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COMMERCIAL USE OF TVA'S HIGH-PRESSURE PIPE-CROSS REACTOR
FOR PRODUCING AMMONIUM PHOSPHATES
JOINT PROJECT
ROYSTER COMPANY AND TENNESSEE VALLEY AUTHORITY
for presentation at
Central Florida section
of
American Institute of Chemical Engineers
Clearwater, Florida
May 23, 1987
by
Frank P. Achorn, Chief Chemical Engineer
Office of Agricultural and Chemical Development
National Fertilizer Development Center
and
W. H. Paulson, Royster Company, Mulberry, Florida
TENNESSEE VALLEY AUTHORITY
Muscle Shoals, AlabamaCOMMERCIAL USE OF TVA'S HIGH-PRESSURE PIPE-CROSS REACTOR
FOR PRODUCING AMMONIUM PHOSPHATES
JOINT PROJECT
ROYSTER COMPANY AND TENNESSEE VALLEY AUTHORITY
This paper discusses TVA's latest technology for producing ammonium
phosphates. This technology uses a pipe-type reactor made of common pipe
fittings and containing a pipe-cross. It is the result of cooperative
work between TVA's National Fertilizer Development Center and the Royster
Fertilizer Conpany.
Ammonium phosphate fertilizer is the most popular phosphate fertilizer
in the United States and in most other countries. Figure 1 is a sketch
of annual production of ammonium phosphate produced in the United states.
Although the most popular anmonium phosphate is diammonium phosphate
(DAP), monoammonium phosphate (MAP) is gaining in popularity. The
pipe-cross reactor (PCR) provides a process whereby a plant can be
designed to easily produce either DAP or MAP with a minimum of down time
required to change grades. two goals of TVA's ammonium phosphate
development program are:
Conserve energy, reduce losses, and increase production rate. This
work has resulted in new developments that include the PCR, increased
airflow through the granulator, and determination of optimum operating
conditions in MAP and DAP plants at which the chemical heat is used
efficiently and losses are kept to a minimum. These improvements
usually cause a lowering of the recycle rate which results in an
increased production rate.
Several producers have reported problems with product quality such as
deficiencies in plant nutrient content, dustiness, storage, and size.
The TVA-PCR process helps solve some of these problems.
Review of Old TVA-DAP Process
In the early 1960s, TVA developed a process which is now being used by
most of the fertilizer industry to produce granular DAP. TVA received a
patent for this process in October 1964 (1). Figure 2 is a flow diagran
of the process. It uses a proneutralizer tank, granulator, scrubber,
éryer, cooler, and product screens. The phosphoric acid feed is split,
with part going to scrubbers and part going directly to the
preneutralizer. The acid to the scrubbers has a low P20s
concentration (typical, 28% Pa0s and 55% H20), while the acid addedto the preneutralizer is concentrated (typical, 54% P20s and 16%
20). «The preneutralizer tank is usually made of 316L stainless steel.
Some preneutralizers, however, are made of mild steel and lined with
acid-resistant brick. The granulator in this process is a typical
Tarotary ammoniator-granulator (4). In operating the plant, partially
ammoniated acid from the scrubber is fed to the preneutralizer along with
concentrated acid and anhydrous ammonia (usually gaseous NH). Enough
ammonia is added to the slurry to maintain an N:P mole ratio of about
1,45:1.55. The slurry's specific gravity is 1.5 to 1.6 and its
temperature is 2300F to 2550F. The slurry is pumped and sprayed onto
the bed of material in the grenulator, where additional ammonia is added
to increase the N:P mole ratio in the product in the granulator to about
1.9. The product from the granulator is dried and then screened for
product size removal. The oversize is crushed and recirculated, along
with the fines from the screens, to the granulator. Product from the
sereens is cooled in either a rotary or fluid-bed cooler. Sometimes some
of the product is also recirculated to the granulator to control recycle
rate. Typical operating data from the conventional plant are tabulated
below.
