Innovative High-Speed Drum Granulation Technology: a flexible, cost-effective and energy efficient technology for production of value-added fertilizers Natalia Kargaeva, Head of international affairs department
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Innovative High-Speed Drum Granulation Technology: a flexible, cost-effective and energy efficient
technology for production
of value-added fertilizers
Natalia Kargaeva, Head of international affairs department
| Steering the Fertilizer Industry through Challenging Times
| Steering the Fertilizer Industry through Challenging Times
Advantages of fortified fertilizers’ application
| Steering the Fertilizer Industry through Challenging Times
Benefits of fortified fertilizers for fertilizer producers
1
2
3
| Steering the Fertilizer Industry through Challenging Times
HSDG performances
Parameter Value
Pilot HSDG Commercial HSDG
Capacity, TPD 0.5 – 2.5 120 – 240
Air consumption, t/t 1.3 – 2.0 1.3 – 2.0
Water consumption (t=22-28 °C), t/t12.0 – 15.0 12.0 – 15.0
Power consumption, kWh ~100 ~35
Size, m 7 х 9 х 8 30 х 36 х 30
| Steering the Fertilizer Industry through Challenging Times
HSDG performances
Maximum current capacity – 240 TPDNew design of HSDG, capacity 480 TPD,
is under development
| Steering the Fertilizer Industry through Challenging Times
Pilot HSDG units
| Steering the Fertilizer Industry through Challenging Times
Research work
| Steering the Fertilizer Industry through Challenging Times
Laboratory-scale HSDG: tests and samples production
| Steering the Fertilizer Industry through Challenging Times
Samples production
| Steering the Fertilizer Industry through Challenging Times
HSDG for production of fortified fertilizers based on the customer’s recipes,
capacity – 2,4 TPD at Petrovietnam Fertilizer & Chemicals Corporation, Vietnam
| Steering the Fertilizer Industry through Challenging Times
PFD of the pilot HSDG unit at Petrovietnam
UREA GRANULES
WATER
NUTRIENTS
AIR FOR SPRAYING
CW
CW
AMB. AIR
CONDENSATE
ATM..
SEEDS
FINISHED PRODUCT
AMB. AIR
| Steering the Fertilizer Industry through Challenging Times
Fortified fertilizers produced at Petrovietnam
| Steering the Fertilizer Industry through Challenging Times
The fortified fertilizers produced at Petrovietnam
contain the following nutrients
| Steering the Fertilizer Industry through Challenging Times
Project on the pilot High Speed Drum Granulation unit for production
of fortified urea-based fertilizers, capacity – 100 kg/h at QAFCO, Qatar
Urea with ammonium sulfate
Urea with sulfur
2 production
methods
2 production
methods
The following fertilizers can be produced on the pilot HSDG unit:
| Steering the Fertilizer Industry through Challenging Times
PFD of the pilot HSDG unit for urea
with ammonium sulfate production
UREA MELT FROM EXISTING UREA UNIT
AMMONIUM SULFATE
SULFUR
AIR FOR SPRAYING
COOLING WATER
COOLING WATER
AMBIENT AIR
FINISHED PRODUCT
AMBIENT AIR
CONDENSATE
ATM.
SEEDS
| Steering the Fertilizer Industry through Challenging Times
PFD of the pilot HSDG unit for urea with sulfur production
UREA MELT FROM EXISTING UREA UNIT
AMMONIUM SULFATE
SULFUR
AIR FOR SPRAYING
COOLING WATER
COOLING WATER
AMBIENT AIR
FINISHED PRODUCT
AMBIENT AIR
CONDENSATE
АТМ.
SEEDS
| Steering the Fertilizer Industry through Challenging Times
PFD of the pilot HSDG unit for urea coated with sulfur
UREA MELT FROM EXISTING UREA UNIT
AMMONIUM SULFATE
SULFUR
AIR FOR SPRAYING
COOLING WATER
COOLING WATER
AMBIENT AIR
FINISHED PRODUCT
AMBIENT AIR
CONDENSATE
АТМ.
SEEDS
| Steering the Fertilizer Industry through Challenging Times
Properties of granules produced in the pilot HSDG
Chemical analyses
Nitrogen content Wt % 34 45
Sulfur content Wt % 0,8 30
Biuret content Wt % - 0,95
Water content Wt % - 0,3-0,4
Particle-size distribution
2-4 mm Wt % 92 (70*) -
< 1 mm Wt % - 1 (5*)
Static strength kgf/granule 2,5 (1*) -
| Steering the Fertilizer Industry through Challenging Times
Pilot HSDG units
Petrovietnam (Vietnam). The pilot HSDG unit was
successfully started up. The trial batches of the fertilizers
were produced. The construction of commercial-scale
HSDG unit is being discussed with the Customer.
QAFCO (Qatar). The project at the
commissioning phase.
| Steering the Fertilizer Industry through Challenging Times
HSDG for prilled urea fattening, total capacity – 500 TPD
at Kemerovo Azot, Russia
Undersize prills (smaller than 2 mm) after the prilling tower are fattened (spherodized) in the HSDGs. Result: no undersize prills, finished product with improved properties.
| Steering the Fertilizer Industry through Challenging Times
PFD of the HSDG unit for urea fattening
TO DISCHARDE
CLASSIFIER CLASSIFIER
HSDG
FINISHED PRODUCT COOLER
AIR
HSDG
FAN
DUST SCRUBBER
FINISHED PRODUCT
FAN
FAN
AMB. AIR
STEAM
CON.STEAM
CON.
SOLUTION TANK
STEAM
CON.
UREA MELT
CONDENSATE
MIXING
UREA SOL TO EVAPORATION
CW CW
WATER TANK
CW
| Steering the Fertilizer Industry through Challenging Times
Properties of granules produced in the HSDG
at Kemerovo Azot
Parameter Value
Particle size distribution, %:
>1 mm
- 1-4 mm
- 2-4 mm
- residue on the screen, mesh 6 mm
1 max.
98 min.
92 min.
N/A
Static strength, kgf/granule 0,8 min.
Product temperature, °С 50 max.
| Steering the Fertilizer Industry through Challenging Times
3D Design
| Steering the Fertilizer Industry through Challenging Times
Plant process control
| Steering the Fertilizer Industry through Challenging Times
NIIK’s scope of works for the HSDG project
Thank You!www.gpca.org.ae
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