MAP / DAP Granulation

Features

• JPipe reactor techniques commercialized since 1986
• Single train plant up to 100 tonnes/hour DAP or MAP
• The JPipe reactor functions alone in MAP and NPK grades and in conjunction with a preneutraliser for DAP
• Optimization of water balance provides flexibility of acid strength and source
• Recycle quantity reduced by about 30% compared with conventional processes
• Fuel and electricity consumption reduced by about 25% compared with conventional processes
• Simplicity in operation leads to lower maintenance costs
• Product flexibility - wide range of NPK grades possible based on urea or ammonium nitrate as well as MAP/DAP from the same plant.

The Process

The use of the JPipe reactor permits a significant reduction in the water fed to the granulator, allowing operation at an increased granulation temperature. This leads to a higher granulation efficiency and lower recycle ratio. The higher temperature and lower water content of solids from the granulator reduces the dryer duty, resulting in lower fuel usage.

The detailed experience of pipe reactor operation gained from plants in Brazil was then put to use in the international process licensing market. Initially through revamps and later in new custom designed plants, KEMWorks and JS Associates now has a wide experience with the production of a large range of NP and NPK grades in addition to MAP and DAP, utilizing phosphoric acid from all the major world resources of P2O5.

For DAP, the JPipe reactor provides operation at recycle ratios of about 3:1 compared to 4-5:1 for the conventional atmospheric reactor route.

The JSA process utilizes well proven conventional equipment for granulator, dryers, coolers, screens and crushers. Two-stage gas scrubbing for ammonia recovery ensures a liquid effluent free plant with gaseous emissions to international air pollution standards. Simplicity and flexibility of operation are the key design consideration

Advantages

• Lower Capital Investment
• Operating Simplicity
• Lower Maintenance Costs

JPipe Reactor

The JPipe reactor for producing MAP and DCP has been used in five installations in Brazil and a pipe for Agrium was started up in May 2001. The JPipe's unique shape allows the pipe to have sufficient residence time to reduce ammonia losses in a small overall length.