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Chapter 4EconomicsCost benefits can be presumed.Driving force for implementationCost benefits.References to literature and example plants[57, Austrian UBA, 2001, 58, TAK-S, 2003], Tessenderlo, HamEnergy inputRecovery and lossesItem Property RecoverableGJ/tonne 100 %H 2 SO 4Sulphur burning and wasteheat boiler37 %Catalyst bed and processgas coolingas HP steam67 %3.1 – 3.4Sulphur97 %30 %Acid cooling (intermediateabsorber, final absorber,gas dryer)85 – 120 ºCFor dryingprocesses,as LP steam2.1 – 2.431 %31 %Waste gas (loss)1.5 %-Electricalpower(compression)Product acid (loss)0.5 %--3 %Basis: sulphur burning, 1000 tonnes/day 100 % H 2 SO 4 , 11 % v/v SO 2 inletTable 4.17: Energy balance for a double contact process based on sulphur burning[57, Austrian UBA, 2001]196 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Chapter 4Energy input/outputNumber of catalyst bedsand inlet SO 2 level2+2 / 11 %2+2 / 11 %+ LP steam option3+2 / 11 % 2+2 / 5 %4 / 5 %(single contact)Process step GJ/tonne H 2 SO 4Inlet gas heating + 0.992 + 0.992 + 0.992 + 2.119 + 2.119Cooling of bed 1 - 0.471 - 0.471 - 0.471 - 0.704 - 0.704Cooling of bed 2 - 1.018 - 1.018 - 0.278 - 1.766 - 0.199Intermediate absorption - 1.190 - 0.673 - 1.380 - 1.609Reheating after intermediate absorption + 0.847 + 0.610 + 0.815 + 1.959no intermediateabsorptionCooling of bed 3 - 0.195 - 0.195 - 0.888 - 0.061 - 0.046Cooling of bed 4 - 0.629 - 0.629 - 0.066 - 1.413 - 1.574Cooling of the 5 th bed no 5 th bed no 5 th bed - 0.589 no 5 th bed no 5 th bedFinal absorption - 0.635 - 0.901 - 0.452 - 0.777 - 0.777Cooling of product H 2 SO 4 to 25 ºC - 0.096 - 0.096 - 0.096 - 0.096 - 0.096Potential export of HP and LP steam - 0.475 - 1.384 - 0.486 Import: 0.133 - 0.404Loss by cooling with water or air - 1.921 - 0.997 - 1.928 - 2.482 - 0.873(+) energy input by heat exchange (-) heat recoverable for HP steam production (-) heat recoverable for LP steam production, 180 ºC (-) loss to cooling water/airTable 4.18: Energy considerations of double contact plants with different plant setup in comparison with a single contact plant[58, TAK-S, 2003]Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers 197
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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
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Chapter 2Operational dataSee Descri
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Chapter 22.4.12 Preheating of combu
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Chapter 22.4.14 Isothermal shift co
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Chapter 22.4.16 Stripping and recyc
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Chapter 22.4.18 Use of sulphur resi
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Chapter 22.4.20 Indirect cooling of
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Chapter 22.4.22 Ammonia removal fro
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Chapter 22.4.24 Metal recovery and
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Chapter 2Driving force for implemen
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Chapter 22.5 BAT for ammoniaBAT is
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Chapter 33 NITRIC ACID3.1 General i
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Chapter 3Pressure in bar Temperatur
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Chapter 33.2.5 Tail gas properties
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Chapter 33.3 Current emission and c
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Chapter 3N 2 O emission levelProces
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Chapter 3N 2 O emission levelProces
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Chapter 3Process typeNO x emission
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Chapter 3Process typeNO x emission
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Chapter 3140120Generation factor %1
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Chapter 33.4.2 Optimisation of the
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Chapter 33.4.3 Alternative oxidatio
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Chapter 33.4.4 Optimisation of the
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Chapter 3Achieved environmental ben
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Chapter 33.4.5 N 2 O decomposition
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Chapter 33.4.6 Catalytic N 2 O deco
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Chapter 3According to [89, Kuiper,
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Chapter 33.4.7 Combined NO x and N
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Chapter 3EconomicsInvestment costs.
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Chapter 3Operational dataSee descri
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Chapter 3NOx removal efficiency in
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Chapter 33.4.10 Addition of H 2 O 2
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Chapter 33.4.11 NO X reduction duri
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Chapter 3Installing a low temperatu
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Chapter 3NO x emission level as NO
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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
Page 202 and 203: Chapter 4Achieved environmental ben
Page 204 and 205: Chapter 44.4.3 Addition of a 5 th b
Page 206 and 207: Chapter 44.4.4 Application of a Cs-
Page 208 and 209: Chapter 4EUR/yearWaste gas volume (
Page 210 and 211: Chapter 44.4.6 Replacement of brick
Page 212 and 213: Chapter 4EUR/yearWaste gas volume (
Page 214 and 215: Chapter 4PlantSO 2 sourceInlet SO 2
Page 216 and 217: Chapter 44.4.10 Combination of SCR
Page 218 and 219: Chapter 4Achieved environmental ben
Page 220 and 221: Chapter 4Driving force for implemen
Page 222 and 223: Chapter 44.4.14 Monitoring of SO 2
Page 226 and 227: Chapter 4Energy inputRecovery and l
Page 228 and 229: Chapter 44.4.16 Minimisation and ab
Page 230 and 231: Chapter 44.4.17 Minimisation of NO
Page 232 and 233: Chapter 44.4.19 Tail gas scrubbing
Page 234 and 235: Chapter 44.4.21 Tail gas treatment:
Page 236 and 237: Chapter 4Economics[58, TAK-S, 2003]
Page 238 and 239: Chapter 4EconomicsNo specific infor
Page 240 and 241: Chapter 4BAT is to minimise and red
Page 242 and 243: Chapter 55.2 Applied processes and
Page 244 and 245: Chapter 55.2.2.1 Raw materials5.2.2
Page 246 and 247: Chapter 5OriginChinaMine/regionRare
Page 248 and 249: Chapter 55.2.2.2 GrindingDepending
Page 250 and 251: Chapter 55.3 Current emission and c
Page 252 and 253: Chapter 5Emission of mg/l g/tonne P
Page 254 and 255: Chapter 55.4 Techniques to consider
Page 256 and 257: Chapter 55.4.2 Hemihydrate process
Page 258 and 259: Chapter 55.4.3 Hemi-dihydrate recry
Page 260 and 261: Chapter 55.4.4 Hemi-dihydrate recry
Page 262 and 263: Chapter 55.4.5 Di-hemihydrate recry
Page 264 and 265: Chapter 55.4.6 RepulpingDescription
Page 266 and 267: Chapter 55.4.7 Fluoride recovery an
Page 268 and 269: Chapter 55.4.8 Recovery and abateme
Page 270 and 271: Chapter 5Operational dataNo informa
Page 272 and 273: 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 Applied processes and
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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 Applied processes and
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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 Techniques to consider
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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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