PROJECT REPORT ON

DIAMMONIUM
PHOSPHATE

PREPARED BY:
PARMAR RAHUL D. 216490305007
PARMAR KULDIP D. 216490305012
MARU BHARGAV M. 216490305018
SUTARIYA MAYUR L. 216490305019
VAGHELA DHARMIK S. 216490305024

GUIDED BY:

H.O.D. OF CHEMICAL DIPARTMEN

MR.JIGAR MALAVIYA

SIR BHAVSINHJI POLYTECHNIC INSTITUTE

BHAVNAGAR

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 1

 CERTIFICATE

This is to certify that Mr. MARU BHARGAV M. Enrollment no. 216490305018 has
satisfactorily completed his project work on DI-AMMONIUM PHOSPHATE for the term
ending in November 2023

Course: - DIPLOMA IN CHEMICAL ENGINEERING 5th SEM

Date of Signature
Submission of guide
H.O.D
Chemical Eng.
Department

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 2

PREFACE
• Every person passes through two phases of learning in his career. One is
theoretical knowledge obtained from schools, Universities. Project as a subject
gives exposure to the chemical process industries.
• The actual aim of the project is to get details about operation and process
carried out in industry and more about equipments used manufacturing of
DIAMMONIUM PHOSPHATE
• This report is written by us from the knowledge gained during preparation of
project report on manufacturing of DIAMMONIUM PHOSPHATE

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 3

 INDEX

ABSTRACT…………………………………………………
……….
ACKNOLDEGMENT………………………………………
…….

SR. NO. NAME PAGE

NO.
CHAPTER – 1 7-11
1. Introduction

2. History

3. Present status of product

CHAPTER – 2 12-20

4. Properties

5. Uses

CHAPTER -3 21-27

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 4

6. List of production methods

7. Selected process

CHAPTER – 4 28-35
8. Major instrumentation and equipment

9. Utilities

CHAPTER – 5 36-45
10. Material balance

CHAPTER – 6 46-52
11. Site selection parameters

12. Plant layout and location

CHAPTER – 7 53-63
13. MSDS of product

CHAPTER – 8 64-66
14. Effluent treatment method

CHAPTER – 9 67-69

17. Conclusion

18. Reference

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 5

 ABSTRACT
➢ The objective of this project is to design plant to produce Ethanol from
molasses, with the rate of 1000 ton per day.
➢ The important use of ethanol as a fuel additive and as an engine fuel. Ethanol
is used as antiseptic for sterilizing wounds. The main units of this process are
reactor and distillation columns. Based on thus process the materials, unit
operations and processes involved are identified. Material balance was
sequentially carried out for each unit in the same order by which they appear
in the rough flow sheet. Steady sheet simulation was done. The production of
Ethanol with purity of 95%. Process equipments were designed with their
corresponding control system. Also economic viability of plant was studied
and the plant found to be feasible.

ACKNOWLEDGMENT
➢ Completion of project work under guidance of experienced person is an
achievement in life.
➢ We are especially thankful to Mr. JIGAR MALAVIYA, Lecturer and H.O.D
of chemical Eng. Department, Sir Bhavsinhji Polytechnic Bhavnagar, Who
has given us opportunity to work on this project.
➢ We are also thankful to our guide Mr. JIGAR MALAVIYA, (lecturer and
H.O.D of chemical department) for her excellent supports and guidance. We
are fortunate enough to have considerable supports from our guide during the
every stage of this project work.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 6

 ➢ We are also sincerely thankful to the all other faculty members of
chemical engineering department for their direct or indirect coordination for
the preparation of the project report.

CHAPTER - 1

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 7

INTRODUCTION:-
➢ Fertilizers are the products that improve the levels of the available plant
nutrients and/or the chemical and physical properties of the soil, thereby
directly or indirectly enhancing the growth, yield and quality of the plant.
Fertilizers are compounds used to promote plants growth. They are usually
applied either through the soil, for uptake by plant roots, or uptake through
leaves. They can be naturally occurring compounds such as peat or mineral
deposits, or manufactured through natural processes or chemical processes.
➢ The world food demand is increasing with increase in population and to
produce large quantity of raw food, fertilizer demand is also increasing. The
DAP fertilizer is main source of phosphorous, nitrogen and potash for plant
growth. Fertilizer demand in India is increasing continuously.
➢ The phosphate fertilizer industry uses phosphate rock as its major raw
material. After preparation, the rock is used directly in the production of
phosphoric acid, normal superphosphate, triple superphosphate, nitro
phosphate, electric furnace phosphorous and defluorinated animal feed
supplements, in addition to those products made directly from phosphate
rock, there are others that rely on products produced from phosphate rock as
a-principal ingredient.
➢ Diammonium phosphate (DAP) is the world’s most widely used phosphorus
fertilizer. It’s made from two common constituents in the fertilizer industry,
and it has relatively high nutrient content and excellent physical properties
make it a popular choice in farming and other industries.
➢ Ammonium phosphate ((NH4)3PO4) also known as ammonium
orthophosphate is the salt of ammonia and phosphoric acid. It is water soluble
and the aqueous solution on boiling losses ammonia.
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 8
 ➢ Ammonium phosphates refer to a generic class of phosphorus fertilizers and
are manufactured by reacting anhydrous ammonia with orthophosphoric acid
or super phosphoric acid. These are either in solid or liquid form.
➢ DAP is a highly concentrated granulated nitrogen-phosphoric compound
fertilizer. Produced by neutralizing phosphoric acid with ammonia.
Diammonium phosphate is used for all soil types for ground and bed
applications for all agricultural crops.
➢ There are two major types of ammonium phosphate which are mono
ammonium phosphate (MAP, NH4H2PO4) and diammonium phosphate
(DAP, (NH4)2HPO4) and these can be produced by changing ammonia or
phosphoric acid as needed. Mono ammonium phosphate is manufacture by
reacting ammonia with phosphoric acid, centrifuging and drying in a rotary
dryer. The granulation process followed by neutralization is completed in
rotary dryer, which is heated by a furnace using fuel.

Two grades of ammonium phosphate are available

1. Mono ammonium phosphate (MAP) Anhydrous ammonia added to liquid
phosphoric acid gives mono ammonium phosphate (MAP). It is a fertilizer or
fertilizer intermediate with high P 2O5 content of about 55% and nitrogen content
11-12%.

Diammonium phosphate (DAP)With more ammonia, technical grade

diammonium phosphate (DAP) containing 16 to 18% nitrogen and 20 to 21 %
phosphorus (46% P2O5) is formed. (18N – 46P2O5 – 0K2O).
Its IUPAC name is Diammonium hydrogen phosphate.

STRUCTUER OF DIAMMONIUM PHOSPHATE

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 9

HISTORY
➢ Diammonium phosphate fertilizers first became available in 1960s and DAP
rapidly became most popular in this class of products.
➢ In the 1960s, the Tennessee Valley Authority (TVA) and the large grant
colleges changed the way fertilizers were produced and began to promote
higher analysis fertilizers so that more phosphate could be delivered to
farmers at lower cost.
➢ The fertilizer that quickly became the item of commerce because it had the
highest concentration of phosphate and nitrogen at 18N-46P2O5-0K2O.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 10

LIST OF MANUFACTURING INDUSTRIES
Sr. No. Name of State Name of Industries
1. Gujarat 1) Gujarat State Fertilizers &
Chemicals Ltd, Vadodra.
2) Hindalco industries Ltd,
Dahej.
3) IFFCO Ltd, Kandla.
2. Karnataka 1) Manglore Chemicals and
Fertilizers Ltd.Manglore
3. Orissa 1) IFFCO Ltd.Orissa
2) Paradeep Phosphate
Ltd.Orissa
4. West Bengal 1) Tata Chemicals Ltd. Babrala,
West Bengal.
2) M/S Tata Chemical Ltd.
Haldia, West Bengal.
5. New Delhi 1) Oswal Chemicals &
Fertilizers Ltd.
2) Madras Fertilizers Ltd.
6. Tamil Nadu 1) Southern Petrochemical
Industries Corporation Ltd.
7. Andhra Pradesh 1) Krishak Bharti Co-operative
Ltd. Nellore.
8. Uttar Pradesh 1) National Fertilizers Ltd.
Noida.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 11

 CHAPTER - 2

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 12

Properties of Di-ammonium Phosphate:-
Chemical Formula
Molecular Weight
Appearance Granular Solid
Color Gray to brownish black and White
Odor Weak ammonia odor or odorless
pH 8.0 (conc: 1% at 20 )C0
Melting Point 155 0 C(322 0F, 428 K)
Boiling Point Decompose when heated
Vapor Pressure < 1 mm Hg (at 20 )0C
Self-Ignition Not flammable
Temperature
Density 1.619 𝑔𝑚⁄𝑐𝑚3 (at 20 )0C
Water 588 𝑔𝑚⁄𝑙 ( at 20 )0C
Solubility
Insoluble in ethanol, acetone and Liquid ammonia
Taste Saline, cooling taste
When heated to decomposition emits very toxic fumes
Decomposition
of phosphorus oxides, nitrogen oxides, and ammonia

2) Gypsum
Chemical Formula CaSO4.2H2O
Molecular Weight 172.164 gm/mol
Color Colorless to White, Maybe Yellow, Blue,
Pink, Brown, Reddish brown or Gray due to
impurities.
Appearance White crystalline Powder or Lumps,
Crystalline powder
Order Low to No order
Melting point 1450 oC
Density 2.32 gm/cm3
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 13
 PROPERTIES OF RAW MATERIALS

1) PHOSPHORIC ACID

Chemical Formula H3PO4

Molecular weight 97.994 gm/mol
Physical state Liquid
Appearance White solid or colorless Viscous liquid
above 42 oC
Color Colorless
Odor Odorless
Melting point 21 oC
Boiling point 158 oC
Decomposition temperature 300 oC
Vapor Pressure 0.03mmHg
Viscosity 147 cP (100%)
Density 1.885 gm/mL (Liquid)
1.685 gm/mL (85% solution)
2.030 gm/mL (Crystal at 25oC)
Solubility Soluble in Water and Ethanol.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 14

2) AMMONIA

Chemical Formula NH3

Molecular weight 17.031 gm/mol
Appearance Colorless gas
Order Strong pungent, Ammonical order
Melting Point -77.73oC (195.45K)
Boiling Point -33.34oC (239.81K)
Freezing Point -77.7oC (195.45K)
Critical Temperature 133oC (406.15K)
Critical Pressure 11.425 MPa
Vapor Pressure 857.3 KPa
Density 681.9 Kg/m3 at -33.3oC (Liquid)
Viscosity 0.276 cP (-40oC)
Solubility in water 47% w/w (0oC)
31% w/w (25oC)
18% w/w (50oC)
Solubility Soluble in Chloroform, ether, ethanol,
methanol
Decomposition When heated to decomposition emits very
toxic fumes of phosphorus oxide, nitrogen
oxides and ammonia.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 15

3) SULFURIC ACID

Chemical Formula H2SO4

Molecular Weight 98.08 𝑔𝑚⁄𝑚𝑜𝑙
Appearance Water white slightly viscous liquid
Color Colorless to dark-brown, oily, odorless liquid.
Odor Odor less
1 N Solution = 0.3
pH 0.1N Solution = 1.2
0.01N Solution = 2.1
Melting Point 10.31°C (50.56 °F; 283.46 K)
337°C (639 °F; 610 K) When sulfuric acid is
Boiling Point above
300 °C (572 °F), it will decompose slowly
Vapor Pressure 0.001 mmHg (20 °C)
Viscosity 26.7 cP (20 °C)
Density 1.8302 gm/cm3, liquid
Relative Density 1.8302 (20 °C)
Vapor Density 3.4 (20 °C)
Miscible with water, with generation of much
Solubility
heat, also with ethanol
Strongly corrosive
Corrosivity Concentrated acid is non-corrosive to lead and
mild steel but dilute acid attacks most metals
Marked acid taste
Persons who have drawn concentrated sulfuric
acid into a pipet with oral suction and obtained
Taste
the acid on the tongue through poor technique,
report that it tastes sweet before the onset of
corrosive action

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 16

4) WATER

Chemical Formula H2O

Molecular Weight 18.015 𝑔𝑚⁄𝑚𝑜𝑙
Appearance Water in two states: liquid, and solid (ice).
Color Colorless liquid
Odor Odorless
Melting Point 0 °C
Boiling Point 100 °C
At the normal boiling point of 100 °C, it equals
Vapor Pressure the standard atmospheric pressure of 760 Torr or
101.325 kPa.
Density 1 gm/cm3
Dynamic Viscosity 0.8949 cP at 25 °C

5) MONO AMMONIUM PHOSPHATE

Chemical Formula NH4H2PO4
Molecular Weight 115.025 gm⁄mol
Dry Powder, Pellets Large Crystals, Liquid,
Appearance
Pellets Large Crystals
Odor Odorless
Color White crystals, Brilliant white crystals or powder
Melting Point 190 °C
pH aqueous solution: 4 to 4.5
Density 1.80 gm/cm3
Soluble in Water 40.4 g/100 g water at 25 °C
Solubility Slightly soluble in ethanol; insoluble in acetone

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 17

APPLICATIONS OF DAP:-
➢ DAP is used as a highly effective non-chloride N, P compound fertilizer for
farming. When applied as plant food, it temporally increases the pH of the
soil. The average pH of the solution is 7.5-8. It contains totally 73% fertilizer
element. It’s also used as a row material for N, P and K compounds.
➢ DAP is also used as a yeast nutrient in winemaking and mead-making; as an
additive in some brands of cigarettes purportedly as a nicotine enhancer; to
prevent afterglow in matches, in purifying sugar; as a flux for soldering tin,
copper, zinc and brass; and to control precipitation of alkali-soluble and acid-
insoluble colloidal dyes on wool.
➢ It’s also used as a fermentation agent and a nourishment agent.
➢ It’s used in buffer solutions and in analytical chemistry.
➢ Used as a fire prevention agent for fabric, timber and paper, as well as a fire
prevention coating, and dry powder for fire extinguisher.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 18

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 19
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 20
 CHAPTER - 3

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 21

MANUFACTURING PROCESS OF DAP:-
➢Raw materials
1) Phosphate rock – Ca3(PO4)2
2) Sulfuric Acid – H2SO4
3) Water – H2O
4) Ammonia – NH3
5) Potash (Potassium chloride) - KCl
➢Utilities
1) Cooling air
2) Hot water
3) Steam
4) Hot air
5) Electricity.
➢Chemical Reaction
a) Ca3(PO4)2(s) + 3H2SO4(l) + 6H2O(l) 2H3PO4(aq) + 3(CaSO4.2H2O)(s)
b) NH3(l) + H3PO4(aq) NH4H2PO4(S)
c) NH3(l) +NH4H2PO4(s) (NH4)2HPO4(s)

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 22

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 23
Process description:-
➢ Phosphate rock is ground to 200 mesh and fed to a chute where a recycle stream
of weak H3PO4 washes it into a reaction tank Strong H2SO4 is metered with
automatic control which keeps the acid and rock feed ratio at the desired setting.
➢ A single reactor can be designed by proper baffling and residence time
capacitance to permits a 98% conversion in 4-8 hours.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. In other designs, a series of 4-5
continuous mixing tanks can be used with slightly better efficiency of extraction
by minimizing back mixing.
➢ Heat of reaction is controlled by pulling cooling air across.
➢ The gypsum-phosphoric acid slurry goes to a travelling pan filter where the
40% acid is removed and the cake washed with water. Filtrate from the latter is
returned to the reactor. The gypsum is free-filtering and cake thicknesses about
two inches can be readily obtained. The gypsum can either be dried for use in
plaster paints and cements or reacted with ammonium carbonate to give
ammonium sulphates (fertilizers ingredient) and calcium carbonate.
➢ The dilute acid is concentrated in a single effect evaporator to any grades >50%
acid. Most of the wet process acid is being converted to high concentration
chemical fertilizers.
➢ The two principal steps are,
a) Neutralization and
b) Granulation
a) Neutralization:-
• Quantities of phosphoric acid and ammonia in the neutralization step are
different form mono ammonium phosphate (MAP) and diammonium
phosphate (DAP). To manufacture mono ammonium phosphate, ammonia to
phosphoric acid ratio is 0.6 in the neutralizer and then 1.0 in the granulator.
While for diammonium phosphate, the ratios are 1.4 and 1.0 in the
neutralizer and granulator respectively.Phosphoric and ammonia are added
to the first of three continuous mixed reactors, anhydrous ammonia is added
beneath the slurry level in the first neutralizer in an amount equivalent to
80% neutralization. Further ammonia is added in the 2nd and 3rd tanks to
obtain conversion to the diammonium salt if a higher nitrogen containing
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 24
 fertilizer is needed.The exothermic reaction heats the slurry nearly to the
boiling point (130°C). Unreacted and excess NH3 vapor is collected from the
top of each tank and recharged below the liquid level for reducing NH 3
losses (less than 3%). The hot slurry containing about 16 to 20% water is
pumped into the granulator, where more ammonia is added to increase the
molar ratio to approximately 2.0.
b) Granulation:-
• The function of the granulation system is to transform the slurry and solid
raw materials into a granular fertilizer product with the required composition
and size. Granulation occurs in the drum Granulator, where phosphate
slurries are sprayed onto a bed of dry material, composed by the added solid
raw materials (Urea, Potash, and Filler) plus the fines, crushed oversize and
part of the commercial product returned to granulator. Slurries are directly
sprayed from the Pipe Reactor distribution Pipe, or by pumping from Pre-
neutralizer pumps, in this last case sprayed using a distribution pipe with
spray nozzles.
• Slurry from the third neutralized is mixed with KCl and absorbed in a bed of
dry recycle fertilizer moving through a rotating drum granulator. This
provides a tumbling action to coal recycle material with a slurry film.
• A rotary adiabatic drier reduces the moisture to less than 1%, with 10-minute
contact time with air initially at 150 °C. The plant utilizes vibrating Oversize
Process Screens. The Dryer Elevator feeds the Screens. Directly installed at
the outlet branches of the Screens Splitter there are two Screen Diverters,
also with electrical motor actuator, that will be used for by-passing the
correspondent screen and process crusher for maintenance and cleaning or
when a partial (or total) emptying of the unit is required in a relatively short
period of time. To improve screen efficiency each screen has a dedicated
vibrating feeder to evenly distribute the feed across its entire width. The
Oversize Screens will separate from the on-size and fine product, the
oversize fraction above 4 mm, which is crushed in four Oversize Mills.
Feeding is accomplished by independent chutes from each screen. The
suggested mill type is a double rotor chain mill, which provides and efficient
crushing with small size dispersion on ground product. Dried product is
separated into three fractions on a double deck screen. A portion of the
product from the deck of the lower screen is sent to bagging operations. The
balance, together with pulverized oversize and fines, is returned to the
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 25
 granulator. Rotary Cooler discharges cooled product directly to Final
Product Elevator which lift it to the single desk Polishing Screen. Fines
under 1 mm are separated and returned back to recycle, whereas commercial
size product between 1-4 mm falls by gravity to the Coater drum. Coating
oil is added to the Coater Drum for caking control. Coating is particularly
necessary when bulk storage during long periods of time or ship exportation
is envisaged, because the hygroscopic features of NPK grades can promote
caking, mostly when variations of air temperature and moisture occur.
Coating agent is normally an amine containing high viscosity oil or wax
(paraffin), normally solid at ambient temperature and with a pour point of
around 50°C. The coating oil is kept at around 70-80 °C in the Coating Oil
Tank (using its steam coil heater) and is fed to the coater drum by using the
Coating Oil Dosing Pumps, through LP steam traced pipes and spray
nozzles. After coating, product falls by gravity to the Final Product Belt
Conveyor, which will send product to the final storage, outside B.L, via
several conveyors on series.
•Powder ammonium phosphate:
Powdered ammonium phosphate is still in use because of its high
phosphorus content (as P2O5). In addition, a group of fertilizers, such as
ammonium phosphatesulfates, ammonium phosphate-chloride and
ammonium phosphate-nitrate are produced by a number of processes
involving the neutralization of ammonia with a mixture of phosphoric acid
and plant waste acids like sulfuric acid, nitric acid or hydrochloric acid.
These fertilizers are free flowing and non-hygroscopic (or less hygroscopic)
compared to the individual components and have been successfully used in
many types of soils.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 26

 MAJOR ENGINEERING PROBLEM

A.Temperature
• If the temperature is kept above 100 °C, undesirable semihydrate
(CaSO4.1/2H2O) and anhydrate (CaSO4) crystals are formed which are
rhombic crystals predominate and these can be filtered and washed easily

B. Control of sulfuric acid

• 1-1.5% residual of H2SO4 is left in the slurry going to the filter, again to
produce more filterable gypsum. Small percentages of sulfuric acid can be
tolerated for fertilizer-grade acid. If a purer product is desired, the excess H2SO4
is eliminated with a slower filtration rate resulting
C.NH3 losses
• Ammonia loss should be kept below 3%. It can be achieved by using multistage
reactors along with efficient recycling mechanism of collecting the vapor of
ammonia from top of the neutralization tower and recycle back to the process.
D.Corrosion
• Use of corrosion resistance material like SS316 for hot acid and fumes ducts,
carbon steel for granulation, drying and screening

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 27

 CHAPTER - 4

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 28

UTILITIES REQUIRED FOR SELECTED
PROCESS:-
➢ Plant utilities are items that are not directly involved in the manufacturing
process but are needed facilitate the process. Utility is neither a reactant nor a
product, but utilities are required for maintaining adequate conditions of a
manufacturing unit. Utility area is an important area of a chemical plant. The
utilities such as water, air, steam, electricity etc. are required for must of the
chemical process industries. These utilities are located at a certain distance
from processing area, from processing area hazardous and storage area etc.,
where a separate utility department works to fulfil the utilities requirements.
i. Water
ii. Steam
iii. Cooling
air
iv. Hot air
v. Electricity
1 WATER
➢ It is used in the fume scrubber where water is spray in the scrubber by the
water sprayer. A large reservoir has to be made which received water from
nearby river. Storage also must provide to much extent that turbidity is settling
and then sent to raw water plant for further treatment. Chorine does must be
given to kill bacteria which prevent organic matter. Then this water is sent to
further treatment. To cooling tower, DM plant, service water system, drinking
water system, fire water system.
2 STEAM
➢ It is used in the phosphoric acid plant. Steam is used as a utility for the 75%
phosphoric acid achieved from the dilute solution is pass through the single
effect evaporator. Steam is used in plants for heating purpose, where direct
contacts with substance is not objectionable. The steam, for process heating, is
usually generated in water in tube boiler using most economical fuel available
i.e. coal, fuel oil the site. Steam is the most commonly used heat utility used in
chemical plants, and as a result understanding how it is used is essential in the
study of Utility systems. Steam is used both as a process fluid (feedstock,
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 29
 diluent to absorb heat of reaction, heating agent, and stripping agent in
absorbers and adsorbers) and utility. It can be used to drive pumps and
compressors, ejectors (for producing a vacuum), and heat exchangers. As one
can clearly see, steam is a versatile, and useful utility.

