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of ThyssenKrupp
Technologies
Uhde
ThyssenKrupp
Nitrate fertilisers
Table of contents
Page
1.
Company profile
2.
3.
4.
12
5.
16
6.
18
7.
Calcium nitrate CN
19
8.
20
9.
Main references
22
1. Company profile
With its highly specialised workforce of more than 4,900 employees and its
international network of subsidiaries and branch offices, Uhde, a Dortmund-based
engineering contractor, has, to date, successfully completed over 2,000 projects
throughout the world.
Uhdes international reputation has been built on the successful application of
its motto Engineering with ideas to yield cost-effective high-tech solutions for its
customers. The ever-increasing demands placed upon process and application
technology in the fields of chemical processing, energy and environmental protection
are met through a combination of specialist know-how, comprehensive service
packages, topquality engineering and impeccable punctuality.
Natural gas
Lime stone
NH3
Uhde
HN03
Uhde
CN
NH3
CO2
HNO3
UAN
Uhde
Urea
AN
Stamicarbon,
UFT
Uhde, INCRO
CAN
Uhde
CAN
BASF
Fig. 1:
Uhde fertiliser processes
Nitrogen fertiliser
CN
Uhde
ASN
Uhde
Phosphate rock
Potassium
Sulphur
H2SO4
Monsanto
NH3
H2SO4
H3PO4
Ca3(PO4)2
YFT
KCl/K2SO4
Nitrophos.
BASF
CN
conv.
BASF
Lime
AN sol.
H3PO4
H2SO4
AS
Uhde
NP
BASF
NPK
NP
INCRO
NPK
NP
YFT, INCRO
NPK
MAP
YFT, INCRO
DAP
YFT, INCRO
SSP
YFT, INCRO
YFT:
INCRO
YFT, INCRO
BASF
TSP
YFT, INCRO
Compound fertiliser
Phosphate fertiliser
3. The Uhde
ammonium nitrate
neutralisation technology
General
NH4NO3 - HR
The heat of reaction is released into the circulating stream of AN solution, causing a temperature
rise. Precise control of the reaction system
parameters is essential for highly-efficient ammonium nitrate production. These parameters include in particular good mixing in of the reactants
as well as reliable temperature and pH control.
The Uhde technology comprises an external
circulation loop, either forced or natural, and
also a sophisticated reactant feed and mixing
system for stable operating conditions.
Uhde offers two proprietary types of neutralisation processes for the production of ammonium
nitrate solution:
Vacuum neutralisation and evaporation
This process is the most popular alternative
because it involves the lowest investment costs.
The reaction takes place in a slightly pressurised
neutraliser to prevent the ammonium nitrate
solution from boiling in the mixing and reaction
sections thus minimising ammonia losses.
Subsequently, the solution is flashed into a
vacuum through a restriction orifice adjacent to
the vapour separator, thereby utilising the reaction heat for water evaporation. A solution concentration of 95 wt.% can be achieved with a
preheated feed of 60 wt.% nitric acid. For control and safety reasons, however, the AN solution concentration is mostly limited to 92 wt.%.
The higher concentration necessary for further
process steps, such as granulation (Section 4)
or prilling (Section 5) is achieved by steam
heating the solution under vacuum pressure.
For optimum process control and stability, Uhde
preferably applies a thermosyphon evaporation
system. The scrubbed process vapours are used
for feedstock preheating; surplus vapours are
condensed.
Pressure neutralisation
In order to utilise the heat of reaction more
efficiently, the process vapour system in this
case operates above atmospheric pressure.
Uhde offers two main pressure neutralisation
alternatives for effective heat recovery:
a) The heat of reaction stored in the hot ammonium nitrate solution leaving the neutraliser is
used direct for the final concentration stage.
