THE FERTILIZERS AND CHEMICALS TRAVANCORE

LIMITED
(FACT) COCHIN

TRAINING REPORT
10-07-19 to 09-08-19

DEPARTMENT OF CHEMICAL ENGINEERING

AMAL JYOTHI COLLEGE OF ENGINEERING

KANJIRAPPALLY

INDUSTRY: FACT Ltd. ,COCHIN DIVISION

SUBMITTED BY: MANSOOR ABDUL KALAM

1
 ABSTRACT

I underwent Post Qualification Training to acquaint myself for a period of 1

month from to get an industrial exposure in a practical aspect of technical
implementation. During the course of study I was able to interact freely with the
officials and other employees in the plant and fetch maximum relevant
information from them. I also got an opportunity to visit the work area and get a
‘hands on’ experience on various industrial devices. The training helped me to
get an idea about the various manufacturing processes and the technical
instruments which are used in the plant.

2
 ACKNOWLEDGEMENT

I would like to take this opportunity to express my sincere gratitude to all those
who have helped me throughout this in-plant training. It gives me immense
pleasure to acknowledge all those who have rendered encouragement and the
support for the successful completion of work

I place my sincere thanks to Mr. Velumani, Dy Manager (Trg) of FACT

Training department, for permitting me to do the training at FACT.

I would also like to thank Mr. K B Biju DGM(P) of Cochin Division.

I express my hearty thanks to all the Employees of The FERTILIZERS AND

CHEMICALS TRAVANCORE LIMITED for their entire constant support
during the training

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FACT-AN INTRODUCTION

FACT, India's first large scale fertilizer unit was set up in 1943. In 1947, FACT
Udyogamandal started production of Ammonium Sulphate with an installed
capacity of 10,000 MT Nitrogen. FACT became a Kerala State Public Sector
Enterprise on 15th August 1960 and 21st November 1962, the Government of
India became the major shareholder.

The 2nd stage of expansion of FACT was completed in 1962. The 3rd stage of
expansion of FACT was completed in 1965 with setting up of a new ammonium
sulphate plant.

FACT Engineering and Design Organization was set up on 24th July 1965 to
meet the emerging need for indigenous capabilities in vital areas of
Engineering, Design and Consultancy for establishing large and modern
fertilizer plants. FEDO has since then diversified into Chemicals,
Petrochemicals, Hydrometallurgy, Pharmaceutical and other areas. FEDO offers
services from project identification and evaluation stage to plant design,
procurement, project management, site supervision and commissioning of new
plants as well as revamping and modernization of old plants.

FACT Engineering Works was established on 13th April 1966 as a unit to

fabricate and install equipments for fertilizer plants. Over the years FEW
developed capabilities in the fabrication of pressure vessels and heat
exchangers. FEW have also undertaken lying of cross-country piping and
fabrication and installation of large penstocks of hydelprojects.

The Cochin Division of FACT, the 2nd production Unit was set up at

4
Ambalamedu and the 1st phase was commissioned in 1973. The 2nd phase of
FACT Cochin Division was commissioned in 1976.

As a diversification plans from the traditional field of Fertilizers and Chemicals,

50000 TPA Caprolactam Plant at Udyogamandal was commissioned in 1990.

FACT set up 900 TPD Ammonia Plant at Udyogamandal at a cost of 638 Crores
following an order of the High Court of Kerala in February 1994 on a Public
Interest Litigation, to decommission the existing imported Ammonia storage
and handling facility at Willington Island (Cochin Port). The Ammonia plant
was commissioned in 1998.

The company's main business is manufacture and marketing of :

(a) Fertilizers

(b) Caprolactam and Engineering Consultancy and Fabrication of Equipment.

