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Industrial Report by Arfin

This document summarizes a field work and industrial tour report submitted by a student for their third year chemistry degree. The report describes a tour of TSP Complex Limited, a fertilizer manufacturing company in Chattogram, Bangladesh. The tour provided students with an understanding of TSP Complex's manufacturing processes, products, and raw materials. Key points covered include that TSP Complex produces triple super phosphate (TSP) and single super phosphate (SSP) fertilizers using rock phosphate, rock sulfur, and phosphoric acid as raw materials. The sulfuric acid and phosphoric acid production processes are also summarized.

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Arefin Shahriar
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0% found this document useful (0 votes)
45 views14 pages

Industrial Report by Arfin

This document summarizes a field work and industrial tour report submitted by a student for their third year chemistry degree. The report describes a tour of TSP Complex Limited, a fertilizer manufacturing company in Chattogram, Bangladesh. The tour provided students with an understanding of TSP Complex's manufacturing processes, products, and raw materials. Key points covered include that TSP Complex produces triple super phosphate (TSP) and single super phosphate (SSP) fertilizers using rock phosphate, rock sulfur, and phosphoric acid as raw materials. The sulfuric acid and phosphoric acid production processes are also summarized.

Uploaded by

Arefin Shahriar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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You are on page 1/ 14

Course Title: Field Work and Industrial Tour

Course Code: Chem-3712

SUBMITTED TO
Dr. Sayeda Halima Begum
Chairman
TSP Complex Limited
Exam Committee 3rd Year
Patenga, Chattogram B.Sc. (Hon’s) Examination,
2021
SUBMITTED BY
Md Shaharia Arfin Tasnub
ID: 19202003
Session: 2018-19
Date of Submission
3rd January, 2023
Acknowladegement
All the praises admiration and appreciation to the Almighty Allah who has enabled us to go on
this tour and learn these valuable knowledges. During this knowledge dispersing industrial tour
we learned a lot of about the chemical processes that are used in different industries and
companies. I express my sincere gratitude to our respected teachers
1. Dr. Shamim Akhtar,
2. Dr. M. Abdul Mannan,
3. Dr. Syeda Khurshida Begum,
4. Dr. Sayeda Halima Begum,
5. Dr. Mohammad Nasir Uddin,
6. Dr. Mohammad Ismail Hossain
7. Dr. Md. Kamrul Hossain,
8. Dr. Foni Bushon Biswas,
9. Ms. Jannatul Ferdous
For arranging a visit in such a recognized company. I am grateful to the authority, Officers and
workers of TSPCL. It was pleasure to have a great day with them. The officers were very friendly
and they described each and every process of manufacturing.
Special thanks to our honorable exam committee chairman, Prof. Dr. Sayeda Halima Begum for
her support and arrangements of the tour. The tour will boost our practical knowledge and will
be helpful for our carrier.
Contents:

 Background
 Products
 Raw materials
 Plant description
 Manufacturing process
 Mixed fertilizer
 Other products
 GYPSUM (by-product)
 Future prospect of TSP in Bangladesh
TSP COMPLEX LIMITED
A Company of BCIC

