Section: CRUNS Features

Casale’s fluid bed granulation tail gas treatment for nitrogen-based fertilizer employs double temperature scrubbing technology, which handles the granulator exhaust air separately from the cooler exhaust air. The technology can combine dust removal with ammonia abatement in the same installation to meet strict tail gas limitations such as 10 mg/Nm3 for dust and 10 mg/Nm3 for ammonia. Ken Monstrey of Casale explains the key features of the Casale scrubbing technology.

IPCO has expanded its Rotoform range with the high yield XG model for granulation of suspensions. Designed for applications such as sulphur bentonite and urea mixes as well as NPK and other fertilizers, this new Rotoform model can convert solid-containing product melts into consistent, high quality pastilles from 2-4 mm diameter.

Green ammonia production facilities can be situated in remote areas with access to often fully off-grid renewable power supply. This article examines plant concepts and discusses the challenges and solutions for these plant architectures. Through a case study, an efficient and innovative methodology to compare options and optimise the sizing of the plant is presented. The methodology addresses the intermittency of the power production, the flexibility limits of the main process units, and the costs of investment and operation, using proprietary techno-economic dynamic simulation software, Odyssey.

Demand for nitrates has rebounded after a difficult period following the dislocations caused by the war in Ukraine, with UAN in particular seeing rapid growth. Technical ammonium nitrate is also growing on the back of increased mining activity.

Innovative catalyst systems from Heraeus and Łukasiewicz Research Network – New Chemical Syntheses Institute contribute to reach climate goals by reducing N2 O emissions during nitric acid production. Dr Uwe Jantsch and Jens Hesse of Heraeus Precious Metals report on the process performance results achieved for N2 O reduction in nitric acid production using FTC gauze systems and iron oxide based secondary catalysts.

A round-up of current and proposed projects involving non-nitrogen synthesis gas derivatives, including methanol, synthetic/substitute natural gas (SNG) and gas- and coal to liquids (GTL/CTL) plants.

A look at the safety challenges that face developers of ammonia-powered shipping vessels before it can become used more widely as a low carbon fuel.

Casale, Saipem, Stamicarbon & Toyo Engineering Corporation showcase a selection of innovative technologies that have recently been brought to the market.

The reliability of primary reformers is a key issue for syngas plants. Quest Integrity describes the damage mechanisms and material limitations that impact the reliability of reformer outlet systems and the improvements that may be implemented.

Industrial plants using synthesis gas at elevated temperatures risk metal dusting attack on the equipment, which are typically made of steels or Ni-based alloys. Parameters which impact the metal dusting risk are discussed and factors affecting the material selection and processing are described. One important focus is surface preparation, showing that grinding (40 grit) improves the metal dusting resistance compared to glass bead blasting and brushing. The surface treatment outweighs the impact of welds or the manufacturing route.