World Fertilizer December 2023

MAGAZINE | NOVEMBER/DECEMBER 2023

Solutions to Maximize Asset Value SUPERIOR SERVICE AND SPECIALTY CHEMICAL EXPERTISE

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SUPERIOR SERVICE AND SPECIALTY CHEMICAL EXPERTISE

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CONTENTS 03 05 10

Comment News The MENA Region: Challenges And Prospects

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It’s Wise To Customise

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Grasping a unique opportunity

Zico Zeeman, EMT, the Netherlands, discusses the advantages and disadvantages of the machinery used in the fertilizer blending process, and considers how it can help to create tailor-made solutions for customers.

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n the world of agriculture, fertilizer suppliers who can offer tailor-made solutions to meet the specific requirements of their target market are considered irreplaceable. By doing so, they can help their customers achieve their desired yields while using less fertilizer, resulting in significant cost savings without compromising revenue. To create customised blends and package them for blending, certain machines are required. This article delves into the specifics of these machines, their advantages and disadvantages, and their use in the blending process.

Blenders

Zico Zeeman, EMT, the Netherlands, discusses the advantages and disadvantages of the machinery used in the fertilizer blending process, and considers how it can help to create tailor-made solutions for customers.

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Creating customised fertilizer blends requires the use of specialised blending units. These units can be categorised into two distinct groups: batch blenders and continuous blenders.

Batch blenders are designed to work in cycles, with each batch typically ranging from 2 – 16 t. The blending process begins with a filling stage, where each raw material is weighed, followed by the blending stage, and finally discharging.

The capacity of batch blenders typically ranges from 20 – 70 tph, making them ideal for smaller-scale operations.

On the other hand, continuous blenders are designed to operate continuously and can blend up to 300 tph.

These blenders are ideal for larger-scale operations, and are

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Giedrius Rutkauskas, Arionex Wasseraufbereitung Gmbh, Switzerland, outlines why the fertilizer industry should take the opportunity to mitigate pollution created from water demineralisation.

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Sense And Sustainability

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Seeking Success In Agglomeration

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Enhancing Efficiency And Performance

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The Core Of Fertilizer Plant Reliability

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A Comprehensive Guide To UAN Corrosion Management

Vertical blenders The vertical blender is a blending system that utilises a conical screw to mix raw materials in a wave-like motion.

The World Of Fertilizer Blending

Robert Fitzpatrick, Ag Growth International, USA, provides an insight into fertilizer handling management and blending processes.

Precision As A Priority

Rafael Delgado, Sackett Waconia, Dominican Republic, discusses the importance of efficient and precise blending systems in the fertilizer sector.

Solutions to Maximize Asset Value

Solutions to Maximize Asset Value halliburton.com

SUPERIOR SERVICE AND SPECIALTY CHEMICAL EXPERTISE halliburton.com

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Jose R. Ferrer, Espindesa, Spain, outlines how the efficient use of fertilizers could provide a more sustainable solution to meet growing agricultural demands.

Klaus Wögerbauer, Agglotec GmbH, Austria, explains why precision is key to the success of the agglomeration process in the fertilizer industry.

Thomas Perry and Miles Andrews, QMax Industries, USA, discuss the pivotal role of industrial heating technologies in the production of fertilizers.

Benjamin Wooten, Atlas Copco, USA, explains how plant maintenance and reliability are central to the successful running of a fertilizer plant.

Phil Bureman and Dr. Craig Myers, Nalco Water, USA, discuss the advantages of a comprehensive UAN corrosion management programme.

MAGAZINE | NOVEMBER/DECEMBER 2023

SUPERIOR SERVICE AND SPECIALTY CHEMICAL EXPERTISE

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Paddle blenders Paddle blenders are a versatile option for batch blending and can be used to blend granules or powdery materials, including water-soluble fertilizers. Twin-shaft high-speed paddle mixers are especially well-suited for powdery materials, with both shafts running at high speeds in opposite directions to ensure a thorough mix. With a typical capacity of 1 – 4 t per batch, paddle blenders are a popular choice for a range of industries.

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SUPERIOR SERVICE AND SPECIALTY CHEMICAL EXPERTISE Solutions to Maximize Asset Value

ater plays a crucial role in the fertilizer industry, primarily in steam generation, cooling cycles, and, more recently, hydrogen production. Two main technologies are relied upon for water demineralisation: ion exchange and reverse osmosis. Ion exchange technology generates 5 – 10% wastewater as a byproduct, contaminated with regenerants like NaOH, H 2SO 4, or HCl. In contrast, reverse osmosis technology produces a discharge stream of 20 – 30% from the input water, with salts concentrated four to five times higher than raw water. Both technologies create pollution that is environmentally undesirable for disposal.

However, the fertilizer industry has a unique opportunity to mitigate this environmental pollution using a combined ion exchangemembrane technology. This approach employs HNO3 and NH 3 solutions for regenerations.

The regeneration process of ion exchange resins results in effluents enriched with salts removed during demineralisation, producing both demineralised water and concentrated effluents (15 – 18%). These effluents contain approximately 50% of Ca, Mg, K, Na, SO4, Cl, and Si salts and 50% of NH4NO 3. Rich in minerals extracted from water and ammonium nitrate, the effluent serves as raw material for the production of liquid or solid NPK fertilizers. In this way, minerals originally present in the water return to the soil and plants, completing a sustainable cycle.

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capable of creating blends with a high degree of consistency.

Continuous blenders can also be used to incorporate micronutrients, inhibitors, or other additives into the blend as needed.

Regardless of the type of blender used, the blending process is a critical step in creating customised fertilizer solutions that meet the unique needs of each customer.

By understanding the different types of blending units available and their capacities, suppliers can ensure that they are using the right equipment to meet their production goals while also maximising efficiency and minimising costs.

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Giedrius Rutkauskas, Arionex Wasseraufbereitung Gmbh, Switzerland, outlines why the fertilizer industry should take the opportunity to mitigate pollution created from water demineralisation.

Contributing Editor, Gordon Cope, provides an overview of the current state of the fertilizer industry in the MENA region.

It's wise to customise

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Grasping A Unique Opportunity

ON THE COVER Halliburton Multi-Chem provides water and process treatment solutions to refinery, petrochemical, ammonia/fertilizer, and heavy industrial operations. The company also serves upstream markets with specialty chemicals. Halliburton’s on-site technical service and engineering support helps customers improve reliability, increase throughput, and enhance the efficiency and flexibility of operating units.

Copyright© Palladian Publications Ltd 2023. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither does the publisher endorse any of the claims made in the advertisements. Printed in the UK.

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COMMENT

EMILY THOMAS, DEPUTY EDITOR

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he Environmental Protection Agency (EPA) has recently stirred debate with a proposal to tighten national ambient air quality standards (NAAQS) for fine particulate matter. While the current standard for PM2.5 is set at 12 µg/m3, it has been suggested that this could be revised to around 8 µg/m3. The Fertilizer Institute, among many other heavy industry groups, has been quick to urge that existing standards are maintained, stating that the fertilizer industry is doing all it can to mitigate PM2.5 emissions, and an impressive decline of over 40% of these emissions has already been seen over the past 20 years.1 The company expressed that the new ruling would have an alarming economic impact, and that whilst the industry is working consistently to evolve with technology and innovation, repercussions of lowered air quality thresholds would be felt, and domestic fertilizer production could be severely reduced.

The industry now waits with bated breath to see whether the pending proposal will be withdrawn.

Across the globe, similar concerns over industry emissions have been expressed within the context of Perdaman’s divisive AUS$4.5 billion urea fertilizer plant on the Burrup Peninsula near Karratha, West Australia, which broke ground in May this year. While the area has been dubbed ‘the engine room of Australia’s economy’ due to its high levels of industrialisation, featuring gas operations owned by Woodside, the Burrup Peninsula also contains a wealth of heritage and culture, as home to the largest and oldest collection of rock carvings in the world.

Environment Minister, Tanya Plibersek, faced backlash after deciding not to block the construction of the urea plant, with rock art scientists warning that the carvings in the Burrup Peninsula could be destroyed within a century by pollution from the surrounding industrial area, and acidic industrial emissions.2 Comprehensive studies are therefore ongoing to ensure the protection of the famous petroglyphs, and any signs of accelerated change will be closely observed. Despite concerns, Plibersek has claimed that the project has been backed by many traditional owners in the area, and Perdaman’s Chairman, Vikas Rambal, has also outlined a number of its undeniable advantages. One major benefit is a huge boost to Australian food security; the plant is estimated to produce 2.3 million tpy of urea, reducing the country’s reliance on imports (previously 2.4 million tpy), and feeding approximately 90 million people.3 This is no small feat after local fertilizer supply dwindled during the height of the pandemic. Moreover, the project is set to create 2500 jobs, many of which will be offered to local people.

Additionally, Perdaman has cooperated with the local Aboriginal corporation to reduce the impacted rock art sites from 30 to only three, and it has been agreed that the urea facility will be the last of its kind built on the peninsula. West Australian Premier, Mark McGowan, believes a good ‘balance’ has been struck between industry success and the protection of significant artworks.4 Whilst there is no definitive answer on whether industrial pollution will affect the historic petroglyphs, what is conclusive is that balance and compromise will be crucial in navigating the future of the Burrup Peninsula, in which the past must be respected and preserved, while ensuring the country’s food security.

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www.tfi.org/newsroom/2023/NAAQS www.nationalgeographic.com/travel/article/the-worlds-largest-collection-of-ancient-rock-carvings-is-underthreat#:~:text=That%20is%20tempered%2C%20however%2C%20by,which%20relies%20on%20resource%20 extraction. www.abc.net.au/news/2023-04-26/last-industrial-development-burrup-peninsula-fertiliser-plant/102268706 www.afr.com/companies/manufacturing/the-6b-pilbara-project-that-will-help-feed-australia-and-the-world20230503-p5d5bk#:~:text=Rambal%20said%20he%20had%20worked,to%20be%20World%20Heritage%20listed.

NOVEMBER/DECEMBER 2023 | WORLD FERTILIZER | 3

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Lab Scale Test 100 g batch

2. Pilot Scale Test 1000 kg batch

3.Industrial Solution 1 to 100 ton/hr

WORLD NEWS NORTH AMERICA CoteX Technologies and Nutrien partner up to enhance nitrogen

fertilizer sustainability

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oteX Technologies and Nutrien have entered into a memorandum of understanding (MOU) to explore the joint commercialisation of a coating technology to produce an affordable, environmentally-friendly nitrogen fertilizer solution for large acreage crops in the North American market.

CoteX Technologies, a startup located in Nova Scotia, Canada, has developed a low-cost, customisable controlled-release fertilizer (CRF) coating that minimises environmental impact. The biodegradable coating allows fertilizer to be slowly released into the soil over time, reducing greenhouse gas emissions and reducing potential residual material.

“This MOU is a big step forward for the global agriculture industry,” said Santosh Yadav, CEO of CoteX Technologies. “We are thrilled to partner with Nutrien to explore the application of our product and the impact for the market.”

Over 110 million t of nitrogen fertilizer is applied to crops worldwide every year. Nitrogen is required by every living cell and is a fundamental building block of plant proteins that improve crop yield and quality. Controlled release nitrogen fertilizer delivers this important crop nutrient while helping to minimise losses to runoff into waterways and diminish greenhouse gas emissions.

“Our coating process is lower cost and more versatile than liquid coating and it’s environmentally friendly”, said Yadav.

“Adoption of our technology helps minimise the loss of nitrogen into the environment.”

“We are excited to begin this journey with CoteX Technologies,” said Trevor Williams, EVP and President of Nitrogen & Phosphates at Nutrien. “This innovation has the potential to substantially increase efficiency in nitrogen application which will help farmers increase yield potential in a sustainable way.”

POLAND Grupa Azoty Group demonstrates steady growth in fertilizer output

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he Grupa Azoty Group has released estimates of its production volumes for October 2023, showing a steady increase in product output.

According to the released estimates, in October, companies of the Grupa Azoty Group produced 245 000 t of nitrogen fertilizers (up from 227 000 t in September), 71 000 t of compound fertilizers (compared with 64 000 t in September) and 26 000 t of speciality fertilizers (an increase relative to 15 000 t in September).

A month-over-month increase has also been seen within the urea production segment, with an estimated product output of 110 000 t in October, vs 94 000 t in September.

Otherwise, production volumes in October remained at the levels recorded in September.

“In October we mark the fourth consecutive month of production growth within the AGRO Segment. The output figures are indicative of a positive trend, reflecting gradual stabilisation of the fertilizer market and return of demand to levels reminiscent of previous fertilizer seasons, recorded before the outbreak of Russia’s war against Ukraine in 2022,” says Tomasz Hinc, President of the Management Board, Grupa Azoty S.A.

AFRICA African Fertilizer Financing Mechanism commits to improving farmers’ access

to fertilizers

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he Africa Fertilizer Financing Mechanism will provide a US$2 million partial trade credit guarantee and a US$219 000 grant funding to Nairobi-based Apollo Agriculture Ltd to support the distribution of over 7000 t of fertilizers to some 100 000 smallholder farmers in Kenya.

Between 2024 and 2026, the project will support Apollo Agriculture Limited to sell fertilizer through a part of its network, covering around 150 retail agro-dealers and 800 village-based agents using digital platforms.

