CLEANER PRODUCTION OPPURTUNITIES - gcpc-envisgcpcenvis.nic.in/Experts/Fertiliser Industry.pdf · CLEANER PRODUCTION OPPURTUNITIES FERTILIZER MANUFACTURING – ENVIS CENTRE IN

Gujarat Cleaner Production Centre

CLEANER PRODUCTION

OPPURTUNITIES

FERTILIZER MANUFACTURING

Gujarat Cleaner Production Centre – ENVIS CENTRE

CLEANER PRODUCTION

OPPURTUNITIES

IN


SECTOR

1 | P a g e



Introduction to Fertilizer Industry

India is the second biggest consumer of fertilizer in the world next only to China. The Indian

Fertilizer companies produced around 37.6 million

9% rise in comparison to 34.6 million

Sector-Wise, Nutrient-Wise Installed Capacity Of Fertilizer Manufacturing Units (As

31.03.2012.)

Fertilizers are materials used to provide plant nutrients which are deficient in soils.

industry is essentially concerned

phosphorus and potassium - in plant

form, N, but phosphorus and potash may be expressed either as the oxide (P2O5, K2O) or as the

element (P, K). Sulphur is also supplied in large amounts, partly through the sulphates present in

such products as superphosphate and ammonium sulphate

Nutrient content of common fertilizers

No. Material

1. Ammonium Nitrate

2. Ammonium Sulfate

3. Calcium Nitrate

4. Diammonium Phosphate

5. Monoammonium phosphate

6. Muriate of Potash

7. Potassium Nitrate

8. SKMG or SULPOMAG


Introduction to Fertilizer Industry


Fertilizer companies produced around 37.6 million tones of fertilizer in the year 2012

9% rise in comparison to 34.6 million tones of last year ( 2011-12 ) production.

Wise Installed Capacity Of Fertilizer Manufacturing Units (As

Fertilizers are materials used to provide plant nutrients which are deficient in soils.

industry is essentially concerned with the provision of three major plant nutrients

in plant-available forms. Nitrogen is expressed in the elemental


(P, K). Sulphur is also supplied in large amounts, partly through the sulphates present in

such products as superphosphate and ammonium sulphate

Nutrient content of common fertilizers

(%)

N P2O5 K2O MgO S

35 0 0 0 0

21 0 0 0 24

15.5 0 0 0 0

Diammonium Phosphate 18 46 0 0 0

Monoammonium phosphate 11 52 0 0 0

0 0 60 0 0

13.5 0 44 0 0

SKMG or SULPOMAG 0 0 22 18 22

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of fertilizer in the year 2012-13 with a

Wise Installed Capacity Of Fertilizer Manufacturing Units (As On

Fertilizers are materials used to provide plant nutrients which are deficient in soils. The fertilizer

with the provision of three major plant nutrients - nitrogen,

available forms. Nitrogen is expressed in the elemental


(P, K). Sulphur is also supplied in large amounts, partly through the sulphates present in

24

22


9. Sulphate of Potash

10. Single Super Phosphate

11. Triple Super Phosphate

12. Urea

Highlights of processes for different Fertilizers

(1) Urea

The first Haber Bosch plant was opened in 1913, and nitrogen production has been largely

dependent on ammonia synthesis ever since. Ammonia synthesis requires large amounts of

energy. Initially, this was provided by cheap electricity and derivatives of coa

or cryogenic separation of hydrogen from coke oven gas). These feedstocks were available only

in industrialized countries. Subsequently, more economic processes were developed which

involved the partial oxydation of hydrocarbons by pur

reforming of natural gas or naphta by steam.

Urea accounts for almost 50% of world nitrogen fertilizer production (in terms of N content, and

including multi-nutrient products), compared with only 30% a decade previously.

by combining ammonia and carbon dioxide at high pressure (140

(180-190°C) to form ammonium carbamate, which is then dehydrated by heat to form urea and

water, according to the following reaction:

(1) 2NH3 + CO2 → NH2COONH4

The first stage of the reaction is exothermic and proceeds to virt

conditions. The second stage is endothermic, and conversion is only partial (50

basis). The conversion is increased by i

and/or decreasing the H2O/CO2

ways to separate product urea from the

decompose the residual carbamate to NH3 and CO2 for recycling

There are three main types of process:

• . Once-through process: unconverted CO2 and NH3 are discharged to other plants, where

the NH3 is used for the production of fertilizers such as ammonium sulphate

ammonium nitrate

• Partial recycle process: unconverted CO2 and NH3 are partially separated in the

decomposition section of the first stage and are then recovered in an absorber, the

remainder being delivered to other plants as in the once

• Total recycle process: unconverted CO2 and NH3 are totally separated in multi

decomposers, recovered in corresponding multi

reactor.


