Our Phosphate Experience
PENN PRO engineers have successfully completed thousands of projects during our twenty years of existence. While some have been small in size and scope, others have required a complex multidiscipline approach with detailed planning, estimating and execution. A substantial number of our projects have been full EPCM efforts including everything from a process evaluation and selection of alternatives to process design, detailed engineering, procurement, and construction management. The following provides some examples in the phosphate industry:
- In recent years the phosphate industry has been phasing out the manufacture of granular triple superphosphate (GTSP) in favor of high nutrient fertilizers such as di-ammonium phosphate (DAP) and mono-ammonium phosphate (MAP). PENN PRO has played a major role in helping producers make the needed transition by leading the conversion of two of the largest units in the world. In one of the conversions, PENN PRO acted as the project manager and the construction manager, while in the other PENN PRO was selected as the full EPCM Contractor. The project included preliminary engineering, detailed engineering, project management, construction management and procurement. Operating manuals, employee training and start up were also part of the scope. Major process changes required in the GTSP plant conversion included: new reactor for improved recovery, redesign of the tail gas scrubber and primary scrubbers, upgrade of all vent fans and ducts, addition of an ammonia vaporizer and ammonia feed system, along with controls and instrumentation, replacement of chain mills with cage mills, plus a new rotary drum cooler and a product coating drum.
- Under the EPA’s RCRA rules many chemical processing plants must eliminate very high pH or very low pH wastewater streams or treat them before transporting them to impoundments. This requires wastewater transmission and collection systems, controls, supplemental treatment processes and treated water return pipelines. PENN PRO has just successfully completed design and installation of such a system for one of the three major phosphate producers in Florida. The EPCM project was completed on budget, on schedule and is operating flawlessly. A project for another major phosphate producer has also just begun; however, in addition to collection and treatment of wastewater, this one will require major changes to the existing manufacturing processes.
- In the area of mining, PENN PRO has redesigned existing facilities including washers and beneficiation plants, has designed a pre-washer, has designed numerous matrix pumping systems, and has designed several modular, portable flotation plants.
- PENN PRO has designed a number transmission pipelines for contaminated pondwater transfer across state and county roads, railroads and wetland areas, and in some cases water streams. Pipelines ranged in length from three miles to six miles. Each pipeline had to be a double pipe (carrier in a casing) with leak detection instruments strategically located along the length of the pipeline. Pump stations varied in capacity from 1500 to 3500 GPM.