ENERGY BALANCE AROUN RACTOR:

ENERGY BALANCE AROUND REACTOR:

Reference temperature: 25OC
As we know that,
Q = m Cp T
Heat in with acid from storage tank, Qin H3P04 = 0 at 25 0C
Heat in with acid from storage tank, Qin NH3

= 0 at 25C

Heat in with scrubber slurry at 75 0C,

Qin H3P04 = 410.94 x 372.6 x (75-25) / (24 x 3600)
= 88.6 Kcal / sec
Qin H2O = 523 x 100 x (75 25) / (24 x 3600)
= 302.6 Kcal / sec
Qin NH3 = 2.095 x 523.82 x (75 - 25) / (24 x 3600)
= 0.635 Kcal / sec
Qin Inert = 91.61 x 307.06 x (75 - 25) / (24 x 3600)
= 16.28 kcal / sec
Total heat in with slurry = 408.11 kcal / sec
Heat in by production of MAP in reactor.
NH3 + H3P04 ---------- NH4H2P04
Hr = 0.2963 x 106 kcal / ton
Total H3PO4 = H3PO4 from storage + H3PO4 from scrubber
=

702.7

362.03

= 1113.64 tpd.
NH3 REQUIRED
For 98 tpd H3P04, NH3 required = 17 tpd
For 1 tpd H3P04, NH3 required = 17 / 98
For 1113.64 tpd H3PO4, NH3 required = 0.173 x 1113.64
= 192.65 tpd
Total available in reactor = 253.3 + 2.09
= 255.39 tpd
Excess NH3 = 255.39 - 192.65
= 62.7 tpd

MAP PRODUCED:
98 tpd H3PO4 produce MAP = 115 tpd
1 tpd H3P04 produce MAP = 115 / 98
1113.6 tpd H3PO4 produce MAP = 1.17 x 1113.6
= 1306.8 tpd
Heat generated by
Production of MAP = 1306.8 x 0.2963 x 106 / (24 x 3600)
= 4481.5 Kcal / sec
TOTAL HEAT IN THE REACTOR

Qtotal = Qslurry + Qt MAP

= 408.11 + 448 1.5
= 4889.64 Kcal/ sec.
HEAT OUT WITH PRODUCT:
Qout MAP = 1172.94 x 1306.82 x (200-25) / (24 x 3600)
= 782.6 Kcal / sec
Qout with Excess NH3 = 62.64 x 523.82 x (200 - 25) / (24 x 3600)
= 66.37 Kcal / sec
With NH3 in vapors = 19.31 x 523.82 x (150 - 25) / (24 x 3600)
= 14.6 Kcal / sec
Qout Inerts

= 148.25 x 307.6 x (200-25) / (24 x 3600)

= 154.6 Kcal / sec

Sensiblc heat in water = 510 x 1000 x (150-25) / (24 x 3600)

= 737.84 Kcal / sec
Sensible heat in water = 132 x 1000 x (200 - 25) / (24 x 3600)
= 267.63 kcal / sec
Heat of vaporization of water = 5 10 x 0.5066 x l06 / (24 x 3600)
= 2990.34 Kcal / sec
Total Heat Out = 782.6 + 66.37 + 14.6 + 154.6 + 737.84 + 267.63 + 2990.34
= 5013.98

Accumulation = Heatin + Heatgenerated - Heatout - Heatconsumed

= 408.11 + 4481.5 5013.98
= -124.37 Kcal / sec
The net heat evolved from the reactor is 124.37 Kcal / sec, which shows that
reaction, is exothermic reaction.

HEAT BALANCE AROUND GRANULATOR

Total heat in from reactor stream

Qin MAP = 1306.82 x 295.65 x (200-25) / (24 x 3600)

= 782.5 Kcal / sec

Qin NH3 = 42.68 x 523.82 x (200 - 25) / (24 x 3600)

= 45.28 Kcal / sec
Qin H20 = 132 x 1000 x (200 - 25) / (24 x 3600)
= 267.3 Kcal / sec
Qin Inert = 248.25 x 307.6 x (200 - 25) / (24 x 3600)
= 154.6 Kcal / sec
Qin H2O vap = 510 x 1000 x (150-25) / (24x3600)
= 737.8 Kcal / sec
Qin NH3 vap = 19.31 x 523.82 x (150-25) / (24x3600)
= 14 .63 Kcal / sec
Total heat in from reactor = 2002.1 1 Kcal / sec ------------ (1)
HEAT GENERATED:
NH3 + NH4H2P04 ---------------- (NH4) 2HP04
115 tpd MAP produce DAP

