Digital chemical analysis in pursuit for accuracy in phosphoric acid pilot plant

According to https://www.reportsanddata.com/ published in September 2022, the global phosphoric acid market size was USD 48.75 Billion in 2021 and is expected to register a revenue CAGR of 3.8% by 2030 a synopsis of which is presented in Figure 1.

Phosphoric acid is available in various grades, each with its own specific concentration range, specifications, and applications. Merchant grade phosphoric acid typically ranges from 50% to 75% phosphoric acid (H?PO?) by weight. It finds application in industries such as metal treatment, detergent production, and water treatment. Food grade phosphoric acid, with concentrations generally between 75% and 85%, is widely used in the food and beverage industry as an acidulant, pH adjuster, and flavour enhancer. Technical grade phosphoric acid, falling within the range of 75% to 85%, serves various purposes, including rust removal, pH adjustment in industrial processes, and as a chemical intermediate. Fertiliser grade phosphoric acid, also typically within the range of 75% to 85%, is a key ingredient in the production of phosphate fertilisers, supplying essential nutrients to plants. Lastly, battery grade phosphoric acid exhibits high purity levels, ranging from 85% to 95%, making it suitable for the production of LiFePO4-batteries, and other energy storage applications. Each grade of phosphoric acid plays a vital role in different industries, offering tailored solutions for specific needs.

It is well understood that unexpected obstacles are bound to be encountered during the execution of long continuous pilot plants. It is important to acknowledge that these challenges can have a demotivating effect, particularly when the plant is operated by a dedicated team working in fixed shifts with rotations. As a project manager, the art lies in effectively managing various responsibilities, including project finances, procurement, human resources, technical aspects, and the quality of service. Ultimately, the success of the project hinges upon the quality of service delivered, with a significant role played by precise analytical results.

This is a story if a journey that taught me a lot in utilising innovative techniques to transform our continuous battery-grade phosphoric acid production pilot plant to a success.?Picture this: over 100 days of relentless 24/7 shift work, with a team that refused to settle for anything less than perfection. But here's the catch - running a phosphoric acid pilot plant brings its fair share of challenges. With the P2O5 matrix contaminated by considerable ranges of base metals, it becomes challenging to maintain precise analysis. Given the strict quality limits for the final product, a high level of accuracy is paramount. For us, different techniques like calorimetry, ICP-OES, and titration led to slight discrepancies in results which seemed natural. So, how did we tackle this and generated reliable data?

It is well stablished in the literature that the solution density at a given temperature, varying with P2O5 concentration, plays a crucial role in the transition from merchant grade to battery grade acid, as well as throughout the process steps. However, this variability might not be consistent across different feed sources due to impurities. We adopted two key approaches. Firstly, we constructed graphs using synthetic solutions of varying phosphoric acid concentrations, meticulously analysing their density. This enabled us to establish theoretical correlations between density and concentration. Secondly, as our piloting journey progressed, we continuously generated non-synthetic data and refined the correlations for each stage of the process.

In our two-fold approach, by diligently crunching density-versus-concentration figures and leveraging the power of advanced data analysis techniques, we witnessed the correlations evolve and improve over time. The continuous refinement of these empirical relationships allowed us to reach greater precision in determining P2O5 concentration throughout the pilot plant operation.

This approach, a breakthrough for us, empowered concentration calculation with remarkable accuracy in just a matter of seconds after sample collection which was used to complement accuracy of our analytical measurements and utilised as a guidance for troubleshooting of analysis when needed.

By seamlessly integrating synthetic solution data and real-time results from the pilot plant and laboratory studies, unparalleled accuracy was achieved throughout the project. This remarkable accomplishment stands as a testament to the dedication and collaborative efforts of our team, comprising over 70 passionate individuals.?

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