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MILESTONES OF FACT

• 22-09-1943 - Incorporation
• 26-06-1947 - Production started
• 15-08-1960 - FACT came under Public Sector
• 21-11-1962 - Govt. of India major share holder
• 1959-1960 - UD 1st stage expansion completed
• 1962 - UD 2nd stage expansion completed
• 16-03-1964 - ICMA Award for utilizing byproduct gypsum
• 15-10-1966 - UD 3rd stage expansion completed
• 1971 - ICMA Award for technology transfer
• 01-10-1971 - UD 4th stage Ammonia Plant
• 01-10-1973 - UD 4th stage 150TPD Ammonium Phosphate
• 24-07-1965 - FACT Engineering and Design Organization
• 13-04-1966 - FACT Engineering Works
• 07-06-1966 - CD Phase-I License issued
• 27-04-1973 - CD I Urea Plant commissioned
• 10-11-1976 - CD II Sulphuric Acid Plant commissioned
• 10-12-1976 - CD II Phosphoric Acid Plant commissioned
• 10-01-1977 - CD II NPK trial run started
• 01-04-1976 - CD II NPK commercial production started
• 18-05-1984 - PD Caprolactam technical collaboration agreement
• 14-09-1984 - PD Zero date of ASCL Project
• 06-08-1985 - PD Caprolactam License issued
• 13-12-1989 - FEW shifted to Palluruthy
• 26-07-1989 - Award for excellence in performance 1986/7 from the
Prime Minister of India
• 20-12-1990 - CD-12MW Captive Power Plant
• 01-03-1991 - PD Caprolactam commercial production started
• 01-03-1991 - UD New Ammonium Sulphate commercial production
started
• 25-09-1993 - Foundation stone - 900 TPD Ammonia Plant
• 23-03-1998 - 900 TPD Ammonia plant commercial production started

6
 PRODUCTS OF FACT

STAIGHT FERTILIZERS
AMMONIUM SULPHATE: Ammonium Sulphate is a nitrogenous fertilizer
containing 20.6% nitrogen, entirely in ammonical form. It has excellent
physical properties; non-hygroscopic, crystalline and free flowing. It is ideal as
a straight nitrogenous fertilizer and also as an ingredient in fertilizer mixtures. It
is the most widely preferred nitrogenous fertilizer for top dressing on all crops.
Another unique advantage is that it contains 24% sulphur, an important
secondary nutrient.

COMPLEX FERTILIZERS
FACTAMFOS (AMMONIUM PHOSPHATE SULPHATE): FACTAMFOS
20:20:0:13 is a chemical blend of 40 parts of ammonium phosphate and 60 parts
of ammonium sulphate. It contains 20% N and 20% P2O5. The entire N is in
ammonical form and P is completely water soluble. In addition, FACTAMFOS
contains 13% sulphur, a secondary plant nutrient which is now attaining great
importance in the agricultural scene.FACTAMFOS 20:20:0:13, with the
granular form and non-hydroscopic and free flowing nature, have excellent
physical properties. It is ideal for application on all soils and all crops.
FACTAMFOS 20:20:0:13 can also be used for foliar application

FACTMIX
FACT prepares on a very large scale all the standard NPK mixtures under the
brand name 'FACTMIX' for different crops for Kerala as stipulated by the
Department of Agriculture. In addition, FACT prepares special tailor made
fertilizer mixtures of any required grade for plantation crops like coffee, tea,
rubber, etc. FACT mixtures are superior in quality with the presence of
ammonical nitrogen, water soluble phosphorus, and other major nutrients like
sulphur, calcium, etc.

GYPSUM
A byproduct of phosphoric acid, is a rich and cost effective source of 16%
sulphur and 22% calcium. FACT is marketing bagged gypsum in brand name
FACT Gypsum all 4 southern states as a soil conditioner with fertilizing
properties

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IMPORTED FERTILIZERS
FACT markets imported Urea and Potash from Gulf Countries and Russia for
consumption in all 4 southern states as per requirement. Urea with 46%
Nitrogen in the granular/prilled form and Potash with 60% K20 serves the
nutritional requirement in the 4 southern states.

ZINCATED FACTAMFOS
This special product containing 0.3% Zinc in FACTAMFOS has been launched
to address the widespread deficiency of Zinc in most soils of South India

ZINCATED GYPSUM
This soil amendment and ameliorant contains 2% Zinc in addition to 16%
Sulphur and 22% Calcium for rectifying alkaline soils and improving soil
fertility and physical properties

8
 SAFETY

INTRODUCTION

In the operation and maintenance of any industry, particularly in a Chemical

Industry, certain amounts of hazards exist.