Even if a final concentration of 97 wt.% is
required, there is no need to import additinal
steam. (Fig. 3)
b) Heating steam is imported for final concentration of the ammonium nitrate solution,
while part of the heat of reaction is utilised to
generate low-pressure steam at approx. 5 bar
abs. (Fig. 4)
In both cases the flash steam from the vapour
separator at 2 - 4 bar abs is used for intermediate concentration of the weak ammonium
nitrate solution. Again, the remaining process
vapours are used for feedstock preheating;
surplus vapours are condensed. Depending on
how the vapour condensate is to be used, some
or all of the vapours need to be scrubbed before
condensation in a separate vapour scrubber.
Fig. 2:
Vacuum neutralisation
and evaporation
Process condensate
for scrubbing/saturation
CW
CW
Vapour
separator
Orifice
Vapour
separator
Process condensate
AN
neutraliser
HNO3
Steam
AN
evaporator
NH3 gas
NH3 gas
AN solution
AN melt
10 bar
Clean condensate
Circulation pump
Vapours to scrubber
Fig. 3:
Pressure neutralisation
with direct heat recovery
Process condensate
for scrubbing/saturation
Vapour
separator
Vapour
separator
Orifice
Vapour
separator
AN melt
Final
evaporator
First
evaporator
AN
neutraliser
NH3 gas
HNO3
Circulation pump
Fig. 4:
Pressure neutralisation
with clean steam production
Process condensate
for scrubbing/saturation
Vapour
separator
Vapour
separator
AN melt
Steam
Steam 5 bar
Boiler feed water
NH3 gas
Steam
boiler
First
evaporator
Final
evaporator
10 bar
AN
neutraliser
HNO3
10
Vapour scrubbing
Fig. 5:
Vapour scrubbing
Steam
Steam ejector
CW
CW
Condenser
Steam condenser
Vapours
Process condendates
Clean condensate
Vapour scrubber
Scrubber pump
11
Pressure neutralisation
neutralisation
Fig. 2
kg/tAN
130
kg/tAN
31.0
m3/tAN
2.0
kWh/tAN
213
kg/tAN
kg/tAN
789
Pugmill
granulation
AN 33.5
heat recovery
steam production
CAN 27
Fig. 3
Fig. 4
10
22.5
3.8
213
789
52
240
3.8
4.8
213
789
Fig. 6
90
5.0
29.0
12
General
Today modern fertiliser plants supply granulated
products. Prilling is becoming less common due to
environmental constraints and increased product
quality requirements.
In producing fertiliser from the various solid and
liquid feed materials, the granulation unit must
ensure that the resulting product meets market
requirements with regard to its chemical and
physical properties.
There are many different ways of producing
granules, such as flaking, drum, pan or pugmill
granulation and fluid-bed technology.
In the past, Uhde has built granulation plants for
all common fertiliser grades from straight N fertiliser to NP(K) and P(K) fertilisers. Uhde has a
wealth of experience in the design and operation
of granulation plants and is in a position to build
plants based on all modern granulation processes.
The most common granulation process used
in nitrate fertiliser plants built by Uhde is the
proprietary Uhde pugmill granulation process.
AN granules
13
CAN granules
14
3D model
of Uhde pugmill granulation
The waste air from the drying drum and the air
from the dedusting system are therefore passed
to a wet scrubber. Here, the dust is largely
removed from the air by close contact with the
scrubbing solution while the ammonia reacts
with the nitric acid contained therein.
The bleed from the scrubber is returned to the
evaporation system. Therefore, no liquid
effluents are produced during normal operation.
15
Key features
AN solution
AN granules
Fig. 6:
Uhde pugmill process
to atm.
Clean condensate
HNO3
Screens
Additive
Cyclones
Scrubber
Bleed
Crushers
(to evaporation)
AN melt
Pugmill granulator
Fluidised-bed cooler
AN/CAN
Coating drum
Filler
(limestone, dolomite)
Coating agent
Drying drum
Steam
Steam
Cond. air
16
Grain size 1 - 2 mm
licensed processes.
