PRESENTED BY, NIGHILA V PAUL S2 MTECH,GEC THRISSUR

INTRDUCTION
Population increase->More fertilizers & chemicals
Heavy pollution caused by factories near residential

areas. Pollution due to petroleum industries-> 3 stages -crude oil production -transportation -refining operation Refineries also cause thermal pollution of water bodies

POLLUTION CONTROL IN FERTILIZER INDUSTRIES

FERTILIZER INDUSTRIES
NITROGENOUS FERTILIZERS PHOSPHATIC FERTILIZERS NP OR NPK(COMPLEX)
Ammonia plant Conversion to urea, ammonium sulphate, nitro lime etc Nitric acid, phosphoric acid, sulphuric acid plants Nitrohosphate production

All the above mentioned processes

FERTILIZER INDUSTRY CLASSIFICATION

Classification(5 types)
1.Ammonia & urea plants
2.Ammonia, urea, & ammonium nitrate plants 3. Ammonia, urea, phosphoric acid & complex fertilizers. 4. Ammonia, urea, ammonium sulphate & H2so4. FLUORIDES X X X pH AMMONIACAL N2 POLLUTANTS PLANT CATEGORY 1 X X 2 X X 3 X X 4 X X 5 X X

SUSPENDED SOLIDS
CHROMIUM X X

X
X

X
X

X
X

5. Ammonia, urea, phosphoric acid,

nitric acid, sulphuric acid and complex fertilizer plant

EFFLUENTS FROM FERTILIZER INDUSTRY

POLLUTANT Avg Conc. in waste 732 614 1.6 NA 77 15 source Effects

Ammonia Urea Arsenic Oil Phosphate Fluoride

NH3 & urea plants Urea plants Gas purification Plant Gas compressor houses Phosphoric acid and complex plants Scrubber effluents in phosphoric acid manufacture

Toxicity to aquatic life, eutrophication Toxicity of NH3 after hydrolysis, eutrophication Poison, black foot disease, affects plants & crops Prevents o2 dissolution, floats & forms slicks in water Causes algal blooms Dental & skeletal fluorisis, effects fish hatching

PLANTS CONSIDERED
AMMONIA PLANT AMMONIUM SULPHATE

PHOSPHORIC ACID
COMPLEX FERTILIZER PLANT

I.
1.

AMMONIA PLANT EFFLUENTS

REMOVAL OF CARBON Carbon formed by scrubbing the soot particles with water Effects choking of pipelines -blocks sunlight & o2 supply in water & disturbs aquatic life Treatment-mixing with oil & separation by gravity -pelletization -vaccum filtration

Vacuum filtration method

Carbon cake

condensor

receiver Vaccum filter

pump

pump

Vaccum pump

2.OIL REMOVAL Oil seperator followed by adsorption by coke->oil content <10mg/l 3.HYDROGEN SULPHIDE REMOVAL a) combustion of H2S ->SO2->sulphuric acid b) Converted to sulphur by claus process 4.NITROGEN-WASH TAIL GAS REMOVAL a)Flare the gas b) Catalytic reduction of Nox c) For low presure steam generation & heating

AMMONIUM SULPHATE AND PHOSPHORIC ACID PLANT EFFLUENTS

1. SOLID EFFLUENT

Important solid product->gypsum But Gypsum may contain fluorine By hemi-hydrate dihydrate/ dihydrate- hemihydrate process -> pure gypsum-> uses of gypsum->cement industry ->as soil conditioner phospho-gypsum can also be used to make sulphuric acid by mueller- Kuehne process

2. LIQUID EFFLUENTS Acidic & Fluoride bearing chemicals. Neutralized & precipitated using slaking unit 3.GASEOUS EFFLUENT main component-> Fluorine Fluorine removed by scrubbing with silicic acid followed by cyclone seperator & mist collector Hydro Fluoro silicic acid is used in the manufacture of cryolite

COMPLEX FERTILIZER PLANT

1. LIQUID EFFLUENTS
Integrated treatment plant with slaking unit for lime slurry preparation. effluent+lime(pH 7-8)->lime(pH11)-> clariflocculator Effluent moves downwards and settles down Settled sludge discharged to slude lagoons & dried. Nitric acidulation process-> solid-chalk A cement plant can run on chalk produced.

2.GASEOUS EFFLUENTS
2.1) PARTICULATE MATTER
INDUSTRIAL PLANT Single super phosphate plants Triple super phosphsate plants Urea palnts(existing) Urea plants(new) ALLOWABLE LIMIT 500mg/m3 4kg/tonne 6kg/tonne 2kg/tonne

Causes mist formation in sulphuric acid plants Mist eliminated by mist eliminator(Two Stages) Other methods of separation of dust->

Other methods of separation of dust->

Gravity settling Traps impingement separators louvres Cyclone Separators Wet collectors Packed towers Gravity scrubbers Floating Bed Scrubbing Electrostatic precipitators

2.2)SULPHUR DIOXIDE
Absorbed in two stages

-primary absorber-so3 removed->removed gas again pass through converter -so3 is again absorbed in secondary stage 2 stage scrubbing scrubbing solution ammonium sulphite & bisulphite

2.3)OXIDES OF NITROGEN
absorbed in water
Catalytic abatement(forms CO and cyanides)

 Extended absorption of Nox in water(high P & low

temp)
NOx absorbing solutions-NaOH, NaNO2, NH4NO3
Products should be scrubbed by chemicals.

Masar process-extended absorption in water & urea

Molecular seives Adsorption