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Chapter 5Cross-media effectsTable 5.11 shows an example for emission levels and co-generated output and Table 5.12typical consumption levels for the production of H 3 PO 4 by the thermal process. The mainsources of emissions and waste in the production of phosphorus and phosphoric acid fromelemental phosphorus are:1. Sintering of the phosphate rock pellets and drying of cokes in the sinter furnace.The off-gas from the sinter furnace contains a wide range of pollutants such as dust,fluoride, phosphate, heavy metals, radio nuclides and SO 2 and NO x . The off-gas from theovens is cleaned in two-stage scrubber systems with closed water circuits, before beingemitted to the air. To prevent accumulation, pollutants are removed from the recirculatingwash-water stream through neutralisation followed by flocculation and separation of thesolids. The solids obtained are returned to the process either via the slurry station or via thephosphate rock (after drying).2. Calcination of Cottrell dust, flaring of fuel gas and drainage of liquid slag from thephosphorus furnace.The gas phase produced in the phosphorus furnace contains a considerable amount of dust(so-called Cottrell dust) which is removed through an electrofilter. As a result of closedloops (re-use of waste streams) in the process, the dust is enriched in heavy metals (mainlyzinc) and radionuclides (such as 210-Po and 210-Pb). The dust is mixed with water andrecycled to the slurry station. However, due to the high zinc content in the dust, part of it isremoved to prevent excessive accumulation. The dust is calcined (emission of dust, F andP 2 O 5 to the air) and stored. In the near future, storage will by replaced to a special storagefacility for all kinds of radioactive waste.After the recovery of phosphorus from the gas, the remaining gas mainly consists of carbonmonoxide. This gas is used as fuel gas on the site (e.g. in the sinter furnaces) and is sold tothe nearby power plant. The leftover gas, if any, is flared, which contributes to SO 2 and NO xemissions to the air.Vapours released while draining of the liquid slags from the phosphorus furnace, areremoved, and washed with water in a venturi scrubber before being emitted to the air.Process effluents that have been in contact with phosphorus are sent to the waste waterstation.After treatment (sedimentation followed by neutralisation, flocculation and separation of thesolids formed), 70 to 90 % of the water is recycled to the process. The remaining water istreated with lime for further P 2 O 5 removal and is subsequently treated in an biological wastewater treatment plant before being discharged to the sea. All solids are recycled to theprocess.3. Oxidation of phosphorus in the acid plant and removal of arsenic from the acid.The off-gas from the acid towers is contaminated with traces of P 2 O 5 and phosphoric acid.To minimise emissions, the off-gas is cooled and washed with recirculating acid and water,and subsequently treated in a venturi scrubber (diluted acid) and a demister. The bleed ofthe recovery system is re-used either in the wet phosphoric acid purification plant or theslurry station. The emissions of the acid plant are small compared to the emissions of thesinter plant and the phosphorus plant.Due to the specific fields of application (e.g. food additive and beverages),, traces of arsenicpresent in the phosphoric acid have to be removed. To this end, sodium hydrogen sulphide(NaHS) is added to the acid, upon which arsenic is precipitated as arsenic sulphide (As 2 S 3 ).After separation and further processing, the latter is obtained in concentrated form andstored as hazardous chemical waste.252 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Chapter 5Emission or generation ofPer tonne P 2 O 5Level UnitPhosphate (P) 0.6Fluorine (F) 0.1 kgDust 0.4To airCadmium 1.0Lead 6.0 gZinc 5.9Po-210 3.5Pb-210 0.3MBqPhosphate (P) 0.7Fluorine (F) 0.7kgCadmium 0.2To waterMercury
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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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Chapter 44.4.16 Minimisation and ab
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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
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
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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 293 and 294: Chapter 6Emission of kg/tonne HF Re
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Page 309 and 310: Chapter 6Cross-media effects• 5 -
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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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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