Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
2,000 t
ThyssenKrupp
Industrial Solutions
Content
04
06
08
10
12
13
14
16
17
Ammonium sulphate AS
- Strong Granules
- Low Energy Consumption
- Process description
18
UAN solution
Engineering Excellence3
Think globally, act locally
Having erected several thousand plants, ThyssenKrupp Industrial Solutions is one of the
world's leading engineering companies. Our Business Unit Process Technologies supplies
chemical plants, refineries and coking plants on the basis of tried-and-tested technologies
made by Uhde, while the portfolio of the Business Unit Resource Technologies comprises
complete cement plants and grinding systems of the Polysius brand, as well as machines,
plants and systems for mining, extraction, preparation, processing or transshipment of
commodities.
With many years of experience in the EPC business, we offer our customers concepts,
market studies, plant layouts, design engineering, supplies, manufacturing services,
erection and commissioning all from a single source. Our employees on all continents
use their knowledge and engineering competence to create innovative solutions and to
look for ways to conserve natural resources.
Over 40 locations in 25 countries divided into six regions form a close-meshed
network that allows us to align our services to local conditions consistently. Thanks
to this on-site expertise and global networking, we are able to set standards that offer
our customers a true competitive edge.
Our comprehensive service concepts take the entire life cycle of a plant into account.
We offer OEM spare parts service and complete maintenance management, as well
as servicing, modernisation projects and conversions.
Natural gas
Lime stone
NH3
Uhde
HN03
Uhde
ThyssenKrupp Industrial Solutions offers proven, competitive processes based on both proprietary and renowned licensed technologies, thus putting us in a
position to offer a full range of plants for the production
of single-component and mixed nitrogenous fertilisers.
CO2
NH3
HNO3
UAN
Uhde
Fig. 1:
Uhde fertiliser processes
Urea
UFT
AN
Uhde
CAN
Uhde
CAN
Licensor
Nitrogen fertiliser
Phosphate rock
Potassium
Sulphur
H2SO4
Licensor
NH3
H2SO4
H3PO4
Ca3(PO4)2
Licensor
Nitrophos.
CN
KCl/K2SO4
Licensor
CN
conv.
Licensor
Lime
AN sol.
H3PO4
H2SO4
CN
Licensor
ASN
Uhde
AS
NP
NP
NP
Licensor
Licensor
Licensor
Licensor
MAP
Licensor
DAP
Licensor
SSP
Licensor
UFT:
NPK
Licensor
NPK
Licensor
TSP
Licensor
NPK
Licensor
Compound fertiliser
Phosphate fertiliser
General
Ammonium nitrate is produced from gaseous ammonia and aqueous nitric acid in an
exothermic reaction according to the following equation:
NH3 + HNO3 NH4NO3 - HR
The heat of reaction is released into the
circulating stream of AN solution, causing
a temperature rise. Precise control of the
reaction system parameters is essential for
highly-efficient ammonium nitrate production.
These parameters include in particular good
mixing in of the reactants as well as reliable temperature and pH control. The Uhde
technology comprises an external circulation loop, either forced or natural, and also
a sophisticated reactant feed and mixing
system for stable operating conditions.
ThyssenKrupp Industrial Solutions offers
two proprietary types of neutralisation processes for the production of ammonium
nitrate solution:
Vacuum neutralisation and evaporation
This process is the most popular alternative
because it involves the lowest investment
costs. The reaction takes place in a slightly
pressurised neutraliser to prevent the
ammonium nitrate solution from boiling in
the mixing and reaction sections thus minimising ammonia losses.
b) Heating steam is imported for final concentration of the ammonium nitrate solution, while part of the heat of reaction is
utilised to generate low-pressure steam
at approx. 5 bar abs. (Fig.4)
In both cases the flash steam from the
vapour separator at 2-4 bar abs is used
for intermediate concentration of the weak
ammonium nitrate solution. Again, the
remaining process vapours are used for
feedstock preheating; surplus vapours are
condensed. Depending on how the vapour
condensate is to be used, some or all of the
vapours need to be scrubbed before condensation in a separate vapour scrubber.