Most smallholder farmers in Kenya buy fertilizers through informal credit, microfinance institutions and commercial banks, but challenges remain for farmers to access fertilizer financing as some cannot provide tangible collateral. These new funds will be channelled through the Fertilizer Financing for Sustainable Agriculture Management project.

“The Fertilizer Financing for Sustainable Agriculture Management project will improve farming productivity by facilitating access and use of fertilizer for smallholder farmers at the last mile, with 50% of women among the beneficiaries,” said Marie Claire Kalihangabo, Africa Fertilizer Financing Mechanism Coordinator.

NOVEMBER/DECEMBER 2023 | WORLD FERTILIZER | 5

WORLD NEWS AUSTRALIA thyssenkrupp Uhde selected by Saipem to

NEWS HIGHLIGHTS

ATOME Energy’s green fertilizer project is granted FTZ status Syngenta Group and CNH Industrial announce integration of digital platform with agricultural brands Fertilizer project of Asia-potash International listed in Belt and Road case study

The Iowa Corn Growers Association hopes to make the fertilizer industry more transparent Visit our website for more news: www.worldfertilizer.com

license a urea granulation unit

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hyssenkrupp Fertilizer Technology has signed a contract with the Italian group Saipem to license a urea granulation unit in Karratha, Western Australia.

The project in Karratha is being realised and built for Perdaman Chemicals and Fertilisers by a joint venture (50/50) comprising the Western Australian company, Clough, and the Italian company, Saipem.

Perdaman Chemicals and Fertilisers is a multinational company headquartered in Western Australia. Besides investing in fertilizer production, it specialises in supporting farmers with harvesting and food production. thyssenkrupp Fertilizer Technology will be responsible for the licensing, process design package, and for supplying the main equipment for Saipem’s urea project.

With its UFT® fluidbed urea granulation technology, thyssenkrupp Fertilizer Technology is supplying a technology for the production of urea granules by means of the fluidised-bed process. More than 70% of urea granules produced worldwide are manufactured by means of the UFT® fluid-bed urea granulation technology, contributing to a large extent to secure food supply for the world. The emissions are below the statutory emission limits for urea dust and ammonia.

For this project, thyssenkrupp Fertilizer Technology has been contracted to supply two granulators and two exhaust air scrubbers for the urea granulation unit, which will be used for the manufacture of fertilizers. The granulation unit will have a total production capacity of 6200 tpd, made up of two identical trains with respective capacities of 3100 tpd each. The licensed granulation technology is being successfully used in more than 70 plants in the fertilizer industry worldwide.

Perdaman Chemicals and Fertilisers’ urea project will provide important impetus for the Western Australian economy by creating around 2000 jobs during the three-year construction phase. Upon completion, the plant will create more than 200 permanent jobs in Karratha, Western Australia.

Dr. Cord Landsmann, CEO of thyssenkrupp Uhde, said, “This project for Perdaman marks an important milestone that will further consolidate our position as a technology supplier in the fertilizer industry. We are proud to have been selected as the partner to supply our highly efficient urea granulation technology. With our proven UFT® fluidbed urea granulation technology, we guarantee the production of a consistent top-quality product and, at the same time, strict compliance with environmental standards. We are pleased to be supplying the market with advanced technologies for fertilizer production and furnishing our global customers with the best solutions.”

Vikas Rambal, Chairman Perdaman, said: “We are pleased to be building Australia’s biggest downstream project, which represents a major investment in the Australian production sector. This state-of-the-art plant will contribute to Australia having a safe and reliable source of high-quality urea, thus supporting the farmers and food producers. The decision in favour of thyssenkrupp Fertilizer Technology as the technology supplier and licensor for this urea project not only speaks for the competence of thyssenkrupp Fertilizer Technology, but also for confidence in the ability of the company to supply reliable solutions for the fertilizer industry.”

6 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

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WORLD NEWS DIARY DATES Fertilizer Latino Americano 2024 05 – 07 February 2024 Florida, USA events.crugroup.com/ fertilizerlatinoamericano/home

Phosphates 2024 Conference & Exhibition 26 – 28 February 2024 Warsaw, Poland

events.crugroup.com/phosphates/ home

Nitrogen + Syngas 2024 Conference & Exhibition 04 – 06 March 2024 Gothenburg, Sweden events.crugroup.com/ nitrogenandsyngas/home

Nitrogen + Syngas USA 2024 15 – 17 April 2024 Oklahoma, USA

events.crugroup.com/nitrogenusa/ home

ACHEMA 2024 10 – 14 June 2024 Frankfurt, Germany achema.de/en

ANNA 2024 29 September – 04 October 2024 Montréal, Canada annawebsite.squarespace.com

USA Cinis Fertilizer accelerates production in Kentucky

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inis Fertilizer is set to accelerate its expansion in the USA. The company has decided to prioritise the construction of its planned facility in Kentucky before the facility in Skellefteå, Sweden. The decision to advance the plant for the production of 300 000 tpy of environmentally friendly mineral fertilizer is largely a consequence of the extensive investments that are now being made in green industrial projects in North America.

On 21 September 2023, Cinis Fertilizer signed an agreement for the supply of sodium sulfate from Ascend Elements. In connection with this agreement, the company decided to establish a production facility in Hopkinsville, Kentucky. The preparatory work and contacts with partners and authorities have taken place at a high pace, which is the background to the decision to accelerate the start of planning for the facility in Kentucky.

In order to enable the production of 300 000 t of potassium sulfate in Kentucky, parts of planning for the company’s Skellefteå plant, with a production of 200 000 t of potassium sulfate, have been pushed forward. This means that it will be the third facility in the order of Cinis Fertilizer’s six planned facilities, with a total production capacity of about 1.5 million t, to be in operation in the year 2030. The expansion will be financed with internal cash flows and external loans. The company is also investigating supplementary financing solutions, which include state and federal investment grants.

Ascend Elements is currently building its largest facility in Hopkinsville, Kentucky.

The agreement with Cinis Fertilizer means that Ascend Elements will deliver up to 240 000 tpy of sodium sulfate beginning in 2024. Cinis Fertilizer has also entered into a letter of intent regarding the sale of its end product, potassium sulfate, to K+S and the purchase of potassium chloride from K+S’ production facilities in Saskatchewan in Canada, to Cinis Fertilizer’s facility in Hopkinsville. Cinis Fertilizer’s facility is to be ready in 2025 with a production capacity of up to 300 000 t of potassium sulfate for the North American market.

CHINA Toyo Engineering Corporation awarded licensing

and equipment supply contract for urea fertilizer plant

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oyo Engineering Corporation has been awarded a licensing and equipment supply contract for a fertilizer plant of PT Pupuk Sriwidjaja Palembang in the Palembang District of South Sumatra, China.

TOYO will provide its urea license and process design package, as well as the proprietary equipment, and associated technical services for this project.

The plant will be designed to be compatible with TOYO’s most advanced urea synthesis technology, ACES21-LP, for the first time. ACES21-LP is a technology that combines ACES21 with advanced low-pressure synthesis technology to reduce energy consumption in supplying raw materials, and improve process efficiency. Application of this technology can help lead to a reduction in plant costs due to lighter weight of the synthesis equipment, thereby contributing to low-cost urea production and global environmental conservation.

The demand for fertilizers is expected to continue growing in the future, so to ensure increased food production in line with population growth, many fertilizer plants are currently planned to be constructed around the world.

8 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

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The MENA region:

challenges and prospects 10

Contributing Editor, Gordon Cope, provides an overview of the current state of the fertilizer industry in the MENA region.

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ver the last several years, the fertilizer industry has been bombarded with blows, from COVID pandemic lockdowns, export bans and rising production costs, to the disruption of the Ukraine war. The Middle East and North Africa represent major consumers and producers of fertilizer; while some of the misfortunes in recent years have engendered suffering and social unrest, others have offered opportunities for the industry.

Phosphorous

Morocco holds an estimated 32 billion t of phosphate rock, amounting to over 70% of global phosphate reserves. After China, it is the world’s second largest producer; OCP, the state-owned mining company responsible for phosphate mining and fertilizer production, produced 8.4 million t of phosphate and blended fertilizers in 2022. In order to serve the European Union (EU) and African countries looking to diversify away from Russian sources, OCP has announced a goal of reaching 15 million tpy total capacity by the end of 2023, and 20 million tpy by 2027.

Egypt’s Misr Phosphate Company has broken ground on a new 1 million tpy phosphoric acid plant in Abu Tartur in the New Valley Governorate. The site has an estimated 980 million t of ore grading 30% phosphorous pentoxide (P2O5).

Construction of the US$1 billion facility will be undertaken by a Chinese consortium; China’s Wengfu Group, one of the largest phosphate producers in the world, has signed a long-term contract to purchase approximately 500 000 tpy output.

Nitrogen

Egypt is an important consumer of nitrogen fertilizers along the fertile Nile Valley and Delta, which has encouraged the creation of a significant domestic manufacturing base in the country. Since the 2015 discovery of natural gas at the giant offshore Zohr field (containing 30 trillion ft3 of recoverable reserves), the country has been in the enviable position of having abundant quantities of inexpensive feedstock and energy.

In late 2022, Egypt’s Abu Qir Fertilizers announced that it would be spending US$1.6 billion to build a new facility in Egypt’s Suez Canal economic zone, capable of producing 1 million tpy of methanol and 400 000 tpy of ammonia.

The majority is for export to North America, Europe and Asia.

Oman, with natural gas reserves exceeding 20 trillion ft3, is a major producer of fertilizer in the Middle East, with an estimated output of almost 4 million tpy of nitrogen products. In early January 2023, 1Q, Oman’s state-owned energy firm launched its new ammonia plant in the Dhofar governorate. The US$463 million plant is

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designed to produce 360 000 tpy of liquid ammonia. The output will be exported to international markets through the nearby port of Salalah.

Potash

In March 2023, President El Sisi inaugurated a new nitrogen fertilizer complex in the port of Al-Ain Al-Sokhna, located on the Gulf of Suez. The complex, which is valued at US$800 million, will produce approximately 1.7 million tpy of nitrogen, potassium and phosphate fertilizers destined for domestic and international markets.

Emmerson PLC, based in the UK, is promoting the Khemisset potash project in northern Morocco. It is seeking to develop an estimated 537 million t of potash with an average grade of 9.24% potassium oxide (K2O). Output from the mine would average 735 000 tpy of muriate of potash (MOP), and 1 million tpy of de-icing salt. In March 2023, Emmerson announced that it had secured an estimated US$310 million in project financing from Moroccan and international banks. In all, the company expects to invest US$2.5 billion.

Jordan’s potash reserves are estimated to be almost 2 billion t.

Using mineral-laden water from the Dead Sea, extensive artificial basins are used to produce carnallite evaporites.

The Arab Potash Company (APC), produces over 2.4 million t of potash using the evaporation method. The company reported that its net profits for 2022 had more than doubled from the previous year to US$840 million, and plans to invest US$1.7 billion over the next five years in order to expand its capacity to meet growing demand in its traditional markets in Asia and the EU. For over a decade, Australian-based Danakali has been advancing the Colluli potash mining project with Eritrean National Mining Corporation (ENAMCO). The deposit is considered one of the world’s lowest-cost sources of sulfate of potash (SOP), with reserves of 1.1 billion t. It also contains significant reserves of muriate of potash (MOP). In March 2023, Danakali sold its 50% stake to China-based Sihuan Road and Bridge Group for US$121 million.

Green ammonia

According to the IEA, worldwide ammonia production stands at over 150 million tpy. Of that, two thirds is used for nitrogen fertilizer, and the remainder for non-fertilizer use, such as plastics, explosives and synthetic fibres. By 2030, fertilizer usage is expected to grow to 126 million t, while traditional non-use is expected to grow to 64 million t, for a total of 190 million t.

Under net zero policies, however, an immense new market for green ammonia is emerging; by 2050, marine fuels could add 204 million t of new demand, and a further 70 million tpy for power generation.

In the Middle East, jurisdictions are already planning to tap into new markets. Oman is taking major steps to position itself as a leader in clean energy. India’s ACME group and Scatec ASA, are teaming up with Yara to develop a major green ammonia plant in the country. The plant, being built in the special economic zone in Duqm, a port on the Arabian Sea, will initially have a capacity of 100 000 tpy, with a second phase that could potentially boost output to 1.1 million tpy; the yield is slated for deep-sea shipping, power utilities and fertilizer production.

12 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

Belgian firm DEME has signed a contract with Oman’s national hydrogen company Hydrom to create a facility in Duqm. The plant will produce an estimated 330 000 tpy of green ammonia from 1.3 GW of wind and solar power, with plans to double output to 650 000 tpy.

Other major projects have been slated for construction further down the line. In June 2023, Oman awarded a US$6.7 billion contract with South Korea’s Posco Group and partners to build the world’s largest green hydrogen plant. Construction is slated to begin in 2028, in the Arabian Sea port of Duqm. When completed, the facility will use up to 25 GW of wind and solar power to produce an estimated 6.25 million tpy.

In Saudi Arabia, plans are underway to build an immense green ammonia plant in the NEOM project, a futuristic greenfield development in the country’s northwest, home to abundant solar and wind resources. The US$5 billion plant would produce up to 240 000 tpy, starting in 2026. Air Products, which has a 30-year takeaway agreement, will then ship the product worldwide for use in marine transportation and heavy industry. The output is expected to eliminate approximately 5 million tpy of GHG emissions.