0 0 50 0 18

Single Super Phosphate 0 22 0 0 14

Triple Super Phosphate 0 46 0 0 0

46 0 0 0 0

different Fertilizers



energy. Initially, this was provided by cheap electricity and derivatives of coal (water gas process



involved the partial oxydation of hydrocarbons by pure oxygen and steam and the tubular

reforming of natural gas or naphta by steam.


nutrient products), compared with only 30% a decade previously.

ammonia and carbon dioxide at high pressure (140-200 bar) and high temperature

ammonium carbamate, which is then dehydrated by heat to form urea and

water, according to the following reaction:

NH2COONH4 → CO(NH2) 2 + H2O

The first stage of the reaction is exothermic and proceeds to virtual completion under industrial

The second stage is endothermic, and conversion is only partial (50

increased by increasing the temperature, increasing the NH3/CO2 ratio

ratio. Process design is mainly concerned with the most efficient

ways to separate product urea from the other reaction components, to recover excess NH3

carbamate to NH3 and CO2 for recycling.

There are three main types of process:

through process: unconverted CO2 and NH3 are discharged to other plants, where

the NH3 is used for the production of fertilizers such as ammonium sulphate

Partial recycle process: unconverted CO2 and NH3 are partially separated in the


remainder being delivered to other plants as in the once-through process;

Total recycle process: unconverted CO2 and NH3 are totally separated in multi

decomposers, recovered in corresponding multi-stage absorbers, and recycled to the

3 | P a g e

18

14



l (water gas process



e oxygen and steam and the tubular


nutrient products), compared with only 30% a decade previously. It is produced

200 bar) and high temperature

ammonium carbamate, which is then dehydrated by heat to form urea and

ual completion under industrial

The second stage is endothermic, and conversion is only partial (50-80%, CO2

ncreasing the temperature, increasing the NH3/CO2 ratio

ratio. Process design is mainly concerned with the most efficient

other reaction components, to recover excess NH3, and to

through process: unconverted CO2 and NH3 are discharged to other plants, where

the NH3 is used for the production of fertilizers such as ammonium sulphate and

Partial recycle process: unconverted CO2 and NH3 are partially separated in the


s;

Total recycle process: unconverted CO2 and NH3 are totally separated in multi-stage

rs, and recycled to the


(2) Urea-Ammonium Nitrate (U

UAN solutions provide a large share of the liquid fertilizer market. Concentrated urea and

ammonium nitrate solutions are measured, mixed and then cooled, and both continuous and

batch processes are available. A partial recycle CO2 stripping urea process m

unconverted NH3 and CO2 for conversion into UAN solutions. Typical input requirements per

tonne of UAN solution (30% N) are 328 kg urea, 426 kg ammonium nitrate, 245 kg water, and

steam/electricity equivalent to about 10 kWh. Corrosion inhi

protection, and there are normally traces of ammonia

(3) Ammonium Nitrate And Calcium Ammonium Nitrate

Ammonium nitrate (AN) and calcium ammonium nitrate (CAN) account for about 16% of world

nitrogen fertilizer production. They are particularly important in Europe and the FSU, which

account for about 75% of the world total. Ammonium nitrate is produced by n

acid with gaseous ammonia. The reaction is exothermic, producing AN solution and steam. In a

second stage, the AN solution is evaporated to the desired concentration, depending on whether

it will be finally prilled or granulated. CAN was

declared as dangerous goods (the AN content needs to be less than 80% AN). To produce CAN,

the AN solution is mixed with a filler containing dolomite, calcium carbonate, ground limestone

or, quite frequently, by-product calcium carbonate from a nitrophosphate plant (see below). This

mixture can also be either prilled or granulated. Ammonium sulphate nitrate (ASN) is another

mixture, produced by granulating AN and ammonium sulphate. The AN content needs to be less

than 45% to avoid dangerous good declaration.


Ammonium Nitrate (UAN)



batch processes are available. A partial recycle CO2 stripping urea process m



steam/electricity equivalent to about 10 kWh. Corrosion inhibitor may be added for equipment

protection, and there are normally traces of ammonia.

Ammonium Nitrate And Calcium Ammonium Nitrate



account for about 75% of the world total. Ammonium nitrate is produced by n



it will be finally prilled or granulated. CAN was developed to avoid the AN fertilizer being



product calcium carbonate from a nitrophosphate plant (see below). This



than 45% to avoid dangerous good declaration.

4 | P a g e



batch processes are available. A partial recycle CO2 stripping urea process may also provide



bitor may be added for equipment



account for about 75% of the world total. Ammonium nitrate is produced by neutralizing nitric



developed to avoid the AN fertilizer being



product calcium carbonate from a nitrophosphate plant (see below). This




Fertilizer Production Routes


Fertilizer Production Routes

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(4) Single And Triple Superphosphate

Superphosphates account for over one quarter of world phosphate fertilizer production. Single

superphosphate (SSP) is produced by reacting mineral phosphate with sulphuric acid in

proportions which convert most of the phosphate to the water

Unlike the similar reaction which produces phosphoric acid, this process retains the calcium

sulphate in the product; and it is for this reason that SSP retains its importance wherever sulphur

deficiency limits crop yields. Triple superphosphat

produced by acidulating the mineral phosphate with phosphoric acid, instead of sulphuric acid.