Serubber
W:P mole ratio 0.5 to 0.7
Sp Gr 1.3 to 1.35
Temperature,°F (slurry) 150 to 200
Preneutralizer
:P mole ratio 1.4 to 1.5
sp Gr 1.45 to 1.55
Temperature, OF 240 to 250
Slurry moisture, % 15 to 20
Granulator product
W:P mole ratio 1.9 to 2.0
Temperature, OF 190 ~ 215
Moisture, % 3to4
Dryer, product temperature °F 170 to 200
Gooler, product temperature OF 115 to 145
Retrofitting Conventional Plant with New PCR
Figure 3 is a sketch of TVA's PCR. The
pipe-cross are used for adding phosphoric acid and ammonium phosphate
arms on the side of the
slurry. The direction of their flows oppose each other. This causes
thorough mixing of these fluids before they are ammoniated. Anhydrous
ammonia is added through a third arm of the cross and through an ammonia
sparger. This sparger extends about 8 feet into the reactor tube and past
the acid and slurry inlets. The fourth arm of the cross delivers these
materials to the reaction chamber. Because of the pipe-cross and because
the reactor operates at pressures higher than other reactors, it has been
named TVA's high-pressure POR (2) (3).Pilot-plant tests and some tests in regional granulation plants showed
‘the following advantages in using the PCR to produce either DAP or MAP:
1, Slurry of low moisture content (lower than preneutralizer) can be
sprayed directly from the PCR onto the bed of material in the
granulator, This eliminates problems in pumping low-moisture thick
slurries.
2, Estimated recycle rates are usually lower when the PGR instead of the
tank preneutralizer is used.
3. ‘The PCR can be operated under pressure so that the slurry has a high
energy content and temperature before it is sprayed into the
granulator. Therefore, larger quantities of water can be removed from
the slurry before it enters the bed of material in the granulator.
This reduces the total addition of moisture to the bed. Pilot-plant
tests show this allows the recycle rate to decrease. No drying of the
product is required. Royster Fertilizer Company has used no fuel to
dry the product during over a year of operation.
4. The product has less tendency to cause dustiness during handling and
there is less dust within the plant.
5. Shifting from DAP to MAP production and vice versa is easy.
6. The product has excellent hardness (15 Ibs, size ~6+8) as compared
with 10 lbs for DAP made by the conventional process.
There is usually less nitrogen loss from the PCR and granulator than
‘there was from the preneutralizer and granulator of the old process.
This means less stress on the scrubbing system when the PCR is used.
Some plants that have high retention times in the preneutralizer have
problems with unacceptably high CI P20s in the products. Because
the PCR has a very low retention time, it will holp alleviate this
problen.
Because of these advantages, Royster decided to retrofit its plant
with a POR. Figure 4 is a sketch of the Royster plant. A two-stage
scrubber as well as a high-pressure PCR was used. This was easily
accomplished by using the old preneutralizer and its exhaust system as an
impingement-type, first-stage scrubber. Spray nozzles have been installed
in the ductwork. Partially ammoniated slurry is recirculated through
these nozzles. The second-stage scrubber is the original scrubber of the
old plant. It has a common sump (seal tank) with the dryer scrubber.
Weak acid (28-32% P20s) is fed to this seal tank. Scrubber liquor
from the second-stage scrubber is pumped to the first-stage scrubber.
Medium strength acid (38 to 42% P20s) and concentrated acid (50 to 54%
P20s) are fed to the PCR along with ammonia and partially amnoniated
slurry from the first-stage scrubber.The design of this PCR is different from the type used in more than 20
regional granulation plants producing granular homogenous mixtures.
Although they work well for producing MAP and ammonium phosphate sulfate,
they do not have sufficient length for producing DAP.
Figure 5 is a pictorial sketch of the reactor used by Royster. Its
anmoniation volume (in3/1b ammonia/hr) is about twice that of the
low-pressure PCR used to produce NPK mixtures. It has about one percent
of the volume of a standard conventional preneutralizer. Pilot-plant
tests and some commercial tests were made in similar reactors to produce
DAP. The design criteria were established in these tests.
Royster's reactor is made of a 10-in standard stainless steel pipe
(type 316L). It has an overall length of 47 ft and a slope of 10
degrees. The reaction is completed in this section. The distribution
section is positioned to discharge melt from the reactor ento the rolling
bed of material in the granulator. There is usually an air space of two
to three feet between the discharge slot of the reactor and the surface of
material in the granulator. This provides space for moisture to leave the
melt.
