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How our Phosphoric Acid expertise helped AZFC, Egypt,
increase 100% of its output
Over the last 24 years we have been partnering and serving a wide range of customers
Case Studies
AZFC Plant (An existing Phosphate Fertiliser Complex in Egypt)
The complex was built with different production lines like Sulphuric acid, Phosphoric acid, TSP, SSP & NPK. The total production chain was suffering from chronic problems in throughput, up-time, capacity utilisation, technical efficiency and equipment failures.
ARMACO was appointed for revamping the SSP and Phosphoric acid units.
- For the Phosphoric acid concentration unit, a detailed study and analysis of the process steps was done by ARMACO. A root cause analysis indicated the presence of excessive dissolved solids in the feed acid.
ARMACO implemented a solution that ensured good manufacturing & maintenance practices for sustained process improvement across the Graphite Heat Exchanger. This reduced fouling across Heat Exchanger, and also increased operating hours and sustained throughput by taking necessary corrections & measures in reducing the load of both dissolved and suspended solids in the Concentrator feed acid. In addition, ARMACO devised and upgraded some of the on-line checks and controls and chalked down strict operating & maintenance schedules & practices. In the process the capacity utilisation across Concentrator improved to a global level of 100%.
- The Single Superphosphate (SSP) Plant was suffering from repeated breakdowns, enhanced corrosion, low throughput and large liquid effluent generation. ARMACO did thorough evaluation and root cause analysis of the process steps to establish shortcomings in Rock grinding, De-dusting & de-gasification, Mixer & Den, uncontrollable spillage across conveyors, etc. ARMACO re-engineered the conveyors & Den, modified layout of ducts with provision for both manual & on-line cleaning, and tightening daily cleaning & maintenance schedule especially across Mill, MIXER and Scrubber & its seal tanks. After refurbishment of equipments & ducts and configuring freshly the Mill, Mixer and Den, the SSP plant was transformed to its upgraded version working at a capacity utilization of 85 – 90% instead of the earlier < 50%.
- The granulated TSP plant based on SIAP process used dilute Phosphoric acid and was facing chronic problem in capacity utilisation and especially product quality. ARMACO evaluated the total chemistry involved in different steps, and put down improved control in feed ratio of raw materials and temperature control across its Digestion reactor. After thoroughly revamping the Granulator and its vapour handling & exhaust system. The TSP unit is being upgraded to a high efficiency unit.
- Weak Phosphoric Acid Plant – The existing plant in AZFC was based on the FISSION process with a capacity of 250 TPD, 28 – 30% P2O5 acid. The plant was operating at lesser than 50% capacity utilization and uncontrolled quality. Armaco provided the complete detailed engineering, site management services to overhaul the plant to a 290 TPD unit. The basic engineering licence was provided by Prayon.
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