PHYSICAL PROPERTIES OF PHOSPHORIC ACID MOLECULAR FORMULA : H3PO4 MOLECULAR MASS : 98g

CHEMICAL NAME
COMMON NAME BOILING POINT MELTING POINT DENSITY VAPOUR PRESSURE SOLUBILITY ODOUR

: orthophosphoric acid
: phosphoric acid : 133c : -1733 : 1.83g/cc : 267 Pa at 20C :miscible in water : slight acid odour

APPEARANCE

: bronish/greenish viscous liquid

STRUCTURE OF PHOSPHORIC ACID

 THERMAL PROCESS
ELECTRIC FURNACE PROCESS BLAST FURNACE PROCESS WET PROCESS(SULFURIC ACID)

The raw material used is elemental phosphorus . This process has been abandoned because large amount of energy is required.

 REACTIONS INVOLED :
Ca3(PO4)2 + 3H2SO4 +6H2O (ROCK PHOSPHATE) 2H3PO4 + 3(CaSO4.2H2O) (GYPSUM)

SIDE REACTIONS:
CaF2 + H2SO4 + 2H2O 2HF + CaSO4.2H2O

6HF + SiO2

H2SiF4 +2H2O

SLURRY TO LAGOON HOT WASH WATER VENT GAS

H3PO4 GYPSUM
TRAVELLING PAN FILTER

FUME SCRUBBER HF(l)

WEAK ACID WASH WASHED GYPSUM

TO GYPSUM PLANT

RECYCLE H3PO4

40% H3PO4
GROUND PHOSPHATE ROCK 93-98% H2SO4 COOLING AIR REACTOR HF(g) SLURRY

SLUDGE

CLARIFIER

SIDE REACTION
STEAM

SINGLE EFFECT EVAPORATOR

Ca3(PO4)2 + CaF2SO42SO4+2H2O 3H2 +H +2H2O

2HF+CaSO4.2H2O 2H3PO4+3(CaSO4.2H2O)

75% H3PO4

 Igneous found in Kola, South africa,Brazil sedimentery rocks found in Jordan ,Algeria,Morocco,etc

Flourapatite (found in igneous) Francolite(found in sedimetary)

DESCRIPTION OF PRODUCTION PROCESSES

Raw Materials for Phosphoric Acid Production
Bones used to be the principal natural source of phosphorus but phosphoric acid today is produced from phosphatic ores mined in various parts of the world. Phosphate ores are of two major geological origins: Igneous as found in Kola, South Africa, Brazil, etc. Sedimentary as found in Morocco, Algeria, Jordan U.S.A., etc. The phosphate minerals in both types of ore are of the apatite group, of which the most commonly encountered variants are: Fluorapatite Ca10(PO4)6(FOH)2 Francolite Ca10(PO4)6x(CO3)x(FOH)2+x Fluorapatite predominates in igneous phosphate rocks and francolite predominates in sedimentary phosphate rocks.

Principles of the Process

The basic chemistry of the wet process is exceedingly simple. The tricalcium phosphate in the phosphate rock is converted by reaction with concentrated sulphuric acid into phosphoric acid and the insoluble salt calcium sulphate.

The insoluble calcium sulphate is then separated from the phosphoric acid, most usually by filtration. The reaction between phosphate rock and sulphuric acid is self-limiting because an insoluble layer of calcium sulphate of the particles of the rock. This problem is kept to a minimum by initially keeping the rock in contact with recirculated phosphoric acid to convert it as far as possible to the soluble monocalcium phosphate and then precipitating calcium sulphate with sulphuric acid.

forms on the surface Calcium sulphate exists in a number of different crystal forms depending particularly on the prevailing conditions of temperature, P2O5 concentration and free sulphate content

The fluorine is liberated as hydrogen fluoride during the acidulation of phosphate rock. In the presence of silica this reacts readily to form fluosilicic acid via silicon tetrafluoride.

CaF2 + 2H+ 4HF + SiO2

2HF + Ca++ SiF4 + 2H2O

3SiF4 + 2H2O

2H2SiF6 + SiO2

The fluosilicic acid may decompose under the influence of heat to give volatile silicon tetrafluoride and hydrogen fluoride. H2SiF6 SiF4 +2HF

GAS SCRUBBING SYSTEMS

A number of different scrubbing systems have been used for removing fluoride. These can vary both in the scrubbing liquor and in the type of scrubber used. The most widely used scrubber is the void spray tower operating at atmospheric pressure but others, such as packed bed, cross-flow venturi and cyclonic column scrubbers have been Extensively employed. A product containing up to 22% fluosilicic acid is recovered in the fluoride recovery system at atmospheric pressure and the removal efficiency is better than 99% (90% with one absorber). Silica is removed from the acid by filtration. Fresh water, recycled pond water, sea water and dilute fluosilicic acid have all been used as scrubbing liquor. Gas from the evaporator flash chamber is first fed through an entrainment separator if a system operating under vacuum is used. Essentially, this removes any P2O5 values from the gas. Only one scrubbing stage is generally used and 17-23% fluosilicic acid is obtained with a recovery efficiency of about 83-86%.