China Energy, which has a significant number of major energy projects underway in Egypt, has announced that it had Cairo’s blessing to build a US$5.1 billion green hydrogen plant.

The China-based company revealed in March 2023 that the project will involve the development of a wind farm, solar park and ammonia synthesis plant in order to produce 140 000 tpy of green hydrogen for conversion into ammonia.

While hosting COP27, the 2022 UN climate talks, Egypt announced the finalisation of several deals. UAE’s AMEA Power is to build a 235 000 tpy green ammonia plant in Al-Ain Al-Sokhna.

Electrolysers would be used to desalinate seawater and turn it into clean hydrogen. Egypt and Norway also announced that the two countries would work together to establish a plan to generate green hydrogen on the Red Sea. Traditional fertilizer usage will also see green shoots. Blended fertilizer is a major component of OCP Group’s output, taking home-grown phosphate and mixing it with imported nitrogen and potash. When global prices for the latter two commodities jumped after the conflict in Ukraine commenced, however, the Moroccan state-owned company faced massive input increases. In order to mitigate potential future disruptions, OCP has announced plans to domestically produce 200 000 tpy of green ammonia by 2026, with a long-range plan to reach 3 million tpy by 2032.

Qatar, with its vast reserves of natural gas, is the world’s largest exporter of liquid natural gas (LNG), but it is also a significant nitrogen fertilizer manufacturer. The Qatar Fertilizer Co (QAFCO) produces 3.8 million tpy of ammonia and 5.6 million tpy of urea, primarily for export. In August 2022, QAFCO announced that it would build the world’s largest blue ammonia train. The US$1 billion plant, to be located in its MIC complex, will produce up to 1.2 million tpy while capturing and sequestering 1.5 million tpy of CO2. The latter initiative is part of Qatar’s greater plan to reduce its energy sector’s carbon blueprint by attaining CCS capacity of 11 million tpy by 2035. The blue ammonia output can be used as part of the company’s urea production, or exported.

In 2019, OCI and Abu Dhabi National Oil Company (ADNOC) merged their fertilizer businesses in Egypt, Algeria and the UAE to create the JV Fertiglobe. The new company has a production capacity of 5 million tpy of urea and 1.5 million tpy of ammonia.

As part of the UAE’s plan to supply up to 25% of imported, low-carbon hydrogen in key global markets, Fertiglobe and UAE-based Abu Dhabi Chemical Derivatives Company (also known as TA’ZIZ) are developing a blue ammonia plant as part of a larger petrochemical complex being built in the port of Ruwais. The plant is expected to produce 1 million tpy when it comes on stream in 2025.

Problems

The availability of food is the most immediate, near-term concern in the region, with wide-spread protests and political turmoil recently erupting in Morocco and other jurisdictions.

In Egypt, food subsidies are a massive drain on the country's economy; recently, Qatar, the UAE and Saudi Arabia stepped in with US$23 billion in aid to prevent civil unrest. During the ceremony to inaugurate Egypt’s new nitrogen fertilizer complex in Al-Ain Al-Sokhna, President Sisi stressed that the new plant’s output was vital to producing grain to feed Egyptians, especially in the face of mounting prices for both fertilizer and imported food due to the Ukraine war.

The government has embarked on an ambitious, four year plan to add over 3.5 million acres of new farmland in the Delta, expanding existing cultivated lands in the country by one third.1 While 2022 was a bumper year for MENA fertilizer companies benefitting from export curtailments from Belarus, Russia and China, 2023 is producing more sobering financial results for some firms, as prices for ammonia, potash and phosphate return to earth. In 2022, OCP’s first quarter EBITDA amounted to US$1.23 billion; by 2023, that amount had

dropped by two thirds, to US$455 million. Saudi Arabia’s SABIC Agri-Nutrients is a major fertilizer manufacturer in the Gulf region; in 2022, it produced over 7 million t of fertilizer products (mostly urea and NPK blends). In August 2023, SABIC posted its H1 2023 results, showing a decrease in net profits of 66% from the same time in 2022, from US$1.65 billion to US$558 million.

On the other hand, Abu Qir Fertilizers, a major producer in Egypt, reported impressive earning growth for the first three months of 2023, registering net income of US$184 million vs US$120 million for the same time period in 2022. The company cited strong domestic demand, higher factory utilisation rates and lower feedstock and energy input prices for the increase.

Conclusion

MENA’s fertilizer sector faces both tremendous challenges and significant prospects within the coming decade. While record profits in 2022 have been curtailed by lower consumption and commodity prices in 2023, companies are taking an optimistic approach to future demand, both regionally within the African continent, and beyond. The growth in net zero carbon emissions around the world is also creating new opportunities for low-carbon ammonia, and national chemical companies and private enterprises are already investing billions in an effort to establish international market dominance.

References 1.

www.sis.gov.eg/Story/178255/President-El-Sisi-Inaugurates-theNitrogenous-Fertilizer-Complex-iwn-Al-Ain-Al-Sokhna?lang=en-us

DELIVERING FERTILIZER SOLUTIONS FOR OVER 50 YEARS BLENDING | MIXING | CONVEYING

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Zico Zeeman, EMT, the Netherlands, discusses the advantages and disadvantages of the machinery used in the fertilizer blending process, and considers how it can help to create tailor-made solutions for customers.

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It's wise to customise I

n the world of agriculture, fertilizer suppliers who can offer tailor-made solutions to meet the specific requirements of their target market are considered irreplaceable. By doing so, they can help their customers achieve their desired yields while using less fertilizer, resulting in significant cost savings without compromising revenue. To create customised blends and package them for blending, certain machines are required. This article delves into the specifics of these machines, their advantages and disadvantages, and their use in the blending process.

Blenders

Creating customised fertilizer blends requires the use of specialised blending units. These units can be categorised into two distinct groups: batch blenders and continuous blenders.

Batch blenders are designed to work in cycles, with each batch typically ranging from 2 – 16 t. The blending process begins with a filling stage, where each raw material is weighed, followed by the blending stage, and finally discharging.

The capacity of batch blenders typically ranges from 20 – 70 tph, making them ideal for smaller-scale operations.

On the other hand, continuous blenders are designed to operate continuously and can blend up to 300 tph.

These blenders are ideal for larger-scale operations, and are

capable of creating blends with a high degree of consistency.

Continuous blenders can also be used to incorporate micronutrients, inhibitors, or other additives into the blend as needed.

Regardless of the type of blender used, the blending process is a critical step in creating customised fertilizer solutions that meet the unique needs of each customer.

By understanding the different types of blending units available and their capacities, suppliers can ensure that they are using the right equipment to meet their production goals while also maximising efficiency and minimising costs.

Paddle blenders Paddle blenders are a versatile option for batch blending and can be used to blend granules or powdery materials, including water-soluble fertilizers. Twin-shaft high-speed paddle mixers are especially well-suited for powdery materials, with both shafts running at high speeds in opposite directions to ensure a thorough mix. With a typical capacity of 1 – 4 t per batch, paddle blenders are a popular choice for a range of industries.

Vertical blenders The vertical blender is a blending system that utilises a conical screw to mix raw materials in a wave-like motion.

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This system is designed to prevent product build up inside the container thanks to a 60˚angle at the bottom cone of the blender. Additionally, a Salem valve located at

the bottom of the blender, combined with a sweep at the bottom of the auger, ensures that the blender is completely emptied during cleanout.

This blending system has a capacity of up to 60 tph, making it a high capacity machine suitable for large scale operations. The entire system is mounted on a digital weighing system, allowing for the precise measurement of raw materials during the blending process.

The use of the vertical blender ensures an accurate and efficient blending process with minimal product waste.

Its unique design helps ensure uniformity in the blend and complete cleanout, enhancing the quality of the final product.

Horizontal rotating blenders

Figure 1. 17-hopper weighing continuous blender.

Horizontal rotating blenders are widely used in various industries to blend different raw materials. The process of blending is simple and efficient. The turning drum, which has internal flighting, folds the materials together to create a homogeneous blend with minimal degradation or segregation.

These blenders come in different capacities, ranging from 2 – 14 t, with a corresponding capacity of 2 – 14 m3. A weigh hopper with the same capacity as the blender is mounted on a digital weighing system, ensuring the accurate measurement of the raw materials.

In this type of blender, the weighing and blending processes are separated. This allows for a more controlled and precise blending process. The end result is a well mixed blend that meets the desired specifications.

Continuous blenders

Figure 2. Big bag line capacity of 80 tph.

Continuous blenders, like the EMT Weightcont blender in the Ballance project, operate continuously and have the ability to fill and discharge simultaneously. They can use a blending screw to mix materials, with capacities that can reach up to 300 tph. These blenders employ modern technology, with a computer system controlling the entire weighing and blending process through a variable electro system to ensure optimal quality.

The system works as follows: operators use a wheel loader or forklift with a bucket to fill the hoppers with raw materials.

Each hopper is equipped with a digital weighing system, and stainless steel dosing conveyors in combination with the digital weighing systems ensure proper dosing of the raw materials. There is an unlimited number of hoppers.

The complete blender is made of stainless steel and has a hopper capacity of 4 – 15 t/m3.

Micronutrients, inhibitors, or additives can be added to the blend using both types of blenders. It is crucial to determine which type of product needs to be added to enhance the product's value for customers. Depending on the requirements, a powder-adding unit or a liquid-adding unit may be installed in the blender.

Blending software

Figure 3. Factory setup 3D impression: blending, screening, truck loading and bagging.

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To optimise the blending process, software can be used.

Software packages to support the blending process, such as Optiblend by EMT, help to make cost effective calculations for fertilizer blending. This is an optimisation programme and can help to make the right formulations for the lowest possible costs. In addition, a complete product analysis can

be calculated, including the NPK value, as well as all required micronutrients. The programme helps to calculate the right raw material that can be used for the blending process. In the programme, it is possible to add the nutrient value of crops, organic fertilizer, soil quality, manure, and mineral fertilizer.

Then, a field hectare or acre calculation based on the farmer’s information can be made, so that the farmer receives the correct amount of fertilizer. Through the use of programmes like this, in combination with a blender system, the correct quantity of fertilizer will be spread onto the field, therefore reducing costs and environmental pressures.

Bagging

When the blender line has a high capacity per hour, the bagging line also needs to have the same capacity. For big bags (jumbo bags), 70 tph per line can be necessary. For 50 kg bags, up to 50 tph per line can be necessary. When a 25 kg bag is necessary, a capacity of 25 tph per line can be required.

By doubling this bagging line, the capacity is easy to increase.

All bagging machines are suitable for powder and granulated material.

The 'small bag single unit' has a stainless-steel scale with a capacity of 60 kg. The complete system operates fully automatically by means of a weight indicator. It is also possible to manually operate the machine. The operator secures the bag around the filling mouth, where a clamp holds the bag so that it stays in position. The weighed product automatically falls into the bag. When the bag is filled, the clamp automatically releases, and the full bag is transported through the conveyor belt to the sewing or sealing machine.

The capacity of the 'small bag single unit' is 400 bags for open

mouth bags and 300 valve bags per hour. This machine is also available as a double unit, which doubles the capacity.

The 'big bag economic' and 'low profile unit' are automatic bag filling systems made for FIBC bags (flexible, intermediary, bulk, containers). The big bag is attached and held by hand around the filler pipe. This prevents dust formation during the filling process. The filling height is determined based on the size of the big bag. When the bag is full, the weight of the product is determined and the bag is transported further by a conveyor belt. The weighing system is equipped with a weight indicator. The entire system can be operated fully automatically or manually. The machines are suitable to be set up in various ways. The 'big bag economic' is a fixed machine with a supply hopper on top. The big bag low profile is a movable machine that can be filled by a shovel. The capacity of both machines is 30 tph for big bags of 1 t and around 40 bags of 500 kg/h.

The 'big bag high speed' is also an automatic bag filling system that fills FIBC bags. The machine weighs and fills automatically and can fill 100 – 1250 kg bags. The height of the filler pipe is adjustable over a length of 500 mm. The scale hopper releases the material through a stainless steel pipe in the big bag, and this can be removed with a forklift.

Conclusion

This article has highlighted the importance of blending units for creating customised fertilizer blends. Batch and continuous blenders offer varying capacities for small and large scale operations, ensuring precise mixing and product quality.

The addition of micronutrients and additives enhances product value, with the choice of powder or liquid units.

The world of fertilizer blending Robert Fitzpatrick, Ag Growth International, USA, provides an insight into fertilizer handling management and blending processes.

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T

he agriculture industry has always been the backbone of global food production, and fertilizer plays a critical role in maximising crop yields.

Technological advancements in fertilizer blending have paved the way for improvements in blend precision and farm profitability.

Achieving optimal crop yields while minimising environmental impact is a key goal for farmers. A large part of this effort is proper fertilization. Fertilizer blending, a crucial process in obtaining higher crop yields, involves the precise mixing of nutrients to create customised recipes that meet specific crop requirements.

This article delves into the world of fertilizer blending, explores various blending system options, and discusses the importance of micronutrients. The latest advancements in blending technology are also highlighted, shedding light on conveyor technology, and tying it all together with a focus on bagging systems.

