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PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 1 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

DESIGN BASIS

REVISION CONTROL PAGE


MAIN DOCUMENT
REV. DATE DESCRIPTION COMMENTS
00 06-May-2013 Issue for Review
01 20-Sep-2013 Issued for Approval

ATTACHMENTS
DOCUMENT CODE DESCRIPTION REV.

TEMPLATES
DOCUMENT CODE DESCRIPTION REV.

PREPARED: REVIEWED: APPROVED:


B. García M. Carrasco J.R.Ferrer

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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INDEX

1. INTRODUCTION 4
2. ABBREVIATIONS 4
3. GENERAL 4
3.1 PROJECT OVERVIEW 4
3.2 PROJECT IDENTIFICATION 5
3.3 UNITS AND MEASUREMENT SYSTEM 5
3.4 DESIGN CODES AND STANDARDS 7
3.4.1 Main equipment 8
3.4.2 Instrumentation 8
3.4.3 Piping and valves 8
3.4.4 Civil works 9
3.4.5 Electricity 9
3.5 SOIL BEARING CAPACITY 9
4. PROJECT SPECIFICATION 9
4.1 PRODUCTION CAPACITY 9
4.2 DESIGN ON-STREAM FACTOR 9
4.3 TURN-DOWN RATIO 9
4.4 SPECIFICATION OF PRODUCTS 9
4.5 SPECIFICATION OF RAW MATERIALS, CHEMICALS, AUXILIARIES AND
UTILITIES 11
4.5.1 Specification of raw materials 11
4.5.2 Specification of chemicals 13
4.5.3 Specification of auxiliaries and utilities 14
4.6 PROCESS DESCRIPTION 17
4.7 SCOPE OF PROJECT AND BATTERY LIMITS 19
4.8 SUMMARY OF GUARANTEE FIGURES 20
4.8.1 Guarantees on production capacity 21
4.8.2 Guarantees on production quality 21
4.8.3 Guarantees on emission 22
4.8.4 Guarantees on raw material and utilities consumption 22
4.9 PERSONNEL REQUIREMENTS 24

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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5. SITE–RELATED DESIGN BASIS 24


5.1 SITE DESCRIPTION 24
5.2 CLIMATOLOGIC DATA 24
5.3 BASIC SITE – RELATED DATA FOR CIVIL DESIGN 25
5.4 GPCB NORMS FOR POLLUTION AND EFFLUENTS 25
5.5 ENVIRONMENTAL PROTECTION REQUIREMENTS 26
5.5.1 Gaseous effluent treatment and emissions 26
5.5.2 Liquid effluents 27
5.5.3 Solid wastes 27
5.5.4 Noise limits 28
5.6 SAFETY AND HEALTH REQUIREMENTS 28
5.6.1 Chemical hazards 29
5.6.2 Equipment hazards 33
5.6.3 Production work safety 35
5.6.4 Protective equipment 37
5.6.5 Fire and explosion prevention and protection 38
ANNEX I: MATERIAL SAFETY DATA SHEETS 42
ANNEX II: BLOCK FLOW DIAGRAM 43

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 4 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

1. INTRODUCTION

This document summarizes the Design Basis of the DAP/NPK Plant (D-Train) Project at
SIKKA Unit of GSFC.

2. ABBREVIATIONS

The following terms are abbreviations and acronyms in use within the present document. For
measuring units see section 3.3. and for national and international codes and standards see
section 3.4
CPCB Central Pollution Control Board
CS Carbon Steel
DAP Di-ammonium Phosphate
DG Diesel Generating
E.O.T. Electrical Overhead Travelling (for cranes)
FBC Fluidized Bed Cooler
GPCB Gujarat Pollution Control Board
GSFC Gujarat State Fertilizers & Chemicals Limited
GTR Guarantee Test Run
ISBL Inside Battery Limits
NPK Nitrogen Phosphorous Potassium
OISD Oil Industry Safety Directorate, Gov. of India
OSBL Outside Battery Limits
PLC Programmable Logic Controller
SS Stainless Steel
TBD To be determined
UPS Uninterruptible Power Supply

3. GENERAL

3.1 PROJECT OVERVIEW

Gujarat State Fertilizers & Chemicals Limited (GSFC) has a fertilizer manufacturing
plants at Sikka Unit, located at P.O. Motikhavadi, Jamnagar District, State of Gujarat,
with three installed trains of di-ammonium phosphate (DAP) with existing capacities of
1320 MTPD (Train A&B) and 1650 MTPD (Train C).

GSFC intends to augment DAP / NPK capacity at Sikka Unit by installing a new process
plant comprising a single additional 4th train (train D) using only pipe reactor system, for
the production of DAP/NPK fertilizers.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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3.2 PROJECT IDENTIFICATION

Project Name Di-Ammonium phosphate / NPK fertilizer production


technology for a new 1650 MTPD DAP & 1870 MTPD NPK Granulation
plant.
Customer Name Gujarat State Fertilizers & Chemicals Limited (GSFC).
Plant / Location Sikka, Dist. Jamnagar, Gujarat, India.

3.3 UNITS AND MEASUREMENT SYSTEM

The International System of Units (S.I.) will be the basis of the measurement system.
Exceptions are to be made where applicable (i.e. line and valve sizes to be identified in
inches, pressure in kg/cm2, etc.).

Angle º
Area, Surface Area m2
Braking Tension kg/cm
Bulk Density kg/m3
Capacity m3, Nm3/h, Am3/h, t/h
Concentration %vol, %w, ppm (mg/kg), g/Am3
Corrosion allowance mm
Current A
Density kg/m3
Diameter m, mm, inches
Efficiency %
Electric capacitance F
Electric charge C
Electric resistivity Ω·cm
Electrical conductivity µS/cm
Energy kWh, kJ, kcal
Enthalpy, latent heat kcal/kg, KJ/kg
Frequency Hz
Fouling factor m2hr0C / kcal
Granulometry, particle size mm
Granulometry distribution %
Hardness kg·m/s2

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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Heat kW
Heat duty kcal/h
Heat transfer coefficient kcal/hm2ºC
Humidity %, kg/kg
Insulation Thickness mm
Lenght m, mm
Mass, weight kg, t, metric tone (MT)
Mass flow rate kg/h, t/h (also referred as TPH)
Molecular weight kg/kmol
Net calorific value (1) kcal/Sm3
Noise / sound level dB(A)
Nominal Pipe Size inches
Piping Thickness Schedule (Sch)
Power kW
Pressure (2) kg/cm2g, kg/cm2a, mm wc
Pressure drop kg/cm2, mm wc
Rotational speed rpm
Slope º, mm/m
Specific Heat kcal/kg·ºC, kJ/kg·ºC
Specific Volume m3/kg
Surface Tension N/m
Temperature ºC
Thermal Conductivity Kcal/hrm0C
Time s, min, h
Vacuum mmWC
Vapor pressure mmWC
Velocity m/s, m/min
Viscosity (dynamic / kinematic) cP (mPa·s) / cSt
Voltage V, kV
Volume (3) m3, Nm3, Sm3
m3/h (liquid),
Volumetric flow rate (3, 4)
Nm3/h (gases and vapors)

(1) Standard conditions for gases and vapors are defined as 15ºC and 1.033 kg/cm2a.
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including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

(2) Preferably kg/cm2g to be used. Gauge pressure is indicated with the suffix “g”.
Absolute pressure is indicated with the suffix “a”. Where suffix is not indicated,
gauge pressure will be considered.
(3) Normal conditions for gases and vapors are defined as 0.0 ºC and 1.033 kg/cm2a.
(4) Steam flow rate will be normally given in kg/h.

The following prefixes will be used:

MULTIPLICATION FACTOR PREFIX SYMBOL


15
1 000 000 000 000 000 = 10 peta P
1 000 000 000 000 = 1012 tera T
9
1 000 000 000 = 10 giga G
1 000 000 = 106 mega M
3
1 000 = 10 kilo k
100 = 102 hecto h
-2
0.01 = 10 centi c
0.001 = 10-3 milli M
-6
0.000 001 = 10 micro µ

3.4 DESIGN CODES AND STANDARDS

This section summarizes the codes, standards and statutory rules and regulations to be
followed in the GSFC D-Train DAP/NPK Plant Project at SIKKA Unit of GSFC. At least
the design codes and standards included in this section (latest editions to be followed)
shall have considered.