: Let us see the manufacture of phosphoric acid by wet process Involving sulfuric acid leaching of dihydrate process.

Bones used to be principal natural source of phosphoric acid . Nowadays phosphoric acid is produced from phosphatic ores mined in different parts of the world.

DIHYDRATE PROCESS

 PROCESS DESCRIPTION :
Grinding :
Some grades of commercial rock do not need grinding ,their particle size distribution being acceptable for dihydrate reaction section (60_70% <150) most other phosphate rock need particle size reduction , Generally using ball or rod mills. Other mills operate with wet or dry rock.

This stage separates the phosphoric acid from the calcium sulphate dihydrate. Five tonnes of gypsum are generated for every tonne (P2O5) of product acid produced. The filter medium must move in sequence through the various stages for continuous operation. The initial separation must be followed by at least two stages of washing, to ensure a satisfactory recovery of soluble P2O5. It is only possible to achieve the desired degree of separation at a reasonable rate if the filtration is either pressure or vacuum assisted and in practice vacuum is always used. The remaining liquid must be removed from the filter cake as far as possible at the end of the washing sequence. The cake must then be discharged and the cloth efficiently washed to clear it of any remaining solids which might otherwise build up and impair filtration in subsequent cycles. The vacuum must be released during the discharge of the cake and it is beneficial to blow air through in the reverse direction at this point to help dislodge the solids. The filtrate and washings must be kept separate from one another and have to be separated from air under vacuum conditions and then delivered under atmospheric pressure, as product, or for return to the process. The pressure difference is usually maintained by delivering the filtrates below the surface of the liquid in barometric tanks placed at a level sufficiently below the separators for the head of liquid to balance the vacuum. The most common filtration equipment is of three basic types: tilting pan, rotary table or travelling belt

 REACTION :
The tri calcium phosphate is converted by reaction with concentrated sulphuric acid into phosphoric acid and insoluble calcium sulphate. The reactor maintains an agitated reaction volume in circulation. The reaction system consists of a series of separate agitated reactors. The operating conditions for di hydrate precipitation are 26-32% P2O5 and 70-80C . This temperature is controlled by passing the slurry through a flash cooler, which also de-gasses the slurry and makes it easier to pump. The temperature can also be controlled by using an air circulating cooler. 2Ca3(PO4)2+3H2SO4+6H2O2H3PO4+3CaSO4.H20

But in the interests of economy of materials and space, the multi-vessel reaction system replaced by a single tank in some processes. Some of these single tanks may be divided into compartments which are virtually separate reactors.The operating conditions for dihydrate precipitation are 26-32% P2O5 and 70-80C .This temparature is controlled by Passing it through flash coolers which also de_gasses the slurry and makes it easier to pum The temparature also controlled by using circulating cooler.

 CONCENTRATION :

There is a long history of direct contact concentrators, in which evaporation is effected by bringing the acid into intimate contact with hot combustion gas from a burner, enabling equipment walls to be made of materials and in thicknesses which are suitable for efficient indirect heat transfer. Various patterns of direct-fired concentrator have been devised. Currently, almost all evaporators that are being built today for this service are of the forced circulation design.

 ADVANTAGES OF DIHYDRATE PROCESS : This is the most diffused process There is no phosphate rock quality limitation On-line time is high Operating temperatures are low Start-up and shut-down are easy Wet rock can be used (saving drying costs)

DISADVANTAGES OF DIHYDRATE PROCESS : Relatively weak product acid High energy consumption in the concentration stage 4%-6% phosphorus tri oxide losses,most of them co crystallizes with ca-sulfate.

HEMIHYDRATE PROCESS

HEMIHYDRATE PROCESS

RECRYSTALLISATION

PROCESS DESCRIPTION :
The forced circulation evaporator consists of a heat exchanger, vapour or flash chamber, condenser, vacuum pump, acid circulating pump and circulation piping. A fluosilicicacid scrubber is usually included in the forced circulation evaporator system. All the evaporatorsin this service are generally of the single-effect design because of the corrosive nature of phosphoric acid and the very high boiling point elevation. The heat exchangersare fabricated from graphite or stainless steel with the rest of the equipment made fromrubber-lined steel. All equipment designs will be made using the best practices of engineering available. More than one evaporator may be used, with the acid passing in sequence through each, depending on the degree of concentration required. Operating conditions are selected in this process so that the calcium sulphate is precipitated in the hemihydrate form. It is possible to produce 40-52% P2O5 acid directly, with consequent valuable savings in energy requirements. Figure 5 shows a simplified flow diagram of a HH process. The stages are similar to those of the dihydrate process but grinding may be unnecessary.

