=d or X= + t + trn – 3c
2

X = 185 or X = 182 + 6 + 0.8 – 3(1.5)

2

X = 98.5 mm

Therefore, X = 185 mm (larger value)

h1 or h2 = 2.5(t-c) = 2.5(2.28-1.5)
= 2 mm
h1 or h2 = 2.5(tn-c) = 11.25 mm
h1 = 50 mm , h2 = 12 mm(Given)
h1 = 2 mm (smallest among all values)
h2 = 0 (no external protrusion is given)

A = dtr = 185*2.28 = 421.8 mm2

As = (2X-d)(t-tr-c)
= 410.7 mm2
Ao = 2h1(tr-trn-c)
= 14.8 mm2
 `

Ai = 2h2(tn-c) = 0 Ar =
A- (As+Ao+Ai)
Ar = 421.8 – (410.7+14.8+0)
= -3.7 mm2
As area is negative, no compensation is required for shell nozzle.

DESIGN OF EVAPORATOR

DESIGN PRESSURE
Shell = 19.916 kPa
Jacket = 40.637 kPa = 0.0406 N/mm2
Shell Diameter:
L 4
=
D 1
V = π D2L ….. (1)
4

Now,
ρ H3PO4 = 1880 kg/m3
ρHCl = 1200 kg/m3
ρButanol = 810 kg/m3
ρH2O = 1000 kg/m3

MHCl = 163.645
MH3PO4 = 617.5
MButanol = 0.3
MH2O = 552

(1800∗617.5)+(1200163.645)+(810∗0.3)+(1000∗550)
ρavg = 63.645+617.5+0.3+552

ρavg = 1432.02 kg/m3

V = 0.93 m3

Substituting in equation (1),

0.93= π*0.25*D2*4*D
 `

D = 0.667 m, L = 2.666
Internal diameter of half coil jacket = 25 mm

Design of shell thickness

pDi
t= +c
2fJ−p

t = 2.07 mm
Use 8 mm shell plate thickness

Design of torispherical head

PRcW
th = +c
2fJ+G
1
∗𝑤(3 + √10) = 1.54
4

=
0.0199∗1.1∗667∗1.54
th = +2
2∗120∗1

th = 2.09 mm
Use 8 mm torispherical head plate thickness

Design of half coil jacket

PiDi
tc= +c
2fJ
0.0406∗1.1∗25
tc= +2
2∗120∗0.6

tc = 2.01 mm
Use minimum 3 mm thickness of half coil

(1) Maximum roof stress in coil at junction with shell

PiDi 0.0406∗1.1∗25
fcc = =
2tcJ 2(3−2)∗0.6

= 0.93 N/mm2
 `

(2) Maximum axial stress in coil at junction with shell

PiDi
fac =
4tcJ+2.5t J
0.0406∗1.1∗25
=
4(3−2)∗0.6+2.5∗(8−2)∗0.6

= 0.07 N/mm2
Since, both stresses are less than allowable stress of material (120 N/mm2), half coil thickness
3 mm selected is satisfactory.

Agitator Design
RPM: 50
Vessel Diameter: 1365.6mm (Drank)
Internal Pressure: 0.1N/mm2

Now, Diag. Agitator: [Da/DRank] = 1/3

Width of blade: w
w/Da = 1/5
w = 91.04mm
No. of blades = Assume 6.
Thickness of Blade = 4mm
Speed = 50rpm.
Liquid In Vessel Weight(in Kg)
CaF2 0.0235 154.242
HCl 0.0412 285.012
H3PO4 0.1556 1000
CaCl2 0.2683 1724.1
H2O 0.4478 2872.968
Total = 6018.322 Kg
Vol. of liquid in vessel = 3.9795 m3
Ρmix = 6018.322/7.9798 = 1512.22 Kg/m3
 `

µCaCl2.H2O = 29 × 10-3 NS/m2

µH3PO4 = 135 Cp = 135 ×10-3 NS/m2
µHCl = 0.6 cP = 0.65 ×10-3 NS/m2
µCaF2 = 23 ×10-3 NS/m2
ν1/3 = 0.0235[23×10-3]1/3 + 0.716[29×10-3]1/3 + 0.1556[135×10-3]1/3 + 0.0412[0.65×10-3]1/3
ν1/3 = 0.3101
ν = 0.0298 Pa-s
Overhang of Agitator = 1000mm
Assume baffles = 4