Regardless of what safety devices may be present in the plants, serious

accidents are likely to occur unless every employee knows about those hazards
and is careful at all times. In the manufacturing process inflammable, explosive,
toxic or corrosive materials are involved, as also high or very low temperatures
and high pressures. Each of them has certain properties which may contribute to
the occurrence of accidents. Every employee should be fully aware and be
familiar with these properties and be ever alert to the hazards and strict
compliance of the preventive or protective measures will ensure perfect safety
to the plant and personnel. Every operator should be convinced that there is no
justification for unnecessary risk and guesswork.

SAFETY IN RELATION TO OPERATION AND MAINTENANCE

WORKS

All operating and service personnel must wear an approved type of dress. The
use of loose dresses is forbidden.

Proper tools maintained in good condition must be used. They should be used
correctly.

Areas where operational or maintenance works are being carried out, must be
kept clean and safe – free from obstacles, unnecessary materials scattered about.
It should also be ensured that there is proper light and ventilation free of any
poisonous or irritant gases.

All guards on machines, railings around machinery, walkways, stand ways,

platforms, etc… must not be removed without proper authority or reason.

Horseplay, wrestling, playing or throwing materials about inside factory is

prohibited. Employees must not tamper with any machines, switches or
equipment not connected with their work.

No machinery, tools, or materials, which are not in proper condition for safety,
should be operated without authority or permission from superiors. No repairs,
adjustments or cleaning should be done on machinery while it is in motion.

9
Before entering any tank, vessel, or closed spaces it should be ensured that the
equipment is isolated, purged and tested for safe working. The interior should
be free from poisonous atmosphere and it should be properly ventilated.

FIRE PROTECTION

All work places, plants, stores/dumps shall be kept free of unwanted

inflammable materials. Waste particles should be put in bins provided for the
purpose and soaked in water. “No Smoking” restrictions shall be strictly
adhered. Any open flame in or around the chemical plant areas or related areas
are prohibited except with a specific clearance from plant foreman or safety
personnel. Welding and cutting in hazardous areas or nearby will be done with
the approval of respective plant foreman or safety department after taking
suitable precautions.

All transport vehicles and plant items operating on liquid fuels will be switched
off while fuelling. Heavy current consuming apparatus such as heaters and
power operated hand tools, etc… must not be plugged into lighting circuit
unless approved by electrical department.

Fuses on electrical circuits will on no account by replaced by heavier fuses.

When buildings, offices, stores, etc… are closed at the end of a working period,
proper check shall be made by the person responsible for looking up to see that
non fires have been left burning and no electrical apparatus has been left
switched on.

The following are the different classes of fire:

A – Materials: Liquids, firewood, paper, textiles, etc...

B – Inflammable: Liquids, oils or grease, paint, gasoline, lubricants, etc…

C – Inflammable gases.
10
D – Metal fires.

E – Electrical: Live electrical machinery/circuits.

The following are the type of fire extinguishers that are to be used in case of
different classes of fires:

Type of Fire Extinguishers Class of fire

Soda Acid type A
Foam type A,B
Vaporizing Liquid type (CTC) B,E
Carbon di-oxide type B,C,E
Dry Chemical powder type B,C,E

None of the equipment for firefighting E.g. Fire buckets, hoses, hydrants, etc…
neigh shall on any account be tampered with or utilized for any other neither
purpose nor otherwise interfered with nor the approach blocked.

In case of any outbreak of fire, Safety Dept. should be immediately notified. In

case of any fire, employees must not leave their places of duty otherwise their
services are specifically required. Perfect discipline and orderliness are essential
in case of fire. Unnecessary crowding, blocking of roads or passages must be
avoided

11
 1000 TPD DCDA SULPHURIC ACID PLANT

Sulphuric acid is made in several stages from SO2, obtained from the oxidation
of sulphur or collection of SO2 from the smelting of sulphide ores such as
copper, zinc or lead. This second collection of SO2 is very attractive as it is
utilising the by-products of other processes and reduces emissions and waste.

SO2 (g) →SO3 (g) → H2SO4 (aq)

In the following slides we will break down this process into three main steps.

Furnace or Burner (Only necessary if raw sulfur is used):

Air is cleaned by electrostatic precipitation, dried then heated to approx. 600 oC.

