SULPHURIC ACID

The most advanced process, Double Conversion and Double Absorption Processes (DCDA), is being adopted for producing Sulphuric.By product steam can be used  in other processes of complex OR to produce Captive Power.Steam is used for melting Elemental Sulphur, in Semi Buried Pits & Impurities are Settled & Separated.Clean Sulphur is finely sprayed in a Furnace, where it is burnt to produce Sulphur Di Oxide .Temperature of Gaseous mixture goes up to 1000 – 1050 deg C & is cooled in a Waste Heat Boiler to produce Steam.Gaseous mixture is passed through Hot Gas Filter, before going to Converter. In Converter SO2 is converted into SO3 in presence of Catalyst in 3-stages.

Heat of Reaction is used to heat Boiler Feed Water & Super Heating by Steam Gaseous mixture containing SO3 is passed through Inter pass Absorption Tower (IPAT). Here available SO3 is absorbed in Circulating Acid.Gaseous mixture going out from IPAT, is taken to Last Stage of Conversion, where remaining SO2 is also converted to SO3 & gaseous mixture is fed to Final Absorption Tower where Total SO3 is converted in to Sulphuric Acid.Circulating Acid is cooled to required temperature in Acid cooler & Acid produced is peeped out to Storage Tank.99.85% Conversion & 99.995% Absorption is achieved.This Plant is Continuous Plant & Stopped once in a Year for maintenance.Cool Concentrated Sulphuric Acid (98.4%), is stored in Mild Steel Tanks for Dispatch to user point.It is Environment Friendly, Zero Liquid Discharge Process

SINGLE SUPER PHOSPHATES

 The phosphatic fertiliser is produced by reaction between rock phosphate & sulphuric acid.Phosphatic rock phosphate ( a mineral ) is stored in covered shed.It is ground to fine powder of 1oo mesh , in a air swept grinding mill & stored in a steel bunker.The system is closed circuit & hence any dust is not evolved in the area of operation.The ground rock & sulphuric acid are fed to a rotating mixer.Here acidulation process takes place & thick pasty material is dumped in to slow moving machine called den. Here the mater is retained for 30 min. & Further reaction takes place.

About 84-86 % of reaction is completed in den & semi dry powdery material (Green SSP) is discharged in to curing yard, by den. In Curing yard the material is reshuffled 3 to 4 times, remaining reaction takes place over here & Fully Cured material is kept in heaps. After quality check the material is fed to packing Hopper & Packed in 50 Kg bags & stacked in Finished storage, for shipment to costumers. Movement of Rock & Loose SSP ,is done with the help of E.O.T Crane ,Installed storage Yard. During Acidulation process , HF Gas is evolved. This is sucked by an I.D. fan through a Scrubbing Train. This Train ( Scrubbing system ) contains High Velocity Jet Scrubber, Venture Scrubber-2 sets, Silica Separator.The gases being sucked are scrubbed in the equipment & converted into Liquid called Hydro flosilicic Acid. The Clean Gases, having Gaseous effluent, within prescribed limit, are discharged to atmosphere at a Height of 41 metres from Ground Level , through a CHIMNEY , attached at discharge Of I.D. fan. The Liquor so generated ( H2SiF6 )is used back in Process , for diluting the Acid in Mixer.This Liquor can be used for producing Sodium Silico Fluoride – chemical used in Glass Industries. Hence There is No Liquid Effluent discharge from This Plant & The Plant is Termed As “ ZERO DISCHARGE PLANT “.
Single Super Phosphate powder can be granulated to small spherical granules in Granulation Plant.

BY PRODUCT STEAM & POWER

Steam produced in Sulphuric Acid Plant is used to produce Electric Power.If Steam is required in any other Product process of Complex. We can Produce Power & Exhaust steam can be used in process of other plants. This is A Clean Energy Plant, as any additional fuel is not required & By Product STEAM is used to produce POWER. Acid Plant is operated with the Power produced in Plant and Extra power can be Exported to other Plant of Complex.