Odda Process Report Copy
Odda Process Report Copy
Odda Process Report Copy
Odda Process
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1 Abstract
One of the toughest challenges the human race will be facing in near future is to
provide every individual with adequate food. According to an estimate by the Food
and Agriculture Organization (FAO) of the United Nations, food production must
increase by 70% by 2050. In order to achieve this, we need to come up with pro-
ductive fertilizers so as to enhance the crop yield. As 40 to 60% of the net global
crop yield is attributable to fertilizers, our purpose will definitely be satisfied.
In order to come up with a detailed flowchart of the Odda process, various sources
had been referred to. Similarly, values of heat capacities, heats of formations, &
heats of combustion of various compounds were obtained using reliable databases.
All these values made the energy calculations of all the intermediate streams pos-
sible.
Given the input feed rate, the mass & energy compositions of various streams have
been calculated. Concepts of material balance & energy balance, have been elu-
cidated & are extensively used for performing the calculations. All the computed
values for every stream of the process have been tabulated. However, for the ease
of calculations, various assumptions have been taken, which are also mentioned
further.
Reactive as well as non-reactive processes observed over each stream have been
described along with the mention of temperatures & pH value conditions, wherever
necessary. Also, the conclusions which are drawn from the analysis of the Odda
process & the importance of process has been explicitly mentioned. Through this
project, we were able to gain an insight of the real world chemical industries as
well as the job of a chemical engineer. Also, we’ve come to a consensus about
the significance of accurate data so as to refrain from the error observed in the
efficiency of the process.
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Contents
1 Abstract 2
2 Introduction 4
3 Material Balance 7
3.1 Dissolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Neutralisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 CAN Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Energy Balance 13
4.1 Dissolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Neutralisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 CAN Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Conclusion 21
7 Calculation Data 23
8 References 24
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2 Introduction
Odda process is an industrial method of the production of nitrogenous fertilizers.
Erling Johnson from Odda, Norway, brought light to this process. This process
involves the acidification of phosphate rock with nitric acid to produce calcium
nitrate and phosphoric acid, which undergoes CAN conversion reaction and neu-
tralization respectively to produce ammonium nitrate.
Nitrogenous fertilizers play a notable role in the growth of the plants by stimu-
lating chloroplasts, which are responsible for photosynthesis. The plants absorb
nitrogen in two forms: nitrate form and the ammoniacal form. The nitrate fertiliz-
ers dissolve easily in water and are quickly accessible to the plants. The ammonia-
cal fertilizers comprise of the positively charged ammonium ions that can interact
with the negatively charges clay or humus and hence are resistant to leaching. They
can also be used by the plants that require nitrogen in the nitrate form because of
its easy conversion into nitrate. The Odda process indulges in the production of
nitrogenous fertilizers by the production of ammonium nitrate. Ammonium nitrate
consists of both ammonia and nitrate; hence, its application lies in a wide range of
industries.
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On the other hand, the mother liquor is subjected to the neutralization reaction in
the presence of ammonia to form ammonium nitrate.
Ammonium nitrate is collected from both the processes and is then subjected to
drying. The final product obtained can be used as a fertilizer.
Step 1:
Dissolution of phosphate rock in excess nitric acid Phosphate rock is pulverized to
increase its surface area and therefore the rate of the reaction. It is then dissolved
in excess nitric acid(60%w/w and 10% excess) in a cascade reactor to produce
calcium nitrate, phosphoric acid, and hydrofluoric acid. The temperature of the
reaction increases to about 70 degrees celcius because of the heat of the reaction,
which results in the evaporation of hydrofluoric acid. The reaction can be repre-
sented by:
Step 2
Crystallization of Calcium Nitrate The solution undergoes a slow cooling process
at -5 degrees Celcius to separate 80-85 % of calcium nitrate in the form of crystals
of calcium nitrate tetrahydrate.
The calcium nitrate is filtered out of the solution and is then processed in the CAN
conversion reactor. The left mother liquor is subjected to the neutralization pro-
cess.
Step 3
Neutralization of mother liquor The mother liquor comprising phosphoric acid, ni-
tric acid, hydrofluoric acid, and other impurities like calcium, magnesium nitrates,
and dissolved cations like iron, aluminum is contacted with ammonia gas. The am-
monia gas initiates the neutralization process under strict ph control. Nitric acid is
the first substance to react during the process because of its high acidic strength.
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There is an increase in the ph of the solution due to the addition of ammonia gas
that results in the precipitation of the dihydrogen phosphate salts of several metals.
