PVC Cable Trays in a Phosphoric Acid Plant Project Case OCP Plant
PVC Cable Trays in a phosphoric acid plant
Project Case OCP Plant Site: Jorf Lasfar Complex City: El Jadida Country: Morocco (Africa) Engineering: Jacobs SA Installer: Samsung C&T Owner: Group OCP Maroc Years: 2014-2016 1. The company: OCP (Office Chérifien des Phosphates)
Office Chérifien des Phosphates is the world’s leading producer of phosphate rock and phos- phoric acid as well as one of the leading global fertilizer players, with more than 90 years of history serving agriculture. OCP Group has access to Morocco’s phosphate rock reserves – the largest global reserve base according to USGS. Fully integrated throughout the value chain, the Group’s activities range from mining mineral resources to producing high value-added products. With a global footprint and revenues of more than US$5.5 billion in 2013, the Group has 23,000 employees and serves every key agricultural market in the world. 3.7 Milliard dollars$ is a investment of the group in Ethiopia during The visite of king Mohhammed 6 at this contry.
2. The site: Chemical complex of Jorf-Lasfar
To respond to the international market and develop a local phosphate industry, OCP acquired the Safi chemical complex in 1965 and the Jorf Lasfar complex in 1984. These world-class facilities specialize in the pro- duction of phosphoric acid and fertilizer derivatives. About half of the production is concentrated then exported as semi-finished products (merchant grade phosphoric acid), while the other half is locally processed into solid fertilizers. Most of these fertilizers are shipped outside of Morocco. The share reserved for local customers is large enough to ensure the local market’s total satisfaction.
In conjunction with the completion of this mineral pipeline, OCP Group built a new phosphoric acid production plant fired with the pulp originating from the terminal station. With a capacity of 1,400 tons of P2O5/ day (i.e. 450,000 tons of phosphoric acid per annum), this new unit allows to raise the production capacity of acid while providing greater flexibility of production and clear improvements in yields.
In addition to water and sunlight, plants have a vital need for three components that are essential to their development: nitrogen (N), phosphorous (P), and potassium (K). Arable lands naturally contain these three ele- ments in varying proportions. Before the early 20th century, agriculture production did not call for large inputs of these elements; however, between 1900 and 2000, agricultural production increased by 600 percent.
As a result of this growth, it became necessary to add various amounts of these three elements to most land in order to improve its productivity. Today, between 40 and 60 percent of global food production requires the use of NPK fertilizer. Phosphorous alone represents a quarter of the 170 million tons of consumed nutrients per year. If global agricultural production does not increase in this decade compared to the prior decade, we may face a global food output shortfall by 2050, when the world’s population is anticipated to reach 9.2 billion people and arable land per capita is expected to drop from its current .20 hectares per capita level to .12. Therefore, food production must increase by 70 percent, or 1.5 percent per year. This would be impossible without the use of chemical fertilizers. Cereal production, for example, will have to grow at an increased pace to serve expected consump- tion levels, which are currently be- tween 400 and 1,500 daily grams per person worldwide. Industrial fertilizers, particularly phosphate fertilizers, provide an essential means to meet the planet’s future dietary needs in a straightforward and effective way. They are the only way for popula- tions to increase yields per hectare substantially and therefore limit the amount of land devoted to agriculture at the expense of an already strained forest cover.