Unless otherwise specifically mentioned, or Indian Standards, codes and/or statutory


rules and regulations are required, the following internationally recognized codes and
standards of latest edition will be applied in design, engineering fabrication,
manufacturing, assembling, inspection and testing of equipment and materials.

In case of conflicts among codes/standards and the technical specifications, the technical
specifications shall govern.

The latest editions of the codes and standards with their addenda are those valid at the
date of the Contract.

Abbreviation of codes, standards, and organization are as follows:


ANSI American National Standards Institute, USA
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including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

API American Petroleum Institute, USA


ASME American Society of Mechanical Engineers, USA
ASTM American Society of Testing and Materials, USA

3.4.1 Main equipment

Mechanical design code of pressure vessels, heat exchanger, towers:

On-shore equipment International or Indian standards


Off-shore equipment (key equipment) AD2000, TEMA, ASME
Conformity assessment of Off-shore Pressure Equipment Directive (PED)
equipment
Pumps ISO and manufacturer’s specification
API 610 for defined items
Blowers Manufacturer standards or API 673
Screw conveyors UNE 58-207-89 / ISO 1050
On-shore equipment International or Indian material standards or
ASTM/ASME
En DIN and-or ASTM/ASME

3.4.2 Instrumentation

General design codes:

IEC (International Electrical Commission)


ISA
ISO
Symbols ISA S 5.1
Electronic instruments ICE or other of manufacturing’s country of
origin
PLC based Emergency Shutdown TUV, VDE Down system (E.S.D.S.),
System IEC 61508
Other instruments Manufacturer’s standards

3.4.3 Piping and valves

All material to ASME standard or equivalent, design, fabrication will refer to common
standards. Flanges connection standard: ANSI/ASME for steel.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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3.4.4 Civil works

Basic/extended basic design according to EURO CODES, with application of


International or Indian standards.

3.4.5 Electricity

Basic/Extended basic design according to DIN, IEC and VDE standards, with
application of International or Indian standards.

3.5 SOIL BEARING CAPACITY R1

The Net Safe Bearing Capacity is 36 T/m2. (Ref. from Page No. 27, Review of Soil
Investigation Report.)

4. PROJECT SPECIFICATION

4.1 PRODUCTION CAPACITY

The design production capacity for the NPK/DAP plant will be 1650 MTPD (75 TPH) for
DAP grade and 1870 MTPD (85 TPH) for NPK grades14-35-14, 10-26-26, and 12-32-16.

4.2 DESIGN ON-STREAM FACTOR

Plant will be designed for 7260 on-stream hours in a year with 22 hours of operation per
day, at the rated capacity.

4.3 TURN-DOWN RATIO

Each pipe reactor is expected to operate in a turn-down ratio of 80% to 110%, and
as the unit is provided with two pipe reactors, each one for half production load,
the overall unit has an expected turndown ratio from 40% to 110%.

4.4 SPECIFICATION OF PRODUCTS

The plant will produce three specific grades of granular fertilizer NPK (14-35-14,10-26-26,
12-32-16) and granular di-ammonium phosphate (DAP) fertilizer (18-46-0). Tolerance
limits for nitrogen, phosphate and potash contents in all the above mentioned
products shall be as stated in section 4.8.

Once plant operates at design conditions with utilities and raw materials under
specification, the quality and specifications of the fertilizer products will be the following:

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 10 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

• DAP:
Formulation (grade) 18-46-0
Total Nitrogen Min. 18% (w/w)
Nitrogen, ammoniacal form Min.18% (w/w)
Water soluble phosphates (as P2O5) Min.41% (w/w)
Total phosphates (as P2O5) Min.46% (w/w)
Moisture content Max.1.5% (w/w)
Particle size 1 – 4 mm: 90% w/w min.
< 1 mm: 5%w/w max.
• NPK:
Formulation (grade) 14-35-14
Total Nitrogen Min.14% (w/w)
Nitrogen, ammoniacal form Min.14% (w/w)
Potash (as K2O) Min.14% (w/w)
Water soluble phosphates (as P2O5) Min.29.0% (w/w)
Total phosphates (as P2O5) Min.35% (w/w)
Moisture content Max.1.0% (w/w)
Particle size 1 – 4 mm: 90% w/w min.
< 1 mm: 5%w/w max.
• NPK:
Formulation (grade) 12-32-16
Total Nitrogen Min.12% (w/w)
Nitrogen, ammoniacal form Min.12% (w/w)
Potash (as K2O) Min.16% (w/w)
Water soluble phosphates (as P2O5) Min.27.2% (w/w)
Total phosphates (as P2O5) Min.32% (w/w)
Moisture content Max.1.0% (w/w)
Particle size 1 – 4 mm: 90% w/w min.
< 1 mm: 5%w/w max.
• NPK:
Formulation (grade) 10-26-26
Total Nitrogen Min.10% (w/w)
Nitrogen, ammoniacal form Min.10% (w/w)
Potash (as K2O) Min.26% (w/w)
Water soluble phosphates (as P2O5) Min.22.1% (w/w)
Total phosphates (as P2O5) Min.26% (w/w)
Moisture content Max.1.0% (w/w)
Particle size 1 – 4 mm: 90% w/w min.
< 1 mm: 5%w/w max.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 11 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

4.5 SPECIFICATION OF RAW MATERIALS, CHEMICALS, AUXILIARIES AND


UTILITIES

4.5.1 Specification of raw materials

The following raw materials are required to be fed to the plant. The conditions are
referred at the battery limit of the D-Train at grade level.

• Ammonia:

State Liquid
Operating Temperature – 33ºC
Operating Pressure 11 – 12 kg/cm2g
Design Temperature -33 / 75 ºC
Design Pressure 41 kg/cm2g
Chemical analysis NH3 (min) 99.5 ± 0.5% wt.
Water content (max) 0.5% wt.
Oil content (max) 10 ppm (weight)

• Phosphoric acid (merchant grade):

State Liquid
P2O5 50 – 54% wt.
H2SO4 (as SO4=) 4.5% wt. max
CaO 0.6% wt. max
Al 2O3 0.1 – 2.0% wt.
Fe2O3 0.2 – 1.9% wt.
R2O3 (Al2O3 + Fe2O3) 3.75%wt. max
F 1.8%wt. max
MgO 1.6%wt. max
Cl 250 ppm (weight)
Suspended solids 1.5 – 2.5% wt.
Specific gravity 1.63 – 1.73
Operating Temperature Ambient
Operating Pressure 4.5 kg/cm2g
Design Temperature 75ºC
Design Pressure 6.68 kg/cm2g

Mass balance will be carried out and issued at a concentration of 52% P2O5 and
design will be based on 50%. A concentration of 54% P2O5 will be considered for
pump design.
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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• Sulphuric acid:

State Liquid
Chemical analysis H2SO4 (min) 98 ± 1.0% wt.
Operating Temperature Ambient
Operating Pressure 4 kg/cm2g
Design Temperature 75ºC
Design Pressure 5.6 kg/cm2g

Size of pipeline will be 2”.

• Potash:

K2O content 60%wt. min.


Moisture 0.5%wt. max
Na as NaCl 3.5%wt. max, on dry basis
Biuret 1.5% max
Bulk density 1220 – 1350 kg/m3
Pressure / temperature Atmospheric / Ambient
Not less than 65 cent of the
material shall pass through 1.7
Particle size
mm IS sieve and be retained on
0.25 mm IS sieve

• Filler:

Type Bentonite / Clay


Size 0.17 mm to 1 mm, 90% min
Bulk density 1200 kg/m3
Pressure / temperature Atmospheric / Ambient
Conditions Free flow and without lumps
Temperature Ambient
Screen analysis: + 1 mm 1% max
– 0.25 mm 40% max
Moisture 8 – 10%wt.
Acid insoluble as silica (SiO2) 40 – 80%wt.
Iron as Fe2O3 25% max
Aluminum as Al2O3 20% max
Calcium as CaO 1 – 2%wt.
Magnesium as MgO 4% max
Carbonate and bicarbonate as 9% max
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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CaCO3
Na2O 2 – 4%w
K2O 0 – 1%w

• Micronutrients: different micronutrients (zinc in the form of zinc sulphate, boron


as borex) can be added to the production process if required to improve fertilizer
quality. Supply in bags.

