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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
Figure 8.1: Overview of the production of urea by total recycling processes .......................................... 325Figure 8.2: Overview of the production of UAN solution ....................................................................... 326Figure 8.3: Example for the heat integration on a total recycling stripping plant .................................... 350Figure 8.4: Example for a process water treatment.................................................................................. 357Figure 9.1: Overview of the production of AN and related products....................................................... 365Figure 10.1: Overview of the production of superphosphates including an example for an exhaust gasabatement system............................................................................................................... 389Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisersxxi
Page 1 and 2: EUROPEAN COMMISSIONIntegrated Pollu
Page 3 and 4: Executive SummaryEXECUTIVE SUMMARYT
Page 5 and 6: Executive SummaryII.Production and
Page 7 and 8: Executive Summarybed, using a cesiu
Page 9 and 10: Executive SummaryConversion process
Page 11 and 12: Executive SummaryBAT is to treat al
Page 13 and 14: PrefacePREFACE1. Status of this doc
Page 15 and 16: Preface5. How to understand and use
Page 17 and 18: 2.2.4.2 Gasification of heavy hydro
Page 19 and 20: 5.4.2 Hemihydrate process (HH) ....
Page 21: 10.4.3 Fluoride recovery and abatem
Page 25 and 26: Table 4.20: Energy balance of a dou
Page 27: ScopeSCOPEThis document on Large Vo
Page 30 and 31: Chapter 197 % of nitrogen fertilise
Page 32 and 33: Chapter 11.1.2.3 High exhaust gas v
Page 34 and 35: Chapter 1the SSD of NPK does not le
Page 36 and 37: Chapter 11,8Relative production cap
Page 38 and 39: Chapter 11.2.3 Supply of steam and
Page 40 and 41: Chapter 11.3 Overview of emissions
Page 42 and 43: Chapter 1ApplicabilityGenerally app
Page 44 and 45: Chapter 11.4.3 Handling excess stea
Page 46 and 47: Chapter 11.4.5 Optimisation/mainten
Page 48 and 49: Chapter 1Operational dataNo informa
Page 50 and 51: Chapter 1ApplicabilityEspecially ap
Page 52 and 53: Chapter 11.4.9 Environmental manage
Page 54 and 55: Chapter 1(v) Documentation- establi
Page 56 and 57: Chapter 1iv. allow for comparison w
Page 58 and 59: Chapter 1A number of studies show t
Page 60 and 61: Chapter 11.5 Common BATIn understan
Page 62 and 63: Chapter 11.5.2 BAT for environmenta
Page 64 and 65: Chapter 2Location CompanyCapacity F
Page 66 and 67: Chapter 22.2.2 Output from ammonia
Page 68 and 69: Chapter 22.2.3.2 Primary reformingT
Page 70 and 71: Chapter 2Process name Solvent/reage
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Chapter 22.2.4 Partial oxidationThe
Page 74 and 75:
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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Chapter 4Country Company Location C
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Chapter 4Country Company Location C
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Chapter 4Figure 4.2 gives an overvi
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Chapter 4Two general converter type
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Chapter 4Figure 4.6 gives an impres
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Chapter 44.2.3 Sulphur sources and
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Chapter 44.2.3.5 Non-ferrous metal
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Chapter 4Sulphur source/SO 2 produc
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Chapter 410Tail gas specific SO2 lo
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Chapter 4Capacity in tonnesof 100 %
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Chapter 4Capacity in tonnesof 100 %
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Chapter 4SO 2 sourceSpent acid and
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Chapter 4Cross-media effectsWithout
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Page 204 and 205:
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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Page 220 and 221:
Page 222 and 223:
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:
Page 236 and 237:
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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Page 252 and 253:
Chapter 5Emission of mg/l g/tonne P
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Page 256 and 257:
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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Page 293 and 294:
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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Page 315 and 316:
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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Page 331 and 332:
Page 333 and 334:
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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Page 343 and 344:
Page 345 and 346:
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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Page 354 and 355:
Chapter 88.2.1.1 Particle formation
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Chapter 8Consumption of Per tonne u
Page 358 and 359:
Chapter 8Per tonne urea Unit Remark
Page 360 and 361:
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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Page 368 and 369:
Chapter 8Operational dataSee Table
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Chapter 8Operational dataSee Table
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Page 374 and 375:
Chapter 88.4.6 Redirecting fines to
Page 376 and 377:
Chapter 8Existing plantCase 2Revamp
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Chapter 88.4.8 Heat integration in
Page 380 and 381:
Chapter 88.4.9 Combined condensatio
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Chapter 88.4.10 Minimisation of NH
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Page 386 and 387:
Chapter 8Other approaches to proces
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Page 390 and 391:
Chapter 88.5 BAT for Urea and UANBA
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Chapter 9Country Company LocationBe
Page 394 and 395:
Chapter 99.2.2 NeutralisationThe ex
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Chapter 9Scrubbing devices• packe
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Page 400 and 401:
Chapter 9Pollutant mg/Nm 3 g/tonne
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Page 404 and 405:
Chapter 99.4.2 Recovery of residual
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Chapter 99.4.3 Energy consideration
Page 408 and 409:
Chapter 99.4.4 Steam purification a
Page 410 and 411:
Chapter 99.4.5 Autothermal granulat
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Chapter 9ApplicabilityIrrigated can
Page 415 and 416:
Chapter 1010 SUPERPHOSPHATES10.1 Ge
Page 417 and 418:
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
Page 425 and 426:
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).
Page 434 and 435:
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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