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How our Spray
Drying technology reduced fuel costs by 50% at Sabuni (SDL) Tanzania
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.
Aswan Fertilisers & Chemicals Ltd. (Green-field Superphosphate & NPK fertiliser project in Aswan, Egypt)
Armaco provided site management, detailed Engineering, isometric drawings, erection and commission for the green field SSP & NPK plant utility support system.
Birla Copper (A Copper project at Dahej, India, with Phosphate Fertiliser as a by-product).
A 325tpd phosphoric acid plant was running with chronic uptime, quality, and technical efficiency problem almost in every segment of its manufacturing steps. ARMACO did performance evaluation, identified problems and devised corrections & measures to improve efficiency across some important process steps like Rock Weigh Feeder to Ball Mill, alignment of Belt Filter with respect to its Weir belt & Vacuum box, Reactor gas duct, Fluorine scrubber & its fan capacity. It also studied and demonstrated the feasibility of fluorine effluent recovery as AlF3 and/or as CaSiF6.
ARMACO also did techno-feasibility study to increase capacity of the Phosphoric Acid plant from 335 tpd to 650 tpd.
How ARMACO used Spray Drying technology to double capacity and halve fuel costs at Sabuni (SDL) Tanzania.
Challenge
- Enhance capacity
- Reduce fuel costs
Results
- Capacity was doubled
- Fuel consumption was reduced by 50%
- Plant automation allowed better controls on product quality
- Loss of powder were reduced by introduction of customized dust handling / recycling systems
How ARMACO used its utility optimization technology to reduce costs and increase the yield of Rallis' gelatin unit by up to 20%.
Challenge
- Reduce Gelatin manufacturing process costs were significantly escalating
Results
- Reduce steam consumption per tonne of product by 33%
- Reduce water consumption per tonne of product by 50%
- Process corrections to ensure increased yield of better quality product by 15-20%
How ARMACO used its Phosphoric Acid expertise to help AZFC Egypt double its phosphoric acid output with no additional equipment.
Challenge
- To ensure the plant matched best-in-class global performance with the existing machinery. Several dissolved solid impurities were found in the acid
Results
- Double Capacity
- Upgrading
- Enhanced capacity utilization
- Triple super phosphate to be manufactured in-house using the concentrated acid
How ARMACO doubled capacity for Sunshine Oleochem using ARMACO's fatty acid expertise
Challenge
- Wanted a cost effective way of doubling the capacity
Results
- Completed the detailed engineering design for a 50TPD glycerol distillation plant using Sulzer structured packaging
- Operating at rated capacities producing IP grade quality
- Simulates fat splitting for True Plant Yields
- Covers the full range of feed stocks and operating conditions
- Benchmarks results with best-in-class
- Identifies areas for plant optimization; or simulates new plant design
- Develops a complete Splitting & Distillation package
- Utilizes Inbuilt Data Bank & calculations for complete DOS with minimal inputs
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