Shaft Material = Commercial coil rolled steel

Permissible Sheer Stress in shaft = 55 N/mm2
Elastic limit in tension = 24.6 N/mm2 Modulus
of Elasticity = 1.95 × 105 N/mm2

Power
NRe = De2 Ns/m
= (4552×10-3) × (50/60) × (1812.22/0.0298)

NRe = 8762.377
NP = 6 [fig. 14.11 Joshi’s]
Power = 102.605 w
Assuming Power transmission = 90%
Gland/loss = 5%

Motor rating = 102.605/(0.9 × 0.95) = 120 w = 0.16 HP ; Say 0.2 HP

Shaft Design
Consider 0.2Hp = 150w

TC = Torque = P/2 𝜋n = 150/(2 𝜋 × 50/60) = 28.64N.m

Maximum Torque = 1.5 × TC = 42.97 × 103 N.mm
 `

Now, Permissible Shear Stress = 55 N/mm2

Polar Modulus ƵP = (𝜋/16) × d3 = 15.846 mm
dshaft = 20mm
Check Stress on Shaft
Fm = Tm/(0.75×Da/2) = 42.97 × 103/(0.75× (455.2/2)) = 251.73N
Maximum bending moment from which shaft overhangs M
= 251.73 × 1000 = 251.73 N.m

Equivalent Bending Moment

MC = 0.5{ M + (M2+Tm2)0.5}
MC = 0.5{251.73 + (251.732 + 251.732)0.5} = 253.55 N.m = 253550 N.mm f
= 253550/(π/32 × 203) = 322.83 N/mm2

This is more than the elastic limit of 246 N/mm2

Use shaft of 30mm.
f = 25350/( π/32 × 303) = 95.65 N/mm2
d = 30mm = dshaft
Critical Speed Consideration
FM = 251.73 N
δL = (Wl3/3EI)
l = 1000mm (overhang) E
= 1.95 × 103 N/mp2
I = (π/64× dshaft4) (Appendix A of Joshi’s)
δL = (251.73×1000×1000×1000)/(3×1.95×103× π/64× 304) = 29160.18
δL = 10.8274 mm
Now, shaft weight of per unit length
W = (π/4× d2× ρ) = (π/4×(30/1000)2× 7850) =5.5489 Kg/m = 5.5489×10-3 Kg/mm

δS = (w×l4)/(8.E×I)
= (5.5489×10-3×9.81×10004)/(8×1.95×108×( π/4)×304) = 0.0548 mm
 `

Nt = 9+6/( δ1+δ2+(δ3/1.25))0.5
= 9+6/(10.8224+8.435+(0.545/1.25))0.5 = 215.327 rpm
Now, our speed = 50 rpm System
is dynamically balanced.
 `

CHAPTER 10: Costing Of Equipments

Reactor
Updated Bare Module Cost =UF*BC(MP+MF-1)
UF= Update Factor
BC= Bore Cost
MPF= Material and Pressure Correction
Factor MF= Module Cost

UF = Present Cost Index / Base Cost Index

= 602/100
= 6.02
Length = L = 4.096 m = 13.44 ft
Diameter = D =1.3656 m =
4.498 ft

L
BC = Co ( )α ( D )β
Lo Do

= $1000(13.44/4)0.81 * (4.498/3)1.05
= $408.35

MF = 4.23

MPF = FM.FP (For Pressure Vessels)

FM = 3.67
FP =1

MPF =3.67*1 = 3.67

`

Updated Bare Module Cost = 6.02 *408.35(4.23+3.67-1)

= $38162.38
= Rs 26,38,165.52

Evaporator
1) Evaporator 1
Area = S=5.55 m2 =59.74 ft2
Updated Bare Module Cost =UF*BC(MP+MF-1)

UF = 600/100
= 6.02

S α
BC = Co ( )
So

= 0.3*103*(59.74/5.5)0.024
= $317.67

MPF = FM(FP +FD) (For Heat Exchangers)

Now, FD = 0.8
FM =2.5
FP =0
MPF = 2.5(0+0.8)
=2
MF = 1.83
Updated Bare Module Cost = 6.02 *317.67(1.83+2-1)
= $5412.6
= Rs 3,73,970.36
`

2) Evaporator 2

Area = S=6.49 m2 =69.86 ft2

Updated Bare Module Cost =UF.BC(MP+MF-1)

UF = 600/100
= 6.02

S
BC = Co ( )α
So

= 0.3*103*(69.86/5.5)0.024
=$318.9

MPF = FM (FP +FD) (For Heat Exchamgers)

