Abstract SYMPHOS 2011

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BACKGROUND Granulation of phosphatic and complex NPK fertilizers, attempts to mechanically bind, blend and compact fine crystalline components into individual spherical granules. This process inherently, is inefficient due to the acicular nature of the crystalline materials and the mechanism of simultaneous crystallization and solidification of such materials, which occurs during the granulation process. These phenomena lead to poor product quality ( high porosity, low crush strength, non uniform shape ) and also lead to inefficiencies in process ( high quantity of fines & recycle, heavy dust generation. Filtra’s work on granulating aids NPTUFF, was aimed at developing a suitable chemical additive, which at low dosages could address the above physical and chemical phenomena that lead to difficulties in granulation, thereby improving product quality and increasing granulation efficiency. These improvements are applicable to various grades of NPK made from phosphatic fertilizers. METHODOLOGY Filtra’s R&D team evaluated various materials to alter the mechanism of crystallization of the N,P,K components, to aid uniform blending and binding of the components. Re-crystallization behavior of fertilizer components was studied under an optical microscope and a distinct change in crystal structure was observed on addition of the granulating aid. NPTUFF series of granulating aids is an outcome of such studies. NPTUFF was then tested in field trials at an 800 TPD, NPK production facility, producing granules by steam granulation. The granulating aid was dosed into the granulator through the fresh water feed line, at a rate of 0.6 – 0.7 Kg per ton of final product. Observations were made on the following criteria : (1) Finished product quality : Crush Strength, Granule Size Distribution, Sphericity (2) Production parameters : Production rate, Recycle rate, Dust Generation OBSERVATIONS Re-Crystallization Study : The microscopic images of crystal growth taken with and without addition of the granulating aid show a distinct change in the nature of crystal growth. Raw materials used in NPK fertilizers are known to have a tendency to form acicular crystals. These are long needle shaped crystals which tend to grow linearly when unhindered. As a result a mass formed of such crystals tends to have crystal planes that have crystals which are directionally aligned. Such a structure is easily fractured under load. The crystal behavior with addition of granulating aid is markedly different. The crystals lose their linear growth tendency and the material appears more polycrystalline with smaller, more polygonal crystals. Such structures have considerably higher crush strength and tend to form more uniform surfaces. 126 USE OF GRANULATING AIDS FOR ENHANCED PRODUCTIVITY OF PHOSPHATE FERTILIZERS WS3 -1 FILTRA CATALYSTS & CHEMICALS LTD.
Re-cyrstalllized structure of a crystalline fertilizer component, without addition of granulating aid. The mass shows several crystal planes unidirectionally alligned. Re-cyrstalllized structure of a crystalline fertilizer component, with addition of granulating aid. The mass shows a more polycrystalline structure with uniformly distributed and non alligned crystals. FIELD TESTS Finished product quality : Crush Strength of granules produced with addition of NPTUFF was found to be 30 – 40% higher than the strength of granules produced without granulating aid. The granules also visually appeared to be more spherical and the final product size distribution was found to be as per specifications Production Efficiency improvement : · Average ratio of Recycle to Production rate decreased from 5.7 without granulating aid to 4.02 during the course of the trial, indicating a productivity increase of over 25% · Recycle showed a declining trend with lower fluctuation during course of trial. ( ref graph ) · Production showed a rising trend during course of trial. ( ref graph ) · Visual presence of dust had decreased at granulator exit and dryer exit. · Solid content measured in scrubber water of de-dusting system was found to be lower by 8 – 10% after extended period of operation using granulating aid 127
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Dear participants, On behalf of the
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EXTRACTION Mansour ASRI, Chercheur
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PLENARY LECTURES KEYNOTES MINING PH
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10 L’INNOVATION TECHNOLOGIQUE DAN
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NANOSTRUCTURE PROCESSING OF ADVANCE
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II - KEYNOTES 15
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LES MÉTHODES GÉOPHYSIQUES DE SUBS
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LES PHOSPHATES, LE LITHIUM ET LE ST
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material engineering concepts can b
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PHOSPHATE FERTILIZER PRODUCTION FRO
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ENVIRONMENTAL ISSUES The plants tha
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FOOD SECURITY AND THE ROLE OF FERTI
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30 CONCEPTION ET RÉALISATION DES T
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LE SURFACE MINING: UN STANDARD INTE
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34 LA STRATIGRAPHIE SEQUENTIELLE OU
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- Calcul de Ressources et Étude É
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38 I
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40 BENEFICIATION OF INDIAN LOW GRAD
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42 Johan SIIRAK, AkzoNobel Surface
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Pour améliorer davantage la qualit
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Results REE elements recovery is ex
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48 Marie VOGNSEN HALDOR TOPSOE A/S,
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This contribution gives an overview
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52 Marten WALTERS KEMWorks Technolo
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PH-O-04 B. Messnaoui : Laboratoire
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at a considerable cost and the wate
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phosphate recovery will be determin
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The residence time of product in a
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62 IMPROVING PHOSPHORUS USE EFFICIE
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PH-O-16 Todd Hutchinson Director of
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Wet process phosphoric acid is fed
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68 Louis Paul Irwin, ArrMaz Custom
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70 FLUOROSILICIC ACID RECOVERY FROM
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VII - ENVIRONMENT & SUSTAINABLE DEV
Page 75 and 76: infiuence, 2 - average, 1 - less es
Page 77 and 78: downstream weir at the end of the p
Page 79 and 80: Pascale Compain Bertin Technologies
Page 81 and 82: WATER MANAGEMENT IN PHOSPHORIC ACID
Page 83 and 84: Suppression of plumes at the exhaus
Page 85 and 86: key pollutants including heavy meta
Page 87 and 88: VIII - INDUSTRIAL MANAGEMENT 87
Page 89 and 90: BELGHITI ALAOUI Mohamed OCP, MOROCC
Page 91 and 92: IX - MATERIALS & NEW PRODUCTS 91
Page 93 and 94: • La supervision des réparations
Page 95 and 96: FLUORINE RECOVERY TECHNOLOGY (INTRO
Page 97 and 98: HCl regeneration CaCl 2 + H 2 SO 4
Page 99 and 100: proposées comme la télomérisatio
Page 101 and 102: PRODUCTION OF GRANULAR AMMONIUM SUL
Page 103 and 104: X - POSTERS 103
Page 105 and 106: La série phosphatée étudiée s
Page 107 and 108: A SIMULATION PACKAGE FOR THE PHOSPH
Page 109 and 110: FABRICATION DES SUPERPHOSPHATES SSP
Page 111 and 112: LA SILICIFICATION DES PHOSPHATES MA
Page 113 and 114: ANALYSIS OF THE LIKELY SUPPLY SIDE
Page 115 and 116: Many REE are well known as luminesc
Page 117 and 118: OPERATION OF SURFACE MINER: RETROSP
Page 119 and 120: Harris Jack, President, VIP Interna
Page 121 and 122: D.Oussi OCP - MAROC PROJET DE RENOU
Page 123 and 124: XI - WORKSHOPS 123
Page 125: De par ses activités dans le secte
Page 129 and 130: Pour les professionnels : - les eng
Page 131 and 132: Pour des engrais de forme aplatie o
Page 133 and 134: Coatings The underlying principle o
Page 135 and 136: HOW IS BINDING ACHIEVED? Trace Elem
Page 137 and 138: MODÉLISATION THERMOCINÉTIQUE DES
Page 139 and 140: Garret Palmquist (MECS-DuPont), Sen
Page 141 and 142: The ideas emerged from looking at h
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