Fertilizer blending systems overview

Fertilizer blending systems have become the foundation of ‘best practices’, enabling farmers to modify fertilizer blend compositions (based on sound agronomy analysis) to meet specific crop requirements.

These systems combine various raw materials, including nitrogen (N), phosphorus (P), and potassium (K), along with essential micronutrients, to create balanced and nutritionally rich blends to meet each section of their fields. These results are a key factor in ensuring healthy plants, exceptional growth, disease resistance, and optimised yields.

Fertilizer blending involves the careful mixing of fertilizer nutrients to create customised blends tailored to specific soil and crop requirements.

This is made possible by recent advancements in the combination of agronomy science, agricultural software development and precision blending equipment control and automation. The process addresses the nutritional needs of crops while minimising waste and environmental impact.

A well-designed fertilizer blending system enhances nutrient efficiency, reduces costs, and contributes to sustainable farming practices.

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Fertilizer blending systems for business growth

global food demand, investing in the right blending equipment is critical to success.

Choosing the right fertilizer blending system for an agricultural operation

High volume dry fertilizer blending systems

The size of the operation, the types of crops planted and harvested, and the overall budget of the operation, are all factors which influence the selection of the fertilizer blending system for its specific needs.

Modern farming demands the most advanced fertilizer blending systems, capable of handling high volumes efficiently and with accuracy and speed. As businesses grow to meet

High volume dry fertilizer blending systems are at the height of agricultural advancement, enabling farmers to produce consistent and tailored fertilizer blends at the scale they need. These systems are designed to manage large quantities of components and ensure precise nutrient recipes.

High volume dry fertilizer blending systems are designed for large scale operations. These systems are capable of blending over 300 tph and can be used to blend a wide range of dry fertilizers. Two standout categories within this segment are tower blending systems and declining weight blending systems.

Tower blending systems

Figure 1. Tower blender.

Tower blending systems are engineered for high volume dry fertilizer operations. These systems use high elevation and gravity to assist the blending process. These blending towers efficiently blend large quantities of fertilizer components, creating precise blends through gravity-driven processes.

Towers start at the top with multiple hoppers of different fertilizer components. Components are precisely weighed and mixed in a high efficiency blender, ensuring uniform mixing, including any liquid additives needed. Tower blending systems offer several advantages: nn Precision: advanced software controls enable precise measurement and blending of fertilizer components. nn Flexibility: tower systems can accommodate a wide range of raw materials and blend recipes, allowing precise blends to be tailored to specific crop and soil requirements. nn Scalability: tower blending systems can be scaled to meet the needs of growing agricultural operations, ensuring future-proof investments.

Blending tower storage capacities can reach over 300 t of different components and blending speed can reach over 300 tph, depending on blend complexity. Wholesale output can be well over 600 tph.

Declining weight blending systems Figure 2. Decline weigh blender.

Figure 3. Rotary drum blender.

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Declining weight blending systems are designed with precision in mind, as well as high volume dry fertilizer blending.

These systems use a series of weigh hoppers to precisely measure fertilizer components and then blend them together.

This process ensures consistent and accurate blends, making them the best choice for large scale blending operations.

Declining weight blending systems are an integral component of the high volume dry fertilizer blending landscape because they offer high volume blending capability with high precision at a low profile. When space is available, these systems provide a good option as they are low to the ground and easy to operate and maintain. Equipment and tools are easily brought to the work area without scaling ladders, stairways or utilising lifts. Expertise in this area ensures that customers can efficiently produce customised blends while minimising waste. Declining weight blending systems offer several key features:

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nn Consistency: the gradual weight reduction ensures that each component is accurately measured, resulting in consistent nutrient distribution. nn Reduced waste: precise control over component dispensing reduces overages and minimises waste, contributing to cost savings and sustainable practices. nn Ease of use: user friendly controls and automation streamlines the blending process, reducing the need for manual controls. nn Maintenance: systems are designed for reliability and ease of maintenance, minimising downtime, and optimising operational uptime.

Low-to-medium volume dry fertilizer blending systems Low-to-medium volume dry fertilizer blending systems are designed for smaller operations. These systems can blend up to 75 tph and can be used to blend a wide range of dry fertilizers.

Rotary drum blending systems Rotary drum blending systems are designed for low-to-medium volume dry fertilizer blending. These systems use a rotating drum to blend fertilizer components together.

Rotary drum blending systems satisfy low-to-medium volume requirements. In these systems, raw materials are conveyed to a weigh hopper and then to the rotating drum, where mixing occurs. This cost-effective option is preferred by many small and mid-sized customers.

Rotary drum blenders provide gentle and efficient blending of dry components, ensuring uniform distribution

Figure 4. Vertical blender.

Figure 5. Liquid blending.

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of nutrients. The tumbling action of the drum promotes thorough mixing without damage to fertilizer components.

Vertical blending systems Vertical blending systems are designed for low-to-medium volume dry fertilizer blending in a small relative footprint.

These systems use a vertical screw, often tapered, to blend the fertilizer components together.

Vertical blending systems utilise a vertical screw to mix raw materials thoroughly. These systems are simple, space-efficient, and well-suited for operations with limited area. A vertical blending system can be as simple as a vertical blender, loadout conveyor and a means to load fertilizer commodities into the blending hopper.

Liquid fertilizer blending systems Liquid fertilizer blending systems are designed for operations that require liquid nutrients. Liquid fertilizers are quickly absorbed by plants, providing nutrients directly to their roots for 'uptake' and crop growth. These systems use many sizes of tanks and pumps along with automation controls to blend the different liquid components/commodities together.

Liquid fertilizer blending systems also employ precision pumps and flow meters to make precise liquid blends.

These blending systems are ideal for producing nutrient-rich liquid blends that can be easily applied through irrigation systems or direct application, and involve highly accurate measurement and mixing of liquid components to create a homogeneous liquid solution.

Improving value with fertilizer micronutrients

Fertilizer micronutrients are essential for plant growth and development. Most standard fertilizer blends include the primary macronutrients (N, P, K) to form the foundation of fertilizer blends. Recent agricultural agronomy advancements have now highlighted the need for essential micronutrients to improve the nutritional value of the mixture.

Micronutrients such as zinc, iron, manganese, and copper are now critical for many soil analyses for strong plant development and crop health. Dry form micronutrients are introduced to fertilizer blends via the following process equipment: nn Powder feeders: powder feeders precisely feed micronutrient powders in tightly controlled amounts.

These feeders ensure accurate dosing, preventing under- or over-application and provide the desired nutrient balance. nn Powder auger: powder augers, like powder feeders, efficiently mix micronutrient powders and granules into the main fertilizer blend. Specialised powder augers typically have a larger screw to manage differing particle sizes while preventing material separation, resulting in a homogenous, nutrient-rich mixture. nn Liquid impregnation systems: liquid impregnation systems are used to add micronutrients in liquid form to dry fertilizer blends. Good impregnation systems provide uniform ‘coating’ of dry fertilizer macronutrients, allowing the full impact of the impregnation component.

This method ensures uniform distribution, maximising nutrient availability and uptake by plants.

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Liquid impregnation systems allow for the precise infusion of micronutrient solutions into the fertilizer granules, enhancing nutrient availability to plants.

Fertilizer blending system advancements

Recent advancements in technology have transformed the fertilizer industry, especially in the approach to blending processes, resulting in heightened efficiency, accuracy, and user convenience.

Blending control advancements Blending control advancements have made it easier to control fertilizer blending systems. These advancements allow for the monitoring and adjusting of blending systems from anywhere on site, and in some cases offsite too.

Automated blending controls ensure consistent product quality, reduce human error, and streamline operations.

These systems are equipped with advanced control systems that enable operators to fine-tune the blending process, adjust mixing parameters (nutrient feed rates), and monitor real-time data, ensuring optimal blend consistency.

Blending automation advancements Advancements in control capabilities have led to blending automation advancements, making it possible to automate many aspects of fertilizer blending systems. These include automated loading, mixing, and bagging systems. In some processes, unattended load capability is possible.

Automation is a notable change in the fertilizer blending industry. Automated systems optimise material handling, mixing, and packaging, leading to faster production cycles, reduced labour costs and reduced errors.

Automation technologies also improve the blending process, reducing human intervention and enhancing operational efficiency. These systems can accurately measure and dispense ingredients on the fly, leading to consistent and highly accurate blends.

Blending software advancements Blending automation advancements are made possible by software advancements, making it easier to manage fertilizer blending systems. These advancements include software that allows inventory levels to be monitored, as well as production rates, and reports to be generated.

Blending software offers real-time monitoring, data analysis, and reporting at the operation or business direction.

This empowers operators to make informed decisions, detect process deviations from specification, and continuously refine the blending process for optimal results.

Blending software solutions allow for direct connection with newer agronomy software systems offering a comprehensive recipe management, formula calculations, and integration with other management systems, helping to achieve better planning and optimisation of fertilizer blends.

A main contributor to these advancements is precision weighing systems for both dry and liquid fertilizer commodities that ensure that each component is precisely added in the correct amount. Advances in mixing technology have led to more precise fertilizer blends, eliminating nutrient separation, and ensuring consistent nutrient distribution throughout the mixture.

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Precision mixing technologies, such as inline mixers and agitators, ensure thorough dispersion of components, including micronutrients, resulting in homogenous blends that deliver maximum crop benefits.

Bagging systems

The last step in the fertilizer blending system is packaging.

Bagging systems range from manual to fully automated, providing smaller, 25 kg (55 lb) bags, up to ‘super sacks’ weighing in at roughly 500 kg (1200 lbs).

The heart of fertilizer bagging equipment is the precision weighing system. Accurate measurement of fertilizer components is essential to ensure product quality and profits.

Highly accurate weighing systems ensure that each bag receives the exact quantity of fertilizer specified, minimising waste, and optimising labour usage.

Newer baggers can process a large volume of fertilizer quickly and consistently, meeting the demands of high production environments. With adjustable bagging speeds, manufacturers and retailers have the flexibility to adapt to varying production needs without compromising accuracy.

User friendly controls simplify the task of managing the bagging process. Interfaces allow operators to monitor and adjust the process while running. This level of control enhances operational capability, reduces downtime, and helps operators to respond quickly to changing production requirements. Manufacturers can achieve higher output levels without compromising the accuracy and quality of their blends. This increase in productivity directly translates to higher profitability for blending operations.

Efficient use of raw materials is key to controlling production costs. New bagging equipment minimises material waste by precisely measuring and bagging the required quantities.

Fertilizer bagging equipment is designed to accommodate various bag sizes and types, allowing manufacturers to cater to diverse market demands.

Conclusion

The evolution of fertilizer blending systems has paved the way for agricultural advancements that directly impact crop yield and quality. As the industry continues to grow, it is critical for farmers and agricultural business leaders to stay informed about the latest technologies. Whether it is high volume tower blending systems or precision-enhancing micronutrient applications, the choices made in fertilizer blending have a direct correlation to high crop yields and ultimately a very successful season.

The world of fertilizer blending systems is ripe with possibilities for enhancing crop yield, minimising waste, and maximising profits. By understanding the diverse types of blending systems, embracing micronutrient integration, capitalising on advancements in blending technology, and optimising conveyance and bagging processes, agricultural businesses can put themselves in a position for success.

As the global population continues to rise, the agricultural industry faces incredible challenges to meet the growing demand for food. Precision blended fertilizers are now a critical component of modern farming practices, enabling farmers to optimise crop yields.

Precision as a priority Rafael Delgado, Sackett Waconia, Dominican Republic, discusses the importance of efficient and precise blending systems in the fertilizer sector.

C

rop nutrition has evolved rapidly in the last decade, seeking efficient administration of the inputs and amendments that make up the nutritional package of every crop, while ensuring the profitability of agricultural producers and protecting the environment. This is how precision crop nutrition has become an essential part of modern agriculture. It provides specific solutions for each soil-crop-environment system,

based on tools such as soil and foliar analysis, that determine what the exact condition of a crop/soil is at a given time.

In practice, meeting the demand for crop nutrition requires tools and technologies capable of managing the increasingly complex package of inputs necessary for nutrition. In this sense, fertilizer bulk blends of specified composition are the most suitable vehicle to deliver the required nutrients in the correct amount, time, and place, and inputs. Various raw materials can be used to produce such fertilizer blends, ranging from granular products, powders and liquids, to performance enhancers, biological products, and chemical stabilisers. All of these materials must be combined in the correct proportion, with some of them in quantities as minimal as 1 lb/t.

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This should be done to replenish the required nutrients within the framework of good practices, such as 4R nutrient stewardship, which promotes the right time, right rate, and the right place from the right sources of fertilizer products.

To face the challenge represented by the production of complex specific blends that require excellent precision, homogeneity and quality, some essential criteria come into play: nn A batch blending system that provides repeated consistency batch after batch, and continuous traceability. nn Production of homogeneous blends in a short mixing time without degradation of the particles. nn Use of physically and chemically compatible raw materials. nn Having an individual dosing system for every major raw material, microelement, dispersible powder, and liquid additive, with accuracy of at least +/- 0.1%. nn Transfer of blends directly to trucks or bagging hoppers, minimising segregation and breakage of particles.

To ensure the most efficient uptake of nutrients, it is not enough to have the best raw materials and field application technology.

It is critical to have a highly efficient blending system.