Location: Potenga, Chittagong 4204, GPO Box No. 378, Bangladesh


Back Ground:
Triple Super Phosphate Complex Limited (TSPCL) is a public sector enterprise registered as a pricate
Limited Co. situated at Patenga, Chittagong, under the administrative control of Bangladesh Chemical
Industries Corporation (BCIC). TSP Complex was established with the objective of producing TSP fertilizer.
Accordingly 2 (Two) units viz TSP-I and TSP-II-1,20,000 MT respectively). Among the units TSP-II was
commissioned earlier. TSP-I unit went into commercial production in April 1977 and TSP-II in September,
1974. TSP Complex is the only Phosphatic Fertilizer Factory of the country. Initially the factory started with
production of TSP. Later on since 1990 manufacturing of SSP Fertilizer was started and his already
established itself as a major fertilizer of the country. On account of technical problem in TSP-I unit, the
Phosphoric Acid (PA) Plant of the unit was abandoned and closed. Due to increasing demand of SSP
Fertilizer in the country, the facilities of TSP-I were then converted to produce SSP. In TSP-II Unit,
necessary TSP-I and TSP-II plants are now known as Unit-I and Unit-II respectively. Production of this
factory is increasing day by day and in 2002-2003 total production of 2,00,528 MT Phosphatic Fertilizer was
achieved. The basic raw materials are Phosphate Rock (PR) and Element Sulphur (S) which are imported.
Triple Super Phosphate (TSP) Fertilizer
Triple Super Phosphate (TSP) fertilizer is composed of inorganic nutrients that are used to restore soil
components essential for farming. TSP is the abbreviation of triple superphosphate with chemical formula of
Ca(H2PO4 ). The concentration of P 2O5 (PHOSPHATE) is around 44-46%. Phosphate is one of the soil
components that is vital to help promote root growth of all kinds of plants, so that the roots will be thicker,
stronger and healthier. Phosphate will thus strengthen the trunk and increase its resistance against disease
and pests, as well as reduce the risk of uprooting and spur flower development and seed maturity, thus
accelerating harvest times. Phosphorous deficiency may cause a plant to have stunted growth, dark green
color on leaves, fewer seedlings, long period of maturation and low productivity (plant will not bear fruits
often.

Specifications of TSP FERTILIZER


Composition of P2O5 = 44%-46%,
Color: Brownish
Form: granular.

Product Name:

▪ TSP(Triple Super Phosphate)


▪ SSP(Single Super Phosphate)
▪ NPKS(Nitrogen, Phosphorus, Potassium and Sulphur)
Intermediate Product: Sulfuric acid and Phosphoric acid

By product : Gypsum

Raw material: 1.Rock Phosphate, 2.Rock Sulphur, 3.Phosphoric Acid.

Water treatment plant


This plant has been planned to supply process water to TSP complex.The water to be
treated is river water.
Treatment Principle:
Pretreatment: Coagulation – Flocculation – Settling

pseudo colloidal suspended solids which must be gathered into a bulky and heavy floc to
allow settling and help retention in the filters.The interfaces of colloids are electrically
charged, which prevents nearby particles from coming close together.
The action takes place in three steps:
Coagulation, which destabilizes the colloids to give rise to a precipitate.
Flocculation, which destabilizes the colloids to give rise to a precipitate,
Flocculation, which is intended to increase the volume and cohesion of the floc formed by
coagulation,

Settling: which is intended to permit particles to settle out.


DEMINERALIZATION:

