Full-process simulation of iron phosphate production and integration of water systems

Based on industrial production data, the complete production process of iron phosphate was established in Aspen Plus V14 software. The process primarily uses ferrous sulfate heptahydrate and ammonium dihydrogen phosphate as raw materials, with hydrogen peroxide as the oxidant. The oxidation reaction yields iron phosphate dihydrate, and the final iron phosphate product is obtained through subsequent washing, drying, and calcination stages.Aiming to address the issue of high water consumption in the iron phosphate production process, research on water system integration and optimization was conducted. This was achieved by varying the number of horizontal screw centrifuges and optimizing water usage in both the raw material dissolution and product washing stages. The process simulation results show an annual iron phosphate output of 25,200 tons, with a relative error of 0.8% compared to the design value. Taking into account both pure water consumption and equipment costs, the optimal configuration was determined to be the use of four horizontal screw centrifuges. Through water system integration, pure water consumption was reduced by 85.88%, and wastewater discharge from the washing process was cut by 99.24%.