Pure (liquid) sulphur is sprayed under pressure into the furnace, reacting with
the oxygen in the air. The product is sulphur dioxide

S (l) + O2 (g) →SO2 (g)

Alternative sources of sulphur dioxide are also used, either extracted from
natural gas (some deposits contain a lot of hydrogen sulphide) or from the
roasting of sulphide ores in the extraction of metals like zinc or lead. If so this
stage can be skipped.

The converter :
The converter contains trays or layers of porous pellets of a catalyst, vanadium
(V) oxide (V2O5). The sulphur dioxide reacts with more air to form sulphur
trioxide. This reaction is reversible and reaches equilibrium. It is also an
exothermic reaction and the temperature will rise to over 600 oC. The mixture is
continuously cooled to 400oC between each tray.

2SO2 (g) + O2 (g)  2SO3 (g)

As the temperature rises the equilibrium shifts to the left (not forming SO3). To
counter this the gases are allowed to cool slightly before they pass over the next
layer of catalyst, by carefully controlling the process almost all sulphur dioxide
is converted to sulphur trioxide

12
The absorption tower:
Sulphur trioxide will dissolve in water to form our final goal of sulphuric acid.
However, it is violently exothermic and usually results in a mist of sulphuric
acid droplets that are very difficult to control.

In practice the sulphur trioxide dissolves almost completely and is bubbled

through concentrated sulphuric acid (that contains relatively little water) to form
98% sulphuric acid, known as Oleum (H2S2O7)

a) SO3(g) + H2SO4(l) → H2S2O7(l)

b) H2S2O7(l) + H2O(l) → H2SO4(l)

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14
 PHOSPHERIC ACID PLANT

INTRODUCTION

Phosphoric acid is an inorganic acid. It has formula H3PO4 and is miscible in all
proportion in water. It specific gravity ranges from 1.2-1.7. it is non-flammable
and is acidic it is corrosive, causes severe irritation and burns to every area of
contact and is also harmful if swallowed or inhaled phosphoric acid liberates
explosive hydrogen gas when reacting with chlorides and stainless steel can
react evidently with sodium tetra hydro borate. It react with aldehydes, amides,
alcohol, amides and glycol, Razo-compounds, carbonates, esters, caustics,
phenols, cresols, ketones, organophosphates, epoxides, explosives, combustible
materials, unsaturated halides and organic peroxides exothermally. Phosphoric
acid form flammable gases and sulphides, cyanides, fluorides, organic peroxides
and halogenated organics. Its mixture with nitro methane is explosive.
Hydrogen is an explosive reaction product. It is stable under ordinary conditions
of use and storage. Substitutes can be super cooled without crystallizing.
Phosphoric acid may form hazardous reaction products on decomposition but
hazardous polymerization will not occur.

PROCESS DESCRIPTION
PRODUCTION OF WEAK PHOSPHORIC ACID

The rayon convertible process is sample one stage process compressing to

successive operation.

The first stage is that the ground rock phosphate and sulphuric acid are made
react in the presence of recycle phosphoric acid obtained from second operation.
Phosphoric acid in its most advantages from calcium sulphate in form of
dehydrate crystal of suitable size are produced simultaneously.

Second stage is that the gypsum and phosphoric acid slurry is filtered, waned
counter currently in order to collect the phosphoric acid and extract maximum
amount of P2O5 from the dehydrate crystals before discharged.

15
The raising of P2O5 strength of phosphoric acid and limiting of its free sulphuric
acid affect the development of highly filtered gypsum crystals the achievement
of through extraction of P2O5 from gypsum make on the filter requires the use
of sufficient amount of wash water. This limits the possible increase of P2O5
concentration of the product.

CONCENTRATION OF WEAK PHOSPHORIC ACID AND

FLOURINE RECOVERY

Concentration of phosphoric acid with low P2O5 strength consists in the

elimination of parts of the dilution water by forced evaporation under vacuum.
This phenomenon is promoted by raising the acid temperature. During this
evaporation stage major portion of the fluorine in the acid evolved which is
received as flout acid in the fluorine tower by recirculation.