The amount of ammonia gas added is regulated so as to avoid the precipitation of
metal fluorides.
Step 4
CAN Conversion reactor The separated calcium nitrate reacts with ammonia in
the presence of excess carbon dioxide to produce ammonium nitrate and calcium
carbonate. The produced calcium carbonate can be further processed in the con-
struction industries.
Step 5
The ammonium nitrate produced in step 3 and 4 finally undergoes the drying pro-
cess. The water present in the solution is evaporated to form a slurry of ammonium
hydrogen phosphate. It is then granulated and ultimately processed to form prills
of the final product, which can be used as nitrogenous fertilizer in the agriculture
industry. The addition of potassium chloride in the final product also results in the
formation of NPK fertilizers.
H2 O(l) −→ H2 O(g)
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3 Material Balance
The most important process to understand the basics of the a chemical process
is to perform the material balance. Material Balance is the application of law of
conservation of mass to the chemical process.Material balance for a stream is an
equation which assures that conservation of mass/moles holds true.
Note:- Material Balance cannot be applied to Nuclear Reactions because the prin-
ciple of mass conservation is violated in these reactions.
3.1 Dissolution
Ca5 (P O4 )3 F(s) + 10HN O3(aq) 5Ca(N O3 )2(aq) + 3H3 P O4(aq) + HF(g)
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Compound 1A 2A Generated Consumed A3B O1
Ca5 (P O4 )3 F F 0 0 F 0 0
HN O3 0 A 0 B A−B 0
Ca(N O3 )2 0 0 C 0 C 0
H3 P O4 0 0 D 0 D 0
HF 0 0 E 0 0 E
N H3 0 0 0 0 0 0
N H4 N O3 0 0 0 0 0 0
CO2 0 0 0 0 0 0
CaCO3 0 0 0 0 0 0
H2 O 0 0 0 0 0 0
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3.2 Neutralisation
HN O3(aq) + N H3(g) −→ N H4 N O3(aq)
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Compound 9E C6E Generated Consumed E10F
Ca5 (P O4 )3 F 0 0 0 F 0
HN O3 0 9.09 0 0 0
Ca(N O3 )2 0 0 0 0 0
H3 P O4 0 0 0 0 0
HF 0 0 0 0 0
N H3 9.09 0 0 0 0
N H4 N O3 0 0 0 0 9.09
CO2 0 0 0 0 0
CaCO3 0 0 0 0 0
H2 O 0 0 0 0 0
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Compound C5D 7D 8D O2 D11F
Ca5 (P O4 )3 F 0 0 0 0 0
HN O3 0 0 0 0 0
Ca(N O3 )2 C 0 0 0 0
H3 P O4 0 0 0 0 0
HF 0 0 0 0 0
N H3 0 D 0 0 0
N H4 N O3 0 0 0 0 F
CO2 0 0 E 0 0
CaCO3 0 0 0 B 0
H2 O 0 0 0 0 0
3.4 Drying
H2 O(l) −→ H2 O(g)
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Figure 4: Dissolution Streams
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4 Energy Balance
Energy balance for a reaction is an equation which assures that the conservation
of energy holds true. The general equation of energy balance is as given below
where,
Einput is the total energy of the input stream
Egenerated is the energy generated during the process
Eoutput is the total energy of the output stream.
Econsumed is the energy consumed during the process.
Eaccumulated is the energy accumulated during the process.
