pap design basis
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MA’ADEN TRAINING
PLANT DESIGN BASIS
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
1460 tpd P2O5
CAPACITY
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
Ex filter40% P2O5
Ex evaporator48% P2O5
PRODUCT ACID QUALITY
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
Al Jalamid
RAW MATERIALSPhosphate Rock
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
ROCK ANALYSISChemical Analysis (dry basis)
3.72 – 4.004.00F0.70 – 1.000.70MgO
0.077 – 0.1000.09Fe2O3
0.068 – 0.1300.07Al2O3
0.730 – 0.9390.89SO3
49.73 – 55.4052.0CaO31.90 – 34.3032.50P2O5
Contract Range Analysis % wt/wt
Design Basis Analysis% wt/wt
Component
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
ROCK ANALYSISChemical Analysis (dry basis)
6.0 max5.0Free H2O0.11 – 0.450.15Combined H2O4.83 – 7.106.70CO2
0.012 – 0.0300.02K2O0.227 – 0.3300.28Na2O0.432 – 8.213.4SiO2
0.0069 – 0.0100.01Cl
Contract Range Analysis % wt/wt
Design Basis Analysis% wt/wt
Component
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
ROCK ANALYSIS
12 to 15+ 38
2 to 3- 38
50 to 59+ 106
21 to 28+ 212
2 to 6+ 300
0+ 700
Amount Retained (wt%)Size (microns)
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
RAW MATERIALSSulphuric Acid
Concentration 98.5% H2SO4
State LiquidTemperature Ambient to 45°C
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
RAW MATERIALSKaolin
Source Saudi ArabiaSiO2 content 39.4%Al2O3 content 33.6%MgO content 0.2%Fe2O3 content 1.5%CaO content 0.92%Bulk density 0.46 g/cm³ (loose)Typical Screen analysis 100% <71 micron
To promote stable crystallisation of hemihydrate and to suppress the corrosivity
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
RAW MATERIALSKieselguhr
Type Diatomaceous EarthSource Ma’adenSiO2 content 86.6%Al2O3 content 5.0%MgO content 0.6%Fe2O3 content 1.7%CaO content 0.4%
To suppress the corrosivity
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
RAW MATERIALSDefoamer
Type: Typically alkylene glycolic fatty acid esterStruktol SB 2094 is suitable
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
RAW MATERIALSAnti-Scaling Additive
To reduce scaling of filter circuits
Type: Sodium hexametaphosphateForm: Powder or glass chipTotal P2O5 68% min.Hexametaphosphate 80% min.Loss on Ignition 0.7% max.Chain Length 9 or aboveNote Hygroscopic
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
UTILITIESProcess Water
Temperature 35°CPressure 275kPa(a)
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
UTILITIESSteam
LP SteamTemperature 155°CPressure 340kPa(g)
MP SteamTemperature 178°CPressure 690kPa(g)
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
Voltageabove 150kW 4160 V0.4-150kW 400 V below 0.4kW 230 V
3 phases60 Hz
UTILITIESElectricity
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
Plant AirTemperature 35°CPressure 800kPa(a)
Instrument AirTemperature 35°CPressure 800kPa(a)
UTILITIESAir
MA’ADEN PHOSPHATE PROJECT
November 2009
Design Basis
UTILITIESEffluents
GypsumQuantity 1125 tph (dry weight)
GaseousFluorine (HF) 5mgF/Nm³
Liquid EffluentNo Liquid Effluent
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