The main advantages of this process, apart from the reduction or elimination of evaporation Heat requirement, are:-

CAPITAL SAVINGS. Purer acid:

Acid from the HH process tends to contain substantially less free sulphate and suspended solids and lower levels of aluminium and fluorine than evaporated dihydrate process acid of the same strength.

LOWER ROCK GRINDING REQUIREMENTS.

A satisfactory rate of reaction can be achieved from much coarser rock than in the dihydrate process, because of the more severe reaction conditions in the HH process. The disadvantages of HH systems are:-

Filtration rate.
Hemihydrate crystals tend to be small and less well formed than dihydrate crystals and thus hemihydrate slurries tend to be more difficult to filter than dihydrate slurries unless crystal habit modifiers are used to suppress excessive nucleation. With a good HH process however, there is no need to use crystal habit modifiers. There are examples of phosphate rocks that produce hemihydrate crystals achieving higher filtration rates than obtained with dihydrate crystals.

HARMFUL IMPURITIES PRESENT IN GYPSUM

Residual acidity (P2O5) Fluorine compounds (These are only harmful if disposal is into fresh water because disposal into sea water results in the formation of insoluble calcium fluoride.) Undesirable trace elements Radioactivity

GYPSUM DISPOSAL
Around 5 tonnes of gypsum are generated per tonne of P2O5 produced as phosphoric acid. This represents a serious disposal problem with the individual phosphoric acid production units of over 1,000t.d-1 capacity now being built. Two methods can be used to dispose of gypsum: Disposal to land Disposal into water

Disposal to water
The gypsum can be pumped through an outfall into the sea at coastal sites and estuaries. Disposal into rivers is no longer practised, as it is not a good environmental option. Disposal of gypsum into the sea has the advantage that gypsum is more soluble in sea water than in fresh water. However, some of the impurities in the gypsum should be controlled. Clean gypsum itself (CaSO4) is soluble and is not harmful to the environment. A phosphoric acid plant with high efficiency is essential for this method of disposal and only clean phosphates can be used in the plant if the pollution is to be kept within local environmental quality standards.

Disposal on land
Disposal on land, under proper conditions, is the best environmental option although it is not possible everywhere because it requires space and certain soil qualities where the gypsum stack is situated. Dry gypsum from the filter in some plants is transported by belt conveyors to the gypsum storage pile. The pile area is completely surrounded by a ditch which collects the runoff water including any rain water

HAZARDOUS EFFECTS OF PHOSPHORIC ACID

To man
Phosphoric acid is corrosive to all parts of the body. Contact with the skin can cause redness and burns. Splashes in the eyes cause irritation and burns. Acid mists may cause throat and lung irritation.

To environment
Phosphoric acid is harmful to aquatic life.

ADVANTAGES OF HEMIHYDRATE PROCESS

Process Single-stage filtration. Produces strong acid directly 40-48% P2O5. No intermediate storage if acid is produced at user's strength. Uses coarse rock. Ease of operation.

DISADVANTAGES
Limited number of rocks processed industrially. Large filter area required for 48% P2O5 acid. High lattice loss, low P2O5 efficiency (90-94%). Produces impure hemihydrate. Tight water balance. Requires higher grade alloys. Care required in design and shut-down.

SEPARATION OF FLOURINE
EMISSIONS INTO AIR ON LINE METHODS Commonly used methods for the determination of fluoride in solutions from gas samplingsystem are colorimetric and ion selective electrode methods. Colorimetric methods include the zirconium SPADNS (sulpho phenyl azo dihydroxy naphthalene disulphonic acid) method as the most widely used. Fluoride reacts withzirconium lake dye to produce a colourless complex for spectrophotometric determination.A fluoride selective electrode using a lanthanum fluoride membrane may be used. MANUAL METHODS A volumetric method may be used which relieson the titration of fluoride ion against lanthanum nitrates to an end point determined bycoloration of an indicator dye asuch as Alizarin Red S or Eriochrome Cyanine R.

