Contract project-2004
With Ministry of the Environment, Japan
Ministry of the Environment
Air Pollution Control Technology
In
Fertilizer Manufacturing Industry
March 2005
Overseas Environmental Cooperation Center, Japan
Air Pollution Control Technology
in Fertilizer Manufacturing Industry
Committee Members
Chairman:
Dr. K. Nishida, Researcher, Department of Urban and
Environmental Engineering, Kyoto University
(Retired)
Member:
Mr. S. Iwasaki, Director, Metocean Environment Inc.
Dr. S. Fujii (P.E.), Takuma Co., Ltd.
Mr. Y. Ogino (P.E.), Environment Technology L.R.C.
Prepared by
Dr. A. Hogetsu (P.E.), Research Commissioner, OECC
Urea Plant in Bangladesh
1. Air Pollution in Fertilizer Plant
Fertilizer Raw materials
Nitrogenous F. : ammonia, Chilean saltpeter, limestone + N2,
Phosphate F. : phosphate rock
Potassium F. : ore (ingredient ; KCl + NaCl), KCl,
Coated F. : N, P, K thermo plasticity resin
Pollutants Origins of Pollutants
Soot
SOx Boiler, Dryer, Calcining furnace, etc.
NOx
Dust Raw material stock yard, Raw material feed equipment,
Belt conveyer, Bucket conveyer, Crusher, Mill, Sieve
HF Phosphate fertilizer plant------ Reactor, Calcining furnace,
Melting furnace, Phosphoric acid concentration plant
NH3 Pelletizer, Dryer
Solvent Coated fertilizer manufacturing process
2. Soot & Dust Collection
2-1 Gravitational, Inertial & Centrifugal Dust Collector
Stokes’ Law
m
in.
pa
rti V=(g/ 18 )( 1- ) D2 (cm/s)
V: settling velocity (cm/sec)
cle
Gravity : gas viscosity (kg/ms)
section g: gravitational acceleration (cm/s2)
dust
3
1: particle density (g/cm )
: gas density (g/cm3)
D: particle diameter (cm)
Principle of dust collection ;
Centrifugal force (F) = mv2 /R ,(N)
Inertia
m: particle mass (kg)
V: particle velocity (m/ s)
Centrifugal R: cyclone radius (m)
2. Soot & Dust Collection
2-2 Scrubbing Dust Collector
Mechanisms of Separation
- Adhesion of dust to water drops & water film by inertia force
- Adhesion by diffusion force among dusts
- Increase of coagulation force of particles by increasing moisture
- Moisture condensation triggered by dust as a nucleus
- Particle adhesion by bubbles
Typical Types of Scrubbers
Type Velocity L/G P Th. demister
m/s l / m3 kPa m
water
Spray 1~2 2~3 0.1~0.5 3
Packed 0.5~1 2~3 1~2.5 1
gas
Jet 10~20 10~50 0~ -1.5 0.2
Venturi 60~90 0.3~1.5 3~8 0.1 packing
Th. : Particle size of threshold to allowing 50 % removal
Packed tower
2. Soot & Dust Collection
2-3 Filter Type Dust Collector Clean gas
Filtration Action in Filter Cloth
Flue Clean
gas gas
0.5~3 cm / s
fan
dust filter cloth
primary layer
P 150 mg Hg dusting Bag filter
Dusting frequency Flue
Dusting drive dust gas
- intermittent
- continuous - vibration
- reverse air
2. Soot & Dust Collection
2-4 Electrostatic Precipitator
Structure of EP
Principle of dust collection ;
high voltage DC
discharge manhole generator
dust collecting electrode
electrode hammering
- discharge drive
- electrode
-
-
- - - -
- - -
- -
- - -
-
- gas distribution
- plate
hammering
device hopper
collecting
electrode
2. Soot & Dust Collection
2-5 Selection of Dust Collector
Factors affecting Dust Collection:
dust concentration, particle size distribution, temperature of dust,
apparent electric resistance rate, due point, gas temperature,
composition of flue gas, gas volume, etc.
Applicable Range of Dust Collector
Type Particle Working Cutback Pressure Equipment Running
( m) Level Drop Cost Cost
(%) (mm H2O)
Gravity 1000~50 d.p. 400 40 60 10 15 S S
Inertia 100~10 d.p. 400 50 70 30 70 S S
Centrifuge 100~3 d.p. 400 85 95 50 150 M M
Scrubbing 100~0.1 no- limit 80 95 300 800 M L
Filtration 20~0.1 no- limit 90 99 100 200 M M
EP 20~0.05 d.p. 400 90 99.9 10 20 L S~M
L: expensive M: average S: cheap
3. SOx Reduction Technology
Sources of SOx: Fuel SOx
- Boiler - Dryer - Calcining furnace - Melting furnace
Wet Type Absorption SO2+ H2O H2SO3
H2SO3+ Mg(OH)2 MgSO3+ 2H2O
Mg(HSO3)2+ Mg(OH)2 2MgSO3+ 2H2O MgSO3+ H2SO3 Mg(HSO3)2
H2SO3+ Mg(OH)2 MgSO3+ 2H2O
MgSO3+ 1/2O2 MgSO4
Mg(HSO3)2+ 12O2 MgSO4+ H2SO3
MgSO3+ 1/2O2 MgSO4
to stack
Flue gas
sludge
water
Mg(OH)2 wastewater
Filter
air
Absorption Oxidation
tower tower
4. NOx Reduction Technology
4-1 NOx Generation in Fertilizer Plant
Air ratio ~ Retention time ~Thermal NOx
5,000
tim ntion
)
Thermal NOx Fuel NOx
e (s
e
ret
1,000
100
NO ppm
NOx concentration increases at:
- higher temp. in combustion
10
- higher O2 conc.
