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Chapter 3Operational dataVarious catalysts are actually available, e.g.1. Catalyst developed by Yara [109, Lenoir, 2006]:• cerium oxide-based catalyst with cobalt as the active component• multicored cylindrical pellets 9 x 9 mm• bulk density of 1.1 – 1.3 g/m 3• radial crushing strength >20 Newton• increasing efficiency with increasing pressure and temperature• no losses in NO yield.2. Catalyst developed by BASF [111, NCIC, 2004, 149, BASF, 2006]:• various types available, “O3-85”-types• composition (w/w): CuO 20 %, ZnO 16 %, plus Al 2 O 3 and promoters• various shapes• operational for low, medium and high pressure oxidation• no measurable loss in NO yield.3. Catalyst developed by Heraeus [113, Sasol, 2006, 116, Jantsch, 2006]:• precious metal deposited over ceramic• no measurable effect on NO yield• N 2 O level adjustable by variation of the catalyst layer thickness.ApplicabilityApplicable to new and existing plants. Table 3.12 shows example plants.In atmospheric pressure plants, the extra pressure drop in the reactor reduces the plant capacity[149, BASF, 2006].Depending on the particular case, limitations for the application of a N 2 O decompositioncatalyst might arise with respect to the following factors [149, BASF, 2006]:• some plants might require modifications to build in a basket• basket design and actual basket condition• available height in the burner basket for filling with a De-N 2 O catalyst, heights might varyfrom about 5 – 14 cm• potential for gas slip at the reactor wall• gas temperature, pressure and velocity• additional pressure drop, depending on the catalyst size and shape• additional load on the statics of the reactor through added weight and additional pressuredrop.Economics• additional costs for the catalyst• easy and cost-effective to install, using the existing basket without any further modifications• an NO x abatement system is still required in most cases.124 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Chapter 3According to [89, Kuiper, 2001], a comparison of various N 2 O reduction strategies (includingYara, BASF and Uhde approach) does not show a significant difference in cost effectivenessand the cost per tonne HNO 3 . The costs are estimated at EUR 0.71 – 0.87 per tonne CO 2 -eq.reduced and EUR 0.98 – 1.20 per tonne HNO 3 produced.References to literature and example plants[87, infoMil, 2001, 104, Schöffel, 2001, 106, Yara, 2006, 109, Lenoir, 2006, 110, F&C, 2005,111, NCIC, 2004, 113, Sasol, 2006], for example plants, see Table 3.12.Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers 125
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EUROPEAN COMMISSIONIntegrated Pollu
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Executive SummaryEXECUTIVE SUMMARYT
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Executive SummaryII.Production and
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Executive Summarybed, using a cesiu
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Executive SummaryConversion process
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Executive SummaryBAT is to treat al
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PrefacePREFACE1. Status of this doc
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Preface5. How to understand and use
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2.2.4.2 Gasification of heavy hydro
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5.4.2 Hemihydrate process (HH) ....
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10.4.3 Fluoride recovery and abatem
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Figure 8.1: Overview of the product
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Table 4.20: Energy balance of a dou
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ScopeSCOPEThis document on Large Vo
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Chapter 197 % of nitrogen fertilise
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Chapter 11.1.2.3 High exhaust gas v
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Chapter 1the SSD of NPK does not le
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Chapter 11,8Relative production cap
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Chapter 11.2.3 Supply of steam and
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Chapter 11.3 Overview of emissions
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Chapter 1ApplicabilityGenerally app
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Chapter 11.4.3 Handling excess stea
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Chapter 11.4.5 Optimisation/mainten
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Chapter 1Operational dataNo informa
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Chapter 1ApplicabilityEspecially ap
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Chapter 11.4.9 Environmental manage
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Chapter 1(v) Documentation- establi
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Chapter 1iv. allow for comparison w
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Chapter 1A number of studies show t
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Chapter 11.5 Common BATIn understan
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Chapter 11.5.2 BAT for environmenta
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Chapter 2Location CompanyCapacity F
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Chapter 22.2.2 Output from ammonia
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Chapter 22.2.3.2 Primary reformingT
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Chapter 2Process name Solvent/reage
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Chapter 22.2.4 Partial oxidationThe
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Chapter 2In the moving bed process,
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Chapter 22.2.6 Storage and transfer
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Chapter 2Production process Feedsto
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Chapter 22.3.2 NO x emissionsTable
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Chapter 22.3.3 Other consumption le
