AdBlue production - Integer Research

insight
beyond
numbers
2010 AdBlue ®
Diesel Emissions Conference
& AdBlue ® Forum Asia 2010
March 23 - 25, 2010. Westin Hotel, Beijing, China

Measuring AdBlue® quality and understanding
requirements of AdBlue® infrastructure
Östen Andersson, Director Technical Support & HESQ
Environmental & Speciality Products
Diesel Emissions Conference & AdBlue Forum Asia 2010

1. Short Introduction
2. Where does the contamination
risk lie in the AdBlue supply
chain
3. Anti-Contamination Risk
Measures Taken in
AdBlue production
Bulk Logistics
Filling of IBCs, Cans and
Drums
Dispensing Equipment
4. VDA Quality Audit Programme
Östen Andersson

1. Yara’s AdBlue solution : Air1
• The leading AdBlue producer in the
world
• We offer a complete solution to meet the
fleet operators, OEMs and oil majors
individual requirements under the brand
Air1 around the world, covering:
– Reagent under the name AdBlue or
DEF
– Storage and handling equipment, of
different sizes
– Telemetry and services
Östen Andersson

1. Yara is the world’s largest AdBlue producer
4 Yara Production Plants centrally
located for the core markets
• Germany (Brunsbüttel)
• The Netherlands (Sluiskil)
• France (Le Havre)
• Italy (Ferrara)
• Unique back-up position and
“safe harbor” for product
availability
• Strategic Air1 locations for local
client needs, including dedicated
terminals
• Over 120 distribution depots
across Europe
Östen Andersson

1. Joint Venture between Yara and
Sinofert – Purico in China
• Yara and Sinofert formed a joint venture, Purico, to provide
DeNOx solutions, including AdBlue, in China.
• Based in Qingdao, Purico will spearhead Air1 marketing in
China.
Yara’s experience,
know-how &
expertise in Europe
Sinofert’s production
capacity & distribution
network in China
Purico aims to be the leading AdBlue solution provider in China
through Air1 concept.
Östen Andersson

1. Sinofert – a strong partner
• Major businesses include the production, import, export,
distribution, wholesale and retail of fertilizer raw materials and
products, as well as research and development and services in
the field of fertilizer-related business and products.
• With 2010 distribution centers spanning across 26 provinces,
Sinofert is the largest integrated supplier of fertilizers in China.
• Sales volume 16 mill mt, Sinofert owned stakes in 13 fertilizer
manufacturers with a total capacity of 10 million tonnes, of which
more than 2.5 million tons are urea.
Östen Andersson

2. Multiple Contamination Risks in the AdBlue
supply infrastructure
AdBlue
production
Plant & Storage
X
X
Possible Contamination Risk
Filling of IBC,
Drums & Cans
X
Land
Transport
Intermediate
Storage
X
Road
Transport
Customer
X
Transport
Truck
Rail
Ship
Land
Transport
X
Road
Transport
X
Storage
Terminal
X
Road
Transport
X
Storage at
Customer
site
X
Östen Andersson

3.1 Anti- Contamination
Measures in AdBlue
Production
Primary production from
Urea Hot melt
Secondary production by
dissolving of solid Urea
Östen Andersson

3.1 Principal Drawing AdBlue Production from
Urea Hot Melt
Closed system
In principal no
contamination risk
Batch Control
Batch Control
Quality Control
Conductivity
Storage Tank
Storage Tank
Demineralised Water
Quality Control
Density
Temperature
Urea Hot melt
Quality Control
Example:
Concentration
Pressure
Temperature
Free Ammonia
Static Mixer
Cooling
Filtration
(Optional)
Loading station
Loading Pump
Östen Andersson

Yara’s Urea Plant, Brunsbüttel, Germany
Östen Andersson

3.1 There is low risk of contamination with
AdBlue produced from Urea Hot melt
• Main contamination risks
– Unstable Urea production
• Control Measures
– Control of process
parameters
– Stop of AdBlue production
at unstable conditions
– Batch analysis
Östen Andersson

3.2 AdBlue Production from Urea Prills,
Dissolving increases the risk of contamination
Batch
Control
X
X
Hopper
Screw
Conveyor
Control System
Concentration
Temperature
X
Mixer
Batch
Control
Storage
Tank
AdBlue
Batch
Control
Storage
Tank
AdBlue
Urea
Big Bags
1 000 kg
Quality Control
Conductivity
X
Demineralised
Water Production
Storage
Tank
Demin.
Water
X
Transfer
pump
Transfer
pump
Loading
Station
Filter
Filter
Loading
Pump
Possible Contamination Risk
Östen Andersson

