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Chapter 7Approx. ktonnesCountry Company Placeof productAMI Linz 400AustriaDonauchemie Pischelsdorf 150BelgiumBASF Antwerp 1200Rosier Moustier 300Czech Rep. Lovochemie Lovosice 160FinlandFranceKemira GrowHowRoullier GroupGrande ParoisseSiilinjärvi 500Uusikaupunki525425CFPR St Malo 250CFPR Tonnay-Charente 200Grand-Quevilly/Rouen400200CEDEST Mont Notre Dame 150Yara France Montoir 500Pec-Rhin Ottmarsheim 200S.Engrais Chim.Orga. Seco Ribecourt 300Roullier Group Sète 200Germany Compo Krefeld 250Greece PFI Kavala 270Hungary Kemira GrowHow Kft Veszprem 200ItalyLithuaniaNetherlandsPolandYara Italy Ravenna 480Roullier Group Ripalta 200Kemira GrowHow/Lifosa Kedainiai 240Eurochem/Lifosa Kedainiai 800Arvi & CO JSC Marijampole 160Amfert Amsterdam 200DSM Agro IJmuiden 230Zuid ChemieSas van Gent260200Fabryka Nawozow Fosforow Gdansk 150Zaklady PolicePolicePortugal Adubos Setúbal/LisbonSlovakia Duslo Sala Nad Vahom 290SpainFertiberia580550250200Avilés 200Huelva 200Roullier Group Lodosa 270Sader Luchana 150Mirat SA Salamanca 150Agrimartin Teruel 200Sweden Yara Sweden Koeping 330UK Kemira Grow How Ince 630Table 7.2: Overview of major NPK plants in the EU-25 with a capacity bigger than 150000 tonnesper year as of February 2006284 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Chapter 77.2 Applied processes and techniques7.2.1 OverviewFigure 7.1 gives an overview of the production of NPK fertilisers. Compound fertilisers can beproduced in four, basically different, ways:• production by the mixed acid route, without phosphate rock digestion• production by the mixed acid route, with phosphate rock digestion• production by the nitrophosphate route (ODDA process)• mechanical blending or compactation of single or multi-nutrient components (not includedin the figure).M i x e d a c i d r o u t eNitrophosphate route(ODDA process)NH 3H 2SO 4/H 3PO 4and/or HNO 3HNO 3NH 3H 2SO 4, H 3PO 4, HNO 3Phosphate rockDirectneutralisation(pipe reactor)Preneutralisation(tank)Phosphaterock digestionPhosphaterock digestionSand removalSand removalMixed acidslurryCa(NO 3) 2crystallisationand filtrationVariousamounts of:• NH 3• urea/(NH 4 ) 2 SO 4• AN solution•H 2 SO 4•H 3 PO 4•HNO 3• SSP/TSP• MAP/DAP•H 2 O/steam•K salts• other nutrients• fillersNeutralisation,evaporation,adjustment ofcompositionParticle formationand conditioning“NP acid”NH 3 /CO 2Ca(NO 3) 2.4 H 2OConversionNH 4NO 3/CaCO 3NPK fertiliserTo NPK, AN, CAN orCN productionFigure 7.1: Overview of the production of NPK fertilisers from phosphate rock or SSP/TSP[154, TWG on LVIC-AAF, 2006]Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers 285
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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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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:
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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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Chapter 5Emission of mg/l g/tonne P
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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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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
Page 274 and 275: Chapter 55.4.12 Use of entrainment
Page 276 and 277: Chapter 5Cross-media effects• dis
Page 278 and 279: Chapter 5Driving force for implemen
Page 280 and 281: Chapter 5Cross-media effectsTable 5
Page 282 and 283: Chapter 5ApplicabilityAt present, o
Page 285 and 286: Chapter 66 HYDROFLUORIC ACID6.1 Gen
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Page 289 and 290: Chapter 66.2.4 Process gas treatmen
Page 291 and 292: Chapter 66.3 Current emission and c
Page 293 and 294: Chapter 6Emission of kg/tonne HF Re
Page 295 and 296: 6.4 Techniques to consider in the d
Page 297 and 298: Chapter 66.4.2 Energy recovery from
Page 299 and 300: Chapter 66.4.4 Valorisation of fluo
Page 301 and 302: Chapter 66.4.6 Scrubbing of tail ga
Page 303 and 304: 6.4.7 Scrubbing of tail gases: fluo
Page 305 and 306: Chapter 66.4.8 Abatement of dust em
Page 307 and 308: Chapter 66.4.9 Waste water treatmen
Page 309 and 310: Chapter 6Cross-media effects• 5 -
Page 311: Chapter 77 NPK AND CN7.1 General in
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Page 317 and 318: Chapter 7Fluorine compounds origina
Page 319 and 320: Chapter7Per tonne productkWh Nm 3 k
Page 321 and 322: Chapter7Emission levelmg/Nm 3 ppm k
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Page 335 and 336: Chapter77.4.6 Recycling warm airDes
Page 337 and 338: Chapter77.4.7 Optimising the recycl
Page 339 and 340: Chapter7Operational dataThe volume
Page 345 and 346: Chapter77.4.11 Recycling of scrubbi
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Page 349: Chapter7ParameterLevelmg/Nm 3Phosph
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Page 354 and 355: Chapter 88.2.1.1 Particle formation
Page 356 and 357: Chapter 8Consumption of Per tonne u
Page 358 and 359: Chapter 8Per tonne urea Unit Remark
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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 99.4.2 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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