Now, FD = 0.8
FM =2.5
FP =0
MPF = 2.5(0+0.8)
=2
MF = 1.83

Updated Bare Module Cost = 6.02 *317.67(1.83+2-1)

=$5432.97
=Rs 3,75,418.35
`

3) Evaporator 3

Area = S=8.64 m2 =93 ft2

Updated Bare Module Cost =UF.BC(MP+MF-1)

UF = 600/100
= 6.02

S
BC = Co ( )α
So

= 5000(162/400)0.65
= $277.854

MPF = FM(FP +FD) (For Heat Exchamgers)

Now, FD = 0.8
FM =3.1
FP =0
MPF = 3.1(0+0.8)
= 2.48
MF = 3.29

Updated Bare Module Cost = 6.02 *277.854(2.48+3.29-1)

= $7978.697
= Rs 5,51,327.39

Total Evaporator Updated Cost = 3,73,970.36+ 3,75,418.35+ 5,51,327.39

= Rs 13,00,716.1
`

Extractor

Length = L = 1.103 m =3.62 ft

Diameter = D =3.312 m = 10.866 ft

UF = Present Cost Index / Base Cost Index

= 602/100
= 6.02

L
BC = Co ( )α ( D )β
Lo Do

= $690(3.62/4)0.78 * (10.866/3)0.98
= $225.3

MF = 3.18

MPF = FM.FP (For Pressure Vessels)

FM = 3.67
FP =1

MPF =3.67*1 = 3.67

Updated Bare Module Cost = 6.02 *225.3(3.18+3.67-1)

= $7934.38
= Rs 5,48,266.3
`
COSTING
COST OF EQUIPMENTS:
Sr.no Equipment
1 Crusher
2 Reactor
3 Decantation Units
4 Extractors
5 Stripper
6 Agitator
7 Pump
8 Evaporator 1
9 Evaporator 2
10 Evaporator 3
Total
Quantity Price(Rs)
1 Rs 2,50,000
1 Rs 26,38,165.52
3 Rs 5,40,000
4 Rs 21,93,065.2
1 Rs 10,00,000
1 Rs 6,00,000
2 Rs 13,34,400
1 Rs 3,73,970.36
1 Rs 3,75,418.35
1 Rs 5,51,327.39
16 Rs 98,56,346.82
`

Estimation Of Capital Requirements :

A) Direct Cost

Sr. No. Component Factor Total Cost

used (% of
equipment
cost)
a)Depriciable Cost
1 Equipment Cost
2 Equipment Installation 0.25 Rs 24,64,086.25
3 Piping Cost 0.35 Rs 34,49,720.75
4 Electrical Cost 0.1 Rs 9,85,634.5
5 Instrumentation and Control 0.25 Rs 24,64,086.25
6 Insulation and Painting 0.03 Rs 2,95,690.35
7 Spares 0.15 Rs 1,47,851.75
8 Construction 0.2 Rs 19,71,269
9 Yard Improvements 0.02 Rs 1,97,126.9
10 Transportation 0.05 Rs 4,92,817.25
11 Service Facilities 0.1 Rs 9,85,634.5
Total depriciable direct cost Rs 1,34,53,917.5
b)Non depriciable
direct cost
1 Land Cost Rs 1,60,00,000
Total non Depriciable Direct Rs 1,60,00,000
Cost
Total Direct Cost Rs2,94,53,917.5

B) Indirect Cost
Sr. No. Component Factor Total Cost
used (% of
Direct
cost)
1 Engineering and Supervision 0.1 Rs 29,45,391.75
2 Construction Expense 0.1 Rs 29,45,391.75
3 Overhead fee 0.08 Rs 23,56,313.4
4 Contingencies 0.08 Rs 23,563,13.4
Total Indirect Cost Rs 1,06,03,410.3
`

Hence Fixed Capital Investment = A+B

= Rs 4,00,57,327.8
Working Capital Investment = 0.18*Total Capital Investment
= 0.18 *(4,00,57,327.8/0.82)
= Rs 87,93,071.956
Hence,
Total Capital Investment = Rs 4,88,50,399.76

Variable Costs
Sr. No. Component Total Cost (per year)
a) Raw
Material
Cost
1) Phosphate Rock Rs 5,05,92,000
2) Hydrochloric Acid Rs 6,13,20,000
Total Raw Material Cost Rs 11,19,12,000
Tax (18%) Rs 2,01,44,160
Actual Raw Material Cost Rs 13,20,56,160
b) Utility
Cost
Steam Rs 4,21,531.2