Double, or enriched superphosphate is also produced, by using a mixture of the two acids. In all

cases, the emissions to air and water are similar to those involved in phosphoric acid production,

except for the problem of gypsum disposal in the latter case. Dust and fluorine removal from the

off-gases exiting the reactor/curing den is usually achieved with a venture scrubbi

involving a circulation solution of weak (less than 23 %) fluorosilicic acid. The venture scrubber

is equipped with a tail-gas scrubber in the form of a packed tower that is usually followed by an

entrainment separator. A modern system can reduce

emission to 0.3-1 kg/t of product.

There are always two stages in the manufacture of granulated single superphosphate, the first to

manufacture powdered single superphosphate and the second to granulate. Howeve

of triple superphosphate, there are two alternatives:

• .As in the case of single superphosphate, run

ROP material is prepared by reacting phosphate rock with phosphoric acid with a P2O5

concentration of 50 to 54%, but a lower concentration may be used, followed by

granulation.

• A slurry of phosphate rock reacted with phosphoric acid of 35% to 38% P2O5

concentration may be granulated directly in a traditional unit with a drum granulator,

drier etc.

(5) Multi-Nutrient Fertilizers

Large quantities of multi-nutrient fertilizers (NP/NPK/NK/PK) are produced simply by dry

mixing (or blending) single-nutrient materials without acidulation or chemical reaction. With

efficient management, such operations do not normally

emissions or wastes. Consequently,

multi-nutrient fertilizers, and these involve a

fall broadly into three groups:

• The mixed acid route,

• The phosphoric acid route,

• The nitric acid route.


Single And Triple Superphosphate



proportions which convert most of the phosphate to the water-soluble mono



deficiency limits crop yields. Triple superphosphate contains little sulphur, because it is



air and water are similar to those involved in phosphoric acid production,


gases exiting the reactor/curing den is usually achieved with a venture scrubbi


gas scrubber in the form of a packed tower that is usually followed by an

entrainment separator. A modern system can reduce fluorine emission to 0.1 kg/t P2O5, and dust

1 kg/t of product.


manufacture powdered single superphosphate and the second to granulate. Howeve

of triple superphosphate, there are two alternatives:

.As in the case of single superphosphate, run-of-pile (ROP) material may be used. The


50 to 54%, but a lower concentration may be used, followed by

A slurry of phosphate rock reacted with phosphoric acid of 35% to 38% P2O5


utrient Fertilizers

nutrient fertilizers (NP/NPK/NK/PK) are produced simply by dry

nutrient materials without acidulation or chemical reaction. With

such operations do not normally give rise to significant environmental

emissions or wastes. Consequently, we are here concerned solely with chemically compounded

nutrient fertilizers, and these involve a wide variety of processes and formulations, which

The phosphoric acid route,

6 | P a g e



soluble mono-calcium form.



e contains little sulphur, because it is



air and water are similar to those involved in phosphoric acid production,


gases exiting the reactor/curing den is usually achieved with a venture scrubbing system


gas scrubber in the form of a packed tower that is usually followed by an

fluorine emission to 0.1 kg/t P2O5, and dust


manufacture powdered single superphosphate and the second to granulate. However, in the case

pile (ROP) material may be used. The


50 to 54%, but a lower concentration may be used, followed by

A slurry of phosphate rock reacted with phosphoric acid of 35% to 38% P2O5


nutrient fertilizers (NP/NPK/NK/PK) are produced simply by dry

nutrient materials without acidulation or chemical reaction. With

give rise to significant environmental

we are here concerned solely with chemically compounded

wide variety of processes and formulations, which


Environmental Issues in Fertilizer Industry and CP options

Cleaner Production means, “

environmental strategy to processes, products and services to increase eco

risks to humans and the environment

Cleaner Production activities with a focus on the actual manufacturing process itself and

considers the integration of better production systems to minimize environmental harm and

maximize production efficiency from many or all inputs.

Nitrogen Fertilizer Plants

(1) Urea

Cleaner production in Air Emission

• In the urea synthesis process, recover and recycle carbamate gases and/or liquids to the

reactor. Operate the top of the prilling

recovery and minimize air emissions by appropriate maintenance and operation of

scrubbers and baghouses.

• Use synthesis NH3 purge gas treatment to recover NH3 and H2 before combustion of the

remainder in the primary reformer.

• Increase the residence time for off

reformer;

• Ammonia emissions from relief valves or pressure control devices from vessels or

storages should be collected and

• Install leak detection methods to detect fugitive emissions of ammonia from process and

storage;

• Implement maintenance programs, particularly in stuffing boxes on valve stems and seals

on relief valves, to reduce or eliminate releases.

• Reduction of dust emissions by producing granular rather than prilled product;

• Installation of prilling towers with natural draft cooling instead of towers with

forced/induced draft air cooling;

• Scrubbing of off-gases with process condensate prior to discharge to atmospher

reprocessing the recovered urea solution;2

• Use of baghouse filters to prevent the emission of dust laden air from transfer points,

screens, bagging machines, etc., coupled with an urea dust dissolving system which

allows recycling of urea to the pro

• Flash melting of solid urea over

Cleaner production in Water Emission


Environmental Issues in Fertilizer Industry and CP options

“the continuous application of an integrated, preventative

environmental strategy to processes, products and services to increase eco-efficiency and reduce

risks to humans and the environment”. Cleaner Technology may be “thought of a subset of

on activities with a focus on the actual manufacturing process itself and


maximize production efficiency from many or all inputs.”