The reactor in figure 5 is mounted on the side of the center sparger
support beam to the anmoniator-granulator. However, Royster recently
installed the PCR inside the granulator’s center support beam. A slot,
cut in the center support beam, is much wider than the one in the PCR so
that melt from the PCR slot passes through the slot in the center support
beam. This design provides more air space between the discharge of the
melt and the top of the bed of material in the granulator. The PCR
discharge slot is equipped with a flange section (figures 3 and 5).
Plates with different size slots are attached to this flange. Royster has
also installed a lip, about 3-in long, on the end of the slot to reduce
splattering of the melt. The operating pressure of the reactor is
controlled by slot size and production rate.
Both pilot-plant and commercial plant tests show that the PCR designed
for producing DAP should have a pipe size (main body of the reactor) so
the maximum heat flux will not exceed 600,000 Btu/hr/in?, To maintain
@ pressure of 35 to 50 psig, the heat flux at the discharge slot should be
about 1.4 x 10° Btu/hr/in? (slot 24 in?). In our original
pilot-plant tests, single-stage scrubbing of the exit gases from the
granulator was used. However, based on the good results received at the
Royster plant, TVA is installing two-stage scrubbing. With two-stage
scrubbing, the quantity of dilute phosphoric acid required by the
scrubbing system is less than that required by single-stage scrubbing
This is because the first-stage scrubber is operated at an N:P mole ratio
of about 1.4 and the second stage is operated at an U:P mole ratio of
0.5. Therefore, the average mole ratio in the system is about 0.95. This
is about twice as high as the mole ratio normally maintained when
single-stage scrubbing is used. Slurries in the scrubbers are kept at
mole ratios of 0.5 and 1.4 to take advantage of the high solubility of
ammonium phosphate at these degrees of ammoniation. Fluorine loss is nilWhen the second-stage scrubber is operating at this N:P mole ratio of 0.5
because most of the acid is added to the PCR and its exhaust gases pass
through the first-stage scrubber which is operating at an N:P mole ratio
of 1.4. Previous data from other plants show this fluorine loss is
dependent upon pH of the slurry. The higher the pH, the lower the
fluorine loss.
The Royster plant has operated very well for more than a year,
producing DAP at rates of 55 to 60 tons/hr. The POR has not been the
limiting equipment for higher production rates. This plant was originally
designed to produce about 30 tons/hr with the old TVA process. The
capacity of the 10- x 20-ft ammoniator-granulator has not been exceeded.
The conveying and cooling equipment causes the production rate to be
limited. One way to help solve the cooling problem is to use liquid
ammonia in the granulator. Another is to install an ammonia vaporizer in
the inlet air duct to the cooler.
Tables 1 and 2 show some of the operating data collected when the
plant was operated at a production rate of 55 tons/hr. The plant is
operating well at 60 tons/hr. During most of the operations, it was
estimated that 25 percent of the ammonia was added in the granulator.
About 35 percent of the total P20s was added as weak acid (30%
Pa0s) in the second-stage scrubber. Calculations show that about 25
Percent and 40 percent of the total P20s were fed as medium and
concentrated acids to the PCR. A small amount of P20s as pond water
was also added to the scrubbers. These and other data show that by using
two-stage scrubbing, larger quantities of concentrated acid can be used in
the PCR. The equivalent concentration of all phosphoric acid added to the
process is about 40 percent P20s, which is about the strength of the
acid used in a tank preneutralizer. High-strength acid and high pressures
in the PCR result in higher slucry temperatures and slurry P20s
concentrations in the PCR.