Hf = 0.1387 x 106 Kcal / ton

= 132 tpd

1 tpd MAP produce DAP

= 132/ 115

1306.62 tpd MAP produce DA = 1.147 x 1306.62

= 1500 tpd

Heat generated by
Formation of DAP = 0.1 3784 x l06 x 1500 / (24 x 3600)
= 2393.05 Kcal/ sec
= Steam at 150 0C & 4.5 bar has Hg = 0.665 x 106 Kcal / sec
= Steam at 150 0C & 1.0 bar has Hg = 0.6414 x 106 Kcal / sec
So,
Heat generated per ton of steam = 0.13 x 105 Kcal / sec
Now,
Heat generated by 510 tpd = 0.136 x 10 5 x 510
= 80.27 Kcal / sec
HEAT CONSUMED BY RECYCLE STREAM:
Qcons DAP = 59089 x 325.76 x (105 - 25) / (24 x 3600)
= 1782.29 Kcal / sec
Qcons H20 = 23 x 1000 x (105 - 25) / (24 x 3600)
= 21.29 Kcal /sec .
Qcons Inerts = 21.33 x 307.06 x (1 05 - 25) / (24 x 3600)
= 606.44 Kcal / sec
Total heat consumed = 24 10.02 kcal / sec
HEAT OUT WITH PRODUCT:
Qout DAP = 5252.1 5 x 325.76 x (105 - 25) / (24 x 3600)
= 1584.2 Kcal / sec

H20 = 157.56 x 1000 x (1 05 - 25) / (24 x 3600)

= 145.8 Kcal / sec
Qout Inerts = 2381 x 307.06 x (105 - 25) / (24 x 3600)
= 676.95 Kcal / sec
Total heat out = 2406.0 Kcal / sec
Accumulation = Heatin + Heatgenerated - Heatout - Heatconsumed
= 2002.1 + 2473.27 2406.9 2410.02
= - 341.55 Kcal / sec
This shows that the overall process in the granulator is heat exiting
process. And the amount of heat that is exiting is 341.55 Kcal / sec .

HEAT BALANCE AROUND COOLER:

HEAT IN:
Qin DAP = 5252.15 x 325.76 x (105-25) / (24 x 3600)

= 1584.2 Kcal/ sec

Qin H2O = 157.56 x 1000 x (105-25) / (24 x 3600)
= 145.8 Kcal / sec
QInerts

= 2381 x 307.06 x (105 - 25) / (24 x 3600)

= 676.95 Kcal / sec

Total amount of heat = 2406.9 Kcal / sec

HEAT OUT:
Qout DAP = 5152.1 x 325.76 x (35 - 25) / (24 x 3600)
= 194.25 KcaI / sec
Qout H2O = 82.74 x 1000 x (35-25) / (24 x 3600)
= 9.57 Kcal / sec
Qout Inerts = 2381.25 x 307.06 x (35-25) / (24 x 3600)
= 84.62 Kcal/ sec
Total amount of heat out = 288.44 Kcal / sec
Accumulation = Heatin + Heatgenerated - Heatout - Heatconsumed
= 2406.9 + 0 - 288.84
= 2118.45 Kcal / sec
This is the amount of heat that is removed in the cooler which was entered with the
product from granulator. So the heat removed from the material in the cooler is
2118.45 Kcal / sec.

ENERGY BALANCE AROUND SCRUBBER:

HEAT OUT IN PRODUCT:

Qout H3PO4 = 410.94 x 372.6 x (75 - 25) / (24 x 3600)

= 88.6 Kcal / sec
Qout H20 = 523 x 1000 x (75 - 25) / (24 x 3600)
= 302.6 Kcal / sec
Qout NH3 = 2.093 x 523.82 x (75 - 25) / (24 x 3600)
= 0.63 Kcal / sec
Qout Inerts = 91.61 x V x 307.06 x (75 -25) / (24 x 3600)
= 16.27 Kcal / sec
Total heat out in product = 407.5 Kcal / sec

HEAT IN:
From vapors,
Qin H20 = 508.3 x 1000 x (105 - 25) x (24 x 3600)
= 470.64 Kcal / sec .
Qin NH3 = 2.1 x 523.82 x (105 - 25) / (24 x 3600)
= 1.0185 Kcal / sec
Total heat in = 471.65 Kcal / sec
Net heat = heat in - heat out
= 471.65 - 407.5
= 64.15 kcal / sec.