From 50 million tons at present, demand for fertilizer will increase to around 70* million tons in 2020, an average growth of 2.6 percent per year. Therefore, 2 million additional tons of fertilizer will need to be produced each year. Introduction 3. The procuct installed: Basorplast BPE
BPE 60x100 to 60x300 Models (HxB): 60x100; 60x150; 60x200; 60x300; 100x200; 100x300; 100x400; 100x600. Types: Slotted or solid bottom. Finishes: PVCM1 UV RAL 7035
Characteristics of the tray: - Non metallic system - Resistant to UV radiation. Excellent behaviour in outdoor installation. - Impact Strength: 20J, except 60x100 with 10J - Minimum temperature: -4 ºF BPE 100x200 to 100x600 - Maximum temperature: 140 ºF - Non-! ame propagating component - Without electrical continuity - Electrical insulating component - Dielectric Strength 18 +/- 2 kV/mm - Hight protection inside and outside against corrosive substances - M1 reaction to “ re acc. to UNE 23727 - Glow wire test degree 1760 ºF, EN 60695-2-11 - Flammability UL 94-VO, ANSI/UL 94-1995 - Limiting Oxigen Index LOI>50%, EN ISO 4589 - Comply with RoHS directive, 2002/95/CE - Raw material without silicone
INSTRUCTIONSINSTRUCTIONS FOR USE FOR USE keeping a minimum distance of 250 in the temperature (ΔT) leave a gap - For the assembly, two union joints mm between each tray. (h) between cable trays according to and four-For M8 the Bolt assembly, sets are needed- To assure for good- Suitable forDepending wet, salty on and the chemical the following table : each twostretch union (8 for joints H100 models).performanceagresive enviroments.expected growth and four M8 Bolt under expansions in the tempera- - Tray installation for electrical systems - To assure good performance ΔT (ºF) h (mm) sets are needed for , the increase in ture (ΔT) leave a shouldeach NOT stretch run under (8 for other temperature types of under must expansionsgap (h) between , the increase 68 5 canalisations such as water, vapour or in temperature must be noted, H100 models). be noted, between cable trays accord- 86 7 gas canalisations.- Suitable for wet, the installationbetween ing the to installation and the 104 9 - To guaranteesalty and chemical a good ventilation,and the maximum maximum the temperature following expected. agresive environ- temperature ex- table: we recommend installing the trays Depending on the expected growth 122 11 ments. pected.
Safe Working Load - kg/m (lb/ft) Safe Working Load - kg/m (lb/ft) MODEL 2,4m (8ft) 1,8m (8ft) 1,5m (5ft) MODEL 2,4m (8ft) 1,8m (8ft) 1,5m (5ft) BPE-60X100 9,7 (6,5) 17,3 (11,6) 25 (16,7) BPE-60X100 6,9 (4,6) 12,3 (8,3) 17,8 (11,9) BPE-60X150 9,9 (6,6) 17,6 (11,8) 25,3 (17) BPE-60X150 7 (4,7) 12,5 (8,5) 18 (12,1) BPE-60X200 28,1 (18,8) 49,9 (33,5) 71,9 (48,3) BPE-60X200 20 (13,4) 35,6 (23,9) 51,3 (34,5) BPE-60X300 55,2 (37) 98,1 (65,9) 141,3 (94,9) BPE-60X300 39,4 (26,4) 70 (47) 100,8 (67,7)
BPE-100X200 69,6 (46,7) 123,7 (83,1) 178,2 (119,7) BPE-100X200 49,7 (33,4) 88,3 (59,3) 127,2 (85,5) BPE-100X300 107,2 (72) 190,5 (128) 274,4 (184,4) BPE-100X300 76,5 (51,4) 136 (91,4) 195,9 (131,6) BPE-100X400 178 (119,6) 316,4 (212,6) 455,6 (306,2) BPE-100X400 127 (85,3) 225,9 (151,8) 325,3 (218,6) BPE-100X600 219,7 (147,6) 390,5 (262,4) 562,4 (377,9) BPE-100X600 156,8 (105,3) 278,8 (187,3) 401,5 (269,8)
BASORPLAST INSTALLATION PRACTICIES | 3 4. Other information about the BPE series
INSTALLATION RECOMMENDATION
- Trays for electrical systems can not be installed under under other types of pipelines with risk of water, vapour or gas loss - The correct support interval must be 3.3ft - To guarantee a good ventilation, the installed trays must be a minimum distance of 250mm between them - No grounding needed