Air Emission

In the urea synthesis process, recover and recycle carbamate gases and/or liquids to the

reactor. Operate the top of the prilling tower at a slight vacuum. Maximize product


scrubbers and baghouses.

Use synthesis NH3 purge gas treatment to recover NH3 and H2 before combustion of the

ry reformer.

Increase the residence time for off-gas in the high temperature zone of the primary

Ammonia emissions from relief valves or pressure control devices from vessels or

storages should be collected and Sent to a flare or to wet scrubber;

Install leak detection methods to detect fugitive emissions of ammonia from process and

Implement maintenance programs, particularly in stuffing boxes on valve stems and seals

on relief valves, to reduce or eliminate releases.

emissions by producing granular rather than prilled product;

Installation of prilling towers with natural draft cooling instead of towers with

forced/induced draft air cooling;

gases with process condensate prior to discharge to atmospher

reprocessing the recovered urea solution;2

Use of baghouse filters to prevent the emission of dust laden air from transfer points,


allows recycling of urea to the process;

Flash melting of solid urea over-size product which allows urea recycling to the process;

Water Emission

7 | P a g e

continuous application of an integrated, preventative

efficiency and reduce

thought of a subset of

on activities with a focus on the actual manufacturing process itself and


In the urea synthesis process, recover and recycle carbamate gases and/or liquids to the

tower at a slight vacuum. Maximize product


Use synthesis NH3 purge gas treatment to recover NH3 and H2 before combustion of the

gas in the high temperature zone of the primary

Ammonia emissions from relief valves or pressure control devices from vessels or

Install leak detection methods to detect fugitive emissions of ammonia from process and

Implement maintenance programs, particularly in stuffing boxes on valve stems and seals

emissions by producing granular rather than prilled product;

Installation of prilling towers with natural draft cooling instead of towers with

gases with process condensate prior to discharge to atmosphere, and

Use of baghouse filters to prevent the emission of dust laden air from transfer points,


size product which allows urea recycling to the process;


An urea plant generates a significant stream of process water containing NH3, CO2 and

urea (e.g., a 1,000 tons per day (t/

day (m3/d) of process water). Other sources are ejector steam, flush, and seal water.

Recommended pollution prevention and control measures include the following:

• Improve evaporation heater/se

• Remove NH3, CO2, and urea from the process water in a process water treatment unit,

and recycle the gases to the synthesis to optimize raw material utilization and reduce

effluents;

• Provide adequate storage capa

shutdown conditions

• Install submerged tanks to collect plant washings and other contaminated streams from

drains for recycling to process

Cleaner production in Solid waste

• Catalysts used in the process need to be disposed off after their activities are significantly

reduced. Normally, the catalyst used in the plant needs to be replaced at intervals of 5 to

7 years. These catalysts are normally

certain standard precautions and stored in closed containers. These spent catalysts have

ready market and are normally sold off, thus, as long as proper precautions are taken are

not likely to pose any environmen

spent catalysts become on unavoidable task not for lowering the catalysts cost but also for

reducing the catalysts waste to prevent the environmental pollution.

• Safe disposal of hazardous waste.

(2) Ammonium nitrate/ Calcium Ammonium Nitrate


In ammonium nitrate plants the following pollution prevention measures are recommended:

• Install steam droplet separation techniques (e.g., knitted wire, mesh demister pads, wave

plate separators and fiber

pad separators using, for example, polytetrafluoroethylene (PTFE) fibers) or scrubbing

devices (e.g., packed columns, venturi scrubbers and irrigated sieve plates) to reduce

emissions of ammonia and ammonium nitrate in the steam

evaporators.10 A combination of droplet separators and scrubbers should be used to

remove ammonium nitrate particulate emissions. Nitric acid should be used to neutralize

any free ammonia;

• Treat and re-use contaminated condensate usin

or steam with the addition of alkali to liberate ionized ammonia if required, or use

distillation and membrane separation processes such as reverse osmosis;11

• Adopt the lowest practical melt temperature to reduce e

ammonium nitrate (and calcium carbonate in calcium ammonium nitrate (CAN)

production) from prilling and granulation emissions;



urea (e.g., a 1,000 tons per day (t/d) plant generates approximately 500 cubic meters per



Improve evaporation heater/separator design to minimize urea entrainment;

Remove NH3, CO2, and urea from the process water in a process water treatment unit,


Provide adequate storage capacity for plant inventory to prepare for plant upset and

Install submerged tanks to collect plant washings and other contaminated streams from

drains for recycling to process or conveying to the process water treatment unit.