Salaries 10% TPC Rs 1,54,04,382.7

Packaging 2%TPC Rs 30,80,876.54
Distribution 2%TPC Rs 30,80,876.54
Total Product Cost Rs 15,40,43,827

Yearly Cost = Rs 15,40,43,827

Yearly Sales = 54,09,300 kg
Cost per kg (Selling Price of Product) = Rs 42/ Kg
Hence, Total Annual Sales = Rs 20,54,05,200
Profit per Year = Rs 5,13,61,373
`

Tax on Profit = 32%

= Rs 1,64,35,639.36

Net Profit = Rs 3,49,25,733.64

Break Even Capacity = 55.5%

Depriciable FCI = Rs 4,00,57,327.8

Hence, Payback Period = Depriciable FCI/Net profit annually

= (4,00,57,327.8/ 3,49,25,733.64)
Payback Period = 1.146 year

Return on Investment = [(Net Profit/year)/TCI ] * 100

= (3,49,24,733.64/ 4,88,50,399.76)*100

Return on Investment = 71.4%

`

Chapter 11: Hazards and Operability Review

Reactor:

Item Process Deviations Possible Possible Action

Para- (Guide Causes Consequences Required
meters Words)
1A Flow No 1. Control 1. Loss of 1. Select valve
valve fails heating, to fail open
closed reaction does
not go to
2. Plugged maximum 2. Install filter,
heating coils conversion Install heating
2. As above flow meter and
low flow alarm,
Install low
temperature
alarm to alert
operator
3. Heating oil 3. As above 3. Check and
service failure monitor
reliability of
4. Controller service
fails and closes 4. As above 4.Place
valve controller on
critical
5. Air pressure instrumentation
fails, closing 5. As above list
valve 5. See 1A.1
1B High 1. Control 1. Reactor 1. Instruct
valve fails heats, operators and
open reactants update
decompose, procedures
possible
2. Controller runaway 2. See1A.4
fails and opens 2. As above
valve
1C Low 1. Partially 1. Diminished 1. See 1A.2
plugged heating,
heating line reaction does
not take place
2. Partial 2. As above 2. See 1A.2
dowtherm oil
source failure
3. Control 3. As above 3. Place valve
valve fails to on critical
respond instrumentation
list
`

1D Reverse 1. Failure of oil 1. Loss of 1. See 1A.2

resulting in heating
backflow
2. Backflow 2. As above 2. Install check
due to high valve
back-pressure
1E Sooner 1. Heating 1.Temperature 1. Interlock
than normally rises, runaway between heating
started early possible flow and reactor
feed
1F Later than 1. Operator 1. None
error
1G Temp. Low 1. Low oil 1. None- 1.None
supply controller
temperature handles
1H High 1. High oil 1. Heating 1.Install high
supply system flow alarm
temperature capacity and/or heating
limited, oil high
temperature temperature
increases alarm
2A Agitation No 1.Stirrer motor 1. No mixing, 1. Interlock with
malfunction possible feed line
accumulation
of unreacted
compounds
2.Power failure 2. Monomer 2. Monomer
feed continues, feed valve must
possible fail closed on
accumulation power loss
of unreacted
compounds
2B More 1.Stirrer motor 1. None
controller fails,
resulting in high
motor
speed
 `

MATERIAL SAFETY DATA SHEET

Phosphoric acid, 85% solution in water

Section 1 - Composition, Information on Ingredients

Component Chemical Name Percent

1 Phosphoric acid 85
2 Water <15

Section 2 - Hazards Identification

EMERGENCY OVERVIEW
Appearance: APHA: 10 max liquid.
Danger! Causes burns by all exposure routes. Hygroscopic (absorbs moisture from the air).
Target Organs: Respiratory system, gastrointestinal system, eyes, skin.

Potential Health Effects

Eye: May cause irreversible eye injury. Contact with liquid is corrosive to the eyes and causes
severe burns.
Skin: Contact with liquid is corrosive and causes severe burns and ulceration. Ingestion:
Causes gastrointestinal tract burns. Causes severe pain, nausea, vomiting, diarrhea, and
shock. May cause hemorrhaging of the digestive tract. May cause corrosion and permanent
tissue destruction of the esophagus and digestive tract.
Inhalation: Irritation may lead to chemical pneumonitis and pulmonary edema. Causes
severe irritation of upper respiratory tract with coughing, burns, breathing difficulty, and
possible coma. Causes chemical burns to the respiratory tract.
Chronic: Prolonged inhalation may cause respiratory tract inflammation and lung damage.
Prolonged or repeated skin contact may cause dermatitis. Prolonged or repeated eye contact
may cause conjunctivitis.