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Chapter 2ParameterProcessEmission l
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Chapter 22.4 Techniques to consider
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Chapter 22.4.2 Processes with reduc
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Chapter 22.4.3 Heat exchange autoth
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Chapter 22.4.4 Revamp: increase cap
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Chapter 22.4.5 Pre-reformingDescrip
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Chapter 2ApplicabilityGenerally app
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Chapter 22.4.7 Advanced process con
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Chapter 22.4.9 Combined Claus unit
Page 102 and 103: Chapter 2Operational dataSee Descri
Page 104 and 105: Chapter 22.4.12 Preheating of combu
Page 106 and 107: Chapter 22.4.14 Isothermal shift co
Page 108 and 109: Chapter 22.4.16 Stripping and recyc
Page 110 and 111: Chapter 22.4.18 Use of sulphur resi
Page 112 and 113: Chapter 22.4.20 Indirect cooling of
Page 114 and 115: Chapter 22.4.22 Ammonia removal fro
Page 116 and 117: Chapter 22.4.24 Metal recovery and
Page 118 and 119: Chapter 2Driving force for implemen
Page 120 and 121: Chapter 22.5 BAT for ammoniaBAT is
Page 123 and 124: Chapter 33 NITRIC ACID3.1 General i
Page 125 and 126: Chapter 3Pressure in bar Temperatur
Page 127 and 128: Chapter 33.2.5 Tail gas properties
Page 129 and 130: Chapter 33.3 Current emission and c
Page 131 and 132: Chapter 3N 2 O emission levelProces
Page 133 and 134: Chapter 3N 2 O emission levelProces
Page 135 and 136: Chapter 3Process typeNO x emission
Page 137 and 138: Chapter 3Process typeNO x emission
Page 139 and 140: Chapter 3140120Generation factor %1
Page 141 and 142: Chapter 33.4.2 Optimisation of the
Page 143 and 144: Chapter 33.4.3 Alternative oxidatio
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Page 149 and 150: Chapter 33.4.5 N 2 O decomposition
Page 151: Chapter 33.4.6 Catalytic N 2 O deco
Page 155 and 156: Chapter 33.4.7 Combined NO x and N
Page 157 and 158: Chapter 3EconomicsInvestment costs.
Page 159 and 160: Chapter 3Operational dataSee descri
Page 161 and 162: Chapter 3NOx removal efficiency in
Page 163 and 164: Chapter 33.4.10 Addition of H 2 O 2
Page 165 and 166: Chapter 33.4.11 NO X reduction duri
Page 167 and 168: Chapter 3Installing a low temperatu
Page 169 and 170: Chapter 3NO x emission level as NO
Page 171: Chapter 3Operational dataNo specifi
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Page 176 and 177: Chapter 4Country Company Location C
Page 178 and 179: Chapter 4Figure 4.2 gives an overvi
Page 180 and 181: Chapter 4Two general converter type
Page 182 and 183: Chapter 4Figure 4.6 gives an impres
Page 184 and 185: Chapter 44.2.3 Sulphur sources and
Page 186 and 187: Chapter 44.2.3.5 Non-ferrous metal
Page 188 and 189: Chapter 4Sulphur source/SO 2 produc
Page 190 and 191: Chapter 44.3 Current emission and c
Page 192 and 193: Chapter 410Tail gas specific SO2 lo
Page 194 and 195: Chapter 4Capacity in tonnesof 100 %
Page 196 and 197: Chapter 4Capacity in tonnesof 100 %
Page 198 and 199: Chapter 4SO 2 sourceSpent acid and
Page 200 and 201: Chapter 4Cross-media effectsWithout
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Chapter 4Achieved environmental ben
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Chapter 44.4.3 Addition of a 5 th b
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Chapter 44.4.4 Application of a Cs-
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Chapter 4EUR/yearWaste gas volume (
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Chapter 44.4.6 Replacement of brick
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Chapter 4EUR/yearWaste gas volume (
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Chapter 4PlantSO 2 sourceInlet SO 2
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Chapter 44.4.10 Combination of SCR
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Chapter 4Driving force for implemen
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Chapter 44.4.14 Monitoring of SO 2
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Chapter 4EconomicsCost benefits can
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Chapter 4Energy inputRecovery and l
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Chapter 44.4.16 Minimisation and ab
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Chapter 44.4.17 Minimisation of NO
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Chapter 44.4.19 Tail gas scrubbing
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Chapter 44.4.21 Tail gas treatment:
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Chapter 4Economics[58, TAK-S, 2003]
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Chapter 4EconomicsNo specific infor
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Chapter 4BAT is to minimise and red
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Chapter 55.2 Applied processes and
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Chapter 55.2.2.1 Raw materials5.2.2
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Chapter 5OriginChinaMine/regionRare
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Chapter 55.2.2.2 GrindingDepending
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Chapter 55.3 Current emission and c
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Chapter 5Emission of mg/l g/tonne P
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Chapter 55.4.2 Hemihydrate process
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Chapter 55.4.3 Hemi-dihydrate recry
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Chapter 55.4.4 Hemi-dihydrate recry
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Chapter 55.4.5 Di-hemihydrate recry
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Chapter 55.4.6 RepulpingDescription
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Chapter 55.4.7 Fluoride recovery an
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Chapter 55.4.8 Recovery and abateme
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Chapter 5Operational dataNo informa
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Chapter 55.4.11 Decadmation of H 3
