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Chapter 1010.3 Current emission and consumption levelsTable 10.3 gives an overview of the consumption levels for the production of superphosphate. For comparison of direct and indirect TSP granulation, see Table 10.4.Table 10.5 gives an overview of emissions to air, Table 10.6 shows an example for water emission levels.Per tonneproductPowerGrindingScrubbingDepends on the type of phosphate rock: about 15 – 18 kWh per tonne phosphaterockThree stage scrubbing: 20 kWh/tonne product due to high pressure drop in theVenturi scrubbers[9, Austrian UBA, 2002]Water 1.2 m 3 This includes 0.8 m 3 H 2 O/tonne product for scrubbingPowerRun of the pile19 kWhWater (powdery product, 0.1 m 3 Most scrubber liquids are recycled back into the processSteam/fuelSSP 18 % P 2 O 5 )No steam and no fuel consumptionPower34 kWh[53, German UBA, 2002]Water Granulate2.0 m 3SteamFuel(SSP 18 % P 2 O 5 )55 kg0.75 GJ For air heatingEnergy Directly granulated SSP 1.4 GJ This includes 0.4 GJ for powder production and 1.0 GJ for granulationPower Powdered SSP 19 kWh[52, infoMil, 2001]Energy Directly granulated TSP 2.0 GJ This includes 0.3 GJ for powder production, 1.0 for granulation, 0.7 for evaporationTable 10.3: Consumption levels for the production of superphosphates390 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Chapter 10Input Indirect granulation Direct granulationH 3 PO 4 Based on 52 % P 2 O 5 > 50 % P 2 O 5per tonne granulated TSPRatio of recycle 1.0 – 1.25Cured TSP 1.02 tonnes -Steam 75 kg 50 – 60 kgCooling water 250 kg 250 kgWater consumption60 – 65 kgFuel0.67 GJElectrical power 29 kWh 36 kWhOperation labour 0.3 work hours 0.25 work hoursTable 10.4: Comparison of some input requirements of direct and indirect granulation of TSPThe table is based on [52, infoMil, 2001, 154, TWG on LVIC-AAF, 2006]Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers 391
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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 77.2.3 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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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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Page 372 and 373: Chapter 8Driving force for implemen
Page 374 and 375: Chapter 88.4.6 Redirecting fines to
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
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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
Page 392 and 393: Chapter 9Country Company LocationBe
Page 394 and 395: Chapter 99.2.2 NeutralisationThe ex
Page 396 and 397: Chapter 9Scrubbing devices• packe
Page 398 and 399: Chapter 99.3 Current emission and c
Page 400 and 401: Chapter 9Pollutant mg/Nm 3 g/tonne
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
Page 412 and 413: Chapter 9ApplicabilityIrrigated can
Page 415 and 416: Chapter 1010 SUPERPHOSPHATES10.1 Ge
Page 417: Chapter 10Emissionto airEmissionto
Page 421 and 422: Chapter 10Volume5 - 10 m 3 /hourTem
Page 423 and 424: Chapter 1010.4.2 Recovery and abate
Page 425 and 426: Chapter 1010.4.4 Recycling of scrub
Page 427 and 428: Chapter 1111 CONCLUDING REMARKS11.1
Page 429: Chapter 11Production of HNO 3 : De-
Page 432 and 433: References26 Dipankar Das (1998).
Page 434 and 435: References89 Kuiper (2001). "High t
Page 436 and 437: References147 Uhde (2006). "The Uhd
Page 438 and 439: GlossaryCalculation of steam proper
Page 440 and 441: GlossaryIPCCIPPCISO 14001Intergover
Page 442 and 443: GlossaryChemical formulasAl 2 O 3Ca
Page 445 and 446: Annexes14 ANNEXES14.1 Cost calculat
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