Industrial Report by Arfin
Industrial Report by Arfin
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
Product Name:
By product : Gypsum
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,
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.
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.
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.
Gypsum:
Specification of
products : TSP SSP