Previous data show the slurry temperature and moisture when the
preneutralizer is used are usually 245°F and 15-20 percent
respectively. Results in table 1 show when the PCR is used, the average
temperature of the slurry in the PCR is about 290°F and moisture of the
slurry discharge from the reactor is 10-13 percent H20. Because of its
higher temperature, the slurry from the PCR contains more energy than the
slurry from the preneutralizer, At the higher temperature the melt will
release its moisture more readily into the exit gas of the granulator than
will slurry from the preneutralizer, Therefore, significantly less
moisture from the melt should impinge on the bed of material in the
granulator than from the comparable slurry from the prencutralizer. with
the lower moisture content of the granulator product, no fuel is required
for drying. The lower moisture content is also favorable to lower recycle
rates and higher production rates. If the dryer is used as a cooler, the
ammonia loss from it should be low. In TVA's pilot plant we hope to show
that use of the new PCR will make it feasible to replace the troublesome
wet-serubbing systens used for dryers with bag filters. This should
further improve the water balance of the process which, in turn, should
decrease the recycle rate and increase the production rate. The totalcapital investment in a new plant should be much less because no dryer and
dryer scrubbing is required. Also, smaller equipment can be used because
of the lower reeycle rate,
Plant operators report there is less dust in the plant and warehouses
when the PCR is used instead of the preneutralizer. By using a
high-pressure slurry spray of small particles from the PCR, a more uniform
coverage of the recycle may be received. This results in well-shaped,
hard granules that resist degradation.
Here is a summary of the advantages in using the PCR as compared to
the preneutralizer:
1. Pilot-plant data indicate lower nitrogen loss and less problem with
nitrogen deficiency.
2. Generally, there is less dust during handling and in production.
3. Wo érying is required.
4, Probably less recycle per ton of product is required which results in
increased production rate.
Product quality is improved.
6. Changing from DAP to MAP and vice versa is easier.
era!
1 Problems with PCR
The main problem in the use of the PCR has been with buildup on top of
the center support beam. Chunks of caked material break off the beam and
clog the chute between the granulator and dryer cooler. Although thie is
troublesome, actual operating time recently has been about 95 percent of
the planned operating time.
A minor problem has occurred because of the low retention time in the
POR. Because the response time to changes is much shorter than when the
tank reactor is used, the board operator must be more alert. This does,
however, force the plant to operate at optimum conditions which generally
ean result in higher production rates.
Some pilot-plant tests indicate there is lower nitrogen loss in
operations with the PCR than with a preneutralizer operated at comparable
slurry temperatures. Probably, one of the reasons for the lower nitrogen
loss is that the PCR is operated at elevated pressures. The data shown in
figure 6 is the partial pressure of ammonia above saturate solutions of
Mis-HeP0<-H20. ‘This data show that at the usual granulator
product temperature of 20007, the partial pressure of ammonia in the
teesaturated solution in the granule is 400 mmHg. At this partial pressure
there would be a significant loss of annonia from the product. Although
this ammonia is recovered in the scrubber, the product may be deficient in
nitrogen. ‘There is no ammonia added to the product after the granulator.
Some companies compensate for this loss by adding urea, anmoniun nitrate,
or ammonium sulfate. Frequently, sulfuric acid and ammonia are added to
supply extra nitrogen. These materials can cause problems with caking;
they also act as diluents. This in tura requires a cleaner acid to be
used, which may cause problens with sludge disposal. VA's pilot-plant
tests during the past 25 years have shown that the optimum granulator
discharge temperature for good granulation efficiency and low ammonia loss
is about 180°F. operators of the conventional plants (with
preneutralizer) report that when this is done, larger quantities of fuel
are required to dry the product and the production rate is decreased.
Perhaps lower granulator product temperatures can be used without
adversely affecting production rate or fuel requirements if more of the
reaction is shifted from the granulator to the prereactor (PCR or
preneutralizer).
The following bench-scale tests show the effect of degree of
ammoniation on physical characteristics of an ammonium phosphate slurry
made from a wet-process phosphoric acid (Central Florida phosphate rock)
containing 40 percent P20s and ammonia and a slurry temperature of
245°R,
Physical Characteristics of an Ammonium Phosphate Slurcy®
at Different Degrees of Anmoniation and 245°F
uP Solidification
Mole Viscosity ‘Temperature
2H Ratio epib op
6.2 Ls 135 170
6.6 1.63 500 186
6.8 1.65 1200 190
7.0 1.78 3464 200
a, Produced from wet-process phosphoric acid, 4.0% P20s,
(Florida rock) and anmonia.
b. Brookfield viscometer, Wo. 3 spindle.
At a mole ratio of 1.65, pumping a thick slurry of this type may be
difficult, if not impossible. Also, there would be danger of plugging the
transfer lines (solidification temperature 190°F).
