Technological breakthroughs
Southern Fertilizer Enhances Workplace Safety Through Automation of Acid Mixing and Dilution System
Automating the acid mixing and dilution system for Supe phosphate fertiliser production has enabled Southern Fertilizer Joint Stock Company to improve operational precision, ensure product quality, reduce direct handling of chemicals, and enhance working conditions for employees.
In Supe phosphate fertiliser manufacturing, the dilution of sulphuric acid (H₂SO₄) is a stage that directly affects the reaction process and product quality. Precise control of acid-to-water ratios and stable acid concentration post-dilution are therefore crucial for the entire process.
Previously, this stage at Southern Fertilizer was largely manual. Operators adjusted acid and water flow rates based on experience, then sampled and checked concentrations using a hydrometer. This approach required constant supervision in the production area and relied heavily on the operator’s skill and judgement.
Meanwhile, 98% H₂SO₄ is highly corrosive. The acid supply system operates at 15 kW power, with a flow rate of around 30 m³/h and a head of 30–40 mH₂O. In the event of a pipeline incident, any acid leak or spray could pose direct risks to operators.
Recognising these challenges, Southern Fertilizer’s engineers developed and implemented the initiative: “Automating the acid mixing and dilution system for Supe phosphate fertiliser production.”
The innovation lies in shifting from manual adjustment to automated control. The system now integrates flow, pressure, and concentration sensors with a central controller. Operating parameters are continuously collected and processed, ensuring that the mixing of 98% H₂SO₄ and water follows preset specifications.
As a result, operators no longer need to make frequent manual adjustments in hazardous areas. Operating parameters are monitored on the system, and any irregularities can be promptly detected and addressed. Reducing manual intervention also limits the risk of worker exposure to concentrated acid.
Beyond improving safety, automation stabilises the dilution process. Accurate control of flow rates and mixing ratios maintains consistent acid concentrations, minimising batch variation and reducing adjustment time during production.
A stable feedstock flow also boosts overall process efficiency, lessening reliance on individual experience and enabling more rational use of manpower. These are practical benefits for a process with strict technical and chemical safety requirements.
Previously, this work required operators to be constantly present for inspection, sampling, and adjustment. The new system gradually introduces automatic operation, monitoring and alerts. This approach aligns with the company’s drive to harness science, technology, digital transformation, and automation in production.
The initiative also demonstrates that technological innovation in chemical enterprises is not only about raising productivity or cutting costs. For operations with high chemical safety risks, automation is a vital solution to reduce direct exposure and enable staff to control equipment and respond to incidents from safer locations.
From practical application on the Supe phosphate production line, Southern Fertilizer continues to affirm the value of technical innovation in driving production renewal. Combining the technical team’s experience with automated measurement and control equipment has led to a marked change in operations, improved production efficiency, and a safer working environment for employees.
This is also a concrete step in the company’s drive to modernise production, apply technology to frontline operations, and move towards an efficient, safe production model in line with the green orientation of the chemical industry.