TECHNICAL SPECIFICATIONS
- Product: Cable Management System for outdoor - Raw Material: PVC polymer. UV resistant - Listing according to UL-568 - Minimum temperature: -20º/ -4Fº - Maximum temperature: 60º/140 Fº - Accessories: Flat bend, inside bend, outside bend & supports (Tee & Cross under demand) - Insulating - Covers: For accessories & end covers - Fittings: Union joints, screws, nuts & derivations - Material Dimensions: Height: 2.2/5” & 4” Width: 4”, 6”, 8” Resistencia �quimica acorde a ISO/TR 10358 133
Resistencia �quimica acorde a ISO/TR 10358 133
5. Chemical Resistance according to ISO/TR 10358
agressive Concentra- temper- material agressive Concentra- temper- material agressiveagressive Concentra-Concentra-temper- material agressivetemper- Concentra- temper- materialmaterial agressive Concentra- temper- material medium tion ature pp pVC pe medium tion ature pp pVC pe medium tion ature pp pVC pe medium tion ature medium tion ature mediumfruit wine tion20 paraffinature oil 20 phosgene* technically 20 pp pVC pe pp pVC pe 40 pp40 pVC pe pure, gase- ous 60 60 40 80 80 fruit wine 20 paraffin oil 20 phosgene* technically 13620 Resistencia �quimica acorde a ISO/TR60 10358 100 100 80 fats and oils*, pure,20 gase- perchlo- technically 20 100 40 vegetale roethylene pure 40 (tetrachlo- phosphor 20 40 ous roethylene) chloride:* 60 40 -phosphor- technically 40 80 tri-chloride pure 60 60 60 100 -phosphor- 60 40 80 penta- oleum low 20 100 chloride 80 80 vapours* perchloric 10%, 20 80 40 acid* 60hydrous 100 60 40 -phosphoryl 20 ng ng ng 100 agressive Concentra- temper- material agressive Concentra- temper- material 100 80 60 chloride medium tion ature pp pVC pe medium tion ature pp pVC pe 100 80 40 vinyl chloride80 technically 20 50%, 20 fats and oils*, 20 perchlo- technically 20 olive oil* 20 100pure 60hydrous 40 10070%, 20 40 80 40 60 hydrous 60 100 60 vegetale roethylene pure 80 40 80 phosphoric up to 30%, 20 80 acid hydrous phosphor 100 20 60 100 100 (tetrachlo- viscose-spin- 20 4090%, 133 20 Resistencia �quimica acorde a ISO/TR 10358 oleic acid technically 20 80 ning solution 60hydrous 40 pure 100 chloride:* 40 80 40 roethylene) 40 petroleum technically 20 60 100 60 60 ether* pure 80 up to 50%, 20 80 60 80 40 -phosphor- technically 40 100 hydrous 100 40 60 100 wax alcohol* technically 20 wine, red and 40usual 20 pure white tri-chlorideoxalic acid* cold pure20 80 60 80 saturated, 40 40 100 80 60 hydrous 60 60 petroleum technically 20 100 40 pure 80 80 -phosphor- 60 85%, 20 100 60 100 100 40 hydrous 80 detergent* for suds 20 wine vinegar* usual 20 80 60 40 penta- usual (vinegar) 100 80 oleum low 20 40 60 40 oxygen* up to 2%, 20 100 60 80 60 100 chloride in air phenol* up to 10%, 20 80 100 80 vapours* 40 hydrous 100 phthalic acid* saturated, 20 100 60 perchloric 10%, 20 80 water 40 20 hydrousacidity of each, 20 80 (distilled, 60 wine 40hydrous 40 100 deionized, 80 60 40 completely acid* hydrous 80 60 cold 20 100 desalinated) 100 saturated, 80 up to 90%, 20 40 100 60 hydrous 100 hydrous 60 picric acid* 1%, hydrous 20 40 40 xylol technically 20 -phosphoryl 20 ng40 ng80 ng 40 60 pure 60 100 60 80 40 chloride 80 water, drink- 80 20 80 60 60 100 ing water 100 100 chlorinated 80 palmitic acid* technically 20 phenylhydra- technically 20 potassium cold 20 40 100 100 pure zine 40pure carbonate saturated, 80 60 hydrouszinc salts each, 20 40 40 hydrous 80 40 60 60 40 olive oil* 20 60 100 60 80 80 60 100 water, 20 80 100 sewage 100 80 100 palm oil* 20 phenylhydra- hydrouswater without 20 100 40 80 compressed 