7
Fig. 2:
Vacuum neutralisation
and evaporation
Process condensate
for scrubbing/saturation
CW
CW
Vapour
separator
Orifice
Vapour
separator
Process condensate
AN
neutraliser
HNO3
Steam
AN
evaporator
NH3 gas
NH3 gas
AN solution
AN melt
8 bar
Clean condensate
Circulation pump
Vapours to scrubber
Fig. 3:
Pressure neutralisation
with direct heat recovery
Process condensate
for scrubbing/saturation
Vapour
separator
Vapour
separator
Orifice
Vapour
separator
AN melt
First
evaporator
Final
evaporator
AN
neutraliser
NH3 gas
HNO3
Circulation pump
Vapours to scrubber
Fig. 4:
Pressure neutralisation
with clean steam production
Process condensate
for scrubbing/saturation
Vapour
separator
Vapour
separator
AN melt
Steam
Steam 5 bar
Boiler feed water
NH3 gas
Steam
boiler
First
evaporator
Final
evaporator
10 bar
AN
neutraliser
HNO3
Vapour scrubbing
The vapours formed in the ammonium
nitrate neutralisation and evaporation process are scrubbed either direct in the vapour separator or in a separate scrubbing
column. Depending on the quality of the
process vapours, a single or dual-stage
scrubber is applied. The condensed overhead vapours from the scrubber can be
used for various purposes, e.g. as scrubbing make-up water or as feed for a demineralised water plant. Contaminant levels in
the clean condensate are as low as 15 ppm
nitrogen. The sump concentrate can be
used for nitric acid make-up.
Steam
Fig. 5:
Vapour scrubbing
Steam ejector
CW
CW
Condenser
Steam condenser
Vapours
Process condensates
Clean condensate
Vapour scrubber
Scrubber pump
Pugmill
granulation
AN 33.5
CAN 27
Fig. 2
Fig. 3
Fig. 6
Steam import
(4.5/10 bar a)
kg/tAN
130
10
52
Steam export
(6.5/4.5 bar a)
kg/tAN
240
Cooling water
m3/tAN
31.0
22.5
3.8
5.0
Electrical energy
kWh/tAN
2.0
3.8
4.8
29.0
Ammonia
kg/tAN 213
213
213
Nitric acid
kg/tAN 789
789
789
Fig. 4
90
10
General
Today modern fertiliser plants supply
granulated products. Prilling is becoming less common due to environmental
constraints and increased product quality
requirements.
In producing fertiliser from the various
solid and liquid feed materials, the granulation unit must ensure that the resulting
product meets market requirements with
regard to its chemical and physical properties.
There are many different ways of producing granules, such as flaking, drum, pan
or pugmill granulation and fluid-bed technology.
In the past, ThyssenKrupp Industrial
Solutions has built granulation plants for
all common fertiliser grades from straight
N fertiliser to NP(K) and P(K) fertilisers.
ThyssenKrupp Industrial Solutions has
a wealth of experience in the design and
operation of granulation plants and is in
a position to build plants based on all
modern granulation processes.
The most common granulation process
used in nitrate fertiliser plants built by
ThyssenKrupp Industrial Solutions is
the proprietary Uhde pugmill granulation
process.
AN/CAN pugmill granulation plant,
Fertiberia S.A. (formerly Enfersa) in Sagunto/Spain
Capacity: 1,100/1,400 tpd (33.5 wt.%/26 wt.% N)
AN granules
CAN granules
11
12
3D model of
the Uhde pugmill granulation
13
Key features
AN solution
to atm.
Clean condensate
Screens
Additive
Cyclones
Scrubber
Bleed
Crushers
(to evaporation)
AN melt
Pugmill granulator
Fluidised-bed cooler
AN/CAN
Coating drum
Filler
(limestone, dolomite)
Coating agent
Drying drum
Steam
Steam
Cond. air
14
Fig. 8:
Uhde LDAN prilling process
Prilling additive
Screens
Prilling air
scrubber
Fluidised-bed cooler
Drying air
scrubber
Coating drum
AN prills
CW
Anti-caking agent
Conditioned air
Scrubber bleed
to evaporation
AN melt
Pre-drying drum
Prilling tower
Drying drum
Bucket
elevator
Steam
Steam
15
Ammonium nitrate prilling unit for
Queensland Nitrates Pty Ltd., Australia.