• Zinc Sulphate Heptahydrate (21%) FCO Grade– Free Flowing Powder


1. Zi nc (as Zn) : 21.0 wt.% (min)
2. Matter insoluble in water : 1.0 wt.% (max)
3. Lead (as Pb) : 0.003 wt.% (max)
4. Copper (as Cu) : 0.1 wt.% (max)
5. Magnesium (as Mg) : 0.5 wt.% (max)
6. Sulphur (as S) : 10.0 wt.% (min)
7. Cadmium (as Cd) : 0.0025 wt.% (max)
8. Arsenic (as As) : 0.01 wt.% (max)
9. pH not less than 4.0

• Borax (Agriculture Grade) (as per FCO 1985)


(Sodium Tetraborate) – Free Flowing Powder
1. Content of boron as (B) : 10.5 wt.% (min)
2. Matter insoluble in water : 1.0 wt.% (max)
3. pH : 9.0-9.5
4. Lead (as Pb) : 0.003 wt.% (max)

4.5.2 Specification of chemicals

The following chemicals are required to be fed to the plant.

• Defoamer:

State Liquid
Type / composition Fatty acid oil
Supply In barrels / carboys.
Specific gravity 0.87 – 0.93
Viscosity 20 – 30 cP

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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• Coating agent: the coating oil shall have the following specifications or equivalent
specifications depending on availability in India. The following specification is
tentative and may vary with the supplier.

State Liquid
Type Fatty / amine oil
Stearyl amine 15 – 18%
Stearic acid 8 – 10%
Soyalecithin 6 – 8%
Furnace oil 75 – 80%
Specific gravity 0.9 – 1.0
Viscosity 60 cP
Supply In barrels / carboys.
4.5.3 Specification of auxiliaries and utilities

The following utilities are required to be fed to the plant. The conditions are referred at
plant battery limit at grade.

• Steam:

Specification Saturated steam


Operating Pressure 10 kg/cm2g
Operating Temperature Saturation at 10 kg/cm2g
Design Pressure 15 kg/cm2g / Full Vacuum
Design Temperature Saturation at 15 kg/cm2g

The steam condensate will be recovered and collected at the D-Train and,
after a conductivity analysis, can be pumped to the soft water tank of the
existing boiler house. Pumping calculations will consider a distance of 200
m from the D-Train to the soft tank of boiler house, which operates at
atmospheric pressure, and 10 m of pipe rack elevation.

• Process / service water:

Turbidity NIL
pH 7.5 – 8.5
P value: 0 – 15 ppm (weight)
Alkalinity as CaCO3
M value: 100 – 330 ppm (w)
Total hardness as CaCO3 570 ppm
Ca hardness as CaCO3 90 – 165 ppm
Mg hardness as CaCO3 30 – 125 ppm
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

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Chloride as Cl 225 ppm


SO4 225 ppm
Total dissolved solid 1000 ppm
Conductivity 1800 micro mho/cm
Sodium as Na 98 ppm
Free chlorine as Cl2 NIL
Fluorine as F 0.6 ppm
Operating Pressure 3 kg/cm2g
Operating Temperature Ambient
Design Temperature 75ºC
Design Pressure 5 kg/cm2g

• Potable water:

Specification Standard
Operating Pressure 3 kg/cm2g
Operating Temperature Ambient
Maximum water temperature 38ºC
Design Temperature 75ºC
Design Pressure 4 kg/cm2g

• Fire water:

Operating Pressure 7 kg/cm2g


Operating Temperature Ambient
Design Temperature 75ºC
Design Pressure 10 kg/cm2g

• Plant air:

Specification Dry and dust free


Operating Pressure Min. 5.0 kg/cm2g R1

Operating Temperature Ambient


Design Temperature 75ºC
Design Pressure 7 kg/cm2g
Dew point ---

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

• Instrument air:

Specification Dry, oil free


Operating Pressure Min. 5.0 kg/cm2g R1
Operating Temperature Ambient
Design Temperature 75ºC
Design Pressure 7 kg/cm2g
Dew point – 40ºC at atmospheric pressure

• Fuel (natural gas):

Component Range
Methane Greater than 80%
Ethane Less than 8%
Propane Less than 3.3%
iC4 <2% by volume
iC5 + nC5 Less than 0.25%
Inerts 10% vol, max
Free water 112 kg / MMSCM
Sulphur Max. 10 ppm (weight)

Parameter Value
Net calorific value 8200 kcal/Sm3, min
Specific gravity 0.65
Operating Temperature 35ºC
4 kg/cm2g downstream reducing
Operating Pressure
valve provided by GSFC.
Design Temperature 75ºC
Design Pressure 6 kg/cm2g

• Nitrogen gas: will be available at NPK/DAP plant battery limit by cylinders, for
pipes flushing purpose.

• Electric Power:
Process area:

High voltage 11 kV ± 5 %
Low voltage 415 V ± 10 %
R1
Phase 3

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including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 17 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

Frequency 50 Hz + 2 to -6 %

Combined variation of voltage and frequency is 10% absolute (Refer page no 6


of 7, Electrical Power specs of Appendix-III, Basis of Design of Contract
Document)

Distribution: Voltage and phase:

Service Power range Voltage Phase Remarks


≤150 kW 415 V AC, 50Hz 3 phase
Motors > 150 kW and
3.3 kV AC, 50 Hz 3 phase
< 750 kW
Input: 3 phase.
Lighting 415 V AC, 50Hz Output: single Note 1
phase 230 V
PLC 110 V L–N From UPS

NOTE 1: With lighting transformer. Transformer type: Oil-Immersed


(Distribution).

Fault level :

– For 11 kV supply: - 26.24 kA for 1 second.


– For 3.3 kV supply: - 26.24 kA for 1 second.
– For 415 V supply: - 50 kA for 1 second.

4.6 PROCESS DESCRIPTION

A detailed description of the process can be found in document No.A4-120010-F-201


(“Process Description”). This section only highlights the main features of the ESPINDESA
process for the DAP/NPK plant.

The plant will be capable to produce NPK or DAP products as required, according to a
changeover procedure; pipe reactor operation will be adjustable to both NPKs or DAP
grade, giving the system a great flexibility.

The ESPINDESA process for the production of DAP and NPK fertilizers is based on the
ammonization of phosphoric acid. The neutralization between the gaseous ammonia and
liquid phosphoric acid as raw materials proceeds according to the following reactions:

NH3 + H3PO4  NH4H2PO4 (MAP) + Heat


NH3 + NH4H2PO4  (NH4)2HPO4 (DAP) + Heat

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 18 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

These reactions are instantaneous and strongly exothermic, and the released heat of
reaction is used to vaporize part of the water content of the phosphoric acid fed as raw
material to the plant.

The key steps of the DAP/NPK manufacture according to ESPINDESA design are the
following:
– Reaction and granulation.
– Solids handling (drying, screening).
– Product conditioning (cooling, coating).

The neutralization of phosphoric acid to DAP/NPK is performed under pressure in a pipe


reactor with unique pipe design, to obtain a concentrated melt of DAP/NPK which is sent
to the granulator to get in contact with the recycle material from the upstream sections,
consisting of pulverized oversize product, product fines and dust, being wetted particles
together to form granules. Additional solid raw materials (filler, micronutrients, potash) are
fed to the granulator when required together with the recycle.

Inside the granulator the ammonium phosphate melt crystallizes over the bed of solids
and leads to the manufacture of round and hard granules. This product is discharged to a
rotary drier where the moisture content is reduced by drying with hot air. The dry solids
are screened to separate proper sized product from the oversize and fine material, and
the on-size solids are cooled with air in a fluidized bed cooler, and coated before being
sent to storage, while the oversize granules are crushed, mixed with the undersize
granules and recycled to the granulator.

Apart from the above mentioned key process steps, some additional steps are required to
develop the ESPINDESA process:

– Raw material handling, comprising the reception from battery limit, storage,
distribution and dosing systems.