3 COOLING AIR
➢ Cooling air id used in the reactor-1 for the temperature condition maintaining.
Cooling air is generally produced in plant by cooling towers.

4 HOT AIR
➢ Hot air and flue gases are used in rotary adiabatic drier to be dried at 130°C to
150°C. A rotary adiabatic drier reduces the moisture to less than 1%, with 10-
minute contact time with air initially at 150 °C.

5 ELECTRICITY
➢ It is required for motor drive, lighting and general use. It may be generated on
site or purchase from GEB & G.I.P.C.L. Transformers will be to step-down the
supply voltage to the voltage used on site. A three-phase 415-volt system is
used in general industrial purpose and 240-volt single phase for lighting and
other low power requirements. For large motors, high voltage 600 to 1100 is
used.
MATERIAL OF CONSTRUCTION
➢ Reaction tanks constructed of steel and lined with acid-proof brick.
➢ All air vents systems are polyvinyl chloride (PVC) coated steel.
➢ Filter is type SS316 with polypropylene filter cloth and rubber-lined vacuum
receivers of steel.
➢ Storage tanks of rubber-lined steel.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 30

MAJOR EQUIPMENT USED IN THE
SELECTED PROCESS
1) Travelling Pan Filter

➢ A travelling pan filter is a chemical equipment used in continuous

solid-liquid filtration. Travelling Pan Filter belongs to the top feed
group and has found its main application in the phosphoric acid
industry and, to some extent, in the washing of phosphate rock. As
already mentioned in the Horizontal Belt Filters section there was a
traditional rivalry over the years between the Pan and Belt Filter
which now, owing to the substantial progress in rubber technology,
swings in the favor of the later. A tilting pan filter is a chemical
equipment used in continuous solid-liquid filtration. It is formed by
several trapezoidal pans arranged in circle. At the center of the
equipment there is the main valve which is connected to every pan
through pipes. The pans are rotating continuously around the main
valve, which provides the air or the vacuum necessary for the
operation. In each pan it is carried out the filtration in a cyclic
process that involves these stages:
• Feed is poured in the pan; the material to be filtered formed in this way a
“Cake”
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 31
 • cake is washed out;
• cake is dried through the aspiration of the liquid;
• cake is washed out again;
• cake is dried again;
• pan is tilted in order to discharge the solid;
• pan is sprayed with water to be cleaned;
• pan is tilted back to the initial angle and the process
continues with the feeding stage.

2) Single effect evaporator

➢ In single effect evaporator, as shown in figure, the steam is fed to the

evaporator which condenses on the tube surface and the heat is
transferred to the solution. The saturated vapor comes out from the
evaporator and this vapor either may be vented out or condensed.
The concentrated solution is taken out from the evaporator. Now we
can see if we want the further concentrate, the solution has to be sent
into another similar evaporator which will have the fresh steam to
provide the necessary heat.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 32

➢ It may be noted that in this process the fresh steam is required for the
second evaporator and at the same time the vapor is not utilized.
Therefore, it can be said the single effect evaporator does not utilized
the steam efficiently. The economy of the single effect evaporator is
thus less than one. Moreover, the other reason for low economy is
that in many of the cases the feed temperature remains below the
boiling temperature of the solution. Therefore, a part of the heat is
utilized to raise the feed temperature to its boiling point.

3) Rotary dryer

➢ The rotary drier is basically a cylinder, inclined slightly to thEhorizontal, which

may be rotated, or the shell may be stationary, and an agitator inside may
revolve slowly. In either case, the wet material is fed in at the upper end, and the
rotation, or agitation, advances the material progressively to the lower end,
where it is discharged. Figure (2.2) shows a direct heat rotary drier. Typical
dimensions for a unit like this are 9 ft diameter and 45 ft length. In direct-heat
revolving rotary driers, hot air or a mixture of flue gases and air travels through
the cylinder. The feed rate, the speed of rotation or agitation, the volume of
heated air or gases, and their temperature are so regulated that the solid is dried
just before discharge.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 33

➢ The shell fits loosely into a stationary housing at each end. The material is
brought to a chute that runs through the housing; the later also carries the
exhaust pipe. The revolving shell runs on two circular tracks and is turned by a
girth gear that meshes with a driven pinion. The inclination is one in sixteen for
high capacities and one in thirty for low ones. As the shell revolves, the solid
carried upward one-fourth of the circumference; it then rolls back to a lower
level, exposing fresh surfaces to the action of the heat as it does so. Simple
rotary driers serve well enough when fuel is cheap. The efficiency is greatly
improved by placing longitudinal plates 3 or 4 in. Wide on the inside of the
cylinder. These are called lifting flights. These carry part of the solid half-way
around the circumference and drop it through the whole of a diameter in the
central part of the cylinder where the air is hottest and least laden with moisture.
By bending the edge of the lifter slightly inward, some of the material is
delivered only in the third quarter of the circle, producing a nearly uniform fall
of the material throughout the cross section of the cylinder. The heated air
streams through a rain of particles. This is the most common form of revolving
rotary cylinder. It has high capacity, is simple in operation, and is continuous.

4) Granulation

➢ Granulation is carried out for various reasons, one of which is to prevent the
segregation is due to difference in the size or density of the component of the
mix. Normally, the smaller and denser particles tend to concentrate at the base
of the container with the larger and less dense ones on the top. An ideal
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 34
 granulation will contain all the constituents will contain all the constituents will
contain all the constituents of the mix in the correct proportion in each granule
and segregation of granules will not occur.
➢ Many powers, because of their small size, irregular shape or surface
characteristics, are cohesive and do not flow well. Granules produced from such
a cohesive system will be larger and more isodiametric, both factors
contribution to improved flow properties.
➢ Some powders are difficult to compact even if a readily compactable adhesive is
included in the mix, but granules of the same powders are often more easily
compacted. This is associated within the granule and is a function of the method
employed to produce the granule.
➢ For example, if one were to make tablets from granulated sugar versus
powdered sugar, powdered sugar would be difficult to compress into a tablet
and granulated sugar would be easy to compress. Powdered sugar’s small
particles have poor flow and compression characteristics. These small particles
would have to be compressed very slowly for a long period of time to make a
worthwhile tablet. Unless the powdered sugar is granulated, it could not
efficiently be made into a tablet that has good tablet characteristics such as
uniform content or consistent hardness.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 35