Solid waste

Catalysts used in the process need to be disposed off after their activities are significantly


7 years. These catalysts are normally pyrophoric and have to be removed by taking

standard precautions and stored in closed containers. These spent catalysts have


not likely to pose any environment problem. The recovery of valuable elements from


reducing the catalysts waste to prevent the environmental pollution.

Safe disposal of hazardous waste.

/ Calcium Ammonium Nitrate



Install steam droplet separation techniques (e.g., knitted wire, mesh demister pads, wave

plate separators and fiber



emissions of ammonia and ammonium nitrate in the steam from neutralizers and


ammonium nitrate particulate emissions. Nitric acid should be used to neutralize

use contaminated condensate using techniques including stripping with air



Adopt the lowest practical melt temperature to reduce emissions of ammonia and


production) from prilling and granulation emissions;

8 | P a g e


d) plant generates approximately 500 cubic meters per



parator design to minimize urea entrainment;

Remove NH3, CO2, and urea from the process water in a process water treatment unit,


city for plant inventory to prepare for plant upset and

Install submerged tanks to collect plant washings and other contaminated streams from

or conveying to the process water treatment unit.

Catalysts used in the process need to be disposed off after their activities are significantly


pyrophoric and have to be removed by taking

standard precautions and stored in closed containers. These spent catalysts have


t problem. The recovery of valuable elements from



Install steam droplet separation techniques (e.g., knitted wire, mesh demister pads, wave



from neutralizers and


ammonium nitrate particulate emissions. Nitric acid should be used to neutralize

g techniques including stripping with air



missions of ammonia and



• In Prill tower, Reduce

entrainment.

• In Granulator reduce dust emissions from the disintegration of granules.

• For dusty products, use covers and hoods on

Handling

• Remove ammonia emissions from prilling and granulation by neutralization in a wet

scrubber. Wet scrubbers normally

wet scrubber will normally be recycled to the process;

• Remove ammonium nitrate fumes from prilling through scrubbing;

• Remove small particles of ammonium nitrate (miniprills), carried

through cyclones, bag filters and wet scrubbers;

• Adopt an enclosed granulation process instead of prilling technique where feasible;12

• Install an extraction, capture and filter system for ventilation air from areas with dust

generating product-handling activities to prevent fugitive


Ammonium nitrate (AN) / calcium ammonium nitrate (CAN)

water to be treated for discharge

fertilizers production complex. Their process effluents typically include

containing up to 1percent ammonia and up to

(neutralizers) and evaporator boil

wash-down. Unabated emissions into water can be up to

2,500mg NH3 as N/l (6 and 3 kilograms

Pollution prevention and control measures for

• Internally recovery of ammonium nitrate and ammonia (e.g.

granulation plant air cleaning

stages on the granulation plant);

• Integrate AN/CAN plants

• Treat steam contaminated with ammonia or ammonium

droplet separation techniques and scrubbing devices · Treat process water (condensate)

by stripping with air or steam with the addition of alkal

needed; ion exchange; distillation; or


• Solid wastes are principally spent catalysts that originate in ammonia production and in

the nitric acid plant. Other

Phosphate Fertilizer Plants


• Maximize the recovery and recycling of dust from rock and product handling;


Reduce micro prill formation & Reduce carryover of fines through

educe dust emissions from the disintegration of granules.

For dusty products, use covers and hoods on conveyors and transition points for Material

Remove ammonia emissions from prilling and granulation by neutralization in a wet

scrubbers normally use an acid circulating solution. The solution from a

wet scrubber will normally be recycled to the process;

Remove ammonium nitrate fumes from prilling through scrubbing;

Remove small particles of ammonium nitrate (miniprills), carried out with the air stream

through cyclones, bag filters and wet scrubbers;

Adopt an enclosed granulation process instead of prilling technique where feasible;12

Install an extraction, capture and filter system for ventilation air from areas with dust

handling activities to prevent fugitive emissions of particulates


Ammonium nitrate (AN) / calcium ammonium nitrate (CAN) plants produce a sur

discharge or possibly recycled to other units in the nitrogenous

production complex. Their process effluents typically include

containing up to 1percent ammonia and up to 1percent ammonium nitrate from reactors

evaporator boil-off, and ammonium nitrate and nitric acid from

emissions into water can be up to 5,000mg AN as N/l and

2,500mg NH3 as N/l (6 and 3 kilograms per ton (kg/t) of product respectively).13

Pollution prevention and control measures for A/CAN plants include the following:

Internally recovery of ammonium nitrate and ammonia (e.g. scrubber liquor from the

granulation plant air cleaning section being recycled through the further evaporation

stages on the granulation plant);

Integrate AN/CAN plants with nitric acid production;

Treat steam contaminated with ammonia or ammonium nitrate, before condensation, by

techniques and scrubbing devices · Treat process water (condensate)

steam with the addition of alkali to liberate ionized

needed; ion exchange; distillation; or membrane separation processes.


Solid wastes are principally spent catalysts that originate in ammonia production and in

the nitric acid plant. Other solid wastes are not normally of environmental concern.

