FLASH COOLER VACCUM

SYSTEM
ARUN KUMAR
DM-ACIDS
 IMPORTANCE OF LLFC
• Good reactor temperature control is essential. Too low a temperature will
increase viscosity and slow down the rate of reaction and crystal growth

• Too high a temperature can cause anhydrite formation and also lead to
increased rates of corrosion and deterioration of the rubber lining. The
optimum temperature for this process is 98-100oC

• The heat load removed by the LLFC is controlled by adjusting the vacuum
setting on the LLFC. Adjustments to the vacuum should be made gradually
noting the ΔT which is an indication of the heat load and the escape
velocity of the evaporated water vapour. Excessive heat removal causes
entrainment and contamination of the H2SiF6.
OPTIMUM REACTION COOLING
• Production rate stability
• High P2O5 recovery
• Low Filter wash heating requirement
• Improved FSA recovery
• Optimum temperature and excess sulphate
• Minimise the scaling
• Complaints with environmental regulation
TYPES OF REACTION COOLING
• Surface cooling
• Flash cooling
Surface cooling:
Pulling large quantity of air through the reactor with high capacity
exhaust fan
Limited CAPEX & OPEX
Smaller reactor
 WHY TO COOL
Thermal balance
H2SO4 98% (H2) Recycled Phos. Acid (H3)

Phosphate enthalpy(H1)
E1 Reaction + Total cooling
Degassing (E6)
Radiation (E4) E2 Dilution H2SO4 +
E3 agitation + effect
LLFC (E7)
E5

Slurry to filter enthalpy (H4)

Input Output
Phosphate: H1 Slurry to filter H4
H2SO4 98%: H2 Radiation: E4
Recycled acid H3 Total cooling effect E5
Reaction: E1
Dilution H2SO4 98%: E2 Degassing: E6
Agitation: E3 LLFC: E7

Q kcal/h = Q kcal/h
 WHY TO COOL
Thermal balance
H2SO4 98% (H2) Recycled Phos. Acid (H3)

Phosphate enthalpy(H1)
E1 Reaction + Total cooling
Degassing (E6)
Radiation (E4) E2 Dilution H2SO4 +
E3 agitation + effect
LLFC (E7)
E5

Slurry to filter enthalpy (H4)

Input Output
Phosphate: H1 Slurry to filter H4
H2SO4 98%: H2 Radiation: E4
Recycled acid H3 Total cooling effect E5
Reaction: E1
Dilution H2SO4 98%: E2 Degassing: E6
Agitation: E3 LLFC: E7

Q kcal/h = Q kcal/h
 LLFC operation

Vacuum
system

Water vapour pressure P ab s.: P2

P1=f (T slurry, %P2O5) Water vap o ur
f lo w: W

P1

T2 T1

Slurry level Atm. P

# 1 # 8

Slurry f lo w: F
LLFC operation

Vacuum
system

Water vapour pressure P abs.: P2

P1=f(T° slurry, %P2O5) Water vapour
flow: W

P1

T2 T1

Slurry level Atm. P

#1 #4

Slurry flow: F
COOLING IS CONTROLLED BY P2

Vaccum impact graph

270 26%
260 27%

Vap. Press. / Abs. Press. (mmHg)

250 28%
240 29%

230
220
210
200
190
180
170
160
150 33%
32%
140 31%
130 30%

120
68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
[LLFC Outlet] Temperature (°C)
26 % P2O5 27 % P2O5 28 % P2O5 29 % P2O5 30 % P2O5 31 % P2O5
32 % P2O5 33 % P2O5
CONTROL
Reaction & Flash cooling layout
Flash cooler

 Since temperature in Reactor-3 (V 2030) is high, the slurry is pumped to V 2040 by P 2040 pump.

 The temperature is reduced by applying vacuum which is done by Liquid ring vacuum pump (K – 2190).

 The temperature difference is around 5 to 6°C and again return to V-2030 by a Dip pipe.

 The thickness of Flash cooler is,

 Base plate- 16mm

 shell plate- 16mm

 Cone Roof- 16mm

 Internal diameter is 4500mm and Total Height is 8980mm (From bottom plate to top of Gas Outlet).
 FLASH COOLER GAS SCRUBBING
• The off-gases from the Flash Cooler are drawn through the Fluorine
Recovery system by the Vacuum Pump Droplet Separator, (V 2151) and
two stages of scrubbing in the towers, 1st Flash . The gases first pass
through Wet Scrubber, (V 2150) the gases pass through a H2SiF6 Cooler
FSA Scrubber, (V 2160) and 2nd Flash Cooler FSA Scrubber, (V 2161) flow
through the Pre Condenser, (V 2170), Condenser, (V 2180), Wet Scrubber
Duct, (V 2181) and finally to the Vacuum Pump, (K 2190).
• CaF2 + H2SO4  2HF + CaSO4
• 4HF + SiO2  SiF4 + 2H2O
• 3SiF4 + 2H2O  2H2SiF6 + SiO2
• recovery acid Concentration is 20% H2SiF6
3.Flash cooler Scrubbing Section
 This section is to scrub the Fluorine vapors from flash cooler due to vacuum.

 This section has following Scrubbing vessels,

Wet scrubber (V 2150) Pre condenser(V 2170)

Droplet Separator(V 2151) Barometric Condenser(V 2180)

1st stage FSA Flash cooler(V 2160) Wet Scrubber duct (V 2181)

2nd Stage FSA Flash cooler(V 2161)

 This section has following Seal tanks,

Wet scrubber Seal Tank (V 2155) 1st FSA FC seal tank ( V 2165)

2nd FSA FC Seal Tank (V 2195) Hot water Tank (V 2175)

Flash Cooler Section
DCS VIEW
DCS VIEW
THANK YOU