PHYSICAL AND CHEMICAL CONDITIONS OF THE

PROCESS PRINCIPLE REACTION
Ca3 (PO4)2 + 3H2SO4 + 6H2SO4 ------------------------3CaSO4 + 6H2O + 2H3PO4

SECONDARY REACTION

CaF2 + H2SO4 --------- CaSO4 + 2HF

HF + SiO2 --------- H2 SiF6 + 2H2O

CaCO3 + H2SO4 --------- CaSO4 + CO2 + H2O

Na2CO3 + SiF6 --------- Na2SiF6 + H2O + CO2

K2CO3 + H2SiF6 --------- K2SiF6+ H2O +CO2

SiO2 +2H2SiF6 --------- 3SiF6 + H2O + CO2

The major part of remaining metal oxide (FeO3-Al2O3-MgO) are dissolved and
partially degrade the phosphoric acid by fixing ((PO4)-(HPO4)) ions in complex
formula.

In general, the reaction temperature is fixed at 720C for P2O5 strength of 30%
P2O5. Too low temperature for instance 650C, renders the slurry very viscous
and adversely affect the reaction. 800C=formation of CaSO4.1/2H2O

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CRYSTALLISATION

Crystallisation of gypsum CaSO4.2H2O is of rhombohedra type as the size of

the crystals inversely proportional to their number. It is necessary to limit as far
as possible. The formation of micro-crystals and this can be done by keeping a
super saturation in the attack tank. This is achieved by large recirculation and
constant excess of SO42- ions in the slurry. There are some important parameters
conditioning the gypsum in the phosphoric acid.

PERCENTAGE OF P2O5 IN THE ACID

The free sulphate can be expressed in free SO3 or in the free H2SO4 in gpl or
percentage. There should always a slight excess of free sulphate in the acid in
order to allow maximum number of Ca2+ ions to combine with SO42- ions which
are both in solution. Moreover the HPO42- ions have fairly with the same electro
physical configuration as SO42- ions and a definite tendency to take place of
SO42- ions. When the latter is not in sufficient numbers, thus creating a
dicalcium phosphate crystals containing P2O5 which consequently constitutes a
cost of product.

SO3 CONCENTRATION
The degree of saturation with free SO3 should be kept within a rather narrow
range that is in between 20 gpl of SO3.

This slight free sulphate super saturation directly influence the size of the
dehydrate crystals. When this percentage for intake about 35 gpl. The gypsum
crystals grow longer but beyond this value, the crystals break or degrade.

SOLID PERCENTAGE

A Very thick slurry will result in a poor combination of Ca2+ and SO4 2- ions for
crystallisation and also result in difficult pumping. A thin slurry leads to too dense
degasifying with strong formation of foam. Normally a solid percentage between 37
and 40 percentage is maintained.

17
PERCENTAGE OF ORGANIC MATTER AND IMPURITIES
PRESENT IN ROCK

The presence of small amount of impurities tends to influence the condition of

development of crystals. The presence of carbonates emit certain amount of
CO2 which added to the action of organic matters allow the formation of foams
at the slurry surface mainly affecting the operation of pump.

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19
 NPK PLANT

BASIC PROCESS DESCRIPTION

The production of N:P:K:S – 20:20:0:13 involves the conversation of NH3,
H3PO4 and H2SO4 into dry granular material that meets the fertilizer
specification.

REACTION
The reaction between NH3, H2SO4 and 23% H3PO4 is carried out in an
agitated tank reactor. The mole ratio between NH3 and H3PO4 is maintained at
145 for maximum solibility. Ammonia is fed into the reactor in the for of liquid
and vapour. Phosporic acid fed in the reactor is the for of scrubber liquor with
the % of P2O5 being 23, which H2SO4 is pumped from battery limits. The
reaction produces a slurry consisting of Ammonium Sulphates and Ammonium
Phosphates.

The reactions are as follows

2NH3 + H2SO4 --------- (NH4) 2SO4

NH3 + H3PO4 --------- NH4H2PO4

NH3 + NH4H2PO4 --------- (NH4) 2HPO4

The production of DAP involves the predominant use of NH3 and H3PO4 with
the % of P2O5 being 54. H2SO4 is also used depending upon the extent for
which slurry composition and specific gravity is to be adjusted.

Partial neutralization is accomplished with the resultant slurry having a specific

gravity of almost 1.48 to 1.5. the reaction being exothermic, result in the
liberation of large quantity of heat. The heat is lost in the form of water vapor
leaving the system. Ammonia escaping along with the fumes is scrubbed in a
frame scrubber. The resultant slurry consisting of approximately 80% solids
pumped to a rotary drum granulator (1201) using slurry pumps (1106).