 CHAPTER - 5

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 36

MATERIAL BALANCE

FEED PHOSPHORIC ACID,

AMONIA

DI-AMMONIUMPHOSPHATE,
PRODUCT
MONO AMMONIUM PHOSPHATE

CHEMICAL REACTION :-

➢ NH3(l) + H3PO4(aq) NH4H2PO4(s)

NH3(l) + NH4H2PO4(s) (NH4)2HPO4(s)

➢ BASE : 1000 kg DAP/hr

➢ Molecular weight of DAP =132

➢ Molecular weight of MAP=115
➢ Molecular weight of phosphoric acid =98
➢ Molecular weight of amonia=17

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 37

 ➢ MATERIAL BALANCE OF DAP
OVERALL MATERIAL BALANCE
• Selected capacity: 1,000 kg/hr.
• DIAAMMONIUM PHOSPHATE: 1,000 kg/hr of 100% purity

COMPOSITION OF THE FINAL PRODUCT :-

• DAP: 100% (1,000 Kg/hr)
• Assumption: Overall conversion to DAP is assumed to be 100%

➢ TOTAL PHOSPHORIC ACID REQUIRED IN PROCESS:

1kmol/hr H3PO4 reacted ≡ 1 kmol/hr MAP produced
98 kg/hr H3PO4 reacted ≡ 115 kg/hr MAP produced
(?) kg/hr H3PO4 reacted ≡ 871.21 kg/hr MAP produced

H3PO4 reacted = (871.21 * 98) / 115 = 742.42 kg/hr

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 38

 ➢ TOTAL MONO AMMONIUM PHOSPHATE REQUIRED IN
PROCESS
1kmol/hr MAP reacted ≡ 1 kmol/hr DAP produced
115 kg/hr MAP reacted ≡ 132 kg/hr DAP produced
(?) kg/hr MAP reacted ≡ 1000 kg/hr DAP produced

MAP reacted = (1000*115) / 132 = 871.21 kg/hr

➢ TOTAL AMONIA REQUIRED IN PROCESS (FOR MAP) :
1kmol/hr NH3 reacted ≡ 1 kmol/hr MAP produced
17 kg/hr NH3 reacted ≡ 115 kg/hr MAP produced
(?) kg/hr NH3 reacted ≡ 871.21 kg/hr MAP produced

NH3 reacted = (871.21 * 17) / 115 = 143.1 kg/hr (CONSIDERING 90%

PURITY)

➢ TOTAL AMONIA REQUIRED IN PROCESS (FOR DAP) :

1 kmol ammonia reacted = 1 kmol DAP obtained
17 kg/hr ammonia reacted = 132 kg/hr DAP obtained
(?) kg/hr ammonia reacted = 1000 DAP obtained

amount of ammonia reacted = 1000×17/132

· AMMONIA REACTED =128.78 kg/hr

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 39

 INPUT OUTPUT

AMONIA FOR MAP=128.75 kg/hr MAP =871.21 kg /hr

AMONIA FOR DAP =128.78 kg/hr DAP=1000 kg /hr

PHOSPERIC ACID=742.24 kg/hr

MAP=871.21 kg/hr

TOTAL=1870.98 kg/hr TOTAL=1871.21

INPUT = OUTPUT

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 40

 CHAPTER – 6

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 41

 PLANT SITE & PALNT LAYOUT
PLANT SITE
The geographical location of the final plant can have strong influence on the success of an industrial venture.
Considerable care must be exercised in selecting the plant site, and many different factors must be considered.
Primarily, the plant should be located where the minimum cost of production and distribution can be obtained, but
other factors, such as room for expansion and safe living conditions for plant operation as well as the surrounding
community, are also important.

A general consensus as to the plant location should be obtained before a design project reaches the detailed
estimate stage, and a firm location should be established upon completion of the detailed-estimate design. The
choice of the final site should first be based on a complete survey of the advantages and disadvantages of various
geographical areas and, ultimately, on the advantages and disadvantages of available real estate. The following
factors should be considered in selecting a plant site:

i. Raw materials availability

ii. Market
iii. Energy availability
iv. Climate
v. Transportation facilities
vi. Water supply
vii. Waste disposal
viii. Labor supply
ix. Taxation and legal restrictions
x. Site characteristics
xi. Flood and fire protection
xii. Community factors
The factors that must be evaluated in a plant-location study indicate the need for a vast amount of
information, both quantitative (statistical) and qualitative. Fortunately, a large number of agencies, public and private,
publish useful information of this type greatly reducing the actual original gathering of the data.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 42

 Raw material availability: The source of raw materials is one of the most important factors
influencing the selection of a plant site. This is particularly true if large volumes of raw materials are consumed,
because location near the raw-materials source permits considerable reduction in transportation and storage charges.
Attention should be given to the purchased price of the raw materials, distance from the source of supply, freight or
transportation expenses, availability and reliability of supply, purity of the raw materials, and storage requirements.

Markets: The location of markets or intermediate distribution centers affects the cost of product distribution and
the time required for shipping. Proximity to the major markets is an important consideration in the selection of a plant
site, because the buyer usually finds it advantageous to purchase from nearby sources. It should be noted that markets
are needed for by-products as well as for major final products.

Energy availability: Power and steam requirements are high in most industrial plants, and fuel is ordinarily required to
supply these utilities. Consequently, power and fuel can be combined as one major factor in the choice of a plant
site. Electrolytic processes require a cheap source of electricity, and plants using electrolytic processes are often
located near large hydroelectric installations. If the plant requires large quantities of coal or oil, location near a source
of fuel supply may be essential for economic operation. The local cost of power can help determine whether power
should be purchased or self-generated.

Climate: If the plant is located in a cold climate, costs may be increased by the necessity for construction of
protective shelters around the process equipment, and special cooling towers or air-conditioning equipment may be
required if the prevailing temperatures are high. Excessive humidity or extremes of hot or cold weather can have a
serious effect on the economic operation of a plant, and these factors should be examined when selecting a plant site.

Transportation facilities: Water, railroads, and highways are the common means of transportation used by major
industrial concerns. The kind and amount of products and raw materials determine the most suitable type of
transportation facilities. In any case, careful attention should be given to local freight rates and existing railroad lines.
The proximity to railroad centers and the possibility of canal, river, lake, or ocean transport must be considered: Motor
trucking facilities are widely used and can serve as a useful supplement to rail and water facilities. If possible, the plant
site should have access to all three types of transportation, and, certainly, at least two types should be available. There
is usually need for convenient air and rail transportation facilities between the plant and the main company
headquarters, and effective transportation facilities for the plant personnel are necessary.

Water supply: The process industries use large quantities of water for cooling, washing, steam generation, and as a
raw material. The plant, therefore, must be located where a dependable supply of water is available. A large river or
lake is preferable, although deep wells or artesian wells may be satisfactory if the amount of water required is not too
great. The level of the existing water table can be checked by consulting the state geological survey, and information
on the constancy of the water table and the year-round capacity of local rivers or lakes should be obtained. If the water
supply shows seasonal fluctuations, it may be desirable to construct a reservoir or to drill several standby wells. The

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 43

 temperature, mineral content, silt or sand content, bacteriological content, and cost for supply and purification
treatment must also be considered when choosing a water supply.

Waste disposal: In recent years, many legal restrictions have been placed on the methods for disposing of waste
materials from the process industries. The site selected for a plant should have adequate capacity and facilities for
correct waste disposal. Even though a given area has minimal restrictions on pollution, it should not be assumed that
this condition will continue to exist. In choosing a plant site, the permissible tolerance levels for various methods of
waste disposal should be considered carefully, and attention should be given to potential requirements for additional
waste-treatment facilities.