– Acid Preparation, to dilute the merchant phosphoric acid coming from battery limit
allowing the reaction to take place in a safe manner and leading to on-spec
production. The dilution of merchant phosphoric acid is achieved in a dust
scrubber, where the acid also fixes most of the ammonia evolved in the dryer and
dissolves most of the dust entrained in the exhaust gasses.

– Ammonia Preparation. Liquid ammonia from battery limit is vaporized in a kettle


type vaporizer (and also in an auxiliary ammonia vaporizer when required) prior to
be sent to reaction. The steam evolved in the reactor and entrained in the process
air in the granulator is sent to a contact condenser to produce a hot water
stream that will be used in the ammonia vaporizer as heating medium.

– Fluidized Bed Cooler Air Conditioning, to adjust both the temperature and the
relative humidity of atmospheric air to be used in the fluidized bed cooler.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 19 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

– Dust recovery system. Exhaust gases from the dryer and the dust collection
system provided for all the plant area are firstly de-dusted in high efficiency
multiple-cyclone separators to recycle the recovered fertilizer dust into the
process. Gases are further cleaned in a dust scrubber prior to be discharged to
atmosphere, in order to fulfil with the required emission levels in NH3, dust and
fluorine.

– Ammonia gases recovery. Ammonia-rich gases from the granulator are sent to a
two-stage ammonia scrubber to recover the ammonia prior to be sent to the
contact condenser. Phosphoric acid is used as scrubbing liquid, and as it fixes
the ammonia it gets partially neutralized.

The D-Train process for the production of NPK/DAP can be divided in three sections or
areas, as follow:

1. Raw material section, which is considered from the battery limit supply of solid raw
materials up to the discharge of the feeding conveyor to the different raw material
hoppers of the D-Train (first stage of the raw material handling)

2. Wet section, comprising the scrubbing systems, the defoamer system and the liquid
raw material feeding to the reactor.

3. Dry section, comprising all of the systems not included in previous raw material
section or wet section.

4.7 SCOPE OF PROJECT AND BATTERY LIMITS

A new process plant for the production of NPK / DAP (Train D) is to be installed at Sikka
Unit, for the production of DAP and NPK (fertilizer grades 14:35:14, 10:26:26 and
12:32:16) on swing basis.

The systems included within battery limits (ISBL) are only those related to the DAP/NPK
granulation plant, D-Train. The NPK/DAP plant will be integrated with the existing
facilities. For both incoming and outgoing lines to/from the new NPK/DAP plant,
comprising raw materials, utilities, products, etc., interconnections between the new plant
and existing facilities OSBL shall be provided by HDO.

Not any ancillary systems, components or supporting equipment outside the battery
limits of the process plant (OSBL) will be included, e.g., storage and transfer systems
(tanks, pumps, conveyors, silos, bagging trains, truck loading systems, reclaiming
systems, etc) for handling of liquid and/or solid raw materials and products from/to
existing areas such as raw material storage area or product storage and bagging areas.
OSBL utility systems, e.g. instrument and plant air system, raw water and potable water
systems, steam and condensate system, fire fighting system, natural gas system, or
wastewater, sanitary and storm water sewers, shall be supplied by HDO.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 20 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

Only a conveying system comprising one (1) belt conveyor will be included ISBL for the
transport of solid raw materials from raw material to the dosing hoppers of the D-Train.

The plant will be provided with a plant sump and an effluent sump inside
battery limits. Under normal running conditions, the plant shall produce zero
liquid effluents as all the liquid drains from piping, equipment and other
components will be collected in the plant sump to be pumped into the
process.

All the steam condensate from the NPK/DAP plant will be collected in a
condensate tank and the condensate with acceptable conductivity will be
pumped to the soft water tank of the existing boiler house. Otherwise any
contaminated condensate will be routed to the effluent sump tank to be sent
back to D-Train plant. Trap condensate will be drained.

The storm water will be discharged to nearest existing storm water drain and
the sewerage / sanitary water will be discharged to nearest existing sewerage water
drain. Discharges will be throughout channels to the existing drainage systems.

All the incoming and outgoing liquid lines from OSBL to the NPK/DAP plant will be
provided at the unit battery limit with double isolation block valves with an spectacle blind
and drain (bleed).

Further details will be included in document No.L-08170-200-BL-001 (“Battery Limit


Conditions”).

4.8 SUMMARY OF GUARANTEE FIGURES

ESPINDESA guarantees that the facility shall be capable of complying with the
guaranteed figures as stipulated in this section.

The Guarantee Test Run (GTR) will be conducted for five (5) consecutive days. The
detailed procedure for carrying out GTR will be mutually agreed upon between Owner
and Licensor for two of the agreed fertilizer grades of NPK and DAP.

An interruption time of two (2) hours per day of the performance test for reasons
attributable to Licensor will be accepted.

The methods of measurement and analysis together with the acceptable tolerances for
chemical analysis and measuring instruments or equipment related to these methods
shall be as per FCO.

The instruments will be calibrated before starting of Guarantee Test Run and the
instruments error will be mutually agreed.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 21 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

Licensor will guarantee following parameters of plant provided plant is run on continuous
and stable manner using adequate quantities of raw material and utilities both shall be
under specification and as per Licensor’s Operating Manual.

4.8.1 Guarantees on production capacity

Licensor guarantees the production capacity of various fertilizers from the DAP/NPK
granulation plant will be as follows:

Grade Total product for 1 day


DAP (18-46-0) 1650 MT
Grade Total product for 2 days
NPK 10-26-26 3740 MT
NPK 12-32-16 3740 MT
NPK 14-35-14 3740 MT

4.8.2 Guarantees on production quality

When the plant is running at design capacity, under design conditions, the guaranteed
product quality is as follows:
NPK NPK NPK DAP
Parameter
12-32-16 14-35-14 10-26-26 (18-46-0)
Total nitrogen (%weight, min.) 12 14 10 18
Total phosphates as P2O5
32 35 26 46
(%weight, min)
Water soluble phosphates as
27.2 29 22.1 41
P2O5 (%weight, min)
Potash as K2O (%weight, min) 16 14 26 ---

Moisture (%weight, max) 1.0 1.0 1.0 1.5

– Screen analysis: not less than 90% of the material shall pass through 4 mm IS
sieve and not more than 5% shall be below 1 mm IS sieve.

– Tolerance limits for nutrient composition:

NPK NPK NPK DAP


Nutrient
12-32-16 14-35-14 10-26-26 (18-46-0)
N ± 0.5 ± 0.5 ± 0.5 ± 0.5
P2O5 ± 0.6 ± 0.6 ± 0.6 ± 0.5

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 22 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

K2O ± 0.6 ± 0.5 ± 0.6 ---


11.5/12.5 – 13.5/14.5 – 9.5/10.5 – 17.5/18.5 –
Grade
31.4/32.6 – 34.4/35.6 – 25.4/26.6 – 45.5/46.5 –
tolerance
15.4/16.6 13.5/14.5 25.4/26.6 0

Tolerance is for both plus (+) and minus (–) side of each nutrient composition
subject to maximum of 2.0% for all combined nutrients. The average formulation
shall be between the minimum and maximum composition.

4.8.3 Guarantees on emission

• Liquid effluent: the liquid effluent will not be generated on continuous basis while
the plant is running on continuous basis under normal condition.

• Gas emission: when the plant is running at design capacity, under design
conditions, gaseous emission will have following limits:

– Particulate matter: 50 mg/Nm3.