Air Emission

Maximize the recovery and recycling of dust from rock and product handling;

9 | P a g e

Reduce carryover of fines through

conveyors and transition points for Material

Remove ammonia emissions from prilling and granulation by neutralization in a wet

use an acid circulating solution. The solution from a

out with the air stream

Adopt an enclosed granulation process instead of prilling technique where feasible;12

Install an extraction, capture and filter system for ventilation air from areas with dust-

particulates.

plants produce a surplus of

recycled to other units in the nitrogenous

production complex. Their process effluents typically include condensates

1percent ammonium nitrate from reactors

d ammonium nitrate and nitric acid from plant

5,000mg AN as N/l and

per ton (kg/t) of product respectively).13

include the following:

scrubber liquor from the

section being recycled through the further evaporation

nitrate, before condensation, by

techniques and scrubbing devices · Treat process water (condensate)

i to liberate ionized ammonia as

Solid wastes are principally spent catalysts that originate in ammonia production and in

solid wastes are not normally of environmental concern.

Maximize the recovery and recycling of dust from rock and product handling;


• Minimize the discharge of sulphur dioxide from sulphuric a

double contact double absorption process with high efficiency mist eliminators;

• Prevent spills and accidental discharges through well

installing spill catchment and containment facilities, and through

maintenance practices;

• Minimize the discharge of dust and fluorine from superphosphate plants to the

atmosphere by treating off

system.

• In the phosphoric acid plant, minimize

digester/reactor by scrubbers that are well

Again, design for spill containment

Maintain an operating water balance

• Where contamination of groundwater is a concern, a management and monitoring plan

should be implemented.

• Scrubbers are used to remove fluorides and acid from air emissions. The effluent from

the scrubbers is normally recycle

operating water balance in the phosphoric acid plant, then treatment to precipitate

fluorine, phosphorus, and heavy metals may be necessary. Lime can be used for

treatment. Spent vanadium catalyst is r

unavailable, then locked into a solidification matrix and disposed in a secure landfill


• The discharge of sulfur dioxide from sulfuric acid plants should be minimized by using

the double-contact, double

Spills and accidental discharges should be prevented by using well

by installing spill catchment and containment facilities, and by practicing good

housekeeping and maintenance. Residues from the roasting of pyrites may be used by the

cement and steel manufacturing industries.

• Scrubbers are used to remove fluorides and acid from air emissions. The effluent from

the scrubbers is normally recycled to t

operating water balance in the phosphoric acid plant, treatment to precipitate fluorine,

phosphorus, and heavy metals may be necessary.


• Lime can be used for treatment. Spe

recovery, or, if that cannot be

in a secure landfill.

• Opportunities to use gypsum wastes as a soil conditioner (for alkali soil and soils tha

deficient in sulfur) should be explored to minimize the volume of the gypsum stack.

• Consider the use of phosphor gypsum to produce gypsum board for the construction

industry.


Minimize the discharge of sulphur dioxide from sulphuric acid plants by using the

double absorption process with high efficiency mist eliminators;

Prevent spills and accidental discharges through well bonded storage tanks, through

catchment and containment facilities, and through good housekeeping and

Minimize the discharge of dust and fluorine from superphosphate plants to the

treating off-gases using an efficient wet scrubbing/fluorine recovery

In the phosphoric acid plant, minimize emissions of fluorine compounds from the

scrubbers that are well-designed, well-operated, and well

Again, design for spill containment is essential to avoid inadvertent liquid discharges.

Maintain an operating water balance to avoid an effluent discharge.

Where contamination of groundwater is a concern, a management and monitoring plan

Scrubbers are used to remove fluorides and acid from air emissions. The effluent from

the scrubbers is normally recycled to the process. If it is not possible to maintain an



treatment. Spent vanadium catalyst is returned to the supplier for recovery or, if

unavailable, then locked into a solidification matrix and disposed in a secure landfill

Water Emission

The discharge of sulfur dioxide from sulfuric acid plants should be minimized by using

contact, double-absorption process, with high efficiency mist eliminators.

Spills and accidental discharges should be prevented by using well-bonded



cement and steel manufacturing industries.


the scrubbers is normally recycled to the process. If it is not possible to maintain an


phosphorus, and heavy metals may be necessary.

Solid waste

Lime can be used for treatment. Spent vanadium catalyst is returned to the supplier for

recovery, or, if that cannot be done, it is locked in a solidification matrix and disposed of

Opportunities to use gypsum wastes as a soil conditioner (for alkali soil and soils tha


Consider the use of phosphor gypsum to produce gypsum board for the construction

10 | P a g e

cid plants by using the

double absorption process with high efficiency mist eliminators;

orage tanks, through

good housekeeping and

Minimize the discharge of dust and fluorine from superphosphate plants to the

gases using an efficient wet scrubbing/fluorine recovery

emissions of fluorine compounds from the

operated, and well-maintained.

is essential to avoid inadvertent liquid discharges.

Where contamination of groundwater is a concern, a management and monitoring plan


d to the process. If it is not possible to maintain an



eturned to the supplier for recovery or, if

unavailable, then locked into a solidification matrix and disposed in a secure landfill.