TVA tests have shown that the POR can be operated quite well at W:P
mole ratios of 1.65 if the temperature of the slurry is kept >280°P.
With these conditions and high pressures, the slurry is fluid enough to be
sprayed onto the bed of material in the granulator as very small particles
of spray. This type of operation will release more heat in the vapor
space of the granulator. This heat needs to be removed by increased
airflow through the granulator.
geTests have shown that because the slurry from the PCR has a low
moisture content, no drying is required. Perhaps the granulator discharge
temperature can be lowered without causing the need to dry the product.
At these lower temperatures there should be less problem with nitrogen
deficiencies in the product. We plan to conduct pilot-plant tests with
the PCR to investigate the advantages of shifting more of the reaction to
the POR.
PCR for MAP and Ammonium Polyphosphate (APP)
Some phosphate producers report their main objective is to produce
products high in P20s. They are interested in selling P20s.
Nitrogen is added to convert the P20s into a usable form, and these
producers would prefer to ship 52 units of P20s as MAP instead of 46
units of P20s as DAP. Perhaps these are some of the reasons for MAP's
increased popularity.
The PCR has been used effectively to produce DAP, MAP, and APP in the
same granulation facility.
In changing from the production of DAP to MAP, the recycle load is
lowered and the N:P mole ratio in the POR is lowered to 1.0. This can be
done in minutes instead of the hours it takes to change the N:P mole ratio
of the slurry in a tank preneutralizer (from N:P mole ratio of 1.45 to
0.6). Those who have attempted to make that change know how difficult it
is. The solubility curves in figure 7 explain one of the reasons. To
decrease the W:P mole ratio to 0.6, the operator must pass from a
solubility of about 400 1bs of salt per 100 lbs of water at an W:P mole
ratio of 1.45 and a temperature of about 250°F, to about 200 lbs of salt
per 100 lbs of water at this same temperature and an N:P mole ratio of
1,0. Therefore, the slurry becomes viscous and sonetimes solidifies,
since only acid is added during this adjustment. To avoid this problem,
the operator usually adds water to the preneutralizer which causes
Problems with water balance in the plant. This is not a problem with the
PoR because there is very littie hold-up of material in it and the change
can be made rapidly. Therefore, changing from the production of DAP to
MAP with the PCR process is a rathor simple procedure. Royster has
produced a significant amount of MAP in its DAP plant that has been
converted to the PCR process. The mole ratio of the recirculating solid
load must be changed. We recommend the following procedure:
1. Lower or empty the DAP recycle load from the plant.
2. Recharge the recycle system with geanular MAP.
3. Restart the plant with MAP recycle and slurry.
Only single-stage scrubbing is required for producing MAP. Pond water
can be used as a scrubbing medium. Ammonia losses from the POR and
granulator are so low that at times some fluorine has been lost from the
scrubber. This problem probably can be eliminated by adding a smallamount of anmonia to the scrubber liquor to keep its pH near neutral. No
fuel is required to dry the product if the phosphoric acid concentration
is as high as 46 percent P20s and vaporized anmonia is used.
Another advantage in using the PCR for MAP is that all of the ammonia
can be added in the PCR. Because the melt is sprayed directly into the
granulator and does not need to be pumped, the PCR can be operated at an
W:P mole ratio of 1.0 and a low moisture content. The need for the
troublesome ammonia spargers in the granulator is eliminated. This allows
the granulator operators to keep these spargers free of caked material.
Producing granular APP is quite similar to that of MAP except all of
the phosphoric acid is added as merchant-grade (0-54-0 grade) (5). This
acid is preheated by steam to 2500F before it is pumped to the PCR. The
maximum temperature of the melt in the reactor is between 450° and
480°F, At this temperature the melt is anhydrous and contains some
pyrophosphate (polyphosphate). The product produced by Royster contained
from 8 to 15 percent polyphosphate and had very good storage
characteristics and quality. Grades that have been produced are 12-52-0
and 11-56-0, The product has worked well for producing both fluid and dry
blends of fertilizers. Its cost of production is about the same as MAP if
there is no charge for steam. It does, however, have a wider market
potential because it can be used to produce suspensions or dry mixed
fertilizers. High-quality acid is necessary to make 11-56-0 and sludge
acid mst be used to produce other products. This may cause the cost of
production of the 11-56-0 grade of APP to be higher than the other
ammonium phosphates.