– Ammonia: 50 mg/Nm3.
– Fluorine: 10 mg/Nm3.
– NOx : 50ppm
– SOx : 100ppm
4.8.4 Guarantees on raw material and utilities consumption

Licensor guarantees the raw material consumption and utility consumption within the
battery limit of the DAP/NPK plant while producing fertilizer at rated capacity will be as
follows:

GRADE DAP (18-46-0)


Maximum consumption
Ammonia (100%), kg/MT 222
P2O5 (100%), kg/MT 463
Potash (60% K2O), kg ---
Process Power, kWh/MT 42
Process Steam, kg/MT 30
3
Natural Gas, Sm /MT, density 0.64 9.5
3
Process water, m /MT 0.3

GRADE NPK 14-35-14


Maximum consumption
Ammonia (100%), kg/MT 171
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 23 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

P2O5 (100%), kg/MT 352


Potash (60% K2O), kg 236
Process Power, kWh/MT 41
Process Steam, kg/MT 30
3
Natural Gas, Sm /MT, density 0.64 10.15
3
Process water, m /MT 0.3

GRADE NPK 12-32-16


Maximum consumption
Ammonia (100%), kg/MT 147
P2O5 (100%), kg/MT 323
Potash (60% K2O), kg 269
Process Power, kWh/MT 41
Process Steam, kg/MT 30
3
Natural Gas, Sm /MT, density 0.64 10.15
3
Process water, m /MT 0.25

GRADE NPK 10-26-26


Maximum consumption
Ammonia (100%), kg/MT 123
P2O5 (100%), kg/MT 262
Potash (60% K2O), kg 437
Process Power, kWh/MT 41
Process Steam, kg/MT 30
3
Natural Gas, Sm /MT, density 0.64 10.15
3
Process water, m /MT 0.25
Note: TBD: to be determined.
Steam consumption for flushing purposes is not included in guarantee values.

Guarantee consumption are related exclusively to ISBL DAP/NPK equipment in


process unit excluding OSBL facilities and excluding consumption for lighting, control
room, PLC or DCS.

Raw material consumption is based on the actual grades (18-46-0, 14-35-14, 12-32-
16, 10-26-26). The guaranteed raw material consumption figures will be liable to be
corrected and updated to reflect the actual formulation of DAP/NPK grades.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 24 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

4.9 PERSONNEL REQUIREMENTS

During normal operation five (5) operators per shift plus a shift supervisor will be required.
Typical personnel distribution is:
– One panelist at PLC.
– One granulation operator at granulator
– Two field operators for granulation floors operation and reaction area.
– One operator at Raw Material Section.

Other arrangements could fit process needs, but this is the usual one.

5. SITE–RELATED DESIGN BASIS

5.1 SITE DESCRIPTION

Plant is to be located in a coastal complex called Sikka Unit, at Motikhavdi, near


Jamnagar, Gujarat State, India. In the following sections are summarized all the available
site-related data for Sikka Unit, required for the design and construction of the new plant.

5.2 CLIMATOLOGIC DATA

The climate can be described as tropical with monsoon rain. The following data have
been taken from available sources:

Design max. dry bulb temperature: 46ºC


Design min. dry bulb temperature: 7ºC
Average dry bulb temperature: 36ºC
Design wet bulb temperature: 29.6ºC
Design relative humidity: Max. 90%
Design rainfall, max: 203 mm/hour
Wind speed (plant): 150 km/h
Site elevation above sea level Coastal
The design dry bulb air temperature and relative humidity will be 41ºC and 60% for the
process unit (NPK/DAP plant).

• Seismic requirements:
Motikhavdi falls within the seismic zone No.4 as described in the Indian Seismic
Code IS 1893. Design earthquake factors shall be as per IS 1893.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 25 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

• Other ambient data:


In general, all the equipment, even more electrical equipment, shall be suitable for
location in atmosphere containing highly corrosive vapours of organic
disulphonetes, sulphur dioxides, vapours fumes of sulphuric acid, phosphoric
acid, hexane, hexanone, hydroxylamine sulphate, ammonia and dusts of
ammonium phosphate, di-ammonium phosphate, etc.

Adequate protective treatment shall be given to external surfaces of equipment


and also to copper parts (e.g. for electrical equipment) to withstand above type of
atmosphere without any adverse effect.

5.3 BASIC SITE – RELATED DATA FOR CIVIL DESIGN

The following site-related data have to be considered for civil design:

• Basic data:

Site elevation (above MSL) (1) –25.0 – 30.0 m


Site elevation (above sea level) Coastal
Allowable bearing capacity for shallow foundations 30 T/m2
Anticipated settlements 15 – 20 mm (2)
Ground water Table 22.5 m during monsoon
Earthquake data Seismic zone No.4 (IS 1893)
(1) MSL: mean sea level.
(2) For stress intensity of 30 T/m2.

• Nature of soil / geology:


The area represented by western most extent of massive volcanic eruption in
the Lateritious to the Paleocene period of the earth history. Deccan traps
of western and central India are considered to be of same geological age.
However the volcanics at the site are marked by their layering and have varied
composition in different layers. Varieties of lava structures associated with
different composition are represented in the area. The lava flows are horizontal to
sub horizontal with longitudinal flow bands.

5.4 GPCB NORMS FOR POLLUTION AND EFFLUENTS

According to Gujarat Pollution Control Boards (GPCB) Norms, the following parameters
are to be fulfilled.

Flue gas emission through DG set Stack, GPCB Norms


Particulate matter 150 mg/ Nm3

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 26 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

SO2 100 mg/ Nm3


NOx 50 mg/ Nm3

Industrial effluent parameters, GPCB Norms


pH 6.5 – 8.5
Temperature 40ºC
Colour 100 units
Suspended solids 100 mg/l
Oil and grease 10 mg/l
Ammoniacal nitrogen 50 mg/l
BOD (5 days at 20ºC) 30 mg/l
COD 250 mg/l
Chlorides 600 mg/l
Sulphates 1000 mg/l
Total dissolved solids 2100 mg/l
% Na 60%

Hazardous waste, GPCB Norms


Used / spent oil 16 MT/Annum
Cotton waste containing oil 1 MT/Annum
Discarded container 1 MT/Annum

5.5 ENVIRONMENTAL PROTECTION REQUIREMENTS

5.5.1 Gaseous effluent treatment and emissions

The plant is provided with high efficiency cyclones to dedust the gases coming from
the dryer, the dust recovery system and the fluidized bed cooler. The gases coming
from the granulator are rich in ammonia and are sent to a two-stage ammonia
scrubber for ammonia recovery.

Dedusted gases from the fluidized bed cooler are used under normal operation as
dilution air in the combustion chamber of the dryer, thus contributing to the overall
energy saving, while dedusted gases from the dryer and the dust recovery system are
sent to the dust scrubber and further to the fluorine scrubber.

Also the ammonia – poor gases from the ammonia scrubber are sent to the dust
scrubber and fluorine scrubber. In this two scrubbing system, gases are dedusted and
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 27 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

cleaned prior to be discharged to atmosphere (safe place), by means of a phosphoric


acid washing and a water washing.

The plant has a stack for the total gases leaving this scrubbing system. The contents
of this flow to atmosphere shall fulfil with the required emission levels in NH3, dust and
fluorine. When the NPK/DAP Plant is operating under normal design condition, with
utilities and raw materials under specification, the gaseous emissions at stack will be
as follows:

Gaseous emissions at stack Limits


Dust – Particulate matter ≤ 50 mg / Nm3
Ammonia (NH3) ≤ 50 mg / Nm3
Fluorine ≤ 10 mg / Nm3

5.5.2 Liquid effluents

When the NPK/DAP Plant is operating under normal design condition, with utilities and
raw materials under specification, the plant shall produce zero industrial liquid
effluents.

All the liquid drains from piping, equipment and other components will be
collected in a drainage network and sent to the plant sump to be pumped into
the process and thus treated in the plant itself. Phosphoric acid drains will be
collected in an independent drainage network an also sent to the plant sump to
be pumped into the process.

The low pressure condensate, produced from the steam used in both
continuous and intermittent operations, will be collected in a condensate tank
inside battery limits and the recovered condensate will normally be pumped
OSBL, to the Owner’s boiler house. If condensate is found to be contaminated,
it will be diverted to the effluent sump inside the NPK/DAP plant to be sent back
to the process.

5.5.3 Solid wastes

When the NPK/DAP Plant is operating under normal design condition, with utilities and
raw materials under specification and the plant running on continuous basis, solid
wastes will not be generated on continuous basis.

Also product spillages are expected to occasionally happen, and these spillages
are recovered to be reprocessed.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 28 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

5.5.4 Noise limits

Noise is generated from large rotating machines, including blowers, pumps, electric
motors, air coolers, rotating drums, conveyors belts, crushers, etc.