GRANULATION
Wet slurry is metered in to the granulator so as to distribute it into a stream of
dry recycle material slurry is distributed through two nozzles located on the
slurry header. The recycle material largely consists of undersize material,

20
ground oversize, fines separated in the cyclones and product recycle if used.
Slurry wets and coals the fine material forming product size particles. This
process is referred to as accretion. Granule form action by agglomeration also
occurs, simultaneously.

Ammonia vapour is also introduced during granulation through two

sprayers. Ammonia is introduced so as to further the neutralized reaction and
raise the moleratio to 1.8. The granulated material overflow the discharge dam
plate of the granulator and enters in to the rotary drier (1501).

DRYING
The granular material entering the dyer has a moisture content ranging from 2.0
to 2.5%. The drying process reduces the moisture content to about 1.0% with
out decomposing the material. The granules are dried by direct contact with hot
gases co-currently. Drying is also aided by the lifting and distributing flights as
the material passes along the length of the dryer.

The temperature of the inlet gases range from 400 – 600 deg c. The temperature
of the gases may be varied by varying the flow of combustion oil . Escape of
ammonia from the material occurs when a high mole ratio and specific gravity
is coupled with a high dryer temperature.

The dried material is discharged through a bar grizly into a bucket elevator.
Dryer discharge elevator (2168). This material is discharged into a screen feed
conveyor (2101).

SCREENING
The dry material from this conveyor is distributed to four single deck vibrating
screens (1401). Screening classifies the granular material into fines, product size
and oversize,

The feed to each screen is controlled through a specially designed control gate.
This splits and spreads the flow evenly over and screening area. The three
screen nets starting from the top end to the 60% of the screens of 2 mm mesh
size. This is used to separate the fines. The next to screen nets are of 3.5 mm
mesh size and separate the product size particles.

The oversize material is sent for size reduction to a chain crusher (1001). The
fines along with the crushed oversize from the recycle and passes into the

21
recycle conveyor (2102). The product granules flow to the product cooler
(1604).

COOLING
The temperature of the product size particles is brought down to prevent product
decomposing and also to solidify any traces of product phase still existing. The
is done also to prevent caking in storage.

Cooling is done in a rotary drum cooler by direct contact with atmosphere air
flowing counter currently.

The cooled product is elevated to the product surge bin (2329) by the product
elevator (2166). From the surge bin it may be recycled as per requirement or
discharged as product by means of conveyors N1, & N2, N3 & N4.

RECYCLING
Recycle material essentially consists of ground oversize, fines, spillages charged
from outside and also products size granules if recycled. The dry recycles
materials from the recycles conveyor (2102) is elevated by means of a recycle
elevator (2167) and discharged into the granulator providing the recycle stream.

22
23
AIR PROLLUTION
This minimizes chemical loss and also reduces its harmful effects on to the
surrounding environment.

CYCLONES
The hot dusty gases from the rotary dryer and rotary cooler pass inti the dryer
cyclones (1726) and cooler cyclones (1728) respectively.

The gases passes into the plenum chamber of the cyclones. The cyclonic action
produced causes the separation of dust from these gasses which separate as fines
and fall into the hopper below. A chain provided scrapes away the dust adhering
to the walls of the cyclones. The fines separated fall by gravity to the recycle
conveyor below.

When appreciable fall in the temperature of the dried product occurs. Cyclones
chocking is bound to happen. The dust free gasses pass into the scrubbers to the
scrubbed with phosphoric acid.

SCRUBBER
The gases from Dryer and Cooler cyclone pass in to the Dryer scrubber (1711)
and Cooler scrubber (1715) respectively.

The scrubber consist of a venturi section. The gases are sprayed with scrubber
liquor just above the venturi section. The venturi is an internal one formed by an
cone shaped structure placed in the centre of the inner duct. Spray nozzle
provided, spray the necessary scrubber liquor in this section. The gas from this
section pass through three swirler openings at the bottom in to the cyclonic
section. Counter current scrubbing is effected in this section with scrubber
liquor bring sprayed from the top.

The used scrubber liquor flows to the scrubber seal tank. Inward flow of H3PO4
is maintained through a launder from the fume scrubber section. A portion of
this scrubber liquor is sent as H3PO4 feed to the reactor.

