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Chapter 5Driving force for implementationEnvironmental and cost benefits.References to literature and example plants[29, RIZA, 2000]. Kemira Agro Pernis performed pilot tests before they were closed down. Themain target of these tests was to make the gypsum suitable for, e.g. construction works250 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Chapter 55.4.15 Thermal processDescriptionAbout the thermal process, see also [155, European Commission, 2006].The production of thermal phosphoric acid is carried out in two stages. First, elementalphosphorus is produced from phosphate rock. Then the elemental phosphorus is oxidised withair to P 2 O 5 , which is subsequently hydrated to produce phosphoric acid.Elemental phosphorus is obtained from phosphate rock. The example plant uses a mixture ofsedimentary rock and igneous rock. The process starts with the grinding of the phosphate rock.The ground phosphate rock is mixed with a slurry consisting of water, clay and various wastestreams containing phosphorus, to produce pellets in a granulator. The pellets are sintered in afurnace at a temperature of about 800 °C. Phosphorus is released from the sintered pellets byheating the pellets to about 1500 °C in an electric resistance furnace together with cokes (toprovide a reducing environment) and gravel (slag formation). The overall reaction can besummarised as follows:2 Ca 3 (PO 4 ) 2 + 6 SiO 2 + 10 C f P 4 + 10 CO + 6 CaSiO 3The process mainly produces gaseous phosphorus, carbon monoxide and a liquid slag. The gasphase is first passed through an electro filter to remove dust (Cottrell dust). Subsequentlygaseous phosphorus is recovered completely through condensation. The remaining gas phasemainly consists of carbon monoxide. This gas is used as fuel gas on-site (e.g. in the sinterfurnaces) and is sold to the nearby power plant. The leftover gas, if any, is flared. The liquidslag is tapped from the furnace in batches, and yields a phosphorus slag (the major part) and aferrophosphorus slag (a minor amount) by-product. After further processing, the former is usedas foundation material in large construction works, while the latter is used as a steel additive inthe iron and steel industry. The P-recovery efficiency of the phosphorus process is about 94 %.The remaining phosphorus will mainly end up in the furnace slag (as unreacted phosphate).Minor amounts end up in ferrophosphorus (as an alloy) and the Cottrell dust.To produce phosphoric acid from elemental phosphorus, first the phosphorus is brought into areaction vessel together with air, after which the phosphorus oxidises to P 2 O 5 . The heat evolvingfrom this reaction is used for the generation of high pressure steam. Subsequently, the P 2 O 5 iscontacted with diluted phosphoric acid, and reacts with the water present in the acid to formphosphoric acid. Two configurations for this process are used. In one case, the absorption ofP 2 O 5 by diluted phosphoric acid is carried out in the same reaction unit as where oxidation ofthe phosphorus takes place. In the other, preferential, case, the reaction of P 2 O 5 to phosphoricacid is carried out in a separate absorption tower, allowing energy recovery as high pressuresteam. The production of phosphoric acid from elemental phosphorus is represented by thefollowing reactions:P 4 + 5 O 2 f 2 P 2 O 5P 2 O 5 + 3 H 2 O f 2 H 3 PO 4Achieved environmental benefits• production of purer acid.Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers 251
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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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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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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 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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Page 236 and 237: Chapter 4Economics[58, TAK-S, 2003]
Page 238 and 239: Chapter 4EconomicsNo specific infor
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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
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Page 256 and 257: Chapter 55.4.2 Hemihydrate process
Page 258 and 259: Chapter 55.4.3 Hemi-dihydrate recry
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Page 264 and 265: Chapter 55.4.6 RepulpingDescription
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Page 270 and 271: Chapter 5Operational dataNo informa
Page 272 and 273: Chapter 55.4.11 Decadmation of H 3
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Page 280 and 281: Chapter 5Cross-media effectsTable 5
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Page 285 and 286: Chapter 66 HYDROFLUORIC ACID6.1 Gen
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Page 311 and 312: 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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Chapter7Driving force for implement
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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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