Equipment and machinery shall be designed to keep noise level below 89 dB (A) at 1
meter distance from equipment. The dryer will be a deviation of this requirement
because in some cases this equipment will exceed the permissible noise level of 89 dB
(A). To palliate noise effects, the area shall be classified as restricted area and
personnel will have to use ear protection. Sound baffling devices shall not be included
in the dryer area as it would interfere in the normal operation of the plant and in the
layout.

5.6 SAFETY AND HEALTH REQUIREMENTS

Phosphate fertilizer manufacturing plants use, store, and distribute significant amounts of
hazardous materials e.g.ammonia and acids, vapours. Also the reaction between the
ammonia gas and phosphoric acid in the Pipe Reactor is highly exothermic and the
temperature goes up to 150°C.

The purpose of this section is to identify the main operating hazards typical of this plant.
Although the DAP/NPK unit is a relative safe unit, special attention shall be paid to
several issues for safe operation:
– Chemical hazards.
– Equipment hazards.
– Production work safety.
– Protective equipment.
– Fire and explosion prevention and protection.

General safety rules of the Factory are fully applicable to this plant.

All personnel must be thoroughly trained in safe operating and maintenance procedures
and must understand the hazards associated to improper operation or careless
techniques.

Safety showers and eye wash with potable water supply are to be provided near every
service station. Once each operating shift, all safety showers and eye-washers must be
tested and reported any trouble. All operators will know safety shower location. Also
every operator shall know the location and use of firefighting equipment in the building or
area, and shall assist in keeping it in good condition for use.

All leaks should be reported and repaired as quick as possible, since erosion or corrosion
may quickly increase the leak and may cut into the metal so severely as to require
replacement of a portion of the equipment or apparatus.Cartridge or autonomous
respiratory apparatus must be available in the Plant for emergencies.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
permission of TECNICAS REUNIDAS and ESPINDESA
PROJECT: DAP/NPK PLANT AT SIKKA UNIT OF GSFC PROJECT: 08170

DESIGN BASIS PAGE 29 OF 43

DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

5.6.1 Chemical hazards

5.6.1.1 Ammonia
Ammonia is a toxic chemical. Gaseous ammonia is a colourless gas having a
characteristic pungent odour It is a primary irritant, mainly to the eyes; and upper
respiratory tract.

The violent respiratory reflex produced by inhalation of ammonia fumes shall


reduce the likelihood that an individual would remain very long in a seriously
contaminated atmosphere. Nevertheless, if an individual is trapped in strong
ammonia fumes, serious injury will result. The following data apply to ammonia
fumes in air:

Least detectable odor: 35 ppm


Least amount causing immediate irritation to the eye: 700 ppm
Least amount causing immediate irritation to the throat: 400 ppm
Least amount causing coughing: 1720 ppm
Maximum concentration for prolonged exposure: 100 ppm
Maximum concentration for exposure from ½ to 1 hour: 300 to 500 ppm
Maximum concentration for exposure less than ½ hour: 2500 to 4500 ppm
Rapidly fatal for short exposure 5000 or higher

Serious exposure to ammonia fumes will produce irritation of eyes and upper air
passages. Congestion of the lungs followed by edema and death may also result.
Do not handle ammonia without wearing rubber gloves and an ammonia mask.
When handling or sampling liquid ammonia, wear a face shield and rubber gloves.

Ammonia gas is not harmful for prolonged exposure in concentrations up to 100


parts per million in air, although it is so intensely irritating to the skin, eyes and
respiratory tract, that leaking gas in immediately detected. However, since
ammonia represents a panic hazard and, in concentrations above 2500 parts per
million, may be even fatal, provisions should be made by the ammonia user for
action in an emergency.

Exposed persons to high concentrations of gaseous ammonia, and/or splashed by


liquid, should be removed to an uncontaminated area promptly. If the exposure
has been to minor concentrations for a limited time, usually no treatment will be
required. In case of contact of the liquid with the eyes or skin, immediate flushing
with large quantities of running water is imperative. In all cases of injury, medical
aid should be obtained, giving a complete account of the accident to avoid
permanent eye and/or skin damage. If liquid ammonia has been swallowed a
doctor should be called immediately. If able the patient should drink large amounts
of water, to dilute the ammonia.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

Chemical cartridge type respirators are useful in protecting the wearer from
disagreeable but relatively harmless concentrations of ammonia. In the event of an
accident this type of respirator should be used for escape purposes only. For
rescue work, self-contained breathing apparatus is essential

Ammonia forms flammable and explosive mixtures with air. At atmospheric


pressure, the explosive range is 13.5 - 32.0% of ammonia by volume.

Consequently, it is advised to wear gas-tight goggles whenever ammonia pipes


have to be dismantled.

The best treatment for an ammonia burn is washing with large amounts of water.

In case of liquid ammonia leakage, drenching with water is required to dilute the
ammonia. In the case of a big leak, and if the ammonia flows into a pit or sump,
never add water suddenly, since this would cause a large amount of ammonia to
vaporize all at once, but wait for the ammonia to evaporate slowly of itself. In
addition, the faulty pipe should immediately be isolated by closing the valves.

For further information, see the attached Ammonia Safety Data Sheet in Annex I.

5.6.1.2 Phosphoric acid


Phosphoric acid is a corrosive liquid that may cause burns on contact with any
part of the body. Except for acid in the eyes, prolonged contact may be required
before some individuals notice burning or irritation of the skin. Sustained or
intermittent skin contact with phosphoric acid may cause dermatitis at the site of
the contact.

Phosphoric acid may cause local damage if taken internally, and a spray or mist is
irritating. Phosphoric acid itself is not irritating to the eyes or nose but in the form of
a mist in air, it can cause respiratory difficulties.

A threshold limit value of 1 mg/m3 for 8 hours has been set for phosphoric acid
mist. This limit is probably conservative value from sulphuric acid, which is
considerably more toxic, has the same limit. There is no evidence that systemic
effects, respiratory problems, or phosphorus poisoning can result from contact
with phosphoric acid.

Contact with phosphoric acid heated to over 60ºC may cause burns, probably
more as a result of the heat than the chemical effect of the acid. Phosphoric acid
heated to over about 300ºC will evolve toxic phosphorus pentoxide fumes.

Phosphoric acid is not explosive or flammable; but in contact with ferrous metals
less resistant than type 316 stainless steel, it liberates hydrogen gas. The
hydrogen gas is explosive in the range 4-75 vol. % of hydrogen in air.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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Wet-process phosphoric acid is no more hazardous than pure phosphoric acid in


regard to external contact. However, the fluorine in the acid can cause dangerous
poisoning if enough acid is swallowed to give about 1 g of fluorine. It is unlikely;
however, that this much acid would be swallowed.

In the event of anyone being splashed by phosphoric acid, contaminated clothing


shall be removed, and the affected parts of the body flushed with large quantities of
water. This is, perhaps, most easily achieved under a shower. Medical help shall be
sought as soon as possible. Washing with large quantities of water and immediate
medical attention is particularly important if acid has splashed into the eyes.

The prompt removal of phosphoric acid with large amounts of water is the most
effective treatment for eye or skin contact. If pain in the eye persists after 15
minutes of irrigation with water, a drop of mineral oil, olive oil, or castor oil may be
applied to relieve the pain. An eye pad or piece of cotton should be placed over
the closed eye, the eye bandaged, and a doctor consulted.

Face shields must be worn in the vicinity of phosphoric acid plants and full
protective clothing when the risk of gaseous contamination is present. Dust masks
should be worn to avoid breathing mist, the pads in the masks shall be changed at
frequent intervals.

For burns from hot acid, the acid should be washed off with large amounts of
water. One or two aspirin may be taken to relieve pain or, in severe cases, a clean
towel or sheet soaked in tap water or dilute sodium bicarbonate solution may be
laid over the burned area; the water should be squeezed out of the cloth, taking
care not to touch the side that will contact the burn. Exposing a burn to the air,
increases pain. Salves or greases should be avoided.

When phosphoric acid has been swallowed, copious quantities of water should be
drunk to dilute the acid. A neutralizer such as milk of magnesia (several
teaspoons per glass of water), lime water, aluminum hydroxide gel, or soap
solution may also be taken. Carbonates are preferably avoided because of gas
evolution.