Fig. 8:
Uhde LDAN prilling process
Prilling additive
Screens
Prilling air
scrubber
Fluidised-bed cooler
Drying air
scrubber
Coating drum
AN prills
Anti-caking agent
Conditioned air
Scrubber bleed
to evaporation
AN melt
Pre-drying drum
Prilling tower
Drying drum
Bucket
elevator
Steam
Steam
17
18
Fig. 9:
Ammonium sulphate nitrate process
to atm.
Vent
CW
Scrubber
Scrubber
to process
HNO3
HNO3
Screen
AS (case by case)
Dedusting
Crusher
Al2(SO4)3
from points
FeSO4
to saturator
Orifice
NH3 gas
HNO3
Air
Steam
ASN conversion
Drying drum
Air
Fluidised-bed cooler
ASN
7. Calcium nitrate CN
19
CN can be granulated in either a drum or pugmill granulation unit to yield well-shaped round
granules, the appearance of which is similar to
that of calcium ammonium nitrate granules.
(see page 14).
The calcium nitrate melt is fed to the granulator
via a metering station along with the recycled
material (the fines, the crushed oversize, and
the dust from the dust-collecting facilities).
The granules are then air-cooled in a cooler.
The cooled product is screened, and the on-size
fraction is bagged or sent to the bulk storage area.
The waste air from the cooler is treated in a wet
scrubber before being discharged to atmosphere.
CN solution from nitrophosphate production
The nitrophosphate (ODDA) route for the
production of NP(K) fertiliser produces CN solution
as a by-product. This solution, too, can be used
to produce CN granules or liquid CN fertiliser.
CW
Screen
Process condensate
Vapour separator
Crusher
Evaporator
Steam
CN granules
Process condensate
Granulator
to solution
Additive
Scrubber
NH3 gas
CaCO3
HNO3
Cooling/Drying Drum
Sludge
CN conversion unit
20
8. Liquid N fertiliser
UAN and CN
UAN
Fig. 11:
UAN solution process with ammonia gas
CW
Condenser
Vapour
separator
Orifice
Process condensate
Ammonia
heater
AN
neutraliser
NH3 gas
AN solution
HNO3
Process
condensate tank
Urea solution
NH3 gas
Circulation pump
CW
UAN cooler
Corrosion
inhibitor
21
CN
Calcium nitrate solutions are non-pressurised
liquids mainly used for drip or irrigation systems
in horticulture. A typical solution is CN-17 with
a composition AN : CN : H2O = 31 : 36 : 33%.
This solution is a fast-acting fertiliser containing
both nitrate (for quick response) and ammonium
nitrogen (for retarding nutrition) while the calcium
buffers the pH in the soil.
The production of AN and CN is described in
detail in Section 3 and 7, respectively.
Fig. 12:
UAN solution process with urea off-gas
CW
Vapour
separator
Off-gas
scrubber
Urea off-gas
AN neutraliser
AN solution
Clean condensate
HNO3
Process
condensate tank
HNO3
Corrosion inhibitor
CW
Urea solution
UAN solution
UAN solution tank
9. Main references
22
Plant site
Raw
materials
Process
Nitrogen
content
%
Capacity
Remarks
2000
ANWIL SA
Wloclawek, Poland
AN solution, dolomite
33.5
27
1,500
CAN Granules
1999
Arklow, Ireland
AN solution, dolomite
27.5
1,400
CAN Granules
1999
AZOCHIM S.A.
AN solution, dolomite
33.5
mtpd
Final Products
1,200
AN Granules or
700
AN Granules or
26
1,000
CAN Granules
1,600
CAN Granules
1993
Sasol Fertilizers
AN solution, dolomite
28
1991
AN solution, dolomite
Fluidised-bed Granulation
33.5
1989
Chemie Linz
Linz, Austria
28
1,800
CAN Granules
26
475
CAN Granules
33.5
1,100
26
1,400
(reconstruction)
Chemical Industries Co.