1
100
0.1
- longer retention in high temp. zone
0.01
10
0.6 1.0 1.4 1.8
Air ratio
4. NOx Reduction Technology Remarks
lowering heat
Decreasing
dust increase
4-2 NOx Control Methods
equipment
effect
efficiency
enlarging
lowering
out put
NOx Reduction Methods Thermal Fuel
NOx NOx
Improving operating condition
Lower air ratio combustion
Lower heat load
Decreasing pre-heat air temp.
Improving equipment configuration
2-stege combustion
Rich-lean burner
Exhaust gas recirculation
Steam or water injection
Low NOx burner
mixing accelerate type
flame-divided type
self-circulate type
stepwise combustion type
Emulsion combustion
5. Dust Scattering Prevention
Dust generating equipment Equipment protected work shop
& location designated by air environment from dust scattering
pollution control law - silo, hopper for raw material
- belt conveyer & product
- bucket conveyer - transporting equipment except
- crusher, mill belt & bucket conveyer
- sieve
- packing machine, etc.
- ore stock yard
Measures
- indoor allocation
- outdoor stock - closed cover, negative pressure
with sheet cover - Sealed dust collecting cover
(phosphate rock) - dust collecting hood
- cyclone
- bag filter
6. NH3 Removal Technology
1. Permissible NH3 emission:
1~ 5 ppm at boundary of premise (set forth by prefecture governors)
Q = 0.108 X He2 X Cm
Q : gas volume (Nm3 / h)
He : effective height of exhausting outlet (m)
Cm: concentration at boundary line of premise (ppm)
2. In compound fertilizer plant :
Process Origin Abatement
(NH4)2SO4 reservoir type wet scrubber
pelletizer & drying (NH4)3PO4 pressurized water scrubber
CO(NH2)2 packed bed water scrubber
(NH4 removal 70~90%, 20~50ppm)
3. In urea plant fan
demister NH3 several 10 ppm
rectification plate
guide vane
pelletizing tower water
7. F Removal Technology
Generation of F
- reaction & condensation process for H3PO4 production
- reaction process for Ca(H2PO4)2 production
- reaction furnace for fused P and calcined P production
HF, SiF4
(with greater hydrophile property)
1st Absorption tower 2nd Absorption tower
to wastewater
treatment
water
exhaust
gas
NaOH
(2 %)
8. Odors Abatement technology
8-1 Abatement Processes
Deodorizing Method Process
Incineration method decompose to CO2, H2O by heat
direct incineration at 800
regenerative thermal oxidizer regeneration, heat efficiency 80%
catalytic incineration using catalysis at 200~ 350 , rem. 99%
Scrubbing method scrubbing by chemical solution
water, acid, alkaline, oxidant, etc.
Adsorption method
recovery type
fixed bed activated carbon, steam regeneration
fluidized bed activated c., heat regeneration by N2 gas
concentration type
honeycomb separating odor from low concentration gas
replacement type replacing saturated adsorbent or oxidant
Biological method biodegradation by microorganisms
soil bed using soil bacteria
packed tower using bio-film on the media
Deodorizer, masking agent deodorize or easing offending gas
8. Odors Abatement technology
8-2 Troubles in Abatement Processes (examples)
Deodorizing Method Trigger Trouble
Combustion method
direct incineration NOx permission level
regenerative thermal ox. mixture of Cl2, paint, etc. HCl , clogging
catalytic incineration mixture of Cl2, paint, S, etc. catalyst deterioration
Adsorption method
recovery type
fixed bed mixture of ketone, high B.P. firing, deterioration
substance of activated carbon
fluidized bed high temp. of exhaust gas A.C. deterioration
concentration type
honeycomb mixture of cyclohexane firing
replacement type conc. several ppm short term A.C.
replacement
Biological method
soil bed drying of soil malfunction
packed tower slow acclimatization slow starter
Scrubbing less sprinkling water malfunction
dust in gas clogging internals
9. Solvent Recovery & Abatement technology
1. Sources of Generation
coated fertilizer (thermoplasticity resin)
2. Abatement
recovery of solvent brings profit production cost reduction
residual solvent value recovery cost pollution control
3. Abatement Process
- cooling condensation method
cool down flue gas below vapor pressure
- absorption & dispersion method
absorbing of solvent to absorbent with lower vapor pressure
- adsorption & dispersion method
applicable to compositions with low vapor pressure and non-
existence of antagonist. Adsorbed at under pressure or lower temp..
adsorber: fixed bed, moving bed, fluidized bed
adsorbent: A.C., silica gel, molecular sieve, aluminum gel
regeneration method: heated gas, steam, heat transfer,
extraction under decompression
10. Environmental Management System
1. Environmental Management System EMS
- Organization for Environmental Control
- ISO 14000 series----- PDCA cycle
- Responsible for environmental protection
ISO 14000
2. Environmental Control Manual
- Operation Standard Manual
3. Education & Training
- legally qualified expert of environment control
- training program and preparation of manual
4. Environmental Control at Work Shop
5. Environment Monitoring
- maintaining monitoring system
- monitoring of air pollution state
- legal emission permissible level
