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    Anp Front.

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    Akhil Parikh
    This presentation provides an overview of the ANP-Front plant, which processes raw materials like rock phosphate, nitric acid, ammonia, and carbon dioxide to produce ammonium nitrate (AN) and other products. It describes the key sections and processes involved, including dissolving rock phosphate, crystallization, AN evaporation, and refrigeration. Safety aspects of AN storage, handling, and dispatch are also covered, emphasizing the need to maintain proper pH, avoid confinement, and minimize contamination and inventory when dealing with AN.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Anp Front.

    Uploaded by

    Akhil Parikh
    21 views40 pages
    This presentation provides an overview of the ANP-Front plant, which processes raw materials like rock phosphate, nitric acid, ammonia, and carbon dioxide to produce ammonium nitrate (AN) and other products. It describes the key sections and processes involved, including dissolving rock phosphate, crystallization, AN evaporation, and refrigeration. Safety aspects of AN storage, handling, and dispatch are also covered, emphasizing the need to maintain proper pH, avoid confinement, and minimize contamination and inventory when dealing with AN.

    Original Title

    ANP FRONT.

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    This presentation provides an overview of the ANP-Front plant, which processes raw materials like rock phosphate, nitric acid, ammonia, and carbon dioxide to produce ammonium nitrate (AN) and other products. It describes the key sections and processes involved, including dissolving rock phosphate, crystallization, AN evaporation, and refrigeration. Safety aspects of AN storage, handling, and dispatch are also covered, emphasizing the need to maintain proper pH, avoid confinement, and minimize contamination and inventory when dealing with AN.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    21 views40 pages

    Anp Front.

    Uploaded by

    Akhil Parikh
    This presentation provides an overview of the ANP-Front plant, which processes raw materials like rock phosphate, nitric acid, ammonia, and carbon dioxide to produce ammonium nitrate (AN) and other products. It describes the key sections and processes involved, including dissolving rock phosphate, crystallization, AN evaporation, and refrigeration. Safety aspects of AN storage, handling, and dispatch are also covered, emphasizing the need to maintain proper pH, avoid confinement, and minimize contamination and inventory when dealing with AN.

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    You are on page 1of 40

    A

    PRESENTATION

    ON

    ANP – FRONT
    BY
    Mayur Kachhiya
    M A Shaikh
    ANP – FRONT
    NITRO(P)
    Content
    • Overview of Nitro Complex
    • Introduction
    • Where ANP – Front stands ???
    • Products and Side Products
    • Objective of Each Section
    • Block Diagram me
    • Process
    • Safety during AN storage, handling
    and dispatch.
    Overview of Nitro Complex
    WNA

    Ammonia NA (61-62%)
    Rock
    Sec 43
    CO2
    ANP – F
    NP Acid Lime

    85% AN Sale
    ANP – R AN (94%) CAN
    Introduction
    – Design Capacity : 475 MTPD of ANP
    – Technology Supplier : M/s BASF Germany
    – Detail Engineering : UHDE India
    – Based on ODDA Process
    – Raw Materials : Rock Phosphate

    Nitric Acid

    Gypsum

    Carbon Dioxide

    Ammonia
    – Product : ANP (20:20:0)
    – Side Products : Lime
    Where ANP – Front stands???

    It's a plant which provides the raw


    materials for both ANP-Rear and CAN
    plants, Also produce 85% AN for sale -
    by processing Rock Phosphate and
    60% of Nitric Acid produced in WNA
    Plant. Also consumes Ammonia and
    Carbon Dioxide from Ammonia Plant.
    Products & Side Products

    » NP acid
    » Ammonium Nitrate ( ~ 60/85/94%
    Concentration)
    » Calcium Carbonate ( ~ 10-12%
    moisture)
    » Inert - Sand (Acidic in Nature)
    Objective of Each Section
    – Unit 31 : Handling and storage of Rock Phosphate
    – Unit 32 :Dissolving of Rock Phosphate in NA to
    convert insoluble P2O5 into water
    soluble.
    – Unit 33 :Crystallization and Separation of DDIS