Precision horizontal blending systems

Sackett Waconia has developed AccuBlend™ as a precision horizontal blending system. This system is floor-based and features the advantages of a horizontal system combined with precision batch blending. The technology features a system of NTEP certified weigh hoppers, arranged horizontally, smart automation controlled declining weight dosing, and precision blending.

Systems such as this provide flexibility and can work in multiple configurations and capacities. The system is a modular concept which allows it to be expanded.

Precision blending systems are also manufactured to produce specific blends of water-soluble fertilizers. This system is

Figure 1. Precision horizontal blending system with 8 t Orbital mixer.

Figure 2. Precision horizontal blending and bagging systems at the Mayafert plant.

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specifically designed for the dosing, blending and bagging of powder or crystalline materials. It also allows for the addition of trace elements and colourants in liquid or dry powder form.

In many cases, especially in countries that have mountainous terrains and where growers cultivate small areas, the best option for the distribution and field application of fertilizer blends is to bag those blends. Doing so allows for fertilizer to be easily handled and transported to its destination. Different types, sizes and weights of bags are used depending on the local regulations and customs of each region or country.

High-speed and precise bagging systems collaborate through precision blending systems. This technology can cover a wide range of different configurations ranging from semi-automatic bagging machines with capacities ranging from 8 – 20 bags/min., to fully automatic packaging systems with capacity for 25 – 30 bags/min. Each bagging machine integrated into a blending system is designed and built to adhere to fertilizer industry standards.

Fertilizer blends are negatively impacted by relative humidity in the environment, temperature changes and other environmental elements. This is why selecting an appropriate bag is critical to maintain the integrity and composition of a blend once it is bagged. There are multiple bag options, with the most common being open-mouth woven polypropylene raffia bags, open-mouth polyethylene bags, and valved polypropylene/polyethylene bags. In many cases, the use of an inner liner provides additional protection.

Closing or sealing of the bags can be done by thread sewing or heat sealing in the case of polyethylene bags.

The type of product to be packaged determines the most convenient type of bagging machine for each case.

For free-flowing granular products, gravity-fed net-weight bagging machines are used, and for products in powder or crystalline form that are not free-flowing, variable-speed belts or screw-fed gross-weight bagging machines are used.

The maximum net weight for individual bags varies by region and application method, normally ranging from 25 – 1000 kg big bags.

Precision blending systems ensure a homogeneous and consistent composition batch by batch. This is of utmost importance when each batch must be divided into portions as small as 25 kg, while ensuring analysis of the content in every single bag.

Labelling is required when bagging fertilizer bulk blends.

The label constitutes a guarantee regarding the nutrients contained in each fertilizer bag. In many countries, there is a standard that regulates the tolerances allowed in the variation of the actual content of each nutrient, vs what is established on the bag label. A given blend can be classified as deficient if the analysis of any of the nutrients is below what is guaranteed by a value that exceeds the value established by the allowed tolerance, which can be as low as 0.5%.

Precision blending systems are consistent when working in conjunction with bagging systems, providing complete reliability proven by hundreds of follow-up samples taken in multiple locations and conditions.

PFB towers

In PFB (precision fertilizer blending) tower systems, all granular raw materials are de-lumped before any weighing or mixing;

each ingredient is then individually weighed in a legal-for-trade weigh dosing hopper before entering a high intensity mixer to produce a homogeneous blend.

Tower blending effectively reduces the overall footprint of the blending system, and these can vary in capacity from 90 t towers to over 300 t of overhead storage.

Mayafert Guatemala: blending and bagging

Fertilizers Maya is a leading company in the production and distribution of fertilizers in the Central American region (Guatemala, El Salvador and Mexico) where it produces and delivers around 400 000 tpy.

In the last decade, Mayafert has made a transition promoting the use of specific prescription formulas.

This transition has been carried out at various levels, beginning with the education of agricultural producers and continuing with the adoption of new technologies and practices. It also included the modernisation of its existing fertilizer blending and bagging plant located in Escuintla Guatemala.

As Mayafert's Plant Manager, Mr. Rodrigo Puaque commented that the plant had reached a point where the blending systems did not have the capacity to work efficiently with complex blends. He specified that the loss-in-weight dosing system and continuous blending did not provide the company with the necessary consistency and reliability in the composition of its special blends. He concluded that the company needed to find a better way to properly serve its customers' growing demand for specific formulas.

Mayafert engaged Sackett Waconia to design and manufacture a new blending and bagging plant that would

provide the company with the precision, blending quality, consistency and performance required to be efficient and competitive producing their specific formulas. Sackett Waconia configured a solution tailored to the specific needs of Mayafert, and proposed an Accublend horizontal precision blending system with an Orbital precision mixer. The new system has the capacity to produce 80 tph of blended product and a two-line bagging system with duplex bagging machines, with capacity for 23 bags of 50 kg/min. each.

Mayafert's Accublend system has five weighing hoppers to dose major raw materials such as urea, DAP, MOP and ammonium sulfate. It also has an impregnation system for liquid applications that allows the plant to treat urea and other materials with volatilisation inhibitors or polymers to improve nitrogen use efficiency.

Weighed materials go through a bulk conditioner to eliminate lumps and clumps before entering the 8 t Orbital mixer. After an average mixing time of 1.6 min., the batch is transferred from the mixer to the bagging hoppers through a bucket elevator.

The system’s duplex baggers, with a digital controller, can make a total of up to 23 cycles/min.

Once the bags are full, they are transported by a bag-closing conveyor to a high-speed sewing head with automatic start-up thread cutting, and then are transferred by a conveyor belt directly to the trucks for distribution.

The fertilizer company now has new growth opportunities for precision crop nutrition and is motivated to evaluate the possibility of acquiring a second system for many of its locations in throughout Central America.

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UREA LOGISTIC, STORAGE AND 1

The urea is loaded into the patented ISG containers at the processing plant and the containers are sealed.

Each container holds around 30 tons of urea.

4

From the database a report can be generated using the RFID information so you can manage the amount of product being shipped.

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At the port the containers are block stacked awaiting the bulk ship to arrive.

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Case Study Number 01: Urea transport in Bolivia Brunei Urea loading

The containers are fitted with RFID tags so they can be tracked on their way to the ocean or river port.

PHONE: +61 40 0035 548 EMAIL: gpinder@isgpts.com

3

The containers are transported via road or rail and then stored at the port.

“The environment matters”

6

When the ship arrives the product is tipped into the bulk ships hold using a tippler. Some customers have a bagging facility at river ports. They use this system to move the bulk product to the river bagging plant.

7

The bulk ship departs with your product on board. The containers are returned to the processing plant, for the cycle to start over again.

Giedrius Rutkauskas, Arionex Wasseraufbereitung Gmbh, Switzerland, outlines why the fertilizer industry should take the opportunity to mitigate pollution created from water demineralisation.

30

Grasping a unique opportunity W

ater plays a crucial role in the fertilizer industry, primarily in steam generation, cooling cycles, and, more recently, hydrogen production. Two main technologies are relied upon for water demineralisation: ion exchange and reverse osmosis. Ion exchange technology generates 5 – 10% wastewater as a byproduct, contaminated with regenerants like NaOH, H2SO4, or HCl. In contrast, reverse osmosis technology produces a discharge stream of 20 – 30% from the input water, with salts concentrated four to five times higher than raw water. Both technologies create pollution that is environmentally undesirable for disposal.

However, the fertilizer industry has a unique opportunity to mitigate this environmental pollution using a combined ion exchange-membrane technology.

This approach employs HNO3 and NH3 solutions for regenerations. The regeneration process of ion exchange resins results in effluents enriched with salts removed during demineralisation, producing both demineralised water and concentrated effluents (15 – 18%).

These effluents contain approximately 50% of Ca, Mg, K, Na, SO4, Cl, and Si salts and 50% of NH 4NO3. Rich in minerals extracted from water and ammonium nitrate, the effluent serves as raw material for the production of liquid or solid NPK fertilizers. In this way, minerals originally present in the water return to the soil and plants, completing a sustainable cycle.

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History

Half a century ago, a specialised ion-exchange treatment and recovery process known as Fertarex was invented.

This process aimed to address issues related to condensate contaminated with ammonium nitrate.

Utilising specific cation and anion ion-exchange resins, regenerated with 50 – 60% nitric acid (HNO3) and 15 – 20% ammonia (NH3), the Fertarex process is now used in many nitrogen fertilizer complexes. Its purpose is to produce demineralised water and recover the discharged nitrogen products as an 18 – 20% NH4NO3 solution, obtained from the regeneration of cation and anion resins. This recovered solution is either recycled directly into the ammonium nitrate production plant or concentrated to 75 – 80% NH4NO3 through a supplementary vacuum evaporation plant. Due to the production of demineralised water and the recovery of all discharged nitrogen products as ammonium nitrate fertilizer, no contaminated nitrogen (N) wastewater is discharged into the environment, resulting in significant cost savings. A medium-sized ammonium nitrate production plant can save up to US$1 – 1.5 million per year, making it possible to recoup the initial investment in less than five years.

Existing water demineralisation technologies

Demineralised water is a critical product, especially for the chemical industry and as boiler feed water for power stations. For over a century, demineralised water has been primarily produced using ion-exchange techniques.

This approach employs cation resins (R-H) to remove calcium (Ca), magnesium (Mg), sodium (Na), and anion resins (R-OH) to remove sulfate (SO4), chloride (Cl), nitrate (NO 3), bicarbonate (HCO3), silica (SiO2), and more.

Mixed bed ion-exchange polishing yields high quality demineralised water with conductivity values below 0.1 µS/cm. When the ion-exchange resins become exhausted, they are regenerated using acids such as hydrochloric acid (HCl) or sulfuric acid (H 2SO4) for cation resins, and caustic soda (NaOH) for anion resins.

Typically, the waste effluents from resin regeneration contain high levels of salts and excess acids or caustic, leading to significant environmental pollution.

A more advanced technology is reverse osmosis membrane technology, which separates water into two streams: demineralised and concentrated flow (with low and high salt concentrations, respectively). Pressure is applied to the membrane to achieve this separation.

While membrane technology does not employ regenerants, its recovery rate varies between 70 – 80%, resulting in a concentration factor four to five times higher than the inlet water. This technology generates less polluted wastewater than ion exchange but in significantly larger quantities.

Both processes produce wastewater, which, under certain environmental conditions, cannot be discharged into natural water sources such as rivers and lakes.

Zero discharge water demineralisation processes

Figure 1. Fertarmix plant.

Figure 2. Recycling scheme.

32 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

Considering the principles of the circular economy, the idea emerged to use historically-used technology for concentrating ammonium nitrate from condensate in a new water demineralisation process. This approach enables the recycling of salts extracted from water, as natural water from surface or ground sources inherently contains minerals that have dissolved into it. Water acts as a natural solvent, and minerals originate from the soil and rocks. Returning these minerals to the soil in small quantities creates a fully recyclable demineralisation process, as opposed to accumulating minerals in one place and causing pollution. Growing plants require not only nitrogen, phosphorus, and potassium for their growth, but also other elements like calcium, iron, manganese, magnesium, and sulfur.

In this way, minerals from water are incorporated into fertilizers as part of their composition, ultimately returning to the soil and plants where they originally came from. The Fertarmix ion-exchange water demineralisation process is primarily applicable in NPK complex fertilizer fabrication plants for producing demineralised water from pretreated surface water.

Fertarmix is a modern ion-exchange demineralisation system that regenerates loaded cation and anion resins with nitric acid (HNO3) and ammonia (NH3).

Through selective fractioning of the regeneration effluents and neutralisation of excess NH3 with HNO3 to a pH value of 4.5, the process results in 12 – 16% TDS effluents, primarily containing NH4NO3 and small amounts of NO3 and NH4 salts. These effluents are then recycled back into NPK production plants.

Utilising on-site-produced HNO3 and NH3 regenerants, the process significantly reduces water demineralisation operation costs and eliminates the discharge of contaminated waste effluents into the environment, achieving a zero discharge system.

The process

To implement this process, the inlet water must undergo pretreatment using the same technologies as conventional water treatment plants. This involves removing suspended solids and reducing organic content, which can be accomplished using conventional clarifiers or ultrafiltration technology. The effluents from these processes can be easily converted into more or less dry cakes, suitable for disposal in landfills or use as inert material for various products. The pretreated water is then recycled back into the process. Subsequently, the water passes through cation and anion ion-exchange filters to remove Ca, Mg, K, Na on cation resins and SO4, Cl, HCO3, NO3 on anion resins. After a filter cycle, the cation resin is regenerated with concentrated HNO3, while the anion resin is regenerated with NH3. The effluents from these regeneration processes are fractionated, with the most concentrated effluents collected separately as raw

material for NPK production. Other regeneration waters are recycled within the process. The water emerging from the cation-anion filters undergoes further polishing using electrodeionisation (EDI) technology, which combines membrane and ion-exchange technologies. The resulting demineralised water, with a salt content of just 0.1 ppm, is suitable for various industrial processes. The EDI concentrate passes through an ion exchange filter to remove silica (Si). This filter is regenerated with KOH, and the effluents containing K and Si are mixed with the main process effluents, which are used to feed NPK production.

While this process description is general, the main mineral conversion technology can be combined with other technologies, such as nanofiltration, lime clarification, pellet softening, and reverse osmosis, depending on the quality of the inlet water. A thorough analysis of water quality is essential to determine the optimal combination of technologies, aiming for the best capital expenditure (CAPEX) and operational expenditure (OPEX).