Section 3 – First Aid Measures

Eyes: Immediately flush eyes with plenty of water for at least 15 minutes, occasionally
lifting the upper and lower eyelids. Get medical aid imme diately.
Skin: Get medical aid immediately. Immediately flush skin with plenty of water for at least 15
minutes while removing contaminated clothing and shoes.
`

Ingestion: Do not induce vomiting. Get medical aid immediately. Call a poison control center.
Inhalation: Get medical aid immediately. Remove from exposure and move to fresh air
immediately. If breathing is difficult, give oxygen. Do not use mouth-to-mouth resuscitation if
victim ingested or inhaled the substance; induce artificial respiration with the aid of a pocket
mask equipped with a one-way valve or other proper respiratory medical device.
Notes to Physician: Treat symptomatically and supportively.

Section 4 - Fire Fighting Measures

General Information: As in any fire, wear a self-contained breathing apparatus in

pressure-demand, MSHA/NIOSH (approved or equivalent), and full protective gear.
Substance is noncombustible.
Extinguishing Media: Substance is noncombustible; use agent most appropriate to
extinguish surrounding fire.
Flash Point: Not applicable.
Autoignition Temperature: Not applicable.
Explosion Limits, Lower:Not available.

Upper: Not available.

NFPA Rating: (estimated) Health: 3; Flammability: 0; Instability: 1

Section 5 - Accidental Release Measures

General Information: Use proper personal protective equipment as indicated in Section 8.

Spills/Leaks: Absorb spill with inert material (e.g. vermiculite, sand or earth), then place in
suitable container. Wear a self contained breathing apparatus and appropriate personal
protection. (See Exposure Controls, Personal Protection section). Provide ventilation. Do not let
this chemical enter the environment.

Section 6 - Handling and Storage

Handling: Do not get in eyes, on skin, or on clothing. Do not ingest or inhale. Use only in a
chemical fume hood.
Storage: Store in a cool, dry place. Store in a tightly closed container. Corrosives area. Do not
store in metal containers.

Section 7 - Exposure Controls, Personal Protection

Engineering Controls: Facilities storing or utilizing this material should be equipped with an
eyewash facility and a safety shower. Use only under a chemical fume hood.
 `

Exposure Limits

Chemical ACGIH NIOSH OSHA - Final

Name PELs
1 mg/m3 TWA; 3 1 mg/m3 TWA
Phosphoric acid mg/m3 STEL 1000 mg/m3 1 mg/m3 TWA
IDLH
Water none listed none none listed
listed

OSHA Vacated PELs: Phosphoric acid: 1 mg/m3 TWA Water: No OSHA Vacated PELs are
listed for this chemical.
Personal Protective Equipment
Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described by
OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard EN166.
Skin: Wear appropriate protective gloves to prevent skin exposure.
Clothing: Wear appropriate protective clothing to prevent skin exposure.

Respirators: A respiratory protection program that meets OSHA's 29 CFR 1910.134 and ANSI
Z88.2 requirements or European Standard EN 149 must be followed whenever workplace
conditions warrant respirator use.

Section 8 - Physical and Chemical Properties

Physical State: Liquid

Appearance: APHA: 10 max
Odor: odorless
pH: Not available.
Vapor Pressure: Not available.
Vapor Density: 3.4 (air=1)
Evaporation Rate:Not available.
Viscosity: Not available.
Boiling Point: 158 deg C @ 760 mmHg
Freezing/Melting Point:21 deg C Decomposition
Temperature:300 deg C Solubility: Miscible.
Specific Gravity/Density:1.680
MMolecular Formula:H3O4P
Molecular Weight:98

Section 9 - Stability and Reactivity

Chemical Stability: Hygroscopic: absorbs moisture or water from the air.