dissolved salts from the raw water. These salts are essentially bicarbonates, sulphates,
chlorides and silica.
Two types of ion exchangers are available :
Cation exchangers, featured by the presence of acid, sulphonic functional radicals in the
molecule.They exchange their cations (H+ or any other cation) bound with the active radicals
for the cations in the liquid with which they are in contact (Ca, Mg, Na, etc.), and this in
a reversible manner.
They are regenerated with an acid solution.
Strong acid cation exchangers (sulphonic function) can take up all cations. Including those in
equilibrium with strong anions : sulphates, chlorides, nitrates.
Anion exchangers, featured by the presence of basic functional radicals in the molecule.
They exchange their anions (OH or any other anion) bound with the active radicals for the
anions in the liquid with which they are in contact (Cl -, SO 4 -, NO -, 3
SiO 2, and this in a reversible manner. They are regenerated with an alkaline
solution. Weak-base anion exchangers can only take up the anions from strong acids (HCl,
HNO 3, H2SO4). Strong-base anion exchangers can take up the anions from strong acids and
the anions from weak acids such as carbonic acid and silica. The feed water
successively passes through one H+ cycle cation exchanger and two OH– cycle anion
exchangers. After passing through the strong acid cation exchanger, all the cations in the
water are replaced by the hydrogen ion, H, of the resin; then, the treated water only
contains the acids of the initial salts. The decationized water next passes through the
weak-base anion exchanger and the strong-base anion exchanger. All of its anions are
replaced by the hydroxyl ion, OH–; then, the demineralized water only contains traces
of caustic soda corresponding to the cation leakage.The treated water is highly pure
and has a constant quality at a pH close to neutral.
SULPHURIC ACID PLANTS:
The manufacturing process of sulphuric acid consists of the following principal steps:
● Melting of sulphur.
● Production of sulphur dioxide (SO2)
● Conversion of sulphur dioxide to sulphur Trioxide (SO3)
● Cooling of SO3 gas and absorption of SO3 in water to produce 98.5% sulphuric acid.
Sulfuric acid required for manufacture of phosphoric acid is produced by monsanto contact
process in both the units. In this process Rock sulphur is melted in a melter and brunt in
a furnace in presence of dry air where sulphur is oxidised to sulphur dioxide (SO2) gas. This
gas is then converted into Sulphur trioxide (SO3) gas in a converter in presence of catalyst,
(V2O5) under optimum conditions, SO3 gas is then observed in 98.5% sulphuric acid in an
absorbing Tower. Strength of the absorbing acid is thereby raised which in turn is diluted by
adding demineralized water to maintain the desired strength. The quantity of acid in
absorbing Tower is thus continuously increased and the increased portion is sent to the
storage tanks as 98.5% sulphuric acid.
Reaction: S + O2= SO2, SO2+ ½ O2=SO3, SO3+ H20= H2SO4.

Phosphoric Acid Plant:


Phosphoric Acid required for production of TSP is manufactured by Hemihydrate- Dihydrate
process.
In this process, rock phosphate ground to the fineness of 70% passing through 200 Tyler
mesh is mixed thoroughly with Sulphuric Acid (70%) and dilute Phosphoric Acid (19-
21%) in a tank to acidulate. The reacted slurry is passed into a series of tanks
successively to effect decomposition of rock, crystallization of Gypsum and completion of
reaction. Slurry in each reacting vessel is constantly agitated with agitators.
Temperature and solid-liquid ratio and acid concentration are kept at standard levels
designed for the process. From the last reacting vessel, the slurry is pumped into a Vacuum
Filter to separate the acid form the Gypsum. The first filtrate is the product acid of 30% P2O5.
The residue is the filter cake (Gypsum) which is sent to Gypsum Yard after final washing
with hot water. This residue is the by-product Gypsum (CaSO4.2H2O).
Reaction: Ca3(PO4)2 + 3H2SO4 + 6H2O = 2H3PO4 + 3CaSO4.2H2O

The product acid of 30% P2O5 is then concentrated to 50% P2O5 acid in a
concentrator (Calandria) by heating the material with steam under forced vacuum circulation
system as 50% P2O5 acid is required to manufacture TSP of 46% P2O5.

The preparation of phosphoric acid is occurred by the following way:

TSP Plant:
Triple Super Phosphate is manufactured by decomposition of rock phosphate ground to the
fineness of 80% pass through 200 Tyler mesh in an air swept Ball Mill, with phosphoric
acid (50%) P2O5 in a Reaction Den under standard conditions of temperature and flow are.
The Den product is known as Green TSP. Green TSP is fed in a Granulator through conveying
system, where granules are formed through the principle of agglomeration with steam and
process water. Granular TSP is then dried with hot air generated by combustion of natural gas
and then bagged to get finished product of granular TSP.
Reaction: Ca3(PO4)2 +4H3PO4 + 3H2O=3CaH3 (PO4) 2H2O
SSP Plant:
SSP is manufactured by acidulating finely ground phosphate rock with 70-75% sulphuric
acid in Reaction Den under standard conditions of temperature and flow rate. The outlet Den
product known as Green SSP is kept in a curing house for about three weeks for completion of
the reactions. The cured SSP is then dried by natural air and bagged to get finished
product of powder SSP.
Production of SSP in powder form started since 1988 in Unit No. 1. But with the
rising trend of use of SSP in agriculture, arrangement was made to produce SSP through
Unit No. 2 also.
Reaction: Ca3 (PO4)2 + 2H2SO4 + 5H2O = 2CaSO4.2H2O + CaH4(PO4)2.H2O

