AMMONIUM NITRATE / NITRIC ACID
Ammonium nitrate prilling towers, neutralizers, evaporators, and nitric acid plants often require the removal of solid and liquid particles. These particles lead to unwanted emissions and high opacity at the exhaust stack. Kimre B-GON® Mist Eliminators and Fiber Bed Filters can effectively reduce emissions and provide cost-effective control of ammonium nitrate and nitric acid emissions.
Prill Towers
In prill towers, Kimre™ Fiber Bed Mist Filters are traditionally used at the top of the towers, where air is exhausted. These filters work by coalescing sub-micron mist into larger droplets that drain from the filter, allowing the ammonium nitrate mist to be recovered and recycled back into the process.
Granulators
Poor gas distribution through ammonium nitrate granulator scrubbers can cause considerable droplet and particulate entrainment. Knitted mesh and chevron separators do not always handle maldistribution of the gas stream effectively. B-GON® Mist Eliminator Pads can be installed to improve efficiency and reduce pressure drop. Typically, B-GON® Mist Eliminator Pads are designed for 99% collection efficiency of all particulates and droplets greater than 1 micron in diameter.
Evaporators/Neutralizers
Steam produced by the exothermic reaction is separated from the ammonium nitrate solution and vented from the reaction vessel. Additional steam is generated during the concentration of the solution, a necessary step for converting it to solid prills. Both streams of steam carry ammonium nitrate mist that must often be removed before the steam can be reused in the process or disposed of.
Kimre can provide B-GON® Mist Eliminators and Fiber Bed Filters, along with complete SXF™ Semi-Cross Flow Scrubber systems. Our equipment is designed to meet the specific requirements of the stream being treated, achieving 99% removal of 10-micron and larger particles, and over 99.9% removal of sub-micron particles.
Nitric Acid
Metal knitted mesh mist eliminators corrode quickly. Fluoropolymer knitted mesh used in nitric acid service tends to cold flow over long periods, eventually compacting and failing to handle the liquid load and gas velocity required. This results in entrainment, leading to severe downstream corrosion and product loss. Kimre B-GON® Mist Eliminators made from ETFE and PFA provide the highest level of corrosion resistance, and their unique interlaced design ensures long-term stability and performance.
Use Case for the Ammonium Nitrate / Nitric Acid Industry
Background
- Ammonium Nitrate and Nitric Acid Production
- Importance: Ammonium nitrate and nitric acid are crucial for producing fertilizers and explosives, significantly impacting agricultural productivity and mining operations.
- Production Methods:
- Ammonium Nitrate Production: Involves neutralizing nitric acid with ammonia to produce ammonium nitrate. The ammonium nitrate can then be converted to fertilizer by granulation or prilling processes.
- Nitric Acid Production: Utilizes the Ostwald process, where ammonia is oxidized to produce nitric oxide (NO), which is further oxidized to nitrogen dioxide (NO2). The nitrogen dioxide is then absorbed in water where it converts to nitric acid.
- Key Products:
- Ammonium Nitrate (NH₄NO₃): A widely used fertilizer and explosive component.
- Nitric Acid (HNO₃): A key industrial chemical used in various applications including fertilizer production, explosives, and chemical synthesis.
Challenges
- Pollutants
- Nitrogen Oxides (NOx): Emissions from the high-temperature oxidation of ammonia during nitric acid production.
- Ammonia Emissions: Vapors released during the production and handling of ammonium nitrate.
- Particulate Matter: Dust and granules generated during the production and handling of ammonium nitrate.
- Process Water Contaminants: Residual chemicals and byproducts in wastewater.
- Regulatory Compliance
- Emissions Control: Adhering to stringent environmental regulations for air quality, including NOx and ammonia emissions.
- Waste and Water Management: Compliance with regulations for waste treatment and water discharge.
- Process Efficiency
- Optimization Needs: Enhancing the efficiency of chemical reactions and reducing energy consumption.
- Waste Minimization: Reducing byproducts and optimizing resource use.
Solutions
- Emission Control Technologies
- Scrubbing Systems and Mist Eliminators: Capture and remove NOx, ammonia vapors, dust and particulates from gas streams.
- Fiber Bed Filters: High-efficiency cylindrical filters designed to capture fine particulates and aerosols, ensuring cleaner emission
- Dust and Particulate Management
- High-Efficiency Dust Collectors: Capture airborne particulates from production processes.
- Electrostatic Precipitators: Remove fine dust particles from emissions.
- Nitrogen Oxide (NOx) Control
- Selective Catalytic Reduction (SCR): Utilizes catalysts to reduce NOx emissions by converting them into nitrogen and water.
- Low NOx Burners: Advanced burners designed to minimize NOx formation during combustion.
- Process Optimization
- Reaction Efficiency: Technologies to enhance the efficiency of chemical reactions and increase yield.
- Energy Reduction: Systems designed to lower energy consumption and operational costs through improved process management.
Benefits
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- Compliance: Ensures adherence to environmental regulations, reducing legal and financial risks.
- Efficiency: Enhances overall process efficiency, leading to cost savings and improved productivity.
- Protection: Extends the lifespan of equipment by mitigating the effects of pollutants and corrosive substances.
- Environmental Impact: Minimizes the environmental footprint through effective management of emissions, dust, and waste.
Implementation
- Recommended Products
- Wet Scrubbers with Mist Eliminator Filters: Advanced mesh-type media designed for efficient removal of NOx, ammonia, and particulate matter.
- Fiber Bed Filters: Specialized filters for capturing fine particulates and improving air quality.
- Custom Solutions
- Tailored Systems: Custom-designed to address specific emission profiles and process needs of ammonium nitrate and nitric acid facilities.
- Integration
- Seamless Integration: Incorporate solutions into existing systems with minimal disruption to production.
- Operational Continuity: Ensure that new systems enhance efficiency and environmental compliance without causing operational delays.
This use case history outlines the key aspects of emission control and process efficiency in the production of ammonium nitrate and nitric acid, providing a comprehensive approach to addressing challenges and implementing effective solutions.