For further information, see the attached Phosphoric Acid Safety Data Sheet in
Annex I.

5.6.1.3 Sulphuric acid


Strong sulphuric acid is a heavy viscous liquid. Due to its corrosive oxidising and
sulphonating properties, it produces severe burns and rapid destruction of bodily
tissues. Hazards associated with handling sulphuric acid are of two types: local
effects on the skin and eyes, and irritation of the respiratory tract.

Direct contact of concentrated sulphuric acid on the skin is rapidly destructive to


the tissues and may produce severe burns and be accompanied by shock and
collapse. Repeated contact with dilute solutions may produce dermatitis. Contact
with the eyes may result in severe damage or loss of sight.
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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Sulphuric acid is odourless, but fuming acid or oleum has a sharp penetrating odour
due to the release of dissolved SO3. Sulphuric acid mists in concentration in excess
of 1 mg/m3 are easily detectable, a concentration of 5 mg/m3 is objectionable (a
sensation of breathing dusty air is experienced). A threshold limit value for an eight
hour exposure is 1 mg/m3.

Sulphuric acid vapour and mist are irritating to the mucous membranes of the
eyes and the respiratory tract. Vapours from acid solutions below 98.3 percent
and at temperatures below 100ºC are not of hygiene significance, owing to the
low vapour pressure.

Mechanical operations or boiling solutions, however, may result in the


dissemination of particles into the air. Larger particles from mechanical action are
trapped in the upper respiratory tract and usually produce little damage. Smaller
particles in the range of 1 – 5 µm can reach the deep lung tissue, and more
serious injury may result. Cough, chronic inflammation and chronic bronchitis may
result from repeated exposure. Severe exposure may cause pneumonitis. Erosion
of the teeth has also been reported, particularly in mouth breathers.

The recommended maximum atmospheric concentration is 1 mg/m3 of air.

In cases of contact with sulphuric acid, the most important treatment is immediate
flushing with copious amount of water. Contaminated clothing must be removed.
Both these operations are best carried out under a shower. No neutralizing
substances should be used until the acid has been thoroughly washed away with
water, as otherwise the heat of neutralization may enhance the burn. The patient
must be treated for shock, and medical help called. Washing with water and
immediate medical help is particularly important if acid has splashed into the eyes.
If acid has been swallowed the patient should be made to drink milk, egg white or
water, and a doctor summoned

Workers should at least wear rubber gloves and safety glasses when working with
sulphuric acid.

Sulphuric acid by itself is not flammable, but the higher concentrations may cause
ignition by contact with combustible materials. Sulphuric acid may generate
hydrogen inside a drum, tank ear or a metal storage tank. Because of the very
explosive nature of hydrogen – air mixtures, no open lights or sparks should be
permitted near containers of sulphuric acid.

Spilled sulphuric acid should be removed immediately by flushing the


contaminated area with copious quantities of water. It is axiomatic in the industry
that the sulphuric acid should never be stored or handled where there is not a
supply of water for wash down purposes. The remaining traces of acid should be
neutralized with soda ash or lye.

For further information, see the attached Sulphuric Acid Safety Data Sheet in
Annex I.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

5.6.2 Equipment hazards

5.6.2.1 Granulators and dryers


Beyond the normal hazards of heavy rotating machinery there are some other
hazards to take into account.
– Guard tires, trunnions, ring gears and revolving irregular surfaces such as
mechanical hammers and cams if they are accessible.
– Remove fuses from switches during repairs and lock fuse boxes.
– Empty chutes ahead of equipment.
– Protect personnel by guarding mechanical hammers if they are accessible.
– Do not clean equipment while it is moving.
– Do not hammer on meters, safety or regulating devices.
– Avoid entering dryer or granulator while they are too hot or contaminated.
– Force air through equipment during repairs.
– Have observer on outside during service work. Never work alone.
– Start fan before starting combustion chamber fire and keep it running after
is off to minimize exhaust fumes.

5.6.2.2 Product elevators


– Guards are necessary at elevator head on:
 All drive gears.
 Drive chains.
 Exposed shafts with keyways or set collars.

– If head shafts are greased through grease fittings, extension pipes should
be attached wherever necessary to prevent spillage from having to reach
fitting in tight places or close to gears, chains or other moving machinery.

– Start-up procedures for rotating equipment including belts and elevators


are recommended to operate locally in order to check surrounding of the
corresponding equipment.

5.6.2.3 Belt conveyors


– Guard all drive chains or belts and gears.

– Where a conveyor blocks passageway and employees cannot walk around


it, provide walk-over steps for employees to use. Crawling or stepping over
conveyor should never be permitted.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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– For conveyors above floor level, adequate provision should be made for
catwalks with guard rails and access stairs or ladders for oilers and
maintenance men.

– Start-up procedures for rotating equipment including belts and elevators


are recommended to operate locally in order to check surrounding of the
corresponding equipment.

5.6.2.4 Screw conveyors


– Guard drive chains or belts and gears.

– Provide cover over top of conveyor except where necessary to have


openings for operational purposes.

5.6.2.5 Screens
– Be sure screen is mounted securely to prevent excessive vibration and the
hazard of foreign objects being screened flying off screen and hitting
someone. Keep screen covered.

– Screens should be readily accessible for cleaning.

– Electrical connections should be locked out while cleaning screens.

– No one should be allowed to climb onto the screens when they are in
operation.

– Cleaning tools should be made of wooden-handled leather beaters or


industrial brooms, long enough to prevent workers from climbing onto
screens.

– Goggles should be worn while cleaning screens. Dust respirators should be


worn.

– Excessive dust conditions while screens are being used should be


investigated for possible elimination or partial prevention

5.6.2.6 Crushers
– Guard drive chains or belts and gears.

– Electrical connections should be locked out while cleaning crushers or


inspections.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

5.6.2.7 Electrical equipment


– Most items of electrical equipment are designed and built for specific types
of service. They will operate with maximum efficiency and safety only when
they are used for the purpose and under the conditions for which they are
intended.

– Transformers, control boards, switches, motor starters and other electrical


apparatus should be installed in an efficient and safe manner, so that the
possibility of accidental contact with energized conductors will be reduced to
a minimum.

– When possible, electrical apparatus should be placed in less congested


areas, or in special rooms to which only authorized persons have access.
Proper warning signs should be placed on these to keep workers away.

– All controls should be marked to avoid starting and stopping the wrong
motors.

– Motors should be of the type and size required for the load and conditions.

– All transformers, control boards and motors should be grounded.

– Fuses should be of the right size to protect the equipment. When a fuse
burns out, locate and correct the trouble.

– Electrical repairs should be made by qualified personnel only.

5.6.3 Production work safety

5.6.3.1 Screen operation


– Make sure that the cover is securely latched in place. The cable holding the
lid up could give way.

– Wear gloves to remove trash from screen or while repairing it.

– Always use a rubber mallet to beat the screen to minimize the damage it
might do if it should strike you.

– If fumes should become too strong, be prepared to move quickly to fresh air.

5.6.3.2 Breaking into pipelines


– Isolate line and/or equipment.
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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– Always wear proper protective equipment, such as gloves, gas masks, face
shields, “hard hats” and rubber suits when required.

– Release flange bolts slowly and with caution. Always loosen bolt furthest
away first, to allow splashes and pressure to be directed away from
personnel. Be careful of burred edges on threaded pipes.

– Have adequate lighting.

– Have ample supply of water for emergencies.

– Do not weld or burn until the equipment and adjacent atmosphere have
been cleared of explosive and combustible liquids, solids and gases.

– Use spark-resistant tools if flammable gases are present.

– If possible, keep your face above level of the flange.

– To prevent injuries and accidents caused by opening the wrong valve, the
pipe line and valves should be properly identified.

5.6.3.3 Dryer operation


– Guard trunnions, gears and other drives.

– Be sure that burner functions properly.

– Avoid product build up in dryer and ducts.

– Before dryer burner is turned on, make sure no one is in the dryer.

5.6.3.4 Conveyors
– Power drives should be guarded.

– Never wear loose or ragged clothing around moving conveyors.

– Conveyor should be completely stopped for repairs or clean-up.