Manufacturing process:
The manufacture of triple super phosphate involves following steps:
a) Reaction
b) Denning or Den process step
c) Storage and curing234
d) Granulation
a)Reaction
The reaction is carried out in a cone-mixer. A similar process known as
Kuhlman process uses a mixer that has a high-speed stirrer in a cylindrical vessel. 95 to 98%
of the ground rock phosphate, passed through 100 mesh sieve, is mixed with phosphoric acid
(1kg rock phosphate of 34% P2O5 is mixed with 2.6kg acid). The acid is of commercial
grade with P2O5 content of 52%.

b) Den step
The den step, of TSP is faster (10-30min) than that for SSP (30-120min). The mixture
from the reaction vessel goes to the den where it solidifies owing to continued
reaction and crystallization of monocalcium phosphate.

c)Storage and curing step


Product from den step is stored in piles for curing. Curing requires 3 to 6 weeks,
depending on the quality of raw materials. During curing, the free acid, moisture and
unreacted rock contents decrease and the available phosphorus and the water soluble
P2O5 increase. Fluorine compounds evolved in minor quantities which are scrubbed to
prevent atmospheric pollution.
After storage and curing, TSP is ground to a 6 mesh screen (3.3 mm). This material
is called run off pile TSP or ROP-TSP and is used for making compound fertilizers by
agglomeration granulation.
d) Granulation process
Granulation is preferred due to powder form have dusty nature and caking
quality when moist. The milled and screened TSP is conveyed to a drum granulator where
water is sprayed and steam is spurge underneath the bed to wet the material. The wet
granules are dried in the rotary drier. The dried granules are screened, and the oversized
and the fines are returned to the granulator. The dust and fumes from the drier are
scrubbed or removed by the dust filter.
e)Bagging Process:
The granules are then packed in Polypropylene bags. Each bag contains 50 kg products.

Gypsum:

Gypsum (CaSO4.2H2O) a by-product of Phosphoric acid manufacturing process has use as a


supplementary fertilizer for soil treatment. It is generally used in sulphur deficient areas.

Mixed fertilizer (NPKS):


From the year 2002, TSPC is experimentally producing one grade of mixed fertilizer for paddy
grade as per recommendation of Bangladesh Agricultural Research Council (BARC). Marketing of
this fertilizer has already been started for use at farmer’s end.
We are also working for production of NPKS suitable for tea production. This fertilizer will
increase the fertility of land and also production. The basic raw materials are TSP, SSP,
Ammonium Sulfate (AS), Di-ammonium Phosphate (DAP) and Murate of Potash (MOP).

Specification of
products : TSP SSP

Total P2O5 46% (min) 18 - 20%

Free P2O5 03% (max) 03% (max)


Sulphur - 10% (min)
Available P2O5 43-44% 16-17%
Moisture 05% (max) 08% (max)
Physical character Granular Powder
Other Products:
Sulphuric Acid 98.5%, Phosphoric Acid 48.5% P2O5, Gypsum:S:18%(min), Ca
:22%(min). mixed fertilizer (NPKS) : 8: 20: 14: 5.

Futer Prospect of TSP in Bangladesh


If the installed capacities of TSP complex, DAP plants and SSP plant of Hussain Chemicals Ltd.
Could be fully utilized the net local yearly production of TSP equivalent will be close to
700,000 t. The sector is failing because of
non-availability of elemental sulfur, phosphate rock and phosphoric acid. Placement of fund
timely and procurement procedure have aggravated the situation.
Nevertheless, besides solving the existing problems of this sector; the country should aim
at achieving TSP equivalent production capacity close to 1 million ton. Additional TSP
equivalent of 300,000t can be met by producing SSP for its ability to supply sulfur also
needed in some areas in the country.

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