    – Unit 34 :Brine Circuit and Refrigeration Unit for


    Crystallization Process
    – Unit 41 :Conversion of CN and Separation into AN
    and CaCO3
    – Unit 42 :AN evaporation to make AN concentrated
    for the use in CAN/ANP(R) Plant
    and for sale.
    – Unit 35-36 :Neutralization and Evaporation of NP Acid
    and Granulation of slurry to get finalized
    product ANP granules
    Block Diagram of ANP – F
    ROCK HANDLING

    UNIT:31 ROCK HNO3 60%

    DISSOLVING

    UNIT:32

    WASH
    SAND
    ACID SAND
    SEPARATION

    CN
    BORSING
    CRYSTALLIZATION
    REF. UNIT:34
    UNIT:33

    WASH NA

    ACB AND CN
    CN
    CN NH3
    CONVERSION
    FILTERATION
    MELT CO2
    UNIT:41
    LIME TO CAN

    NP ACID AN EVAPORATION

    NEUTRALISATION UNIT:42

    NH3 GAS AND EVAPORATION AN TO ANP AN TO CAN PLANT

    UNIT:35
    85% TO AN SALE.

    GRANULATION
    GYPSUM UNIT:36
    Dissolving:
    • To convert the insoluble Phosphate from Rock into
    water soluble form
    • Rock Phosphate from Unit- 31 supplied to reactors
    arranged in series with Nitric Acid (NA) ~61.5%
    supplied from WNA Plant which is cooled in
    ANP(F) plant itself in 2 subsequent coolers
    • In addition to that Wash Nitric Acid (WNA) and
    Effluent to be recycled added.
    • Temperature maintained by mean of WNA quantity
    • Water maintained by means of Effluent quantity
    recycled
    Digestion reaction

     Ca5(PO4)3 F + 10HNO3 ---------> 5Ca(NO3)2 +

    3H3PO4 + HF
    Inert Removal:
    • >100 micron size inert separated in Lamella
    Separator (Plate type separator – works under
    laminar flow condition).
    • Reduce erosion and easy to handle.
    • The DIS flows through the inclined plated from the
    bottom to the top in a laminar flow pattern.
    • By means of gravity acting on the inert particles
    heavy inert particles settle down and get separated
    from sludge room (the bottom of the separator)
    through sluice valve system.
    • Inert will be filtered in a belt filter for recovery of
    P2O5
    Crystallization & Filtration:
    • 2 – parallel trains each having 5 crystallizers in
    series
    • Agitated tank type crystallizers having paddle blade
    agitators
    • Contains cooling coils and COB as a cooling media
    • Provision of HOB circulation to remove
    incrustallation over the coil surface
    • DDIS contains NP Acid and Calcium Nitrate.
    • CaO/P2O5 ratio which is about 1.5, cooling the
    DDIS so that the remaining solution has a much
    lower CaO/P2O5 ratio (e.g. < 0.35).
    ACB Synthesis:
    2 NH3 (g) + CO2 (g) + H2O (l) = (NH4)2CO3 (l)

    • Exothermic Reaction temp maintained ~50-55 deg C

    • For this purpose continuous circulation of ACB material with


    ~450 m3/hr and cooling done with the help of Cooling
    Water

    • Ammonium nitrate solution (AN) with a concentration of 60% is


    fed to the top of the packed carbonation tower

    • CO2 concentration of 85% by volume

    • NH3 from evaporator 34 E002


    CN Conversion:
    (NH4)2CO3 + Ca(NO3)2 = CaCO3 + 2 NH4NO3

    • KAN solution preheated to maintain approx. 51 dec.C in the CN

    reactors

    • The reactors operate with a slight ACB (approx 0.3% by wt).