Labor supply: The type and supply of labor available in the vicinity of a proposed plant site must be examined.
Consideration should be given to prevailing pay scales, restrictions on number of hours worked per week, competing
industries that can cause dissatisfaction or high turnover rates among the workers, and variations in the skill and
productivity of the workers.

Taxation and legal restrictions: State and local tax rates on property income, unemployment insurance, and
similar items vary from one location to another. Similarly, local regulations on zoning, building codes, nuisance
aspects, and transportation facilities can have a major influence on the final choice of a plant site. In fact, zoning
difficulties and obtaining the many required permits can often be much more important in terms of cost and time
delays than many of the factors discussed in the preceding sections.

Site characteristics: The characteristics of the land at a proposed plant site should be examined carefully. The
topography of the tract of land and’ the soil structure must be considered, since either or both may have a
pronounced effect on construction costs. The cost of the land is important, as well as local building costs and living
conditions. Future changes may make it desirable or necessary to expand the plant facilities. Therefore, even though no
immediate expansion is planned, a new plant should be constructed at a location where additional space is available.

Flood and fire protection: Many industrial plants are located along rivers or near large bodies of water, and there
are risks of flood or hurricane damage. Before selecting a plant site, the regional history of natural events of this type
should be examined and the consequences of such occurrences considered. Protection from losses by fire is another
important factor in selecting a plant location. In case of a major fire, assistance from outside fire departments should be
available. Fire hazards in the immediate area surrounding the plant site must not be overlooked.

Community factors: The character and facilities of a community can have quite an effect on the location of the plant. If
a certain minimum number of facilities for satisfactory living of plant personnel do not exist, it often becomes a burden
for the plant to subsidize such facilities. Cultural facilities of the community are important to sound growth. Churches,
libraries, schools, civic theaters, concert associations, and other similar groups, if active and dynamic, do much to
make a community progressive. The problem of recreation deserves special consideration. The efficiency, character,
and history of both state and local government should be evaluated. The existence of low taxes is not in itself a
favorable situation unless the community is already well developed and relatively free of debt.
SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 44
 Selection of the Plant Site:
The major factors in the selection of most plant sites are (1) raw materials, (2) markets, (3) energy supply,
(4) climate, (5) transportation facilities, and (6) water supply. For a preliminary survey, the first four factors should
be considered. Thus, on the basis of raw materials, markets, energy supply, and climate, acceptable locations can
usually be reduced to one or two general geographical regions. For example, a preliminary survey might indicate that
the best location for a particular plant would be in the south-central or south-eastern part of the United States.

In the next step, the effects of transportation facilities and water supply are taken into account. This permits
reduction of the possible plant location to several general target areas. These areas can then be reduced further by
considering all the factors that have an influence on plant location.

As a final step, a detailed analysis of the remaining sites can be made. Exact data on items such as freight
rates, labor conditions, tax rates, price of land, and general local conditions can be obtained. The various sites can be
inspected and appraised on the basis of all the factors influencing the final decision. Many times, the advantages of
locating a new plant on land or near other facilities already owned by the concern that is building the new plant
outweigh the disadvantages of the particular location. In any case, however, the final decision on selecting the plant
site should take into consideration all the factors that can affect the ultimate success of the overall operation.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 45

PLANT LAYOUT
After the process flow diagrams are completed and before detailed piping, structural, and electrical design
can begin, the layout of process units in a plant and the equipment within these process units must be planned. This
layout can play an important part in determining construction and manufacturing costs, and thus must be planned
carefully with attention being given to future problems that may arise. Since each plant differs in many ways and no
two plant sites are exactly alike, there is no one ideal plant layout. However, proper layout in each case will include
arrangement of processing areas, storage areas, and handling areas in efficient coordination and with regard to such
factors as:

i. New site development or addition to previously developed site

ii. Type and quantity of products to be produced
iii. Type of process and product control
iv. Operational convenience and accessibility
v. Economic distribution of utilities and services
vi. Type of buildings and building-code requirements vii. Health and safety considerations
viii. Waste-disposal requirements ix. Auxiliary
equipment

x. Space available and space required

xi. Roads and railroads
xii. Possible future expansion

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 46

DESIGN OF PLANT LAYOUT

Figure of Plant layout

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 47

 CHAPTER-7

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 48

 MSDS OF DIAMMONIUM PHOSPHATE

8.1.1 Identification of the substance/mixture and of the company/undertaking

1 Product Identifier

Table 1 Product Identifier of DAP

Product name : Diammonium Phosphate

IUPAC Name : Diammonium Hydrogen Phosphate
Molecular formula : (NH4)2HPO4, H9N2O4P
Chemical family : Ammonium phosphate – Inorganic salt
Primary use : Crop nutrients
: Diammonium Hydrogen Phosphate
Synonyms Fertilizer Grade Ammonium Phosphate DAP 18 - 46 – 0

CAS number : 7783-28-0

EC number : 231-987-8
SDS number : 31
ICSC number : 0217
Relevant identified use(s) Nutrient in manufacture of yeast; ingredient in compound bread improvers.
Flame retardant. Agriculture - Ingredient in specialty all-soluble dry fertilizers.
Building Materials Flame-proofing of wood. Paint - Ingredient in flameproofing
of specialty paper; prevention of afterglow in matches. Pulp and Paper - Flame-
proofing of specialty paper; prevention of afterglow in materials. Textile -
Flame-proofing of fabrics and cotton batting. Nutrient feed for biological
treatment plants.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 49

.2 Composition/information on ingredients

Table 3 Composition of DAP

Name Content (%)

Phosphorus 46
Nitrogen 18
Moisture Content 1.8

3 Hazard identification

Table 3 Hazard identification of DAP

POTENTIAL HEALTH EFFECTS

Eye Eye irritant. Contact may cause stinging, watering, redness and swelling.
Skin irritant. Contact may cause redness, itching, burning and skin damage. No harmful effects
Skin from skin absorption have been reported.
Causes irritation to the respiratory tract. Symptoms may include coughing, shortness of breath.
Inhalation

Ingestion Low degree of toxicity by ingestion, Causes irritation to the gastrointestinal tract. Symptoms may
(Swallowing) include nausea, vomiting and diarrhea.
Pre-Existing
Medical Conditions aggravated by exposure may include skin disorders.
Conditions
Effects of overexposure may include irritation of the nose, throat and digestive tract, nausea,
Signs and vomiting, diarrhea, coughing and shortness of breath
Symptoms

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 50

4 First aid measures

Table 4 First aid measures of DAP

If irritation or redness develops, move victim away from exposure and into fresh air. Flush eyes
with clean water for at least 15 minutes. If symptoms persist, seek medical attention. Remove any
Eye contact lenses and open yields wide apart.

Remove contaminated shoes and clothing, and flush affected area(s) with large amounts of water.
If skin surface is damaged, apply a clean dressing and seek medical attention. If skin surface is not
Skin damaged. Cleanse affected area(s) thoroughly by washing with mild soap and water. If irritation
or redness develops, seek medical attention.

Remove affected person from source of contamination. Move affected person to fresh air and keep
Inhalation warm and at rest in a position comfortable for breathing. Rinse nose and mouth with water. Get
(Breathing) medical attention if any discomfort continues.

Ingestion First aid is not normally required; however, if swallowed and symptoms develop, seek medical
(Swallowing) attention. Do not induce vomiting.

