| | STATE-OF-THE-ART FOR THE PRODUCTION OF FERTILISERS WITH |
| | 0,58 | | MB | REGARD TO THE IPPC-DIRECTIVE |
| | 86 | | stron |
| | 5940 | | ID | Federal Environment Agency Austria |
| | 2003 | | rok |
| | TABLE OF CONTENTS |
| | SUMMARY AND CONCLUSIONS 9 |
| | ZUSAMMENFASSUNG UND SCHLUSSFOLGERUNGEN. 14 |
| | 1 INTRODUCTION. 21 |
| | 1.1 Reference to the IPPC-Directive . 21 |
| | 1.2 Object of the Study 22 |
| | 2 GENERAL INFORMATION 23 |
| | 2.1 Types of Mineral Fertilisers. 23 |
| | 2.2 Economic Situation . 24 |
| | 2.2.1 Consumption and Production of Mineral Fertilisers in Europe 24 |
| | 2.2.2 Consumption and Production of Mineral Fertiliser in Austria 26 |
| | 2.3 Starting Materials for Fertiliser Production . 28 |
| | 2.3.1 Phosphate Rock. 28 |
| | 2.3.2 Nitric Acid. 30 |
| | 2.3.3 Sulphuric Acid 30 |
| | 2.3.4 Ammonia 30 |
| | 2.3.5 Carbon Dioxide (CO2) 32 |
| | 2.3.6 Other Raw Materials 32 |
| | 3 SSP, TSP AND MN-FERTILISER (MIXED ACID ROUTE) 33 |
| | 3.1 Production Processes . 33 |
| | 3.1.1 Production of Single Superphosphate (SSP) . 33 |
| | 3.1.2 Production of Triple Superphosphate (TSP). 34 |
| | 3.1.3 Production of Multi-Nutrient (MN) Fertilisers by the Mixed Acid Route . 34 |
| | 3.2 Resources 35 |
| | 3.2.1 Input/Output Levels 35 |
| | 3.2.2 Energy . 36 |
| | 3.2.3 Water Demand. 36 |
| | 3.3 Emissions to Air and Waste Gas Treatment 37 |
| | 3.3.1 Main Pollutants and Emission Sources 37 |
| | 3.3.2 Waste Gas Treatment 37 |
| | 3.3.3 Reference Plant – Donauchemie GmbH 38 |
| | 3.4 Waste Water Emissions and Waste Water Treatment. 39 |
| | 3.4.1 Main Pollutants and Emission Sources 39 |
| | 3.4.2 Waste Water Treatment and Measures for Reduction of Waste Water Emissions. 39 |
| | 3.4.3 Reference Plant – Donauchemie GmbH 40 |
| | 3.5 Wastes and Residues 41 |
| | 4 State-of-the-art for the Production of Fertilisers |
| | 4 FERTILISER PRODUCTION BY THE NITROPHOSPHATE ROUTE. 42 |
| | 4.1 Processes for the Production of MN-fertilisers and Conversion of Calcium Nitrate Tetrahydrate |
| | (CNTH) . 42 |
| | 4.1.1 Digestion of Phosphate Rock. 43 |
| | 4.1.2 Crystallisation and Filtration of Calcium Nitrate Tetrahydrate (CNTH) 43 |
| | 4.1.3 Conversion of Calcium Nitrate Tetrahydrate (CNTH) . 44 |
| | 4.1.4 Neutralisation/Evaporation of the Nitrophosphoric Acid 44 |
| | 4.1.5 Spherodizer Granulation 44 |
| | 4.2 Resources 45 |
| | 4.2.1 Raw Material Input for the Nitrophosphate Route. 45 |
| | 4.2.2 Energy and Cooling Water Demand 46 |
| | 4.3 Emissions to Air and Waste Gas Treatment 47 |
| | 4.3.1 Main Pollutants and Emission Sources 47 |
| | 4.3.2 Waste Gas Treatment 47 |
| | 4.3.3 Reference Plant – Agrolinz Melamin GmbH. 48 |
| | 4.4 Waste Water Emissions and Waste Water Treatment (MN-fertiliser and CNTH conversion) 52 |
| | 4.4.1 Main Pollutants and Emission Sources 52 |