Dissolving, Mixers and Hopper
Östen Andersson

Dissolving; Storage of Urea Big Bags and IBC
Östen Andersson

3.2 Multiple contamination risks for AdBlue
produced from Dissolving of solid Urea
• Main contamination risks
– Solid Urea quality
– Demineralised water quality
– Not dedicated equipment
– Cross contamination with
other products or ambient
conditions
• Control Measures
– Incoming control of solid
Urea
– On line control of water
quality
– Control of process
parameters
– Dedicated equipment
– Batch analysis
– Routines to handle off spec.
product
Östen Andersson

3.3. Anti
Contamination
Measures for Bulk
Logistics
Östen Andersson

3.3 AdBlue Tanks and Loading area for Trucks
Östen Andersson

3.3 Ship loading Tank and loading area
Östen Andersson

3.3 Loading and unloading of AdBlue is an area
with potential risks of contamination
• Main contamination risks
– Not dedicated transport
vehicles
– Not dedicated transfer
equipment
– Materials in contact with
AdBlue not compatible
– Open handling of AdBlue
• Control Measures
– Dedicated transport
vehicles
– Inspection before loading
and unloading
– If not dedicated, a certificate
of cleaning is mandatory
including information about
3 last products
– Inspection after loading
– Retention samples
– Sealing of all openings
Östen Andersson

3.4 Anti Contamination
Measures for Filling of
IBC, Drums and Cans
Östen Andersson

3.4 Types of Packaged Product
• IBC,1000 liter
• Drum, 200 liter
• Can, 5-10-20 liter
Östen Andersson

3.4 Filling of IBC, Drums and Cans hold also
contamination risks
• Main contamination risks
– Not dedicated filling
equipment
– Materials in contact with
AdBlue not compatible
– Returned IBC
– Not cleaned
– Reconditioned
– Mix with off-spec product
– Mix with wrong product
– Filled in “uncontrolled conditions”
– Emptying with dirty equipment
• Control Measures
– Dedicated filling equipment
– Drums and Cans always
one way package
– Closed IBC with CDS or
Micro Matric coupling and
dip tube
– Inspection procedures for
returned IBC
– Sealing of openings after
filling
Östen Andersson

3.5 Anti Contamination
Measures for
Dispensing Equipment
Östen Andersson

3.5 Examples of IBC and Drum pumps
Östen Andersson

3.5 Pumps for IBC and Drums risks of
contamination
• Main contamination risks
– Not dedicated equipment
– also used for other liquids
– Materials in contact with
AdBlue not compatible
– Wrong handling by operator
– Filling in wrong truck tank
• Control Measures
– Dedicated equipment
– Equipment designed for
AdBlue use
– Closed IBC with CDS or
MicroMatic coupling and dip
tube
– Warning signs, pictograms
– Operating manuals
– Training of operators
Östen Andersson

3.5 Examples of Customer Dispensing equipment
Dry Break Filling
connection
Östen Andersson

3.5 Risks for Dispensing Equipment at
Customer sites
• Main contamination risks
– Materials in contact with
AdBlue not compatible
– Contamination during filling
– Wrong handling by operator
– Filling in wrong truck tank
• Control Measures
– Equipment designed for
AdBlue use
– Magnetic Filling nozzle
– Dry Break Filling coupling
– Warning signs, pictograms
– Operating manuals
– Training of operators
– Regular Maintenance
Östen Andersson

4. What is the VDA Audit Programme?
• Verband der Automobileindustrie e.V. (VDA) is the owner of the name
AdBlue® and to use the name you need a license
• VDA has together with the main AdBlue producers and distributors in
Europe developed an Audit Programme
Minimum requirements on Management Systems
in AdBlue® production and distribution chain,
following the ISO standards 22241, part 1 – 3
• The audits has just started in Europe and Yara is one of the first licensees
that has been audited
Östen Andersson

4. The VDA Audit Programme
• The Audit Programme are divided in 7 sections
– Basic Requirements
– Production process
– Production equipment
– Sampling and testing
– Documentation of test results and certification
– Administration, tracking, batch traceability and labelling
– Handling, transport and storage
Östen Andersson

5. Summary
• There are multiple contamination risks in the AdBlue supply infrastructure
• The contamination risks could be reduced by relevant control measures
– Follow the guidelines and recommendations in ISO 22241 part 1 to 3
– Written procedures for all steps in the supply chain
– Training of all parties involved in the supply chain
– Use the right materials for all equipment in contact with AdBlue
– Use dedicated equipment for production, transport and dispensing
– Audit all parts of the supply chain at regular intervals
Östen Andersson

Östen Andersson
Thanks for your attention