PHOSPHATE FERTILIZERS
Phosphate fertilizers play a critical role in the world’s agriculture and grain production. There are several types of phosphate fertilizers, including MAP, DAP, NPK, SSP and GTSP. The phosphate-fertilizer industry uses different chemical processes to manufacture phosphoric and fluosilicic acids and different end products. Each step in these processes generate off-gases and particulate matter (PM), including:
- Reaction
- Filtration
- Clarification
- Gas Cooling
- Evaporation
- Granulation
- Drying/cooling
- Product storage/handling
Major contaminants for air pollution in the industry include fluorides (HF and SiF4), ammonia, ammonium phosphates and dust. The fertilizer industry is continually challenged to meet and exceed current and future standards.
Kimre is recognized as a world-leader in the control of gaseous emissions from phosphate-fertilizer production facilities. For more than 40 years, Kimre-technology has supplied gas-cleaning systems that have achieved the lowest emission levels in the industry. Kimre’s SXF™ (Semi-crossflow) Technology incorporates the unique characteristics of its KON-TANE® Tower Packing and B-GON® Mist Eliminator to provide stage-wise separation and removal of contaminant gases and particulate matter to meet any level of emission limits while recovering valuable products to return to process. While providing the lowest emission levels, Kimre technology also offers other significant advantages to other technologies,
including:
- Less Susceptible to fouling
- Easy to Clean
- Able to be retro-fitted and modified to meet ever-changing emission standards
Kimre has over 100 installations world-wide and in every stage of the fertilizer manufacturing process, including:
- Rock Drying
- Fume Scrubbers
- Fluosilicic Acid (FSA) Scrubbers
- Vacuum scrubbers
- Ammonium phosphate, single and triple superphosphate scrubbers
Let Kimre’s experienced engineering staff and industry specialists review your process application and allow us to custom design the most optimal, cost-effective separation solution based upon your needs, limitations, and requirements.
Use Case for the Phosphate Fertilizer Industry
Background
- Phosphate Fertilizer Production
- Importance: Essential for improving soil fertility and boosting crop yields.
- Production Methods:
- Wet Process: Utilizes sulfuric acid to produce phosphoric acid.
- Dry Process: Employs thermal processes to produce phosphoric acid.
- Other Techniques: Includes newer, advanced methods for improved efficiency.
- Key Products:
- Superphosphate (SSP): Single superphosphate.
- Triple Superphosphate (TSP): Highly concentrated phosphate fertilizer.
- Diammonium Phosphate (DAP): A high-efficiency phosphate fertilizer.
- Monoammonium Phosphate (MAP): Another effective phosphate fertilizer.
- NPK: Compound fertilizers with a mix of Nitrogen (N), Phosphorus (P), and Potassium (K).
Challenges
- Pollutants
- Particulate Matter: Essential for improving soil fertility and boosting crop yields.
- Fluorides: Emission of harmful fluorides.
- Phosphoric Acid Mist:Acid mist released during processing.
- Regulatory Compliance
- Emissions Control: Adhering to stringent environmental standards for air quality.
- Dust and Mist Management: Addressing new regulations on particulate and mist emissions.
- Optimization Needs
- Optimization Needs: Improving reaction efficiencies and reducing energy consumption.
- Waste Minimization: Reducing the production of waste and byproducts..
Solutions
- Dust Control Systems
- High-Efficiency Dust Collectors: Capture airborne particulates effectively.
- Electrostatic Precipitators: Remove fine dust particles from emissions
- Fluoride and Acid Mist Control
- Scrubbers: Use solutions to absorb or chemical reactions to neutralize fluoride emissions.
- Mist Eliminators: Capture and condense phosphoric acid mist.
- Process Optimization
- Reaction Efficiency: Technologies to enhance the efficiency of chemical reactions.
- Energy Reduction: Systems designed to lower energy consumption and operational costs.
Benefits
-
- Compliance: Ensures adherence to environmental regulations, minimizing legal risks.
- Efficiency: Improves overall process efficiency, reducing operational costs.
- Protection: Extends equipment lifespan by mitigating the corrosive effects of pollutants.
- Environmental Impact: Decreases environmental footprint through effective waste and emission management.
Implementation
- Recommended Products
- Dust Collectors: Advanced models designed for high-efficiency particulate removal.
- Mist Eliminators: Specialized equipment for capturing acid mist.
- Scrubbers: Tailored to handle specific pollutants such as HF, SiF4, NH3 and particulates.
- Custom Solutions
- Tailored Systems: Customized to address the unique emission profiles and process needs of each facility.
- Integration
- Seamless Integration: Incorporate solutions into existing systems with minimal disruption to operations.
- Operational Continuity:Ensure that new systems enhance efficiency without causing operational delays.