Tests

In 2019, a pilot plant was built, and numerous tests were conducted using river water with ultrafiltration pretreatment. The tests were focused on process safety checks (when surface or ground water is treated) and process potential to achieve the highest possible effluent concentration. One of the test results is as follows: nn Cation-anion exchangers, each filled with 14 l resins. nn Inlet water TDS: 205 ppm.

nn Flow rate: 250 l/h. nn Filter cycle: 3200 l. nn Effluents quantity: 20 l, representing 0.62% of the cycle. nn Effluents TDS: 177 000 ppm. nn Treated water quality at the end of the cycle: 10 – 12 microS/cm.

These tests demonstrated that the resins functioned reliably, high effluent concentration could be achieved, the process operated smoothly, and that there were no indications of cation resin degradation.

Experience

The most recent ammonium nitrate condensate treatment plants, utilising cation-anion technology with concentrated HNO3 and NH3 regenerants, were built in fertilizer plants – one in 2005 at Romania's Azomures S.A. Ameropa Holding, and another in 2010 at Turkey's Gemlik S.A. These plants have operated successfully for many years. Despite some resin producers not recommending the use of HNO3 acid for cation regeneration due to its strong oxidising properties, practical experience has shown that a special configuration of resins and safety techniques for regeneration results in stable equipment operation without any incidents over extended periods.

Limitations

There are limitations to applying the aforementioned technology. In cases of high salinity (above 5000 ppm), it may not be economically efficient to treat water using this technology due to the high regenerant consumption and the generation of excessive effluents that cannot be utilised in existing NPK production. Additionally, the salt composition of the inlet water, especially the presence of heavy metals and high chloride (Cl) content, might be unacceptable for inclusion in NPK compositions. Each case for the combination of feed water composition and customer’s production/products possibilities to use obtained salts as additives should be analysed or even tested. This consumes some time and effort.

Conclusions

The circular economy is an important approach to preserving the environment. Any technology that helps protect nature should be considered and evaluated alongside conventional technologies. In some instances, it becomes evident that environmentally friendly technologies can also be economically beneficial for industries.

References 1.

2.

3.

4.

5.

POPOVICI, N. N., HODGE, C. A., “Pollution control in Fertilizer Production” (1994).

PAWLOWSKI, L. & BARCICKI, J., “Stability of Ion Exchangers in Nitric Acid Solutions” (1996).

ARION, N., US Patent No. 4002455/23.07.75 (IPRAN-Bucharest, Romania): “Process for treating and recovering waste water from fertilizer manufacture.”

ARION, N., “Treatment of Waste Water Effluents from the Azomures Nitrogen Fertilizer Complex in Romania” International Conference Nitrogen, Bucharest, Romania (27 February 2005).

RUTKAUSKAS, G., ARION, N., Patent No 2019 526 (Kaunas, Lithuania) “Method of water demineralization and product obtained thereof” (2019).

Sense and Sustainability Jose R. Ferrer, Espindesa, Spain, outlines how the efficient use of fertilizers could provide a more sustainable solution to meet growing agricultural demands.

F

ertilizers provide nutrients that are essential for the development and growth of plants. These nutrients are generally split into macronutrients, with nitrogen (N), phosphorus (P) and potassium (K) being the most critical. More recently, sulfur (S) has been included as a macronutrient. Micronutrients that are more specific to each

crop, such as zinc, magnesium and boron, etc, have also become more important to plant nutrition.

For decades, many have posed the question of how we can continue to feed the growing global population. This has resulted in further development of the fertilizer industry, and commercial fertilizers. Fertilizers have, however, recently 35

to recycle off-spec products to obtain fertilizer. Fertilizer can also be derived from animal or plant residues, however the difficulties of transporting bulk organic residues is leading to a more localised use of fertilizer. Fertilizer made from wastes or organic residues is increasingly being suggested. Manufacturers are now more conscious of releasing CO2: hydrogen use in the manufacture of nitrogen fertilizers is becoming more common as a substitute for natural gas, and there has been a vast increase in the use of ammonia for the production of ammonium nitrate fertilizers.

acquired somewhat negative connotations and a mixed reputation.

This view has been formed as a result of excessive use, and its negative impact on soil properties and health. On one side of the argument, fertilizers provide essential nutrients for plant growth, however overdosing can lead to the disruption of the natural balance of the soil, leading to problems such as water contamination. Today, suppliers and fertilizer manufacturers are attempting to use fertilizer more efficiently, and are focusing on maintaining the balance of the soil nutrients for specific crop-soils.

Commercial or industrial fertilizers are supplied in liquid form as solutions, or in a solid form. Solid fertilizers are created through bulk blending, prilling or granulating. While bulk blending is essentially the mixing of crushed raw materials, prilled fertilizers are produced from a slurry solution countercurrent with the air stream. The granulation of fertilizer is a process where fertilizer particles become attached through agglomeration.

In general, prilled fertilizers are more applicable as a high concentration of ammonium nitrate or ammonium phosphate.

Furthermore, due to particle size and other physical properties, granular fertilizers are considered the most efficient for bagging and the application to soil by spread machines.

Granular fertilizer processes

Granulation technologies have vastly improved from the 1960s, when products were largely obtained through pan granulation.

The granulation pan took the form of a rotary disc where seed materials and slurries were added. Due to the disc’s rotation, the desired particle size was eventually obtained; however, this type of equipment had significant limitations in plant capacities.

As technology advanced, this type of fertilizer manufacturing was replaced by rotary drum granulation. In this process, seed products are added to a rotary drum together with a slurry, steam and raw materials. Due to the rotating effect, together with the temperature and humidity, granulated product is obtained with further drying/cooling steps.

Granulation based on slurry resulting from a reaction where heat and water is provided through a chemical reaction with a solution, is called chemical granulation. This is typical for diammonium phosphate granulation, calcium ammonium nitrate granulation, ammonium nitro-sulfate granulation, ammonium sulfate granulation or NPK, based on the ammonium nitrate or phosphate reaction.

Steam granulation is a process in which moisture is provided via steam or hot water, and is used as a binder, providing the temperature for granulation and binding recycles material, sulfuric acid, ammonia and specific grade urea solutions.

Granular fertilizers and sustainability

Granular fertilizers can be used for a wide range of formulations and raw materials combinations. Waste for other processes or even low quality slurries from mining could be used as raw material for fertilizers, with several fertilizer units used to remove waste or BLOWER GRANULATOR SCRUBBER

CONDENSER

STACK

GRANULATOR FAN

EX-DRYER ELEVATOR

FBC CYCLONES

SCREEN

RECIRCULATION PUMPS

SOLID RAW MATERIALS

MILLS

BLOWER DRYER CYCLONES WATER PHOSPHORIC ACID

RECYCLE CONVEYOR

FLUIDIZED BED COOLER

GRANULATOR BLOWER

LIQ. AMMONIA

PIPE REACTOR

SCRUBBER CIRCULATION TANK

Chemical granulation for NPK

DRYER

KETTLE SCRUBBER PUMPS

PIPE REACTOR RECIRCULATION FEED PUMPS PUMPS

FUEL (BURNER)

COATER

AIR

PRODUCT TO

CONDITIONING UNIT

STORAGE

Figure 1. Process flow diagram for NPK production by phosphate pipe reactor.

BLOWER EX-DRYER ELEVATOR

BLOWER DRYER BAG FILTER

DRYER CYCLONES

RECYCLE CONVEYOR

MELT RAW MATERIAL (OPTIONAL) SULPHURIC ACID AMMONIA

SOLID RAW MATERIALS

MILLS

BLOWER

GRANULATION BAG FILTER

FBC CYCLONES

SCREEN

FLUIDIZED BED COOLER (FBC)

BLOWER GRANULATOR DRYER

STEAM FUEL OIL

COATER

AIR

(BURNER)

CONDITIONING UNIT

PRODUCT TO STORAGE

Figure 2. Process flow diagram – NPK production for steam granulation.

36 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

Figure 1 shows a typical process flow diagram for NPK production based on phosphate slurry. In this process, the water and heat for granulation is mainly provided by a reaction between phosphoric acid and ammonia in the ‘pipe reactor’. To provide a stable process, the ammonia is fed in as gas; this takes advantage of the cooling due to the ammonia evaporation, and fluorides that evolved as a result of the reaction are removed.

Ammonia is fed to the vapouriser, meanwhile the acid is fed to the scrubbing system to adjust the required concentration, so the correct balance between water and heat is provided. The remaining nutrients are provided through other raw materials in solid form, that could include potash (chlorides or sulfates), urea, ammonium nitrate, ammonium sulfate, all types of solid wastes and inert, or micronutrients such as as magnesium oxide, zinc or borax. In order to maximise the heat recovered, the air used for cooling is recycled to the drier after the combustion chamber.

One of the advantages of this granulation process is that all liquid effluents can usually be reprocessed by recycling, although there may be exceptions where there is limited fluorine content in the final product. With gas effluents, most of the dust is firstly partly abated in a

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the recycled heating in the drying section. This type of granulation usually obtains very soft material.

Chemical properties can be improved by adding a small amount of sulfur and ammonia to the granulator and using the high exothermic reaction and sulfate formation to increase granulation temperature.

An addition of urea melt is a modification of this process, providing additional fluid phase and heat, however compatibility of other raw materials needs to be evaluated.

As the main contaminants of this process are solid particles, a system provided with a bag filter could be enough for contaminant abatement.

Figure 3. Granulator with pipe reactor. cyclone system, and finally scrubbers are used. The remaining part of the granulation process is the drying of the product by concurrent air flow in a rotary drum, to create a solid curtain to be dried. The air passes through the curtain, and after drying, the product needs to be selected by the appropriate screen size (double deck or two single deck screen). In the case of granulation by using ammonium nitrate solutions such as 26% N, 28% N or 33.5 % N, or some NPK grades based on ammonium nitrate, the reaction takes place before granulation. In this type of plant, the scrubbing system could be simplified as a bag filter system, and additives for granulation improvement could be necessary in some grades or combinations.

Granulation by steam addition

In the process shown in Figure 1, the heat and water necessary for granulation are mainly provided by steam and

Other general considerations for granulation processes

One of the main controversies with granulation is the type of cooler used for the final stage to obtain the required product temperature that minimises caking and absorption of water.

Several types of coolers can be used, such as fluidised bed coolers with air, rotary coolers with air, and bulk flow coolers with water. The type of coolers depends on the product, availability of services and site conditions. Fludised bed coolers could be considered the most efficient from a heat transfer point of view, as they allow hot air to be recycled after the combustion chamber for drying, However, in very hot and humid sites, this could require regular maintenance to avoid plugging of the perforate plate. Rotary coolers, despite having a robust design, are not so efficient, yet still suitable in all circumstances. Modern bulk flow coolers are less efficient for the recovery of energy, however they do provide efficiency when transferring heat.

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Seeking Success In agglomeration Klaus Wögerbauer, Agglotec GmbH, Austria, explains why precision is key to the success of the agglomeration process in the fertilizer industry.

T

he agglomeration process transforms powdered raw materials into spherical pellets ranging from 1 – 20 mm in size.

Whether it is fertilizers, recycled materials or iron ore, there are compelling reasons to convert powders into manageable pieces. When it comes to agglomeration, success rests upon precision, with each machine needing

39

to be meticulously designed to excel in the most challenging of industrial environments. Agglotec specialises in constructing tailored solutions to meet some of these

specific processing needs, which align with clients' distinct requirements and expectations.

The company has a close relationship with CEMTEC, who specialises in the design of equipment and systems for manufacturing facilities for the mineral processing industry. The partnership combines CEMTEC’s expertise in dry and wet grinding technologies with Agglotec’s proficiency in mixing and pelletising.

Pilot plant

Figure 1. Mobile granulation plant.

In order to develop custom-made systems, the required properties are defined in laboratories and technical centres. This data is the basis for further calculations and design parameters. Pilot plants are equipped with all the required process steps needed to evaluate the technical feasibility of agglomeration projects. Continuous test trials can be performed on a plough shear or intensive mixer, pelletising discs and a fluidised bed dryer, as well as a drum dryer.

The agglomeration process must often cater for different needs. A portfolio of the equipment used in agglomeration by Agglotec is summarised in this article.

Pelletising discs

Figure 2. Pelletising discs for mineral fertilizer production with a diameter of 5 m.

Figure 3. Turn key fertilizer grinding and granulation plant.

40 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

These discs are driven by a central drive unit, featuring a rotating disc mounted in a large diameter slewing bearing, typically around one third of the disc's diameter.

The discs optimise the supporting structure, making the rear of the machine, where the drive and bearing are located, easily accessible for maintenance. Companies such as Agglotec offer a range of options for different pelletising discs, including various lining materials, scraper types, and other accessories to cater to companies' specific needs.

Mixers

Mixers play a crucial role in the early stages of agglomeration. They are primarily used for raw material mixing and pre-humidification/ pre-granulation processes, which are essential precursors to pelletising. Achieving the required mixing quality hinges on factors like the properties of the raw materials.

The assortment of sizes and designs available for these mixers is adapted to industrial mineral applications, ensuring versatility and performance.