20 agressive Concentra- temper- material agressive Concentra- temper- material agressive(palm kernel Concentra- zine-hydro-temper-organic material citric acid 10%, 20 70%, 20 air, oil emul- oil) chloride solvents hydrous 40 sive medium tion ature medium tion ature medium tion40 ature 40 40 pp pVC pe pp pVC pe 100 pp pVC60 pe 40 60 hydrous 60 60 60 80 60 80 80 80 100 80 100 fruit wine 20 paraffin oil 20 phosphoricphosgene* up technically to100 30%, 20 100 80 40 water, con- 20 sugar syrup100 usual 20 paraffin emul- usual, 20 phosgene* technicallydensaton 20 propane technically 20 40 sion hydrous pure, liquid 40 pure, liquid acid hydrouspure, gase- 60 40 40 40 40 60 40 100 60 80 60 60 80 ous 60 100 80 40 80 100 80 60 hydrogen technically 20 oleic acid technically 2060 80 100 100 100 40 pure Key 60 40 resistant 60 pure 80 80 limited resistant 100 80 60 not resistant 100 80 ng not testet hydrogen 10%, 20 10040 100 * stress cracking petroleum technically 20 80 peroxide* hydrous 100 40 GL saturated solution 60 ether* pure 60 ° moisture expansion/softening fats and oils*, 20 perchlo- technically 20 80 100www.ostendorf-kunststoffe.com up to 50%, 20 100 vegetale 80 roethylene pure 40 30%, 20 phosphor 20 hydrous (tetrachlo- hydrous 40 40 60 100 60 chloride:* 80 roethylene) 40 100 60 80 oxalic acid* cold 20 40 -phosphor- technically 6040 saturated, 80 tri-chloride pure 100 80 hydrous 60 100 petroleum technically 20 -phosphor- 60 80 100 40 penta- www.ostendorf-kunststoffe.com oleum low 20 pure 100 chloride 85%, 20 vapours* 60 40 hydrous perchloric 10%, 20 80 8040 60 acid* hydrous 10040 10060 80 40 -phosphoryl 6020 ng ng ng oxygen* up to 2%, 20 100 80 60 chloride 80 in air phenol* up to 10%, 20 100 80 10040 40 hydrous phthalic acid* saturated, 20 olive oil* 20 100 60 60 40 hydrous 40 70%, 20 80 80 60 40 60 hydrous 100 100 80 60 80 40 phosphoric up to 30%, 20 cold 20 100 acid hydrous 80 100 60 saturated, up to 90%, 20 10040 oleic acid technically 20 80 hydrous hydrous picric acid* 1%, hydrous 20 pure 60 40 100 40 4080 40 petroleum technically 20 60 60 10060 60 ether* pure 80 80 up to 50%, 8020 80 40 100 100 hydrous 100 100 60 palmitic acid* technically 20 phenylhydra- technically 20 potassium cold 2040 80 oxalic acid*pure cold 20 zine pure carbonate saturated, 60 saturated, 40 100 hydrous 80 hydrous 40 petroleum technically 20 40 60 60 100 40 pure 60 80 80 85%, 20 60 40 hydrous 80 100 100 80 60 10040 palm oil* 20 phenylhydra- hydrous 20 100 80 compressed 20 (palm kernel zine-hydro- 60 air, oil emul- oil)oxygen* up to 2%, 20 chloride 100 80 in air sive 40 phenol* up to 10%, 4020 100 40 hydrous 40 60 60 phthalic acid* saturated, 20 60 40 hydrous 60 80 80 80 80 60 40 100 100 100 100 80 60 paraffin emul- usual, 20 phosgene* technically 20 propane technically 20 cold 20 100 80 sion hydrous pure, liquid pure, liquid saturated, 100 40 up to 90%, 4020 40 hydrous hydrous picric acid* 1%, hydrous 20 60 60 60 40 40 40 80 80 80 60 60 60 100 100 100 80 80 80 100 100 100 palmitic acid* technically 20 phenylhydra- technically 20 potassium cold 20 pure zine pure carbonate saturated, hydrous 40 40 40 60 60 60 80 80 80 100 100 100 palm oil* 20 phenylhydra- hydrous 20 compressed 20 (palm kernel zine-hydro- www.ostendorf-kunststoffe.com air, oil emul- oil) chloride sive 40 40 40 60 60 60 80 80 80 100 100 100 paraffin emul- usual, 20 phosgene* technically 20 propane technically 20 sion hydrous pure, liquid pure, liquid 40 40 40 60 60 60 80 80 80 100 100 100
www.ostendorf-kunststoffe.com 6. Some pictures of the installation 6. Some pictures of the installation 6. Some pictures of the installation