Conditions to Avoid: Incompatible materials, metals, excess heat, exposure to moist air or
water.
Incompatibilities with Other Materials: Metals, bases, alcohols, amines, halogenated agents,
organic peroxides, amides, azo, diazo, and hydrazines (e.g. dimethyl hydrazine, hydrazine,
methyl hydrazine), carbamates (e.g. carbanolate, carbofuran), esters (e.g. butyl acetate, ethyl
acetate, propyl formate), fluorides (inorganic, e.g. ammonium fluoride, calcium fluoride, cesium
`

fluoride), phenols and cresols, organophosphates, phosphothioates (e.g. methylparathion,

parathion, phorate, thionazin), epoxides (e.g. butyl glycidyl ether), combustible and flammable
materials (e.g. alkyl resins, asphalt, gasoline, grease, methyl acetone, polystyrene, polyurethane),
explosives (e.g. ammonium nitrate, hydrazoic acid, sodium azide), nitromethane, sodium
tetrahydroborate, mercaptans, aldehydes, ketones, glycols, cyanides, sulfides, caustics.
Hazardous Decomposition Products: Phosphine, oxides of phosphorus, hydrogen gas.
Hazardous Polymerization: May occur.

Section 10 - Ecological Information

Ecotoxicity: Fish: Mosquito Fish: LC50 = 138 mg/L; 96 Hr; Unspecified No data available.
Environmental: The acidity of phosphoric acid may be reduced readily by natural water hardness
minerals, but the phosphate may persist indefinitely. During transport through the soil, phosphoric
acid will dissolve some of the soil material, in particular, carbonate-based materials. The acid will
be neutralized to some degree with adsorption of the proton and phosphate ions also possible.
However, significant amounts of acid will remain for transport down toward the groundwater
table.
Physical: No information available.
Other: Dangerous to aquatic life in high concentrations.

Section 11 - Disposal Considerations

Chemical waste generators must determine whether a discarded chemical is classified as a

hazardous waste. US EPA guidelines for the classification determination are listed in 40 CFR
Parts 261.3. Additionally, waste generators must consult state and local hazardous waste
regulations to ensure complete and accurate classification.

Section 12 - Transport Information

US DOT Canada TDG

Shipping Name: PHOSPHORIC ACID PHOSPHORIC ACID
SOLUTION SOLUTION
Hazard Class: 8 8
UN Number: UN1805 UN1805
Packing Group: III III
`

Section 13 - Regulatory Information

US FEDERAL

TSCA
CAS# 7664-38-2 is listed on the TSCA inventory. CAS#
7732-18-5 is listed on the TSCA inventory.
Health & Safety Reporting List
None of the chemicals are on the Health & Safety Reporting List.
Chemical Test Rules
None of the chemicals in this product are under a Chemical Test Rule.
Section 12b
None of the chemicals are listed under TSCA Section 12b.
TSCA Significant New Use Rule
None of the chemicals in this material have a SNUR under TSCA.
CERCLA Hazardous Substances and
corresponding RQs
CAS# 7664-38-2: 5000 lb final RQ; 2270 kg final RQ
SARA Section 302 Extremely Hazardous
Substances
None of the chemicals in this product have a TPQ.
SARA Codes
CAS # 7664-38-2: immediate.
Section 313 No chemicals are reportable under Section 313.
Clean Air Act:
This material does not contain any hazardous air pollutants.
This material does not contain any Class 1 Ozone depletors.
This material does not contain any Class 2 Ozone depletors.
Clean Water Act:
CAS# 7664-38-2 is listed as a Hazardous Substance under the CWA.
None of the chemicals in this product are listed as Priority Pollutants under the CWA. None
of the chemicals in this product are listed as Toxic Pollutants under the CWA.

OSHA:
None of the chemicals in this product are considered highly hazardous by OSHA.
`

CHAPTER 13: BIBLIOGRAPHY

1) https://ihsmarkit.com/products/phosphoric-acid-chemical-economics-handbook.html

2)https://www.transparencymarketresearch.com/pressrelease/phosphoric-acid-market.htm

3) https://www.zauba.com/importanalysis-phosphoric+acid-report.html

4) Phosphates and Phosphoric acid, Pierre Becker

5) Outlines of Chemical Technology, Charles Dryden.

6)https://www.researchgate.net/publication/227891692_The_hydrochloric_acid_route_fo
r_phosphate_rock

7) https://www.jcsp.org.pk/ArticleUpload/4749-21669-1-PB.pdf

8) https://www.sciencedirect.com/science/article/pii/S1018363918305671

9) https://patents.google.com/patent/CN85102768B/en

10)Kiran Hari Ghadyalji,Process Equipment and Design 1

11) L.T.Biegler, Systematic Methods Of Chemical Process Design

12) https://pdfs.semanticscholar.org/544b/26f6ec3dfbbd293402f0b8d96c3d477e2cbc.pdf

13) Jaehyun Lee, Modelling of Multicomponent Multistage Extraction

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