Large Volume Inorganic Chemicals - Ammonia ... - ammk-rks.net

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Executive SummaryAirHydrocarbonsH 2 OAmmoniaNH 3CO 2Methanol 3)Nitric acidHNO 3UreaUANRock grindingANHNO 3Melamine 3)ANCANANCO 2Ground phosphate rockPhosphoric acidH 3 PO 4NH 3H 3 PO 4AirH 2 OPhosphaterockSSP/TSPPAPRSSP/TSPNPKCN 4)CaCO 31)Limestone ordolomiteHydrofluoric acidHF 2)NH 3H 2 OSO 2AirSulphuric acidH 2 SO 4H 2 SO 4H 2 SiF 6FluorsparAlF 33)Figure I: Overview of boundaries and links between the LVIC-AAF industries1) only with NPK production using the nitrophosphate route2) not typically produced on fertiliser sites3) not described in this document4) CN is Ca(NO 3 ) 2 , and is alternatively produced by neutralisation of HNO 3 with lime (not described in this document)iiLarge Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Executive SummaryII.Production and environmental issuesGenerally, LVIC-AAF production is carried out in dedicated equipment and specific processeswhich are a result of decades of development. However, NPK, AN/CAN and phosphatefertilisers can be produced in the same line of equipment and abatement system. The productioncapacities generally vary from some hundred to up to more than 3000 tonnes per day. Thenitrogenous fertiliser plant is especially a major consumer of energy for meeting various heatingrequirements and mechanical energy for driving different equipment, such as compressors,pumps and fans. Often, the bigger equipment is driven by steam turbines and the smaller one byelectrical motors. Electrical power is taken from the public grid or generated on-site. The steamis supplied by boiler plants, cogeneration plants or is produced in waste heat boilers usingenergy from ammonia, nitric acid or sulphuric acid production.Fertiliser production currently accounts for about 2 – 3 % of the total global energyconsumption. For Western Europe, the corresponding figure is about 1 %. Nitrogen fertilisersaccount for a large majority of this consumption. Most of the energy for fertiliser production isrequired by the fixation of atmospheric nitrogen to manufacture ammonia. Considerable energyis also required for the conversion of ammonia to urea. Amongst the LVIC-AAF industries, theproduction of sulphuric acid and nitric acid are candidates for exporting energy as high,medium, or low pressure steam or as hot water.The main pollutants emitted to air are NO x , SO 2 , HF, NH 3 and dust, which are, depending on theparticular source, emitted at high volume flows. In the production of HNO 3 , considerableamounts of the greenhouse gas N 2 O are generated.Some by-products, e.g. phosphogypsum, are generated in high volumes. These by-productsshow potential for valorisation, but transport costs, contamination with impurities and thecompetition with, e.g. natural resources, restrict the successful marketing. Hence, excessvolumes require disposal.III.Best available techniquesCommon issuesBAT is to carry out regular energy audits for the whole production site, to monitor keyperformance parameters and to establish and to maintain mass balances for nitrogen, P 2 O 5 ,steam, water and CO 2 . Minimisation of energy losses is carried out by generally avoiding steampressure reduction without using the energy or by adjusting the whole steam system in order tominimise the generation of excess steam. Excess thermal energy should be used on-site or offsiteand, if local factors prevent that, as a last option, steam might be used for generating onlyelectrical power.BAT is to improve the environmental performance of the production site by a combination ofrecycling or re-routing mass streams, efficiently sharing equipment, increasing heat integration,preheating of combustion air, maintaining heat exchanger efficiency, reducing waste watervolumes and loads by recycling condensates, process and scrubbing waters, applying advancedprocess control systems and by maintenance.Production of ammoniaBAT for new installations is to apply conventional reforming or reduced primary reforming orheat exchange autothermal reforming. In order to achieve the NO x concentration emission levelsgiven in Table I, techniques such as SNCR at the primary reformer (if the furnace allows therequired temperature/retention time windows), low NO x burners, ammonia removal from purgeand flash gases or low temperature desulphurisation for autothermal heat exchange reforming,should be applied.Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisersiii
Page 1 and 2: EUROPEAN COMMISSIONIntegrated Pollu
Page 3: Executive SummaryEXECUTIVE SUMMARYT
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 and 22: 10.4.3 Fluoride recovery and abatem
Page 23 and 24: Figure 8.1: Overview of the product
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
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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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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 77.2.3 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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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 88.2.1.1 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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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
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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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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
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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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Page 404 and 405:
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).
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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