.5 Firefighting measures

Table 5 Firefighting measures of DAP

Suitable Chemical type foam, Carbon Dioxide (CO2), dry chemical, water fog.
extinguishing media
Fire hazard Under conditions of fire this material may produce: Ammonia.
Explosion hazard Product is not explosive.
Reactivity Stable at ambient temperature and under normal conditions of use
Special protective equipment Wear positive-pressure self-contained breathing apparatus (SCBA) and appropriate
for firefighters protective clothing.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 51

 For fires beyond the incipient stage, emergency responders in the immediate hazard area
should wear bunker gear. When the potential hazard is unknown, in enclosed or confined
spaces, a self-contained breathing apparatus should be worn. In addition, wear other
Firefighting instructions appropriate protective equipment as conditions warrant (see Section 8). Cool equipment
exposed to fire with water, if it can be done with minimal risk. Avoid excessive water to
minimize runoff.

.6 Accidental release measures

Table 6 Accidental release measures of DAP

General measures Do not breathe fumes from fires or vapours from decomposition.
If possible, stop flow of product. Contain and collect as any solid. Ventilate area.
Emergency procedures

Follow precautions for safe handling described in this safety data sheet. Provide
Personal precautions adequate ventilation. Avoid inhalation of dust.
Avoid contact with skin and eyes.
Do not discharge into drains or watercourses or onto the ground. Spillages or
uncontrolled discharges into watercourses must be reported immediately to the
Environmental precautions Environmental Agency or other appropriate regulatory body.

Avoid generation and spreading of dust. Collect powder using special dust vacuum
cleaner with particle filter or carefully sweep into suitable waste disposal containers
Methods for cleaning up and seal securely. Collect and place in suitable waste disposal containers and seal
securely.
Recover the product by vacuuming, shoveling or sweeping and place in appropriate
container to be disposed at an appropriate disposal facility according to current
applicable laws and regulations and product characteristics at the time of disposal.
Methods for cleaning up Provide adequate ventilation. Avoid generation of dust during clean-up of spills. If
uncontaminated, recover and reuse product. Practice good housekeeping – spillage can
be slippery on smooth surface either wet or dry.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 52

.7 Handling and Storage

Table 7 Handling and storage of DAP

Precautions for safe handling
Wash thoroughly after handling. Wash contaminated
Handling
clothing/shoes. Use good personal hygiene practices
Additional hazards when
When heated, material emits irritating fumes
processed
Conditions for safe sto rage, including any incompatibilities
When possible store this material in cool, dry, well-ventilated areas to protect product
quality. Keep container(s) tightly closed. Store only in approved containers, if
Storage applicable. Keep away from any incompatible material (see Section 10). Protect
container(s) against physical damage.

Store tightly closed in a dry, cool and well-ventilated place. Protect from moisture.
Storage conditions

Incompatible materials Alkalis and caustic products; strong acids; copper and its alloys.
Specific end use(s)
Main use Agricultural chemical

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 53

.8 Exposure controls/personal protection

Table 8 Exposure controls/personal protection of DAP

Use process enclosure, general dilution ventilation or local exhaust systems where necessary
Engineering Controls to maintain airborne dust concentration below the OSHA standards or in accordance with
applicable regulations.
Personal protective equipment
Approved eye protection to safeguard against potential eye contact, irritation, or injury is
Eye recommended
The use of cloth or leather work gloves is advised to prevent skin contact, possible irritation
Skin and absorption.
A NIOSH approved air purifying respirator with a type 95 (R or P) particulate filter may be
used under conditions where airborne concentrations are expected to exceed exposure limits.
Protection provided by air purifying respirators is limited (see manufacturer's respirator
selection guide). Use a positive pressure air supplied respirator if there is potential for
uncontrolled release, exposure levels are not known or any other circumstances where air
Respiratory purifying respirators may not provide adequate protection. A respiratory protection program
that meets OSHA's 29 CFR 1910.134 and ANSI Z88.2 requirements must be followed if
workplace conditions warrant a respirator.

A source of clean water should be available in the work area for flushing eyes and skin.
Other

General Hygiene
Considerations Wash thoroughly after handling Use adequate ventilation

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 54

9 Physical and Chemical properties

Table9 Physical and Chemical properties of DAP

Chemical Formula (NH4)2HPO4

Molecular Weight 132.06 𝑔𝑚⁄𝑚𝑜𝑙

Appearance Granular Solid

Color Gray to brownish black and White

Odor Weak ammonia odor or odorless

pH 8.0 (conc: 1% at 20 ℃)
Melting Point 155 ℃ (322 ℉, 428 K)
Boiling Point Decompose when heated

Vapor Pressure < 1 mm Hg (at 20 ℃)

Self-Ignition Temperature Not flammable

Density 1.619 𝑔𝑚⁄𝑐𝑚3 (at 20 ℃)

Water 588 𝑔𝑚⁄𝑙 ( at 20 ℃)

Solubility
Insoluble in ethanol, acetone and Liquid ammonia

Taste Saline, cooling taste

When heated to decomposition emits very toxic fumes of phosphorus oxides,

Decomposition
nitrogen oxides, and ammonia

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 55

.10 Stability and reactivity

Table 10 Stability and reactivity of DAP

Stable under normal conditions of storage and handling. Gradually loses up to 8% ammonia
Chemical during long-term storage. Decomposes at 310°F. Material is hygroscopic (May absorb
Stability moisture from air when relative humidity is greater than 82%).

Conditions to Avoid
Possible violent reaction with magnesium and sodium hypochlorite.

Incompatible Materials
Avoid contact with alkalis and heat.

Hazardous
Decomposition When heated to decomposition, oxides of phosphorus, oxides of nitrogen (NO, NO 2, NOx and
Products ammonia (NH3) vapors are released.

Corrosivity Corrosive to iron and mild steels, aluminum, zinc and copper.
Hazardous
Polymerization Will not occurs.

.11 Toxicological information

Table 11 Toxicological information of DAP

Exposure Routes The substance can be absorbed into the body by inhalation of its aerosol.

Particles in the eyes may cause irritation and smarting. Redness and Pain.
Eye Symptoms

Skin contact Skin irritation should not occur when used as recommended.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 56

12 Ecological Information

Table 12 Ecological information of DAP

Ecotoxicity Inorganic phosphates have the potential to increase the growth of freshwater algae, whose
eventual death will

.13 Disposal considerations

Table 13 Disposal considerations of DAP

Sewage disposal This material is hazardous to the aquatic environment. Keep out of sewers and waterways.
recommendations
Waste disposal Place in an appropriate container and dispose of the contaminated material at a licensed site.
recommendations
Additional information Dispose of waste material in accordance with all local, regional, national, and international
regulations.

.14 Transport information

Table 14 Transport information of DAP

No dangerous good in sense of transport regulations.

15 Regulatory information

Table 15 Regulatory information of DAP

Residues of diammonium phosphate are exempted from the requirement of a tolerance when used in accordance with
good agricultural practice as inert (or occasionally active) ingredients in pesticide formulations applied to growing crops
only. Use: buffer, surfactant.
Substance added directly to human food affirmed as generally recognized as safe (GRAS).