24
KNOCKOUT CHAMBER
The scrubbed gas from the dryer and cooler scrubber pass in to the dryer KO
chamber (1718) and cooler KO chamber (1719) respectively.

The KO chamber is provided with FRP/PVC saddles. This is maintained in a

wet condition using water sprays from above. The wetness of the section helps
to coalesce entrained H3PO4 droplets. The large droplets impinge against an
angular baffles provided below and separate from the gas. The gases from the
two chamber are discharged in to the atmosphere by the dryer fan (1308) and
cooler fan (1309) respectively.

FUME SCRUBBER
Water vapour, Ammonia vapour and dust are drawn from the reactor and
granulator in to this scrubber by the fume fan. Scrubbing is effected in the
venture and cyclonic section.

The gases are scrubbed with H3PO4 which overflow a layer of V-neck weirs in
to the venturi. The liquid regenerates in to fine droplets and mixes with the gas
effectively accomplishing scrubbing. Next the gases are conveyed to the
cyclonic section through a pinch section. An over flow baffles provided enables
an additional stage o scrubbing by forming a pool of liquor.

In the cyclone section H3PO4 is sprayed from six hollow cone nozzle mounted
at two different elevation. This is done so as to maximize contact area between
gas and liquid and minimize channeling of gas. The scrubbed gases are sent out
through the stack (2401) by the fume fan.

Used liquor collects n the sump tank. An overflow is maintained in to the

scrubber seal tank. Fresh H3PO4 is metered in to the sump tank as per grade
requirements.

25
FACT CD – II EFFLUENT TREATMENT PLANT

OPERATION MANUAL
INTRODUCTION

With the enforcement of Water Pollution Control Act(1974) by the Kerala State Water
Pollution Control Board, it has become necessary for FACT Cochin Division also to
implement suitable scheme for the control of water pollution. National Environmental
Engineering Research Institute(NEERI),Nagpur, was entrusted with the task of carrying out
the characterization study of the various waste water streams from FACT Cochin Phase I &
Phase II and of formulating and a scheme for treatment of the waste water before
discharging into the Chithrapuzha river. After extensive studies NEERI submitted their report
suggesting separate treatment methods for the waste water streams from Phase I & Phase II
plants. The treatment scheme described here is for the Phase II plant waste water streams
only.

DESING BASIS :
NEERI conducted the characterization study of the various waste water streams from the
sulphuric acid plant, phosphoric acid plant and the NPK plant. The waste water stream from
sulphuric acid plant(about 150m^3/hr) was found to contain occasionally small quantities of
sulphuric acid, presumably due to leaks in the plant. On the other hand, waste water streams
from the both phosphoric acid plant and NPK plant were found to contain pollutants such as
fluoride, phosphate and ammoniacal nitrogen, on a continuos basis. The characterisation
of the waste water from phosphoric acid plant and NPK plant as determined by
NEERI are given below:-

Phosphoric acid plant:

Waste water flow rate :200 M3/hr

Fluoride :1270 mg/L

Phosphate :460 mg/L

NPK Plant :

Waste water flow rate :280 M3/hr

Ammoniacal nitrogen :570 mg/L

Fluoride :236 mg/L

Phosphate :1760 mg/L

26
The waste water from phosphoric acid plant contains more of fluorides and
hence two stage lime treatment is envisaged in the first stage fluoride are
precipitated. The waste water from the NPK plant is treated with lime in single
stage. Both these stream after lime treatment will be under alkaline condition
and this alkalinity is partially removed by mixing with the waste water from
sulphuric acid plant. The mixed waste water is further neutralized by the
addition of sulphuric acid.

The treated waste water is expected to contain

Fluoride less than 10 mg/L

Phosphate less than 5 mg/L

Ammoniacal nitrogen less than 50 mg/L

The waste water from phosphoric acid plant is collected in the equalization tank
1101 the two-compartment provided with facilitate collection of waste water in
one compartment while pumping can be done from the other compartment.
From the eqaulisation tank the waste water is pumped to the fluoride flash mixer
1103A where line slurry from the lime slaking plant is also pumped. The PH in
fluoride flash mixer is maintained in the range 4-5 by automatically controlling
the addition of lime slurry for precipitation of greater portion of fluoride in the
waste water.