Capacity: 400 t/day AN prills (technical grade)
16
The depletion of sulphur in soils is increasing and this has spurred demand
for sulphur-containing fertilisers, such
as ammonium sulphate nitrate.
This is particularly attractive as it can be
produced in a modified AN or CAN pugmill
granulation plant.
Ammonium sulphate nitrate is a double
salt which approximately corresponds to
the following formula:
2 NH4NO3 x (NH4)2SO4
Fig. 9:
Ammonium sulphate nitrate process
to atm.
Vent
CW
Scrubber
Scrubber
to process
HNO3
HNO3
Screen
AS (case by case)
Dedusting
Crusher
Al2(SO4)3
from points
FeSO4
to saturator
NH3 gas
HNO3
Air
Steam
ASN conversion
Drying drum
Air
Fluidised-bed cooler
ASN
17
Ammonium sulphate AS
Granulation additive
Pipe reactor
Recycle conveyor
Sulphuric acid
Crusher
Granulation
drum
Drying
drum
Air
Dryer
furnace
Ammonia
Exhaust
Dedusting
filter
Fuel gas
Droplet
separator
Fluidised-bed
cooler
Scrubber
Air
Coating agent
Coating
drum
Scrubbing
tank
Strong Granules
The rotary drum granulation delivers a
smooth granulate with a hardness of >35 N.
Low Energy Consumption
If sulphuric acid is directly neutralized
with ammonia, a high energy yield reduces
the necessary energy supply for water
evaporation.
Process description
Ammonium sulphate is obtained from
the reaction of gaseous ammonia with
concentrated sulphuric acid in a reactor.
Ammonium sulphate has a low solubility
in water (about 40 - 50 % max.). Therefore,
additional water must be fed into the reactor to obtain a flowing solution/slurry which
is then delivered to a rotary drum for granulation. The solution still contains sulphuric
acid that is neutralized with ammonia within
the rotary drum granulator.
The recycled fines and the small shaped
material are growing along the length of
the rotary drum until they reach the desired
size. The water from AS solution is vaporized using the heat of reaction.
Ammonium
sulphate
18
UAN solution
UAN
The use of liquid fertilisers is a common
practice, especially in North America. A
fertiliser with excellent physical properties
is UAN solution, which is a mixture of ammonium nitrate, urea and water. Standard
solutions contain 28, 30 and 32% nitrogen,
respectively, but can also be enriched with
soluble plant nutrients, such as sulphur,
boron and calcium compounds. A typical
composition of UAN solution with 32% N is
As UAN solution is a liquid with a low viscosity, it can easily be applied by spraying
without the need for additional irrigation.
Depending on its composition, the saltingout temperature of the solution can be well
below zero degrees centigrade and transport and storage are thus simple even in
cold climates.
ThyssenKrupp Industrial Solutions has designed UAN plants based on two process
alternatives:
CW
Condenser
Vapour
separator
Orifice
Process condensate
Ammonia
heater
AN
neutraliser
NH3 gas
AN solution
HNO3
Process
condensate tank
Circulation pump
Urea solution
NH3 gas
Contaminant levels in the process condensate used as make-up water for a nitric
a) UAN solution on the basis of ammonium acid plant are as low as 300 ppm AN and
nitrate neutralisation
100 ppm HNO3.
CW
UAN cooler
Corrosion
inhibitor
19
CW
Vapour
separator
Off-gas
scrubber
Urea off-gas
AN neutraliser
AN solution
Clean condensate
HNO3
Process
condensate tank
HNO3
Corrosion inhibitor
CW
Urea solution
UAN solution
UAN solution tank
PT 009/0/e/1000/201504/PM/Printed in Germany