Agglotec has recently begun to cooperate with EIRICH, a company that is also specialised in granulating/pelletising. To combine the advantages of both companies, joint solutions are currently under development.

Dryers

Drying is a fundamental step in the preparation of bulk materials and granules across various industries. Dryers are necessary in processes such as drying raw material streams before downstream processes or gently drying green granules emerging from the granulating disc to achieve their final strength and properties.

Coolers

In the fertilizer industry, maintaining dry and stable granules is paramount. Understanding the significance of controlling product strength and temperature before storage is vital. Specialised floor cooling systems, meticulously fine-tuned for each specific process, ensure that the required parameters are met.

Mobile plants

Mobile plug-and-play plants capable of handling granulation capacities of up to 4 – 5 tph offer flexible and efficient granulation solutions. These fully functional plants encompass all necessary process steps, from raw material feeding to the drying and packaging of the granulate. Their mobility and versatility make them a convenient choice for various applications.

Case study

Currently, a dolomite pelletising plant is being handled for a German customer. In this project, Agglotec was contracted to build a 25 tph mixing, granulating and drying plant. There are some expertise needed in this project, which requires accurate planning and efficient execution. Since the customer has been in the market for approximately 30 years, there is a large customer base that must be continuously supplied with products. The new plant will be constructed in the same building as the old plant. This will require dismantling of the existing plant, which will result in a temporary loss of production.

The new granulation plant is designed to produce 25 tph of a high quality mineral based compound fertilizer.

Two Agglotec pelletising discs of the latest generation with a diameter of approximately 5 m, including some additional equipment such as special scrapers, wear lining and large angle range for flexible operating parameters, will be used in this project. The raw material is pre-moistened by two mixers, mixed with the binder (molasses-water mixture) and continuously fed to the two pelleting discs. The downstream of the granulation includes two multi-stage drum dryers, which will be supplied by CEMTEC. These gently dry the pellets to a residual moisture content of <1%. Subsequently, the dried granules are cooled down to ambient temperature in a belt cooler, screened and stored in the product silos.

Agglotec is responsible for the entire engineering process, including the dismantling of the existing plant, the supply of equipment and steel construction, the erection, and the commissioning of the new plant.

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Enhancing efficiency and performance Thomas Perry and Miles Andrews, QMax Industries, USA, discuss the pivotal role of industrial heating technologies in the production of fertilizers.

I

ndustrial heating technologies are integral to numerous sectors, playing a pivotal role in processes related to manufacturing, energy production, chemical processing, and the production of fertilizers.

Among the critical applications of these technologies is the heating of processes inside piping systems, tanks, and equipment such as valves, pumps, meters, nozzles, and strainers, etc. Efficient heating of these components is essential for maintaining process temperatures to prevent freezing and ensure processes can flow throughout the manufacturing facility. There are many methods of heating, depending on the temperatures required, environment, and what energy sources are available in each facility.

Process heating in fertilizer facilities

Piping, tanks, and equipment are crucial components of industrial processes that involve the production of fertilizers.

Heating these components can often become an afterthought when commissioning a new system.

However, the importance of heating many of the chemicals in these processes should not be overlooked, as it can serve several vital purposes and prevent critical issues down the road: 42

n Temperature maintenance: certain processes require specific temperatures to be maintained. Industrial heating prevents the cooling or freezing of fluids, ensuring that the intended processes flow smoothly in the piping, tanks, and equipment throughout the facility. Chemicals that need to be heated in production include urea, ammonia, and sulfur liquids and vapours. Liquid sulfur, for example, must be maintained in a very narrow temperature band because of its high freeze point of approximately 247˚F, but also its upper limit of 321˚F, where its viscosity spikes considerably. When it comes to a critical process like liquid sulfur, it is highly recommended to consult with a company who can run thermal calculations to ensure the correct heating technology is being used in each application. n Viscosity control: some fluids, such as heavy hydrocarbons and other chemicals, exhibit high viscosity at low temperatures. The relationship between viscosity and temperature is inversely proportional for all liquid processes. Heating these substances reduces viscosity, facilitating easier flow through piping, tanks, and equipment. n Prevention of corrosion: in industries working with corrosive substances, heating can prevent the buildup of corrosive liquids and solids on the inner walls of pipes, tanks, and equipment.

For example, sulfur vapour piping and the vapour area of a sulfur tank are two critical areas to heat to prevent sulfur from corroding the containment walls. The prevention of forming solids

43

in sulfur tanks can also prevent dangerous fires inside of the tank, playing a critical role in maintaining a safe work environment at a facility. nn Energy efficiency: when choosing the right heating technology for a specific application, energy availability and efficiency must be considered. For example, if a fertilizer plant already has access to steam, it likely makes sense to tap into this available resource and choose a heating technology that can utilise the benefits of steam. Energy efficiency is important today more than ever to reduce the energy consumption in the facility, and small changes today can make significant impacts for years to come.

Industrial heating technologies Steam tracing Steam tracing involves circulating steam through pipes or tubes alongside the main process line, providing indirect heat transfer to the product. It can be utilised in various industries, including the production of fertilizers. This method is commonly used to maintain the desired temperature of liquids flowing through pipes in cold environments. It can also be used for the rapid heating up of a process if heat-up time is critical for that application.

Steam tracing offers uniform heating and prevents heat loss, ensuring consistent process conditions. Aluminium enhancers can be used for even greater efficiency and performance, minimising the number of tracing passes needed and keeping infrastructure costs to a minimum. Steam tracing is normally the most efficient heating source when considering BTU to BTU efficiency. Just like steam tracing, glycol, water, or hot oil can also be used in tracing applications.

Electric heat tracing Electric heat tracing uses electric heating cables attached to pipes, tanks, and equipment. These cables generate heat when electrical current passes through them. This method can be controllable and efficient, allowing for accurate temperature maintenance.

Electric heat tracing is suitable for both freeze protection and low-temperature process heating in industries such as chemical processing and water treatment.

Fully jacketed heating systems Fully jacketed tanks, pipes, and equipment feature an outer shell that encases the main process component. The space between the jacket and the component surface is filled with a heating medium, which is often steam or thermal oil. Heat is transferred

conductively from the medium to the product, ensuring gradual and even heating. This technology is commonly used in the pharmaceutical, food and beverage, and chemical industries.

Concerns with using a fully jacketed system are cross-contamination of the process and heating medium, as well as infrastructure cost. While expensive, this method is a must for the most rapid heat-up of a process.

Infrared heating Infrared heating uses electromagnetic radiation to heat surfaces directly without raising the temperature of the surrounding air.

This method offers rapid and efficient heating, making it suitable for applications where quick temperature changes are required.

Sectors such as plastics processing, automotive manufacturing, and electronics production frequently rely on infrared heating for its speed and effectiveness.

Induction heating Induction heating relies on electromagnetic induction to heat electrically conductive materials, inducing a current that generates heat. It offers precise control, rapid heating, and is well-suited for localised heating applications. Induction heating finds uses in sectors including metal fabrication, aerospace, and electronics.

Flameless catalytic heating Flameless catalytic heaters employ a catalyst to promote combustion without the presence of a visible flame.

This technology provides uniform heating and stands out for its energy efficiency. Applications span various industries, including remote power generation, heat production in oil and gas operations, and environmental tasks such as soil remediation.

A significant advantage of this heating method is its independence from the electrical grid, making it suitable for remote or off-grid locations.

Conclusion

Industrial heating technologies are essential for maintaining the efficiency, safety, and quality of processes involving piping, tanks, and equipment. From steam tracing to flameless catalytic heating, each method offers distinct advantages suited to specific applications. The choice of heating technology depends on factors such as temperature requirements, energy availability, industry regulations, and cost considerations. As industries continue to evolve, efficient heating technologies will remain crucial for enhancing productivity and sustainability across various sectors.

The core of fertilizer plant reliability

Benjamin Wooten, Atlas Copco, USA, explains how plant maintenance and reliability are central to the successful running of a fertilizer plant.

P

lant maintenance and reliability are the central cogs that not only keep plants running, but also provide customer satisfaction and help create shareholder value. In the fertilizer industry, maintenance and reliability are focused on the principal equipment employed, which is often a plant’s gas compressors.

Gas compressors can be employed in a number of different roles, such as for air compression to separate the elements from air and later synthesise urea, and feed gas compression to supply to process vessels and consumers. They can also be used in steam compression for boiling solutions, syngas or recycle compressors, and refrigeration compressors to provide process cooling.

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To provide high quality, reliable equipment to keep plants producing urea, ammonia, and other fertilizer products, compressor manufacturers must strictly adhere

to API (American Petroleum Industry), ANSI (American National Standards Institute), and customer standards from the applications phase to the aftermarket phase, extending through the full life of the equipment.

Calibrated instrumentation and health monitoring

In the early stages of engineering each compressor, the manufacturer recommends high levels of calibrated instrumentation for machine health monitoring. Each compressor system is designed and specified to meet not only the customer’s required process conditions, but also API and ANSI standards and specifications. Several subsystems are highly specified, including the gearbox vibration and temperature systems, process-gas temperature and pressure systems, lubrication-oil system temperatures and pressures, and seal-gas system pressures, temperatures, and flows.

By specifying high levels of instrumentation and monitoring, the plant is able to monitor the compressor’s health by each system and take preventative measures to ensure the machine remains healthy and running. Local gauges and transmitters with indication screens can also be specified so that those in the field are able to monitor compressor conditions at the compressor unit.

The commissioning phase

Figure 1. Plant air compressor’s stage 3 housing and impeller prior to completing the machine overhaul.

Figure 2. The plant air compressor during the overhaul process.

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As the plant transitions to the commissioning phase, the compressor supplier deploys its highly trained commissioning engineers to the requisite site in order to carry out proper installation, cold commissioning, and hot commissioning and startup. The compressor units are checked for compliance with proper preservation, foundation installation, and alignment and connection of process and auxiliary systems during the construction phase.

This phase is critical for several fundamental reasons that revolve around ensuring that the compressors and their subsystem parts are installed according to vendor and API standards so they can run for their entire expected mechanical lifetime.

During the cold commissioning phase, auxiliary systems are confirmed as fully completed, clean, and under power.

All communications between the machine, motor control centre, and DCS (distributed control system) are verified, and all alarm and shutdown setpoints are verified as functional to ensure machine protection under operation.

Finally, once the system is ready for live runs, it is time for the hot commissioning phase.

This includes completing a range of tests, such as a drive motor solo test run, unloaded mechanical run, closed-loop surge testing, and online process integration. By optimising

machine controls and tuning to exact process conditions at each plant, key players in fertilizer production can achieve maximum efficiency and production through optimised gas performance.

Aftermarket solutions

It is also the role of compressor manufacturers to provide several strategies to drive exceptional plant maintenance and reliability with aftermarket solutions. There are several elements that contribute to ensuring the success of a plant and its operations: custom comprehensive preventative maintenance plans are one important element of this, as are the supply of OEM (original equipment manufacturer) parts, OEM services, extensive spare parts, and parts storage solutions. A further key element is providing engineered upgrades and redesigns as and when required.

The Atlas Copco preventative maintenance programmes, for example, are the company’s strategies for optimising plant reliability and health. By taking proactive, prepared, and calculated action to maintain the machines on a calculated interval basis with gradually more extensive maintenance activities, the reliability and lifetime of a plant’s compressors should be significantly improved.

There is a whole host of advantages in following a maintenance plan, with the main benefits outlined.

Cost effectiveness A periodic, fixed, calculated interval of servicing keeps maintenance costs down, and when known in advance, this allows for easy cost forecasting. This then leads to lower administrative costs and fewer unbudgeted events. The plans

cover all required parts and a field service technician to assist in the completion of the maintenance activities.

Scheduling optimisation The service scheduling can be coordinated according to shutdowns and outages in the plant schedule to minimise downtime and production losses.

Compressor lifetime Regular maintenance significantly lowers the risk of deterioration and ensures the compressor’s mechanical lifetime will last longer. It is the role of the specialised technicians to notice and replace poorly working parts, and to log extensive observations for areas to closely monitor in the upcoming years of maintenance.

Reliability, quality, and productivity Regular and well-performed maintenance ensures the reliability of the compressor and the quality of compressed gas. Such maintenance lowers the risks of a possible loss of quality of production or production loss resulting from a breakdown, which in turn helps to boost profitability and protect shareholder value.

Preventative maintenance-plan visit schedules are typically multifaceted and include a semi-annual inspection, annual service intervention, service interventions with oil changes every three years, minor equipment overhauls every five years, and major equipment overhauls every 10 years.

They might typically look something like the following: nn Semi-annual inspections: inspecting and recording various operating parameters across the compressor auxiliary

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systems, such as confirming oil levels are still within specification and all transmitters and gauges show normal operating conditions. nn Annual inspections: taking oil samples, replacing various filters, and visually inspecting impellers. nn Three-year inspections: annual services and an oil change to ensure the machine does not exceed useful lubrication lifetime. nn Minor overhaul maintenance intervals: further services such as bearing and seal replacement, guide-vane overhauls, and extensive inspections of the gearbox and auxiliary system parts.

nn Major overhaul maintenance: essentially, a full overhaul of all compressor core internal materials and auxiliary systems, which sets the machine up for an additional 10 years of service life.

By stocking large amounts of capital spare parts, such as rotors, bearings, seals, and drive gears, plants can ensure preparedness for any breakdown that may occur.