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 57

16: Other information

Table 16 Other information of DAP

Health: 2
NFPA rating Flammability: 0
Reactivity: 1
Avoid contact with eyes, skin and clothing.
Avoid breathing dust.
Label precautions Wash thoroughly after handling.
Keep container closed.
Use only with adequate ventilation
In case of contact, immediately flush eyes or skin with plenty of water for at least 15 minutes.
Remove contaminated clothing and shoes. Wash clothing before reuse. If inhaled, remove to
fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. If
Label First Aid swallowed, induce vomiting immediately as directed by medical personnel. Never give
anything by mouth to an unconscious person. In all cases, get medical attention.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 58

 CHAPTER-8

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 59

EFFLUENT TREATMENT TECHNOLOGY
Following are the main features of the modern scrubbing system technology. Scrubbing System
Technology particularized for each case. This is a key point when designing plants to operate with very soluble
raw materials, since in those cases the water to be recovered from the scrubbing system should be minimized.

Technology Background
The development of scrubbing Technology started long time ago and it has been carried out in parallel
with our granulation technologies, as the answer to a continuous demand for lower emissions, both to comply
with the more stringent legislation and to recover most of the nutrients.

Licensed Plants
This technology has been successfully applied to DAP / NPK factories, achieving very low emissions.
The design is always adapted to the local legislation, to avoid at the same time high emissions and unnecessary
expenses on scrubbing equipment.

Ammonia Recovery
This technology includes several washing stages to recover the ammonia, having recorded values as low
as 10-50 ppm NH3.

Dust / Particles Recovery

Modern design consists of medium pressure drop scrubbing systems, which in conjunction with high
efficiency separators, allow us to reach 10-50 ppm particles emission.

Fluorine Recovery
Modern technology includes several washing stages of lower pressure drop operating with water, resulting
in very low fluorine emissions.

Stack gases Opacity

Reduction of stack opacity is based on the use of high pressure drop (HPD) scrubber, consisting on a
sophisticated multi stages venturi, which provides recovery for the smallest sub-micron particles and mists.

Integration in the whole Plant

Modern scrubbing system engineering includes the plant mass & energy balance, stating the suitable
process parameters to assure that the fulfilment of scrubbing system conditions does not interfere with the
operation of reaction section.

Nutrients recovery
Thanks to the use of scrubbing process, which recovers all the liquid into the reaction system, at the
same time that emissions are fulfilled many nutrients will be recovered, greatly increasing plant efficiency.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 60

STORAGE & HANDLING
• Does tend to take up moisture, both in storage and in the field.
• Separated from strong oxidants, strong bases and strong acids. Keep in a wellventilated room.

• Storage in a bulk shed is the preferred storage method. Covering with a tarp may reduce any moist air uptake.

• The use of augers may damage the Fertiliser and increase any handling problems.
• Do not leave exposed to moist air.
• Either fill or empty (completely), the drill or air-seeder Fertiliser box overnight.
• Cover seeding equipment with a tarp.
• Raise the equipment from the soil to stop moisture moving up the tubes.

Separate product conveying system removes fertilizer from each of the granulation units to the fertilizer
storage building. The production from each train is continuously weighed and recorded. The design capacity of
each conveying system is selected to allow for peak loads expected from this type of service. A transfer tower is
located at the top of the fertilizer storage building. A diverter system is installed to allow transfer of material
from either two of the conveying belts to either two of the stock piling belts in the storage building. The storage
building is divided into four equal volume bins and one smaller "off-grade" bin. Manually operated trippers are
located on the stock piling belts so that discharge from the belts can go to any of the five storage compartments.
The total storage capacity of the buildings is 60000 ton. Product is reclaimed from any of the four large storage
bins by an automatic declaimer system at a rate of 1500 t/h. The reclaimed fertilizer is weighed and conveyed to
the dock on an enclosed belt conveyor.

TRANSPORTATION
Diammonium phosphate is transported in bulk in specialized self-unloading cars. When transporting in
closed decked vessels, the fertilizer is packed in bags. Transportation is carried out by all types of transport, in
compliance with relevant goods transportation regulations.

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 61

 CHAPTER-9

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 62

 CONCLUSION
The world food demand is increasing with increase in population and to produce large quantity of raw food, fertilizer
demand is also increasing. With increase demand of fertilizers, it is important to study the production aspects of the
important fertilizer such as Di ammonium Phosphate (DAP). It is very widely used product in Indian farming for the
development of the earth soil and plant growth. Agriculture which accounts for about one seventh of the GDP, provides
sustenance to nearly two-third of our population. With this project study we are able to understand the critical aspects of
the chemical production process of the DAP. It is also very useful to study the material balance and energy balance of
the production process. The raw materials used are in gaseous, liquid and solid phases. Some of the chemicals are toxic
in nature, so it is important to study the safety aspects for the storage, handling and transportation of chemicals. The
design of plant layout and its important are also very useful for the understanding of the production process.

BIBILIOGRAPHY
Books and Journals

1) M. Gopala Rao and Marshall Sitting “Dryden’s Outlines of Chemical Technology” Third Edition, East-West Press

2) Robert H. Perry, Don W. Green. Perry’s Chemical Engineer’s Handbook-7th Edition, McGraw Hill

3) Max S Peters and Klaus D. Timmerhaus “Plant design and economics for chemical engineers”, Fifth Edition,
McGraw Hill

4) Austin G.T. “Shreve’s Chemical Process Industries”, Fifth Edition, McGraw Hill
5) B. I. Bhatt and S.M. Thakore “Stoichiometry”, Fifth Edition, Tata McGraw Hill
6) Frank C. Vilbrandt, Charles E. Dryden “Chemical engineering plant design”, Second
Edition, McGraw Hill

Web References

1) http://www.fert.nic.in/sites/default/files/Annual_Report_2017-2018.PDF
2) https://www.eiriindia.org/diammonium_phosphate.html
3) https://nptel.ac.in/courses/103107086/module3/lecture7/lecture7.pdf
4) https://www.nutrien.com/sites/default/files/201707/POT_SDS_200_%28DAP%29_Diam monium_phosphate.pdf

5) http://www.hmlindia.com/MSDS/DiNH4phosphat.pdf
6) http://www.labchem.com/tools/msds/msds/75509.pdf
7) https://pubchem.ncbi.nlm.nih.gov/compound/ammonium_phosphate

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 63

8) https://pubchem.ncbi.nlm.nih.gov/compound/Ammonium_dihydrogen_phosphate
9) http://www.northeastern.edu/wanunu/WebsiteMSDSandSOPs/MSDS/Msds_Sulfuric_Aci d.pdf

10) http://www.labchem.com/tools/msds/msds/LC25550.pdf
11) https://pubchem.ncbi.nlm.nih.gov/compound/1118
12) http://www.afrox.co.za/en/images/Ammonia%20%28Rev%203%29_tcm266-27591.pdf 13)
http://www.hmlindia.com/MSDS/ANhydrousNH3.pdf
14) https://pubchem.ncbi.nlm.nih.gov/compound/ammonia
15) http://iffco.in/ourproducts/index/dap
16) https://www.dioneoil.com/uploads/6/8/7/4/6874938/plant_design_and_economics_for_ch emical_engineers.pdf

17) https://pubchem.ncbi.nlm.nih.gov/compound/water
18) https://pubchem.ncbi.nlm.nih.gov/compound/calcium_sulfate
19) https://nptel.ac.in/courses/103103027/pdf/mod4.pdf
20) https://www.indiamart.com/proddetail/double-deck-vibrating-screen-14141610962.html
21) https://nptel.ac.in/courses/103103032/40
22) https://www.cropnutrition.com/diammonium-phosphate
23) https://www.pollutionsystems.com/wet-scrubbers.html
24) http://environmentclearance.nic.in/writereaddata/form-1/35_output.pdf

SIR BHAVSINHJI POLYTECHNIC INSTITUTE. Page 64