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Chapter 55.4.12 Use of entrainment
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Chapter 5Cross-media effects• dis
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Chapter 5Cross-media effectsTable 5
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Chapter 5ApplicabilityAt present, o
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Chapter 66 HYDROFLUORIC ACID6.1 Gen
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Chapter 6Component Portion (mass co
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Chapter 66.2.4 Process gas treatmen
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Chapter 6Emission of kg/tonne HF Re
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6.4 Techniques to consider in the d
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Chapter 66.4.2 Energy recovery from
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Chapter 66.4.4 Valorisation of fluo
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Chapter 66.4.6 Scrubbing of tail ga
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6.4.7 Scrubbing of tail gases: fluo
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Chapter 66.4.8 Abatement of dust em
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Chapter 66.4.9 Waste water treatmen
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Chapter 6Cross-media effects• 5 -
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Chapter 77 NPK AND CN7.1 General in
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Chapter 77.2.3 Direct neutralisatio
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Chapter 7Fluorine compounds origina
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Chapter7Per tonne productkWh Nm 3 k
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Chapter7Emission levelmg/Nm 3 ppm k
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Chapter7Emission levelmg/Nm 3 ppm k
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7.4 Techniques to consider in the d
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Chapter7Driving force for implement
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Chapter7Achieved environmental bene
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Chapter77.4.6 Recycling warm airDes
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Chapter77.4.7 Optimising the recycl
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Chapter7Operational dataThe volume
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Chapter77.4.11 Recycling of scrubbi
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Chapter77.4.12 Waste water treatmen
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Chapter7ParameterLevelmg/Nm 3Phosph
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Chapter 88.2.1.1 Particle formation
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Chapter 8Consumption of Per tonne u
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Chapter 8Per tonne urea Unit Remark
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Chapter 8Waste water per tonne urea
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Chapter 8Pollutant Source g/tonne u
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Chapter 8Plant Emission Amount (ton
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Chapter 8Operational dataSee Table
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Chapter 8Operational dataSee Table
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Chapter 88.4.6 Redirecting fines to
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Chapter 8Existing plantCase 2Revamp
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Chapter 88.4.8 Heat integration in
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Chapter 88.4.9 Combined condensatio
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Chapter 88.4.10 Minimisation of NH
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Chapter 8Other approaches to proces
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Chapter 88.5 BAT for Urea and UANBA
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Chapter 9Country Company LocationBe
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Chapter 99.2.2 NeutralisationThe ex
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Chapter 9Scrubbing devices• packe
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Chapter 9Pollutant mg/Nm 3 g/tonne
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Chapter 99.4.2 Recovery of residual
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Chapter 99.4.3 Energy consideration
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Chapter 99.4.4 Steam purification a
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Chapter 99.4.5 Autothermal granulat
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Chapter 9ApplicabilityIrrigated can
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Chapter 1010 SUPERPHOSPHATES10.1 Ge
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Chapter 10Emissionto airEmissionto
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Chapter 10Input Indirect granulatio
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Chapter 10Volume5 - 10 m 3 /hourTem
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Chapter 1010.4.2 Recovery and abate
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Chapter 1010.4.4 Recycling of scrub
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Chapter 1111 CONCLUDING REMARKS11.1
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Chapter 11Production of HNO 3 : De-
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References26 Dipankar Das (1998).
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References89 Kuiper (2001). "High t
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References147 Uhde (2006). "The Uhd
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GlossaryCalculation of steam proper
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GlossaryIPCCIPPCISO 14001Intergover
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GlossaryChemical formulasAl 2 O 3Ca
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Annexes14 ANNEXES14.1 Cost calculat
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