Moreover, storage solutions, such as nitrogen purge containers, can also improve plant performance and reliability, ensuring parts are kept in a clean, dry, climate-controlled environment and are in perfect condition immediately up to installation in the machine.

Continuous evaluation

Figure 3. Plant air compressor’s stage 3 impeller after the impeller was replaced and the diffuser and housing were fully inspected and cleaned.

Engineered solutions are another set of key strategies that help provide optimised reliability to customers. A compressor manufacturer should be continuously evaluating, innovating, and optimising its designs and systems. By evaluating mechanical lifetimes of various parts and systems and keeping updated with current technologies, part lifetime and thus machine lifetime can grow by leaps and bounds.

For example, one innovative solution that can be offered is to replace roller bearings in various oil-system parts with sleeve bearings that receive pressurised oil feed. Roller bearings can wear especially after long, repeated use, but by implementing sleeve bearings, the amount of wear is significantly reduced, and consequently, the mechanical life of the machine can be significantly improved.

With controls systems vastly improving in the age of rapidly developing technology, innovation in controls operations is very important. By connecting and establishing communications between the compressors and the plant DCS with historic data-storing capabilities, plants can have the capability to trend several different data points and evaluate past readings to observe any deterioration in machine performance that could point to slow parts wear. Manufacturers can also implement several different control strategies. Examples are redundant transmitters and transmitter voting to ensure critical processes can remain running if there are no shutdown conditions present but a transmitter fails.

Conclusion

Figure 4. Plant air compressor fully assembled after completion of the overhaul service.

48 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

This article demonstrates that plant maintenance and reliability are central to the successful running of fertilizer plants. Whether employed in air compression, feed gas compression, steam compression, or refrigeration compression, the maintenance and reliability of a plant’s gas compressors are vital.

Each compressor system is designed and specified to meet the customer’s required process conditions, replete with calibrated instrumentation for machine health monitoring, and expert commissioning and aftermarket services. This in turn provides customer satisfaction and helps create shareholder value.

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

Phil Bureman and Dr. Craig Myers, Nalco Water, USA, discuss the advantages of a comprehensive UAN corrosion management programme.

L

iquid urea ammonium nitrate, known as UAN, has gained traction among farmers worldwide for good reason. As a water-based nitrogen fertilizer, UAN offers farmers convenience and efficacy in its application. In the field, UAN fertilizer enables farmers to precisely manage its application to crops. In addition, UAN offers growers three forms of nitrogen – nitrate (NO 3) for fast uptake, ammonia (NH3) for intermediate crop growth and urea for long term nitrogen nutrition. UAN is typically sold as a 32% nitrogen content product (45% ammonium nitrate, 35% urea, and 20% water), referred to as UAN32.

Moreover, UAN is versatile. It blends easily with other liquid fertilizers such as phosphate, micronutrients, herbicides and pesticides. This versatility reduces the number of passes a farmer must make to apply nutrition to their crops. UAN also avoids the serious inhalation hazards posed by anhydrous ammonia, and unlike dry ammonium nitrate prills, UAN poses low risk of explosion.

But UAN does have a potential drawback – especially if not manufactured properly. UAN solution is corrosive, and it must be treated with a quality corrosion inhibitor, specifically formulated for UAN. In addition, the inhibitor must be applied at the correct treat rate and be properly blended with the UAN. Storage tanks, conveyances (pipelines, rail cars and barges), and agricultural equipment are vital to fertilizer businesses, enabling the storage, transportation and application of UAN. UAN can corrode carbon steel, which may jeopardise the structural integrity of equipment and lead to potential leaks or catastrophic failures (Figure 1).

UAN's composition and corrosive nature

UAN contains urea, ammonium nitrate, water, and a small amount of ‘excess’ ammonia. Of these, ammonium nitrate (AN) is the more corrosive component. Although ammonium nitrate has pronounced corrosive behaviour, the ‘excess’ ammonia in the solution can mitigate its effect. The term ‘excess’ refers to the ammonia concentration above the amount needed to form ammonium nitrate and urea. To maintain the solution's integrity and reduce its corrosive tendencies, the excess ammonia is typically kept above 0.01% by weight, or 100 ppm. However, for the best results, the concentration should be 0.02 – 0.05% by weight, or 200 – 500 ppm. Excessive ammonia levels can lead to odour complaints during spray application. The optimal pH for UAN is between 7.0 and 8.0. A pH value below this range will

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A comprehensive guide to UAN corrosion management

51

significantly increase the risk of damaging corrosion, particularly if the solution is exposed to high temperatures.

Challenges arise when ammonia levels diminish and pH levels drop. This is especially true when temperatures rise. A typical scenario that highlights the issue occurs when a rail car, once filled with UAN, gets emptied. This action leaves a thin layer of UAN on the side walls of the car, as well as a heel of UAN on the bottom. As the rail car gets emptied, an influx of ammonia-free

Figure 1. Collapsed storage tank due to catastrophic corrosion damage.

Figure 2. Example of severe pitting corrosion of a

tank bottom and weld joint (where proper mechanical, operational, and chemical corrosion mitigation procedures were not followed).

air can swiftly transfer the ammonia out of the liquid phase and into the vapour space above. As a result, the pH drops rapidly, which then amplifies the corrosiveness of the UAN. Without a robust corrosion inhibitor in the UAN, rust build-up can occur at the bottom of the rail car. This kind of corrosion, created by dwindling ammonia levels, is called 'thin film surface corrosion.'

The resulting corrosion sludge leads to under deposit corrosion on the rail car or tank bottoms, which can result in severe pitting if an effective corrosion inhibitor is not utilised.

Pitting can threaten the structural integrity of storage tanks and rail cars. The potential for localised corrosion is particularly targeted to weld joints and the heat affected zone around the weld joints (Figure 2).

The corrosion described here can be demonstrated in a simple experiment. A 1010 carbon steel corrosion coupon was placed in a glass jar filled with just enough UAN32 (without a corrosion inhibitor) to cover it. After sealing the jar and leaving it in sunlight for seven days in high temperatures, no additional corrosion formed. However, after opening the jar for three hours and resealing it for the night, a thick uniform iron oxide (rust) layer formed on the steel by morning (Figure 3).

The corrosion occurred because ammonia escaped from the thin film of UAN on top of the coupon when the jar was open, resulting in a drop in pH levels. The corrosion product buildup (sludge) creates ideal conditions for localised under deposit corrosion to form. Inspections of tank floors readily show the importance of under deposit corrosion. Areas with solids accumulation, such as the bottom edge of lap welds, can show severe pitting, while the remaining plate surfaces remain without corrosion.

Another important property of UAN is the AN/urea ratio, as it pertains to both corrosion potential and fertilizer performance. UAN contains approximately 80% dissolved solids. If the ratio of AN and weight % urea is between 1.2 and 1.4, UAN32 starts to freeze at approximately 30˚F. However, the freeze point can rise significantly if the UAN is blended outside of the desired ratio. When this happens, salts of either ammonium nitrate or urea will form and drop out of solution. These salts can cause several problems: nn The AN and urea salts create powerful corrosion cells where they settle, which leads to severe pitting corrosion. nn The remaining solution loses nitrogen content, so it does not deliver the required nutrition. nn The remaining weak solution becomes much more corrosive: §§ UAN28 is about 20% more corrosive than UAN32. §§ UAN16 is about 35 – 40 times more corrosive than UAN32.

The fundamentals of UAN corrosion management

While UAN storage and transportation entails corrosion risks, fertilizer producers can manage the risks by focusing on the related mechanical, operational, and chemical factors.

Mechanical measures to minimise corrosion risk

Figure 3. Thin film corrosion developed on coupon after loss of ammonia.

52 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

To enhance the lifespan of storage infrastructure and reduce the corrosive impact of UAN, a proactive mechanical approach is necessary: nn Regular maintenance: drain and clean large storage tanks at a minimum of every five years. This routine

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effectively removes the corrosion sludge that can lead to detrimental under deposit or pitting corrosion. nn Avoid UAN accumulation: ensure no small puddles or heels of UAN are left in storage tanks over prolonged periods. Stagnant UAN can lose its excess ammonia, causing acidic conditions and intensified corrosion.

Be especially careful not to leave puddles of dilute UAN on metal surfaces (Figure 4). nn Optimise flow: install a recirculation header.

Corrosion sludge buildup at the tank's base may lead to corrosive cell pockets. Many UAN producers counteract this by installing a recirculation pipe across the tank’s diameter. Outfitted with 45° angled outlet spigots, this type of pipe encourages constant UAN movement, drastically reducing pitting corrosion. Thin film corrosion sludge sitting at a tank bottom is bad, but when that same sludge does not move, the impact can be devastating.

nn Temperature regulation: aim to keep tank temperatures within the 10 – 47°C (50 – 110°F) range.

High temperatures can speed up chemical reactions and the corrosion rate.

Operational measures to minimise corrosion risk For effective UAN corrosion management, operational actions like the following are key: nn Monitor pH and ammonia: consistently gauge the pH of incoming UAN and watch for proper ammonia levels – both are pivotal quality indicators.

Fertilizer distributors may want to ask their supplier to include excess ammonia levels on the certificate of analysis for each load of UAN nn Understand UAN: know the AN to urea ratio – it signifies when UAN begins to salt out. This number is generally included on the certificate of analysis. From a storage perspective, UAN32 boasts an edge over UAN28 because it is less corrosive by nature. nn Monitor corrosion: use corrosion coupons at essential areas, such as the tank's mid-andbottom levels to monitor long term corrosion.

Utilise two sets – one for short-term quarterly assessments and another for annual reviews.

Remember that under normal conditions, significant corrosion can take years to occur, but a severe pH upset can damage a tank within days. nn Prioritise quality: choose high-grade UAN from trustworthy producers.

Chemical measures to minimise corrosion risk

Figure 4. Example of corrosion that occured in a rail car heel with poorly inhibited UAN.

Figure 5. UAN process dynamics and pH excursions.

54 | WORLD FERTILIZER | NOVEMBER/DECEMBER 2023

The right chemical measures can act as the first line of defense against UAN corrosion: nn Inhibitor insight: investigate the exact corrosion inhibitor type and amount in a UAN. Different UAN sources may use diverse inhibitors, so be wary when combining them.

Chemical corrosion inhibitors all have a minimum effective dose. If UAN is combined from different producers that may use different inhibitors, the blend may not contain enough of any inhibitor to be effective. nn Which inhibitor and how much? Ask a UAN supplier for proof of performance information or their reason for choosing a particular corrosion inhibitor. Make sure the UAN supplier is using a well-regarded and high performing corrosion inhibitor designed specifically for use with UAN. In addition, ask what measures the UAN supplier is taking to ensure they are always adding the recommended amount of corrosion inhibitor.

Corrosion tests run by the inhibitor supplier to prove material efficacy should be carried out with control over excess ammonia, temperature, and pH, to ensure reproducible and relevant results.

The benefits of digital monitoring

The process of manufacturing UAN by making and blending ammonia, ammonium nitrate and urea is extremely complicated. Typically, these complex processes are managed effectively and carefully, but occasional upsets can lead to variations in both quality and corrosivity. Continuous monitoring of key corrosion parameters, such as inhibitor levels, corrosion rates, pH levels and temperature, help mitigate potential challenges in asset protection and UAN product quality. Nalco Water has developed its 3D TRASARTM technology for UAN corrosion management to provide 24/7 monitoring across all four of these critical parameters.

Along with regular on-site technical support from Nalco Water sales-and-service engineers, 3D TRASAR technology for UAN corrosion management helps fertilizer producers manufacture a high quality and minimally corrosive UAN product. This technology uses advanced chemical innovation and specially designed monitoring devices to detect problematic parameters and determine how to optimise performance.

Moreover, its internet-connected communication capabilities ensure that stakeholders stay informed in real time. The technology for UAN corrosion management works in concert with Nitrosolve inhibitor formulations.

One of the strengths of 3D TRASAR technology for UAN corrosion management is its ability to offer deep insights into UAN process dynamics and its correlation with corrosion rates. For instance, in Figure 5, two pH excursions with corresponding high corrosion rates were identified. In the first excursion, after receiving the alarm, operators discovered a faulty nitric acid valve causing bursts of acidic UAN. In this case, the valve was fixed, and the pH fluctuations in the mix tank were buffered in the main storage tank.

The second excursion occurred as a plant began shut-down procedures. The plant was unaware that the shutdown procedures caused negative effects until 3D TRASAR technology was implemented.

After implementing the system and receiving 24/7 monitoring, the plant identified the challenges and adjusted their practices to reduce corrosion disturbances.

If these acidic events were not identified and addressed promptly, they could have dramatically increased corrosion in storage tanks and rail cars. A single major stress event can lead to significant corrosion damage.

Conclusion

UAN offers benefits to farmers as a versatile and efficient nitrogen solution. However, its corrosive nature must be properly managed to ensure long asset life for infrastructure like storage tanks, rail cars, pipelines and agricultural equipment. The complex nature of UAN demands a multifaceted approach to corrosion management, encompassing mechanical, operational and chemical strategies. These include regular maintenance, consistent monitoring, and the use of robust, proven corrosion inhibitors. Regular on-site support by engineers and advanced technologies for UAN corrosion management can offer fertilizer producers an effective strategy to manage UAN corrosion proactively.

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