| | 4.4.2 Waste Water Treatment and Measures for Reduction of Waste Water Emissions 52 |
| | 4.4.3 Reference plant – Agrolinz Melamine GmbH . 53 |
| | 4.5 Waste and Residues 55 |
| | 5 AMMONIUM NITRATE AND CALCIUM AMMONIUM NITRATE. 56 |
| | 5.1 Production Processes . 56 |
| | 5.1.1 Production of Ammonium Nitrate (AN) by Neutralisation of HNO3 and NH3 . 56 |
| | 5.1.2 Production of ammonium nitrate by the conversion of by-product CNTH from the ODDA |
| | process 56 |
| | 5.1.3 Production of Calcium Ammonium Nitrate (CAN) Fertilisers 57 |
| | 5.1.4 Finishing Processes. 58 |
| | 5.1.5 Production of Technical Grade Ammonium Nitrate 58 |
| | 5.2 Resources 59 |
| | 5.2.1 Input/Output Levels 59 |
| | 5.2.2 Energy and Cooling Water. 60 |
| | 5.3 Emissions to Air and Waste Gas Treatment 61 |
| | 5.3.1 Main Pollutants and Emission Sources 61 |
| | 5.3.2 Air Pollution Abatement and Waste Gas Treatment. 61 |
| | 5.3.3 Reference Plant – Agrolinz Melamine GmbH. 62 |
| | 5.4 Waste Water Emissions and Waste Water Treatment. 64 |
| | 5.4.1 Main pollutants and emission sources 64 |
| | 5.4.2 Measures for the Reduction of Waste Water . 64 |
| | 5.4.3 Reference Plant – Agrolinz Melamine GmbH. 64 |
| | 6 UREA 66 |
| | 6.1 Production Processes . 66 |
| | 6.1.1 SNAM-Progetti Ammonia and Self Stripping Processes. 67 |
| | 6.1.2 Stamicarbon CO2-Stripping Process 68 |
| | 6.1.3 Evaporation and Solid Formation Processes 68 |
| | 6.1.4 Urea – Ammonium Nitrate (UAN) Solutions . 69 |
| | 6.2 Resources and Energy 69 |
| | 6.3 Emissions to Air and Waste Gas Treatment 69 |
| | 6.3.1 Main Pollutants and Emission Sources 69 |
| | 6.3.2 Waste Gas Treatment 70 |
| | 6.3.3 Reference Plant – Agrolinz Melamine GmbH. 70 |
| | 6.4 Waste Water Emissions and Waste Water Treatment. 72 |
| | 6.4.1 Emission Sources and Main Pollutants 72 |
| | 6.4.2 Emission Reduction Measures. 72 |
| | 6.4.3 Reference Plant – Agrolinz Melamine GmbH. 72 |
| | 7 DIFFUSE AND NON-PROCESS SPECIFIC EMISSIONS 74 |
| | 7.1 Emissions to Air. 74 |
| | 7.2 Waste Water Emissions. 74 |
| | 7.3 Wastes 74 |
| | 8 APPENDICES 75 |
| | 8.1 Legislative Regulations for the Production of Fertilisers in Austria 75 |
| | 8.1.1 Emissions to Air . 75 |
| | 8.1.2 General Licensing Requirements . 75 |
| | 8.1.3 Ambient Air Concentration and Air Quality Management Plans 75 |
| | 8.1.4 Wastewater Regulations 76 |
| | 8.1.5 Provisions according to the Seveso II-Directive . 79 |
| | 8.1.6 Product Regulations on Fertilisers in Austria 79 |
| | 8.2 BAT Related Work of International Organisations – The Helsinki Convention . 80 |
| | 8.2.1 Wastewater Discharges . 81 |
| | 8.2.2 Emissions into the Atmosphere 82 |
| | 8.2.3 Waste (Phosphogypsum). 82 |
| | 8.3 List of Abbreviations Used 83 |
| | 8.4 Conversion Factors for Nutrients . 83 |
| | 9 REFERENCES 84 |