– Guards must be in place and in proper condition.

– Before the conveyor is started, the operator should be certain all personnel
are in the clear.

– The wearing of safety shoes is recommended.

– Never ride a conveyor belt.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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5.6.3.5 Granulator
– Stop machine to clean.

– Use long-handled sampler.

– Wear goggles, avoid fumes.

– Keep clear of hammers and close fitted moving parts

5.6.3.6 Crushers
– Power drives should be guarded.

– Guards must be in place and in proper condition.

– Crushers must be completely stopped for repairs or clean-up or inspections.

5.6.4 Protective equipment

Protective equipment and clothing should be made available for use as required for
safety. The following equipment is recommended by the Manufacturing Chemists
Association:

– Chemical safety goggles, cut-type or rubber frame, carefully fitted and


equipped with plastic or impact-resistant glass lenses.

– Safety spectacles with unperforated side shields, metal or plastic rim, with
prescription safety lenses if preferred. These spectacles should be worn
where continuous eye protection is desirable, such as in laboratories.

– Plastic face shields with forehead protection. Face shields should be worn
where more complete facial protection is desired but should always be worn
with chemical safety goggles.

– Breathing apparatus and masks. Self-contained breathing apparatus allows


high mobility but requires highly trained men. Passage of the operator
through small manholes is difficult because of the oxygen cylinders that
must be carried. The self-generating type of breathing apparatus is superior
in this respect.

• Positive-pressure hose masks must have the blower air source in a


contaminant-free area. Conditions of use of the hose masks must be
such that safe escape may be made if the air supply fails.

• Plant air-line masks also can be used only if safe escape is possible
upon air failure. A suitable pressure regulator, relief valve, and air
filter must be used. The air should be checked frequently for harmful
gases evolved from decomposing oil.
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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• Chemical cartridge respirators may be used to protect against


disagreeable, harmless concentrations of vapor but not against high
concentrations.

– Gauntlet-type rubber gloves. A rubber suit is desirable to protect against


acid splashes. Rubbers or rubber boots are recommended where acid
splashes or spills on a walk area. A complete rubber outfit with chemical
goggles and plastic mask is recommended for cleaning tank cars. Fresh air
should be blown into the car.

– Hard hats are preferred where there may be falling objects. Soft hats may
be adequate in repairing small liquid leaks. Rubber hats are used with
rubber suits when required.

5.6.5 Fire and explosion prevention and protection

Herein are specified some guidelines about Fire and Explosion Prevention and
Protection in DAP/NPK plants.

5.6.5.1 Fire and explosion prevention

• Electrical:
All light circuits and pieces of equipment should be fused with rating of fuse
less than current-carrying capacity of the smallest wire. Fuse clips or
receptacles never should be bridged. All light and power circuits should be
properly supported and insulated so as to hang clear of structural members,
piping, equipment or each other if separate wires are not in cable.

Light bulbs on all extension cords or on any drop cords which might be pulled
over and hung on a hook or nail against a combustible surface should be fully
guarded.

• Fire proofing:
All vertical structures, mainly vertical columns of the pipe rack, shall be fire
proofed for all hazardous areas.

• Natural gas:
It is a mixture of the low molecular weight paraffin hydrocarbon (mainly
methane and ethane, propane, butane and small amounts of higher
hydrocarbons and other gases).

Properties: Colorless gas, almost odorless; autoignition temperature 480 –


600ºC. Typical heating value: 8200 Kcal/Sm3.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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Containers: As gas, in pipelines; as liquid, limited amounts of high-pressure


cylinders.

Hazard: Flammable; dangerous fire and explosion risk. Explosive limits in air:
3.8 to 17%.

• Ammonia:
Ammonia is combustible as well as toxic, and both hazards must be
considered if liquid ammonia is spilled. The flammable limits are from 16 to
25% by volume in air. The auto-ignition temperature in air is 651ºC. Ammonia
fires should not be fought with water, but allowed to burn out. If this is not
practicable extinguishers of the carbon dioxide or dry-chemical type may be
used.

The explosion range for mixtures of ammonia and dry air is 16.2 to 25.3% by
volume of ammonia. These mixtures have to be ignited before an explosion
can occur. Electrical equipment used on an ammonia plant should therefore
be of a spark-proof pattern and smoking should be prohibited. Maintenance
work involving the use of naked flames, e.g. blow lamps, welding equipment,
etc., should only be carried out under the supervision of an authorized person.

• Phosphoric acid:
This acid itself is not combustible and thus will not burn but hydrogen, which is
a flammable gas, will be liberated if the acid is allowed to react with metal.
Concentrations evolved are unlikely to give rise to a fire or explosion risk. If
phosphoric acid is involved in a fire a dangerous acid mist may be formed.

Steel, cast iron, and some stainless steel are attacked by phosphoric acid.

• Sulphuric acid:
The acid itself is not combustible; however it is an oxidising agent and can
cause the ignition of some highly combustible liquids and solids. Any resultant
fire should be fought according to the nature of combustible material.

Hydrogen will be liberated if the acid is allowed to react with metals. Attention is
drawn to the fact that a considerable quantity of heat is liberated when
sulphuric acid is diluted. Care has to be exercised in this operation to prevent
'boiling' or 'spitting' of the solution.

• Housekeeping:
Discarded bags, paper, splintered wood, etc..., should not be allowed to
accumulate at working areas, under platforms or outside of buildings.
Accumulations should be removed daily or oftener if necessary and burned in
an incinerator.
This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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Wherever it is necessary to use cleaning waste, oily, greasy or paint


impregnated rags, approved covered metal containers should be provided
and used.

Motors, other electrical equipment, fire extinguishers and painted boards or


areas designating location of fire extinguishers specially should be kept clear.

5.6.5.2 Fire protection


– The fire protection facilities should be in accordance with the latest
revision of the Fire Protection Manual, OISD-117/ 118/ 119 and NFPA.

– If within any public fire protection area and fire call box is not located on
or right at premises, telephone number of fire station should be posted at
telephone, and plant location should be shown also so employee can
report fire and location of plant with minimum effort and loss of time.

– Extinguisers:

• Emergency fire-extinguishing equipment should be conveniently


and prominently located throughout the plant. CO2 or dry powder
in vicinity adjacent to the following areas / items:

– Motors.
– Electrical control panels.
– On gasoline powered material handling units (or closely
spaced on posts in aisle-ways in buildings in which this
equipment is used).

• General criteria for placing: extinguisher should be located:

– Where easily seen red or yellow background with white


stripes would make locations more noticeable.
– Where probable fire would not cut off access to
extinguisher.
– At convenient height, not on floor.

• Extinguishers should be periodically inspected:

– CO2: Weighed at least every six months and refilled if


underweight by 10% of CO2 content.
– Dry powder: Every six months, check cartridge to see if
used and check amount of dry powder in cylinder.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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– In addition to specific checks noted above, a monthly


inspection of location and general condition of all
extinguishers should be made.

– Private hydrant, tank and/or fire pump protection:

• Keep tank tell-tale or automatic water level indicator in proper


working order.

• Start fire pump at least weekly.

• See that each hose house is adequately equipped with sufficient


hose, lanterns, spanner wrenches, hose connection washers and
hydrant key.

• Each month check portion of hose with fire pump at maximum


operating pressure in rotation so all hoses are checked at this
pressure at least every twelve months.

• If in public fire protection area, see that local fire department is


familiar with plant system and that fire hose couplings are the
same as used by public fire department.

• Organize plant fire brigade, assign all regular plant personnel to


specific duties in case of fire, and conduct practice drills
periodically.

– Employees should be instructed periodically in the use of all types of


emergency fire-extinguishing equipment and the types of fires on which
each should be used.

This document and its information are property of TECNICAS REUNIDAS/ESPINDESA, any reproduction or use of its content, total or partial,
including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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DOCUMENT CODE: 08170-D-690-ES-0001 REV.: 01

ANNEX I: MATERIAL SAFETY DATA SHEETS

Kindly refer attached MSDS.

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including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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ANNEX II: BLOCK FLOW DIAGRAM

Kindly refer attached Block Flow Diagram.

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including any of its characteristics patented or able to be patented, is forbidden and it cannot be reproduced or used without the
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