An Example of Quality of Water at Other Stacks

Parameter pH Conductivity (umhos/cm) Calcium mg/l Magnesium (mg/l) Sodium (mg/l) Potassium (mg/l) Fluoride (mg/l) Sulfate (mg/l) Total Phosphorus (mg/l) Ammonia Nitrogen (mg/l) Untreated Process Water 2.1 22,100 538 223 2260 210 4120 6200 6600 1240

Florida Institute of Phosphate Research

PHOSPHOGYPSUM PROBLEM
~800 Million to 1 Billion Tons in Stacks in Florida ~30 Million Tons Being Added Each Year

Florida Institute of Phosphate Research

CONCENTRATES MANUFACTURING
Air
Sulfur
Sulfuric Acid Plant Heat Cogeneration Plant Exported Electric Power Gypsum Stack

Sulfuric Acid
Phosphoric Acid Plant Phosphoric Acid

Phos. Rock

Phosphate Rock Storage

Anhydrous Ammonia

NH3 Storage

Granulation Plant

Animal Feed Ingredients Plant

Granular Crop Nutrients

Merchant Grade Phosphoric Acid

Defluorinated Feed Phosphates

CONCENTRATES MANUFACTURING

Sulfuric Acid Plant Phosphoric Acid Plant Animal Feed Ingredients Plant Product Warehouses Gypsum Stack Granulation Plant

GYPSUM PRODUCTION, 1997

Production (Mt/yr) PG in Florida Gypsum in US Gypsum in World 30 20 114 Relative Amount 1 0.67 3.80

Florida Institute of Phosphate Research

PROCESS WATER PROBLEM

Each stack has 1 to 3 billion gallons of process

water pH is about 1 to 2 Dilute mixture of

Phosphoric, sulfuric, fluorsilicic acids Saturated with calcium sulfate Contains numerous other ions and ammonia

Florida Institute of Phosphate Research

PROCESS WATER PROBLEM

Piney Point Other Gypsacks

Florida Institute of Phosphate Research

PINEY POINT PROBLEM

Approximately 1 billion gallons of low pH,

high conductivity water Water near the top of the stack

Threatening to spill into Bishops Harbor

Florida Institute of Phosphate Research

PINEY POINT WATER INVENTORY REDUCTION

Trucking
Lime treatment and removal Reverse osmosis with no pretreatment (US

Filter) Ocean Dumping Pretreatment/reverse osmosis project (IMC/FIPR)-in negotiation

Florida Institute of Phosphate Research

PROBLEMS WITH OTHER STACKS

There are approximately 20 other stacks

which will eventually have to be closed The water in these stacks has a pH of 1 to 2 The conductivity of the water is greater than at Piney Point

Florida Institute of Phosphate Research

AN EXAMPLE OF QUALITY OF WATER AT OTHER STACKS

Parameter pH Conductivity (umhos/cm) Calcium mg/l Magnesium (mg/l) Sodium (mg/l) Potassium (mg/l) Fluoride (mg/l) Sulfate (mg/l) Total Phosphorus (mg/l) Ammonia Nitrogen (mg/l)
Florida Institute of Phosphate Research

Untreated Process Water 2.1 22,100 538 223 2260 210 4120 6200 6600 1240

POSSIBLE SOLUTIONS
Reduce the accumulation of phosphogypsum Reduce the amount of water on the stacks Improve the quality of the water on the

stacks

Florida Institute of Phosphate Research

POTENTIAL USES FOR PHOSPHOGYPSUM

Road building Agriculture Landfills

Oyster Culch
Roofing Tile

Florida Institute of Phosphate Research

RADIOACTIVITY OF PHOSPHOGYPSUM
Phosphogypsum Northern Florida West Central Florida pCi/g 5 to 10 20 to 35

Florida Institute of Phosphate Research

RELATIVE RISKS
Activity
Living Near the Road Building the Road Driving on the Road (Radioactivity) Airplane Crash
40

Relative Risk
1 2 72 652 1304 1957 4565

K Decay in Your Body Dying in a Fire Drowning

Florida Institute of Phosphate Research

BARRIERS TO PHOSPHOGYPSUM USE

Regulatory agencies
Public fear of the word radioactivity

Florida Institute of Phosphate Research

POSSIBLE SOLUTIONS
Reduce the accumulation of phosphogypsum Reduce the amount of water on the stacks Improve the quality of the water on the stacks

Florida Institute of Phosphate Research

EMISSION MONITORING IN PHOSPHORIC ACID PLANT

INTRODUCTION : Monitoring of emissions plays an important part in environmental management. It can be beneficial in some instances to perform continuous monitoring. This can lead to rapid detection and recognition of irregular conditions and can give the operating staff the possibility to correct and restore the optimum standard operating conditions as quickly as possible. Emission monitoring by regular spot checking in other cases will suffice to survey the status and performance of equipment and to record the emission level. In general, the frequency of monitoring depends on the type of process and the process equipment installed, the stability of the process and the reliability of the analytical method. The frequency will need to be balanced with a reasonable cost of monitoring.

PHOSPHORIC ACID PLANT

PRESENTED BY