Summary
The new TVA pressure-type PCR is suited for producing several types of
Sranular ammonium phosphate products. Perhaps the companies that use the
PCR may discover advantages in marketing some ammonium phosphate other
than DAP. Emerging phosphate companies may find it advantageous to offer
more than one conmodity-type product such as DAP. TVA's HPPCR process
appears to provide the phosphate producer a way to easily produce several
amoniun phosphate products in a single plant. There are advantages in
using the PCR to produce either DAP or other ammonium phosphates. The
cost of the reactor is considerably less than a tank preneutralizer system.
TVA is also developing a program plan to improve operations of DAP
plants using either the conventional or PCR process. IVA is prepared to
help engineering and producing companies design and operate plants that
can use this or other processes.References
F. P, Achorn. “Process for Production of Granular Diammoniun
Phosphates.” U. S. Patent 3,153,574, Tennessee Valley Authority.
October 20, 1964.
D. G. Salladay and F. P. Achorn, “Pressure Reactor for Producing
Dianmonium Phosphate," U. S. Patent 4,619,684, Tennessee Valley
Authority. March 24, 1986.
F. P. Achorn and J. S. Lewis. "Granular Anmonium Phosphate Sulfate
and Monoanmonium Phosphate Using Common Pipe-Cross-Type Reactor."
U. S, Patent 3,954,942, Tennessee Valley Authority, April 24, 1975.
F. T. Nielson, “Apparatus for Anmoniation of Granular Dianmonium
Phosphates." U. S. Patent 3,153,574, Tennessee Valley Authority.
October 20, 1964.
B. R. Parker, M. M. orton and T. R. Stumpe. “Pilot-Plant Studies of
‘the Pipe- and Pipe-Cross Reactors in Production of Granular
Polyphosphate Fertilizers," presented at Fertilizer Industry Round
Table, Atlanta, Georgia. October 26-28, 1982.
3345kTable 1
Operating Data - 10 Inch PcR® - Royster Fertilizer Company
Production, rate tons/hr. 38.
Length of test, hrs. 24
Feed rates to PcR, Ibs per ton product
Slucry from scrubbers (29% P20s) 1085.4
Medium acid (38.5% P20s) 584.5
Strong acid (54.0) 703.9
Gaseous anhydrous ammonia
Zn scrubber liquor 104.7
To PCR 223.3
Armonia fed to granulator, lbs per ton product 109.4
Pressure in PCR (average) psig a3
P20s distribution of acids fed, % of total
Weak acid (30% P20s) to scrubbers 34.2
Medium acid (40% P20s) to PCR 24.5
Strong acid (54% P203) to PoR 41.3
Average acid strength fed to process 38.5
Pressure in POR, psig? 47.3
Tenperature in PCR, OF
Maximum 308
Minizum 280
Average 290
Moisture of melt in PCR, percent 10-15
First-stage scrubber slurry to PCR
pH 6.5
Specific gravity 1.4
Temperature, OF 203
N:P mole ratio 1a
Second-stage scrubber slurry
PH 1.9
Specific gravity 1.35
Granulator
Product temperature (average), °F 223
WP mole ratio 1.95
Recycle temperature, °F 181
Moisture in product, percent® 23
Estimated recycle ratio, tons/ton product 45
Dryer Condition
Product temperature, OF 190
Fuel rate, gem °
Air velocity, ft/min® 450-550
Cooler product temperature, °F 144
Across section main pipe of PCR 78.5 in?, area of slot
24 in?, Size of granulator 10-x 20-ft. Size of dryer 10-x-60 ft.
Poptained before discharge of pipe
From similar production run
dgstimated by observing fullness of buckets in elevator at the
discharge end of dryer
From stack gas samples taken in another testTable 2
Chemical And Physical Characteristics Of
Product Produced Using PCR
Production rate, tons/hr 55
Chemical analysis, %
Total nitrogen
Total P20s
G.I P20 <
Moisture
ane
Screen analysis
+6
+14 9
“14
200
Product hardness, pounds (-6+8 mesh)# u
°
@yost commercial DAP made using tank preneutralizer averages about 10
pounds.se6l
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