The discharge of sulfur dioxide from sulfuric acid plants should be minimized by using

absorption process, with high efficiency mist eliminators.

bonded storage tanks,




he process. If it is not possible to maintain an


nt vanadium catalyst is returned to the supplier for

is locked in a solidification matrix and disposed of

Opportunities to use gypsum wastes as a soil conditioner (for alkali soil and soils that are


Consider the use of phosphor gypsum to produce gypsum board for the construction


• Design and operate phosphor gypsum disposal facilities to minimize impacts.

• Prepare and implement an emergency preparedness and response plan (required because

of the large quantities of sulfuric and phosphoric acids and other hazardous materials

stored and handled on the site).

• Consider providing pyrite

Mixed Fertilizer Plants


This section addresses the production of ammonium phosphates (monoammonium phosphate

MAP, and diammonium phosphate

compound fertilizers.

• In the ammonium phosphate plant, pass the gas streams from the reactor, granulator,

dryer, and cooler through cyclones and scrubbers to recover particulates, ammonia, and

other materials for recycling.

• In the nitrophosphate plant, prevent NOx emissions by the addition of urea to the

digestion stage. Prevent fluoride emissions by scrubbing the gases with water. Remove

ammonia by scrubbing. Phosphoric acid may be used for scrubbing where the ammonia

load is high. Balance the p

• Additional pollution control devices beyond the scrubbers, cyclones and baghouses that

are an integral part of the plant design and operations are generally not required for

mixed fertilizer plants.


• Good housekeeping practices are essential to minimize the amount of spilled material.

Spills or leaks of both solids and liquids should be returned to the process. Liquid

effluents, if any, need to be controlled for total suspended solids, fluorides, and

Cleaner production in Solid Waste

• There is no solid waste except sand which can be used as a building material after

washing and separation.

• By-products are converted into commercial products and spillages and off

products are recycled into the NPK production.

Problems with Superphosphate

1. Depletion of the soil traces

2. This occurs for at least two reasons:

a) The increased yield of acreage or tonnage of crops means that more trace elements go

into the crops, and these trace minerals are then removed from the soil when the crop is

harvested.

b) Superphosphates seem to speed up the oxidation rate of the plants, we

microorganisms.

c) Other damage to the soil micro

3. Topsoil erosion.


Design and operate phosphor gypsum disposal facilities to minimize impacts.

Prepare and implement an emergency preparedness and response plan (required because


stored and handled on the site).

Consider providing pyrite-roasting residues to the cement or steel-making industry.


This section addresses the production of ammonium phosphates (monoammonium phosphate

diammonium phosphate-DAP), nitrophosphates, potash (potassium chloride

In the ammonium phosphate plant, pass the gas streams from the reactor, granulator,


other materials for recycling.

plant, prevent NOx emissions by the addition of urea to the



load is high. Balance the process water system to avoid the discharge of an effluent.

Additional pollution control devices beyond the scrubbers, cyclones and baghouses that


Emission

Good housekeeping practices are essential to minimize the amount of spilled material.


effluents, if any, need to be controlled for total suspended solids, fluorides, and

Solid Waste

There is no solid waste except sand which can be used as a building material after

products are converted into commercial products and spillages and off

d into the NPK production.

Superphosphate or N-P-K Fertilization of the Soil

traces minerals.

This occurs for at least two reasons:

increased yield of acreage or tonnage of crops means that more trace elements go


Superphosphates seem to speed up the oxidation rate of the plants, we

c) Other damage to the soil micro-organisms.

11 | P a g e

Design and operate phosphor gypsum disposal facilities to minimize impacts.

Prepare and implement an emergency preparedness and response plan (required because


making industry.

This section addresses the production of ammonium phosphates (monoammonium phosphate-

DAP), nitrophosphates, potash (potassium chloride), and

In the ammonium phosphate plant, pass the gas streams from the reactor, granulator,


plant, prevent NOx emissions by the addition of urea to the



rocess water system to avoid the discharge of an effluent.

Additional pollution control devices beyond the scrubbers, cyclones and baghouses that


Good housekeeping practices are essential to minimize the amount of spilled material.


effluents, if any, need to be controlled for total suspended solids, fluorides, and ammonia

There is no solid waste except sand which can be used as a building material after

products are converted into commercial products and spillages and off-specification

increased yield of acreage or tonnage of crops means that more trace elements go


Superphosphates seem to speed up the oxidation rate of the plants, weeds, and the soil


4. Reduced soil permeability.

5. More severe poisoning of the soil, plants, animals, humans and the environment with

newer toxic pesticides and insecticides.

