Authors:
M. Dionne, P. Lavoie
AiChE: 34th International Phosphate Fertilizer & Sulfuric Acid Technology Conference, Clearwater Beach, USA, June 2010
Abstract
This paper presents an approach that can be applied for Plant optimization and debottlenecking. Hence, it will emphasize methodology and experimental description rather than end results, although this project was successful and created value for the client. A capacity increase program was initiated which was divided into multiple study Phases to reduce complexity thereby maximizing the probability of success. The were two major bottlenecks addressed subsequently with the respective objectives of 1) understanding identifying and solving the filter cloth blinding problem and 2) identifying the Flotation Plant bottlenecks and recommend solution for immediate improvements. The developed approach was based on an R&D project model that included: internal and external literature review, development of an ARENA model of the Plant, Process Performance Assessment to establish the base case process KPI’s, historical and in-plant DOE for process parameters optimization, mechanical and process equipment Audits to bring equipment back to original equipment manufacturer design, as well as the use of advanced microscopic characterization techniques that enabled the identification of the cause of the filter cloths blinding and the proposal of practical solutions to be tested in-Plant.
Process Performance Assessment combined with Design of Experiment resulted in recommended parameter changes/adjustments for optimal/improved filtering efficiency for a possible filtering rate capacity increase of 5 to 10 %. The Flotation Plant performance Audit established the current flotation circuit capacity and identified the bottlenecks for capacity increase, resulting in a list of recommendations for process control improvements. Finally, literature review generated some additional benefits. New flotation reagents have been identified and tested at the laboratory scale and might lead to Flotation Plant efficiency improvements while lowering the cost of reagents by 30 to 50%.