While doing the energy balance calculations, we made the following assumptions:
⇒ Enthalpy Calculation:
Z T2
h= ∆Hfo + cp dT
T1
4.1 Dissolution
⇒ Reaction
⇒ Reaction Conditions
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• Tf inal =70 degrees celcius
• P =1 atm
Z T2
h= ∆Hfo + cp dT
T1
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where, ∆Hfo denotes the standard enthalpy of formation
Z T2
oCa (P O ) F
h1 = ∆Hf 5 4 3 + cpCa5 (P O4 )3 F dT
T1
Z T2
h2 = ∆HfoHN O3 + cpHN O3 dT
T1
Z T2
oCa(N O3 )2
h4 = ∆Hf + cpCa(N O3 )2 dT
T1
Z T2
h5 = ∆HfoH3 P O4 + cpH3 P O4 dT
T1
Z T2
h6 = ∆HfoHF + cpHF dT
T1
h1 + h2 = h3 + h4 + h5 + +h6 + Q
4.2 Neutralisation
⇒ Reaction
HN O3(aq) + N H3(g) −→ N H4 N O3(aq)
⇒ Reaction Conditions
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• Tf inal = degrees celcius
• P =1 atm
⇒ Reference: HN O3(aq) , N H3(g) , N H4 N O3( aq) at 298K and 1 atm Pressure
Z T2
h= ∆Hfo + cp dT
T1
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Z T2
h2 = ∆HfoN H3 + cpN H3 dT
T1
Z T2
h3 = ∆HfoN H4 N O3 + cpN H4 N O3 dT
T1
h1 + h2 = h3 + Q
⇒ Reaction Conditions
• Tinitial = 70o C
• Tf inal = 25o C
• P =1 atm
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Figure 7: CAN Conversion Stream
Z T2
h= ∆Hfo + cp dT
T1
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Z T2
h4 = ∆HfoCO2 + cpCO2 dT
T1
Z T2
h5 = ∆HfoCaCO3 + cpCaCO3 dT
T1
h1 + h2 + h4 = h5 + h3 + Q
4.4 Drying
⇒ Reaction
H2 O(l) −→ H2 O(g)
⇒ Reaction Conditions
• T = 25o C
• P =1 atm
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Figure 8: Drying Streams
Z T2
h= ∆Hfo + cp dT
T1
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Compound E10F (MJ) D11F (MJ) F12 (MJ) F13 (MJ)
Ca5 (P O4 )3 F 0 0 0 0
HN O3 0 0 0 0
Ca(N O3 )2 0 0 0 0
H3 P O4 0 0 0 0
HF 0 0 0 0
N H3 0 0 0 0
N H4 N O3 9.1 90.9 100 0
CO2 0 0 0 0
CaCO3 0 0 0 0
H2 O 0 0 2.23 145.99
5 Conclusion
Having learned about the Odda process, we came to know about the importance
of nitrogenous fertilizers in food and agriculture. They are necessary to enhance
crop yield. The byproducts formed in the reaction are also very useful in industries.
We came to know about the reactions that took place in the process and the con-
ditions that were applied to get a particular product. We came to know about how
plants are exactly operated. While going through the process, we understood the
real complexity involved in the production at the industry level. It really helped us
understand the importance of the material balance and energy balance which we
learned the entire course. We came to know about the actual application part.
The application of calculating the degree of freedom and solving the equation
through the table method was also clearly visible as in a big process as odda pro-
cess it almost becomes impossible to judge whether the equation are solvable or
not.
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So we can conclude that the Nitrophosphate route provides an interesting avenue
for producing an agronomically balanced complex fertilizer.
Summing it up the project helped us understand the basic operations and calcula-
tions taking place in a real industry and gave us real insights about how chemical
engineers operate.
2. Maitreya Thakur:
Prepared the flow-chart for the overall Odda process. Also, prepared a table
with variables and assumptions for the degree of freedom analysis of the
entire process. Prepared and edited content for the report.
3. Pratyush Bhatt:
Worked on preparing the presentation. Prepared the content for the report.
Helped in material and energy balance calculations. Helped in the manual
energy balance of certain units.
4. Sakshi Baheti:
Involved in preparing the latex report for certain units. Played a crucial role
in the energy section of the latex report, along with the material balances.
Also, helped in creating the individual data tables for the report.
5. Sakshi Kabra:
Assisted in preparing the flow chart. Prepared the material balance tables,
results and other details in the report in latex. Was also involved in sorting,
proof-reading and organization of the content.
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7 Calculation Data
Compound Cp ∆Hof
Ca5 (P O4 )3 F 730 -13558
HN O3 53.29 -173.2
Ca(N O3 )2 149.4 -938.2
H3 P O4 150 -1271.66
HF 29.14 -268.6
N H3 35.564 -46.2
N H4 N O3 139.27 -365.5
CO2 37.12 -393.5
CaCO3 83.5 -1207.0
H2 O 75.348 -241.8
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8 References
• https://webbook.nist.gov/chemistry/
• http://nshs-science.net/chemistry/common/pdf/R-standard_enthalpy_of_formation.pdf
• http://www.matweb.com/search/datasheet.aspx?matguid=c4b97bcd7053495087c25611ce1d1d78ck
• https://en.wikipedia.org/wiki/Nitrophosphate_process
• https://chemicalprojects.wordpress.com/projects/production-of-nitrophosphate/detailed-
process-description/
• https://drive.google.com/drive/folders/0ABqLvXvrpU3sUk9PVA
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