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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
sten 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


sten Andersson

1. Yaras 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

sten Andersson

1. Yara is the worlds largest AdBlue producer

4 Yara Production Plants centrally


located for the core markets

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Germany (Brunsbttel)

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

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.
Yaras experience,
know-how &
expertise in Europe

Sinoferts production
capacity & distribution
network in China

Purico aims to be the leading AdBlue solution provider in China


through Air1 concept.

sten 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.

sten Andersson

2. Multiple Contamination Risks in the AdBlue


supply infrastructure
AdBlue
production
Plant & Storage

Possible Contamination Risk

Land
Transport

Filling of IBC,
Drums & Cans

Intermediate
Storage

Road
Transport

Customer
X

X
Transport
Truck
Rail
Ship

X
Land
Transport

Storage
Terminal

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Road
Transport

Road
Transport

Storage at X
Customer
site

3.1 Anti- Contamination


Measures in AdBlue
Production
Primary production from
Urea Hot melt
Secondary production by
dissolving of solid Urea

sten Andersson

3.1 Principal Drawing AdBlue Production from


Urea Hot Melt
Batch Control

Batch Control

Closed system
In principal no
contamination risk
Quality Control
Conductivity

Storage Tank
Demineralised Water

Urea Hot melt

Quality Control
Density
Temperature

Static Mixer

Quality Control
Example:
Concentration
Pressure
Temperature
Free Ammonia

Cooling

Filtration
(Optional)

Loading station

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Loading Pump

Storage Tank

Yaras Urea Plant, Brunsbttel, Germany

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3.1 There is low risk of contamination with


AdBlue produced from Urea Hot melt

Main contamination risks

Control Measures

Unstable Urea production

Control of process
parameters
Stop of AdBlue production
at unstable conditions
Batch analysis

sten Andersson

3.2 AdBlue Production from Urea Prills,


Dissolving increases the risk of contamination
Batch
Control System
Concentration
Temperature

Control
Storage
Tank
AdBlue

Batch
Control

Screw
Conveyor

Batch
Control

Storage
Tank
AdBlue

X
Mixer
Hopper
Urea
Big Bags
1 000 kg

Quality Control
Conductivity

Storage
Tank
Demin.
Water

Transfer Filter
pump

X
X
Demineralised
Water Production

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Transfer
pump

Loading
Station

Filter Loading
Pump

Possible Contamination Risk

Dissolving, Mixers and Hopper

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Dissolving; Storage of Urea Big Bags and IBC

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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

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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

3.3. Anti
Contamination
Measures for Bulk
Logistics

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3.3 AdBlue Tanks and Loading area for Trucks

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3.3 Ship loading Tank and loading area

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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

sten Andersson

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

3.4 Anti Contamination


Measures for Filling of
IBC, Drums and Cans

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3.4 Types of Packaged Product

IBC,1000 liter

Drum, 200 liter

Can, 5-10-20 liter

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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

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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

3.5 Anti Contamination


Measures for
Dispensing Equipment

sten Andersson

3.5 Examples of IBC and Drum pumps

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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

sten Andersson

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

3.5 Examples of Customer Dispensing equipment

Dry Break Filling


connection

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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

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Control Measures
Equipment designed for
AdBlue use
Magnetic Filling nozzle
Dry Break Filling coupling
Warning signs, pictograms
Operating manuals
Training of operators
Regular Maintenance

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

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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

sten 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

sten Andersson

Thanks for your attention


sten Andersson