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Brief
Description of project: Abou Zaabal Fertilizers is owned by Polyserve
Fertilizers and Chemicals group. The annual production of the company is
300,000 tons of sulphuric acid, 450,000 tons of single super phosphate,
35,000 tons of phosphoric acid, and 30,000 tons of triple super
phosphate. Abou Zaabal Fertilizers employs 1,400 workers and occupies a
total area of 284,000 m2. Abou Zaabal Fertilizers is planning to
construct a new sulphuric acid plant with a total annual production
capacity of 1250 t/d. The production process of sulphuric acid entails
burning of melted sulphur using dry air to convert it to sulphur
dioxide. This process is an exothermic process where large quantities of
heat are released with the resulting gases. The temperature of exhaust
gases produced reaches 1200 oC. These gases are directed to a waste heat
recovery boiler to be cooled before entering the reactor where sulphur
dioxide is converted to sulphur trioxide. The estimated power needed for
the new plant is approximately 4 MW. The plan of the company is to use
part of the steam generated from the waste heat recovery boiler to
generate the electricity needed for the new sulphuric acid plant and to
condense the remaining portion to be fed into the waste heat recovery
boiler again. This will be done utilizing a 4 MW steam turbine. The
project aims at increasing the capacity of the cogeneration unit to 11
MW where the excess electricity produced will replace current
consumption of the old plant from the grid which amounts to 4.7 MW. The
remaining 2.3 MW will be exported to the grid. An additional component
of the project is to use the exhaust steam from the cogeneration unit to
replace the steam produced by 3 natural gas operating boilers for the
phosphoric acid plant. Brief description of technology: The technology
to be employed by the project is steam turbine cogeneration package. The
cogeneration unit will utilize the steam produced from the waste heat
recovery boiler at a pressure of 60 bar and temperature of 450 oC |