The precipitated fluoride are to be separated and for this waste water is
sent to fluoride clariflocculator .The clariflocculator consists of central wall
called flocculating zone and an annular wall called clarifying zone .The feed to
the clariflocculator is through a pipe from the bottom extending up to the
top.The under flow from the clariflocculator is a slurry containing precipitated
fluorides.This slurry is filtered in the fluoro filter the cake is disposed off and
the filtrate is recycle to the process.

The overflow from the fluoride clariflocculator containing the residual

fluoride and phosphate is treated again with lime in phosphate flash mixer
1103B for precipitation of the phosphate and balance quantities of fluoride the
PH of waste water is maintained at 9-10 by automatically controlling the
addition of lime slurry the wastewater from the flash mixer is sent to the
phosphate clariflocculator for separation of the precipitated phosphate adradial
fluorides. The under flow sludge from the clariflocculator is filtered in the

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phosphate filter and the cake is disposed off. The chemical composition of this
cake is expected to be similar to that of rock phosphate and hence the possibility
of recycling it to the attack tank in phosphoric acid plant can be looked in to
filtrate along with the overflow from the clariflocclator is mixed waste water
from sulphuric acid plant for pH correction and eventual disposal to the
chithrapuzha river.

The waste water from the NPK plant is collected in NPK equalization
tank 1102, comprising of two compartment. As the fluoride content is less
compared to that of the waste water from phosphoric acid plant, single stage line
treatment is envisaged. For single stage treatment the pH of the waste water is
raised to 11-12 by automatic addition of lime slurry in to phosphate flash mixer,
where the waste water from the NPK equalisation tank also is pumped. From the
flash mixer were the waste water from the NPK equalisation tank is also
pumped. From the flash mixer at waste water at pH of 11-12 flows to the NPK
clariflocculator (3402). Precipitation and settling of the solid takes place in
clariflocculator. The under-flow sludge from the clariflocculator is filtered in
the NPK filter and the cake is disposed off. The possibility of recycling of this
cake to the attack tank in phosphoric acid plant can be looked into. The filtrate
along with the overflow from the clarifloccultor is collected in the stripper feed
tank 1107.

The waste water collect in the stripper feed tank contain ammoniacal
nitrogen. For the removal of this cooling tower type ammonia stripper is used.
The stripper striper feed pumps feed water from the stripper feed tank to the top
of stripper cells. At the bottom of the stripper the ammoniacal nitrogen content
of the water ia expected to be reduced to be less than 50 pp. Water outlet from
the stripper is sent through channels to be mixed with the waste water from
suplhuric acid plant for PH correction and for eventual disposal of Chithrapuzha
river

Lime slurry preperation section :

The quantity of lime required per day for the treatment of waste water as per
quality and quantity mentioned above is estimated to be 75 TPD assuming
available CaO at 65%. As the requirement is of this magnitude, burned lime is
proposed to be purchased and a slaking unit is included in the scheme. The lime
slurry with 10% CaO is used for the treatment
Burned lime is fed to the feedbin(1115) by means of spy loaders. The
lime
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conveyor fed from the feed bin dischargers burned live to the boot of the lime
elevator(3303). The lime elevator lifts the material to the limein(1116). From
the lime bin,limefalls on to the table feeder which feeds the lime slaking units.
The lime slaking unit consist of a rotary slaker with hood and stack and a
classifier to remove the grits from the slurry. Hot water at 65°C required for the
slaking operation is prepared by mixing steam at 3.4 ata with water. On lime
mixing envisaged for which necessary check valves and control valves are
provided.

Burnt lime fed into the rotary slacker along with hot water get slaked and
the large sized grit particles are separated .From the rotary slacker the material
flows to the classifier where more hot water is added fine grit particles are
separated in the classifier and clear lime slurry flows to the lime slurry tank
(1117) agitator provided in the lime slurry tank keeps the slurry in suspension.
From the lime slurry tank slurry is pumped to the various flash mixers by means
of lime slurry pumps (3209).

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CONCLUSION
The training I got in FACT was of immense help for me and I was fortunate to
be guided by experienced operators and engineers.

All in all the training at FACT was a lifetime experience which lends me the
opportunity to get an on hand experience of how this govt. of KERALA
enterprise works for producing best quality of FERTILIZERS

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