6. Reduced general soil fertility.

7. More toxic metals in the soil

Bibliography

1. The Fertilizer Industry's Manufacturing Processes and Environmental Issues

2. Reference Document on Best Available Techniques for the Manufacture of

Volume Inorganic Chemicals

3. Death in the Air: Air Pollution from Phosphate Fertilizer Production

4. Environmental, Health, and Safety Guidelines

5. Pollution Prevention and Ab

1998

6. Project Profile : NPK Fertilizers by APTICO ltd.

7. Fertilizer Mixing Plant Feasibility Study

Development (AID-SI] -165T)

8. India’s Fertilizer Industry:

9. Productivity and Energy Efficiency by Katja Schumacher and Jayant Sathaye

10. Competition Assessment Of Fertilizer Sector: India,Submitted to Competition

Commission of India Under the Guidance of Mrs. Renuka Jain Gupta , 2011

11. Supply of and access to key nutrients NPK for fertilizers for feeding the world in 2050 by

Maria B LANCO, Final version: 2011

12. Best Available Techniques for Pollution Prevention and Control in the European

Fertilizer Industry Booklet No. 7 of 8: Production Of

Nitrophosphate Route,2000 EFMA (European Fertilizer Manufacturers’ Association)

13. Important questions on fertilizer and the environment by YARA

14. Impact Assessment of Fertilizer Industry Waste on Environment by R.P. Prajapati*and

Rashmi Singhai , Journal of Environmental Science, Computer Science and Engineering

& Technology

15. Best Available Techniques for Pollution Prevention and Control in the European

Fertilizer Industry Booklet No. 6 of 8: Production Of Ammonium Nitrate And Calcium

Ammonium Nitrate, 2000 EFMA (European Fertilizer Manufacturers’ Association

Website

1. http://fert.nic.in/sites/default/files/Annual_Report2012

2. file:///E:/ENVIS/S_R%2029%20%20Air%20Pollution%20from%20Phosphate%20Fertili

zer%20Production%20%28George%20

3. http://www.drlwilson.com/ARTICLES/SUPERPHOSPHATES.htm


Reduced soil permeability.

More severe poisoning of the soil, plants, animals, humans and the environment with

newer toxic pesticides and insecticides.

Reduced general soil fertility.

More toxic metals in the soil

The Fertilizer Industry's Manufacturing Processes and Environmental Issues

Reference Document on Best Available Techniques for the Manufacture of

Volume Inorganic Chemicals- Ammonia, Acids and Fertilizers ,August 2007

Death in the Air: Air Pollution from Phosphate Fertilizer Production by George Glasser

Environmental, Health, and Safety Guidelines Nitrogenous Fertilizers

Pollution Prevention and Abatement Handbook WORLD BANK GROUP Effective July

Project Profile : NPK Fertilizers by APTICO ltd.

Fertilizer Mixing Plant Feasibility Study Prepared for Agency for International

165T) by N. Terry Frederick and Robert T. Smith

India’s Fertilizer Industry:

Productivity and Energy Efficiency by Katja Schumacher and Jayant Sathaye

Competition Assessment Of Fertilizer Sector: India,Submitted to Competition


ly of and access to key nutrients NPK for fertilizers for feeding the world in 2050 by

Maria B LANCO, Final version: 2011

Best Available Techniques for Pollution Prevention and Control in the European

Fertilizer Industry Booklet No. 7 of 8: Production Of NPK Fertilizers By The

2000 EFMA (European Fertilizer Manufacturers’ Association)

Important questions on fertilizer and the environment by YARA

Impact Assessment of Fertilizer Industry Waste on Environment by R.P. Prajapati*and

Singhai , Journal of Environmental Science, Computer Science and Engineering



, 2000 EFMA (European Fertilizer Manufacturers’ Association

http://fert.nic.in/sites/default/files/Annual_Report2012-13.pdf

file:///E:/ENVIS/S_R%2029%20%20Air%20Pollution%20from%20Phosphate%20Fertili

zer%20Production%20%28George%20Glasser%29.htm

http://www.drlwilson.com/ARTICLES/SUPERPHOSPHATES.htm

12 | P a g e

More severe poisoning of the soil, plants, animals, humans and the environment with

The Fertilizer Industry's Manufacturing Processes and Environmental Issues

Reference Document on Best Available Techniques for the Manufacture of Large

,August 2007

by George Glasser

atement Handbook WORLD BANK GROUP Effective July

Prepared for Agency for International

by N. Terry Frederick and Robert T. Smith

Productivity and Energy Efficiency by Katja Schumacher and Jayant Sathaye

Competition Assessment Of Fertilizer Sector: India,Submitted to Competition


ly of and access to key nutrients NPK for fertilizers for feeding the world in 2050 by


Fertilizers By The

2000 EFMA (European Fertilizer Manufacturers’ Association)

Impact Assessment of Fertilizer Industry Waste on Environment by R.P. Prajapati*and

Singhai , Journal of Environmental Science, Computer Science and Engineering



, 2000 EFMA (European Fertilizer Manufacturers’ Association)

file:///E:/ENVIS/S_R%2029%20%20Air%20Pollution%20from%20Phosphate%20Fertili

Documents

CLEANER PRODUCTION OPPURTUNITIES - gcpc-envisgcpcenvis.nic.in/Experts/Fertiliser Industry.pdf · CLEANER PRODUCTION OPPURTUNITIES FERTILIZER MANUFACTURING – ENVIS CENTRE IN