2 x 1,200
AN Granules
(HFT)
from CN conversion
1988
GNFC
Bharuch, India
1987
ENFERSA
Sagunto, Spain
AN solution,
dolomite/limestone
1987
Quimigal
150
AN Granules or
CAN Granules
Alverca, Portugal
CN solution
15.5
CN Granules
Completion Customer
Plant site
Raw
materials
Process
Nitrogen
content
%
2010
Bontang, Indonesia
AN-solution
Prilling (Uhde)
34.8
970
2007
CSBP Ltd
Kwinana, Australia
AN solution
Prilling (Uhde)
34.8
1,060
LDAN Prills
1999
Moura, Australia
AN solution
Prilling (KT)
34.8
400
LDAN Prills
1999
Enaex S.A.
Mejillones, Chile
AN solution
Prilling (KT)
34.8
1,060
LDAN Prills
1996
Rayong, Thailand
AN solution
Prilling (KT)
34.8
220
LDAN Prills
1993
VBC Industries
Visakhapatnam, India
AN solution
34.5
240
AN Prills
1983
Empresa Pblica
Cachimayo, Peru
AN solution
Uhde Prilling
34.5
220
Carseland, Canada
AN solution
Uhde Prilling
34.8
680/1,250
AN prilling plants
Capacity
mtpd
Remarks
Final Products
AN Prills
Industrial Cachimayo
1977
CIL Inc.
LDAN Prills
23
Plant site
Raw
materials
Process
2010
Bontang, Indonesia
HNO3, NH3
2010
Bontang, Indonesia
LDAN solution
UAN Mixing
Nitrogen
content
%
Capacity
Remarks
mtpd
Final Products
990
AN solution
145
UAN solution 29 % N
Evaporation
Urea solution
2009
Ferrostaal
HNO3, NH3,
1,920
UAN Mixing
4,300
UAN solution 32 % N
1,100
AN solution
1,000
2007
Nitrogenmuvek Rt.
Petfrd, Hungary
HNO3, NH3
2006
AN solution
UAN mixing
AN Solution
& Concentration
and Chemical Industries Co.
2004
Urea solution
Belle Plaine, Canada
HNO3, NH3,
255
Urea solution
UAN Mixing
565
1999
Enaex S.A.
Mejillones, Chile
HNO3, NH3
1999
NH3, HNO3
Donaldsonville, USA
HNO3, NH3,
Urea solution
HNO3, NH3,
AN solution
UAN solution 32% N
1,060
AN solution
225
AN solution
1,105
AN solution
2,450
1,460
AN solution
Urea offgas
3,250
and solution
Offgas scrubbing
HNO3, NH3
Tertre, Belgium
NH3, HNO3
Pressure Neutralisation
& Concentration
Uhde Vacuum Neutralisation
1991
CF Industries Inc.
CF Industries Inc.
Donaldsonville, USA
2 x 1,150
AN solution
2,100
AN solution
1,100
AN solution
Kemira
ENFERSA
Sagunto, Spain
HNO3, NH3
1987
Quimigal
Alverca, Portugal
Quimigal/Uhde Process
135
CN solution
1983
HNO3, NH3
800
AN solution
1978
Multan, Pakistan
NH3, HNO3
700
AN solution
680
AN solution
& Concentration
Uhde Vacuum Neutralisation
& Concentration
1977
CIL Inc.
Carseland, Canada
HNO3, NH3
1977
CF Industries Inc.
Donaldsonville, USA
HNO3, NH3,
Urea solution
(1,250)
600
AN solution
1,330
Specialities
Completion Customer
Plant site
Raw
materials
Process
2002
Ammonia, Sulphuric
1,320
DAP
2001
Ammonia, Sulphuric
230
DAP
1980
Bandirma, Turkey
NH3, H2SO4
21
600
AS
1973
Ptolemais, Greece
26
580
ASN
Nitrogen
content
%
Capacity
mtpd
Remarks
Final Products
(diammonium phosphate)
(diammonium phosphate)
PDF 23.4.2009
FL 221e