Phosphoric Acid Plant Design From Phosphorous And Sulfuric Acid With a Capacity Of 60000 ton/year

Abstract

Phosphoric Acid Plant from Phosphoric Rock and Sulfuric Acid with a capacity of 60000 tons/year will be built in Gresik Industrial Estate, East Java with a land area of 26825 m2. The raw materials are Phosphate Rock obtained from Jordan Phosphate Mines Ltd, Jordan and Sulfuric Acid from PT. Petrokimia Gresik, East Java. The factory is designed to operate continuously for 328 days and requires 217 employees. The reaction for making Phosphoric Acid begins with adding Phosphate Rock to the Mixer (M-01) and mixing it with water. After that, feed the slurry of Phosphoric Rock and Sulfuric Acid into the Stirred Tank Reactor (CSTR) which is arranged in series as many as 2 pieces (R-01 and R-02) through the Heat Exchanger (HE-01) at a reactor temperature of 80 oC and pressure 1 atm. This reaction takes place exothermic so it requires water as a coolant to maintain the operating temperature. The product that comes out of the reactor is a mixture of Phosphate Rock, Sulfuric Acid, Florida Hydrogen, Gypsum, Phosphoric Acid and Water. The Florida hydrogen is routed to the storage tank (T-02). While the mixture of liquid and solid phases then enters the Rotary Drum Vacuum Filter (RDVF) to separate the Gypsum from the liquid phase. Then the Gypsum is stored in the Warehouse (G-02) to be packed. While the liquid phase mixture is flowed to the Evaporator (EV-01) to reduce the water content. After that, the solution isflowed to the storage tank (T-03). The utility required by the Phosphoric Acid factory is water taken from the Java Sea with a capacity of 192901.54 kg/hour. Electrical power of 223556.39 kW is supplied from PLN. The need for fuel oil for boilers is 1579845 kg/year, compressed air is 36.95 m3 /hour. The results of the economic evaluation of this factory require that Fixed Capital Investment (FC) is IDR 5,139,570,041,066, Working Capital (WC) IDR 644,806,228,213, Manufacturing Cost (MC) IDR 3,150,033,874,837, and General Expenses (GE) IDR 469,031,437,478. The economic analysis shows the ROI before tax is 29.12% and the ROI after tax is 22%. POT before tax is 3.43 years and POT after tax is 4.58 years. The BEP value is 30.022%, the SDP value is 19.18%, and the DCFR value is 25%. Thus, from a technical and economic point of view, a Phosphoric Acid Plant from Phosphoric Rock and Sulfuric Acid is worthy of consideration.