    • The size distribution of the precipitated lime depends not only on the

    KAN/ACB ration but also on the parameters indicated below:

    Type of rock phosphate

    Residence time in reactors

    Conversion temperature
    Lime Filtration

    • Includes Thickener, Lime filter

    • To Separate 60% AN and Lime

    • Moisture content in the lime is 8 -12 %.

    • Lime for CAN Plant and Sale.

    • 60% AN feed into Evaporation Unit.


    AN Filtration & Neutralisation :

    • AN filtration from pressure filter ( contains >150 micron)

    • pH correction with AN dosing ( 5.5 to 6.5 pH)

    (NH4)2CO3 + 2HNO3 = 2NH4NO3 + CO2 + H2O

    • AN Storage
    Off Gas Scrubbing :
    • Gases from all equipments from section
    41 and 42 containing mainly unreacted
    NH3
    CO2
    CO
    AN vapour
    • Density and pH monitoring.
    • VPC and NA dosing.
    AN Evaporation:
    • 3-stage evaporation (Mixed Feed)
    • MP steam
    • Falling film type evaporator
    • Concentrate AN from 60% to about 94% .
    • Evaporators arranged in series with
    separators 42D004/42D006/42D007.
    • An optimum energy recovery is ensured
    by integration of several heat exchangers
    42E002/42 E006/42E007.
    Refrigeration Unit (BORSIG):
    • Absorption refrigeration plant
    • Brine flows in close loop. It flows
    through:
    Chilling NOx circulating water.
    WNA Plant for chilling water.
    In Crystallizer coils
    For cooling NA.
    cont...

    Kind of plant : Single-stage


    absorption
    refrigeration plant
    Purpose :
    Brine chilling
    Solvent :
    Water(H2O)
    Refrigerant :
    Ammonia(NH3)
    Refrigerating capacity : 2.8 MW (796 TR)
    Cooling water I/l temp : 33 deg C
    Refrigerant :
    Ammonia/Water
    AN Handling:
    • What are AN safety
    Detailed study on AN summaries that :
    Low pH (Below 4.0)
    Confined Space
    Presence of organic materials
    High temperature
    • Any of above two conditions when co-
    exist at a time possibility of AN explosion
    persists.
    Safety Design During
    Storage of Ammonium Nitrate
    • Storing AN at 135-140 deg C
    • Insulated, atmospheric, ventilated
    • Steam coil at bottom of tank
    • Ammonia dosing facility with continuous pH
    monitoring by analyzer as well regular sampling by
    laboratory
    • Overhead tank filled with DM water having
    automatic control valve which will open if high
    temperature initiate in any of tank 42
    T005/T006/F001Same arrangement at other AN
    storage tanks
    Safety Design During
    Storage of Ammonium Nitrate
    • In case of fire/explosion use of plenty of water
    is the best option.
    • To be kept far of transformer, switches, fuses,
    motor etc
    • In silo, bin storage galvanized sheet should
    not used in case of solid storage
    • High density AN is more safe than low density
    pallets
    • Vent should be provided
    Safety Design During
    Storage of Ammonium Nitrate
    • Alkaline status
    • Stored well below 175 deg C
    • Contaminations are kept to a minimum
    • Confinement to be avoided
    • Inventory is kept to a minimum
    • No any hot work allowed near storage tank
    without precaution like asbestoses clothing
    wall or water curtain provision
    Test during inspection
    • Gaskets • TREM Card
    • Flanges • PH
    • Foreign material • MOC
    • Odor • Explosive Test
    • Water free • Hammer Test
    • Drain valve • Mirror Test
    • Mud guards • Vent Valve
    • M seal if found on • No of holes on baffle
    body • No of compartments
    • Washing duration
    • Dedicated status
    AN safety
    • Storage tanks & filling area is separated with
    one anti-blast wall.
    • Filling capacity is 400 mts/day on two shift
    basis.
    • Overhead tank is always ensured for filled
    condition in which in any condition if temp rise
    observed into 42F002/F004/Bay17/Bay18 this
    water is used to dilute AN content.

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