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Chapter 88.4.6 Redirecting fines to the concentrated urea solutionDescriptionWhen granulation is applied as a finishing technique, oversized and undersized products arerecycled to the granulator and form the nuclei of the granules. Dust is often separated after thegranulator and also redirected to the installation, where it is taken along with the fluidisation airto the scrubber and ends up in a dilute solution. This solution is concentrated due toevaporation. However, it is also possible to redirect the dust to concentrated solution instead tothe granulator [52, infoMil, 2001].Achieved environmental benefitsEnergy savings.Cross-media effectsNone believed likely.Operational dataNo specific information provided.ApplicabilityApplicable to all urea plants where a solidification process is applied.YARA Sluiskil, applied this technique in 1999, and saves about 32000 tonnes of steam per year[52, infoMil, 2001].EconomicsThe project cost was EUR 143000, implemented in 1999.Driving force for implementationCost benefitsReferences to literature and example plants[52, infoMil, 2001],YARA, Sluiskil346 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
8.4.7 Revamping conventional plants with stripping technologyDescriptionChapter 8Revamping a conventional plant with stripping technology usually includes one or more of thefollowing changes:• increasing front end production capacity• reducing utility consumption• potential for reducing pollution• reducing maintenance costs• increasing the onstream factor.Table 8.16 shows examples for revamping conventional plants with stripping technology andTable 8.17 shows study cases for a revamp project.Example 1 Example 2Capacity before / afterrevamp1620 / 2460 1065 / 1750 tonnes/dayEnergy saving 30 % per tonne ureaSteam consumption before/ after revampCooling waterconsumption before /after revamp1.6 / 1 tonne/tonne urea100 / 73 m 3 /tonne ureaCO 2 compressionNew centrifugalcompressorInstalled HP stripper Improved ACES StamicarbonInstalled condenser VSCC x Pool condenser xHP NH 3 pumpsNH 3 recycling omitted, lower pumping requirementsdespite of increased capacitySynthesis reactorRelined with 25Cr-22Ni-2Mo steelInstallation of bafflesContinuous monitoring ofthe N/C ratioInstallation of traysx see also Section 8.4.9Table 8.16: Examples for revamping conventional plants with stripping technology[123, Toyo, 2003, 124, Stamicarbon, 2004]Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers 347
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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 Techniques to consider
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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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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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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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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
Page 360 and 361: Chapter 8Waste water per tonne urea
Page 362 and 363: Chapter 8Pollutant Source g/tonne u
Page 364 and 365: Chapter 8Plant Emission Amount (ton
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Page 368 and 369: Chapter 8Operational dataSee Table
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Page 372 and 373: Chapter 8Driving force for implemen
Page 376 and 377: Chapter 8Existing plantCase 2Revamp
Page 378 and 379: Chapter 88.4.8 Heat integration in
Page 380 and 381: Chapter 88.4.9 Combined condensatio
Page 382 and 383: Chapter 88.4.10 Minimisation of NH
Page 386 and 387: Chapter 8Other approaches to proces
Page 390 and 391: Chapter 88.5 BAT for Urea and UANBA
Page 392 and 393: Chapter 9Country Company LocationBe
Page 394 and 395: Chapter 99.2.2 NeutralisationThe ex
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Page 398 and 399: Chapter 99.3 Current emission and c
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Page 402 and 403: Chapter 99.4 Techniques to consider
Page 404 and 405: Chapter 99.4.2 Recovery of residual
Page 406 and 407: 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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Page 415 and 416: Chapter 1010 SUPERPHOSPHATES10.1 Ge
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Page 419 and 420: Chapter 10Input Indirect granulatio
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Page 423 and 424: 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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