Large Volume Inorganic Chemicals - Ammonia ... - ammk-rks.net

List of figuresFigure 1.1: Example A for portfolio and relative capacities of a nitrogen-based fertiliser site ....................8Figure 1.2: Two examples for portfolio and relative capacities of phosphate-based fertiliser sites .............8Figure 1.3: Example B for portfolio and relative capacities of a nitrogen-based fertiliser site.....................8Figure 1.4: Overview of boundaries and links between the LVIC-AAF industries......................................9Figure 1.5: Example for a steam system (or steam grid) on a fertiliser plant .............................................10Figure 1.6: Heating of BFW with steam from the AN plant.......................................................................13Figure 1.7: Recovery of NO x from exhaust gases with a scrubber cascade................................................21Figure 2.1: NH 3 production by conventional steam reforming...................................................................39Figure 2.2: Example of a reformer radiant section and a secondary reformer............................................40Figure 2.3: NH 3 production by partial oxidation ........................................................................................44Figure 3.1: HNO 3 production levels in some European countries in 1997 and 2003 .................................95Figure 3.2: Overview of the production of HNO 3 .......................................................................................98Figure 3.3: Empirical correlation between specific N 2 O emission levels and N 2 O concentrations in tailgases...................................................................................................................................102Figure 3.4: N 2 O generation in relation to the progress of a campaign......................................................111Figure 3.5: Indicative relation of the ammonia burner efficiency and temperature at 1 and 4 bar ...........113Figure 3.6: Applied absorption pressures and related NO x levels in tail gases.........................................118Figure 3.7: Decomposition of N 2 O by extension of the reactor chamber ................................................121Figure 3.8: Achieved N 2 O emission levels at the example plant ..............................................................122Figure 3.9: Catalytic N 2 O decomposition in the oxidation reactor...........................................................123Figure 3.10: Combined NO x and N 2 O abatement .....................................................................................127Figure 3.11: N 2 O emission before and after commissioning of the combined tail gas treatment .............128Figure 3.12: NO x removal efficiencies of SCR units applied in HNO 3 plants..........................................133Figure 3.13: Overview of the combined treatment of NO x and N 2 O with hydrocarbons..........................142Figure 4.1: Plant size distribution in the EU-25 in 2004...........................................................................145Figure 4.2: Overview of the main feedstock, consumers and cycles of the H 2 SO 4 economy...................150Figure 4.3: Overview of the production of H 2 SO 4 ....................................................................................151Figure 4.4: Schematic of a brick-arch converter (left) and a core tube converter (right)..........................152Figure 4.5: Example for a final absorber ..................................................................................................153Figure 4.6: Example for a sulphuric acid plant (top view) .......................................................................154Figure 4.7: Conversion rates of 99.5 to 99.9 % and tail gas SO 2 levels in relation to the SO 2 content beforebed 1...................................................................................................................................162Figure 4.8: Conversion rates of 98.7 to 99.5 % and tail gas SO 2 levels in relation to the SO 2 content beforebed 1...................................................................................................................................163Figure 4.9: Correlation between SO 2 conversion rates and specific SO 2 loads in tail gases.....................164Figure 4.10: Example for a single contact/single absorption process .......................................................171Figure 4.11: Example for a 2+2 double contact/double absorption process .............................................173Figure 4.12: SO 2 inlet concentration and conversion rate of production based on sulphur burning.........174Figure 4.13: SO 2 inlet concentration and conversion rate of production based on Zn roasting................174Figure 4.14: Example for a wet catalysis process.....................................................................................185Figure 5.1: Overview of the production of H 3 PO 4 (wet process with H 2 SO 4 ) ..........................................215Figure 5.2: Forced circulation evaporator for the concentration of H 3 PO 4 ...............................................220Figure 5.3: Overview of the dihydrate process.........................................................................................226Figure 5.4: Overview of the hemihydrate process ....................................................................................228Figure 5.5: Overview of the hemihydrate recrystallisation process..........................................................230Figure 5.6: Overview of the hemi-dihydrate recrystallisation process with double-stage filtration .........232Figure 5.7: Di-hemihydrate recrystallisation process with double-stage filtration ...................................234Figure 5.8: Overview of the repulping process.........................................................................................236Figure 6.1: Overview of the production of HF .........................................................................................259Figure 6.2: Increasing the production capacity for a given kiln and energy supply/recovery ..................260Figure 6.3: Process gas treatment options.................................................................................................261Figure 6.4: Overview of the fluosilicic acid process ................................................................................280Figure 7.1: Overview of the production of NPK fertilisers from phosphate rock or SSP/TSP.................285Figure 7.2: Overview of the nitrophosphoric acid process .......................................................................286Figure 7.3: Example for a plate bank cooler.............................................................................................304Figure 7.4: Overview of the recycling of warm air...................................................................................307Figure 7.5: Multistage scrubbing of exhaust gases containing NO x .........................................................312Figure 7.6: Combined treatment of exhaust gases from NPK production ................................................314xxLarge Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers