2

Chairp

1 DAP Mr.

2 PhosMr. R

3 NoveProdMr. R

4 GuaSysteMr. A

5 UtilMr.:

24th AFA I

person:

Sami

P & PhosphJohn Wing

sphate PlanRichard D.

el Large Scduction Rinat Ander

ranteed (Riems throughArmaghan Y

lization of SZaid Halas

Int’l. Te

i AMARN

horic Acid Pg - Phosphat

nt Yield ComHarrison –

cale Energy

rzhanov, De

isk Free) Engh AvanceonYusuf – Bus

Satellite Imasah - Senior

echnical F

EH

QES Man

Plant Improe Consultan

mparisons Process Sup

Efficient T

eputy Techn

nergy Savinn's Proprietsiness Mana

age To Imprr Chemist

Fertilizers

S

nager – T

vement nt

pervisor / Fe

Technology f

nical Directo

ngs in Watetary "iwaterager

rove Solar P

s Confere

Sessio

The Arab

ertilizer Con

for Urea

or of Innovi

er and Steamr" & “iboile

Ponds Prod

ence

on I

Potash C

J

nsultant P

iations

RU

m er”

A

duction

Company

John Wing

PegasusTSI

R&D InstitUrea

Avanceon

APC

y

, P.E. U

I Inc. U

tute of R

P

C J

USA

USA

Russia

Pakistan

Jordan

Session II

24

Abstrac A selectDAP inn

D B th s P A a D P C T

Phosph

C N C U R R A A P

Project

4th AFA In

D

ct:

tion of attranovations iDual Mole RBFL Vaporihe reactor-scrubbing –Product ScAutomated adjusts proDual diamePipe ReactCooler Air CTran-Tech

oric Acid pConversionNo need foConversionUtilize gypsRecover urRecover fluA variety ofAdvances iPurify phosmanageme

nt’l. Tec

DAP & PHMr

active modnclude: Reactor-Grizer/Scrubb-granulator– potentiallreen DiverRecycle Ccess to kee

eter reactoror Chiller Product Co

plant projecn from Dihyr most eva

n to Hemi-Dsum – mananium – m

uosilicic acif profitable n dry gyps

sphoric acident and sta

chnical Fe

HOSPHORIr. John Win

John

difications a

ranulator Aber - Vapor acid scruby eliminatinrter SystemControl - coep size in mr (pre-neut

ooler

cts to consydrate to Haporation. UDi – similarny ways to

major investid – high-puses for p

sum stackind to technicart-up issue

ertilizers

IC ACID PLng - Phosp Wing, P.E

are describ

Acid Scrubbrizes all ambber. This ng need fo

ms – easy continuouslymid-range.ralizer)

ider includeemi: Make

Usually no r benefits pmake gypstment with urity grade

phosphogypng cal or foodes are disc

Confere

LANT IMPphate ConsE. - USA

bed, based

bing mmonia witunit provid

or any tail-gcapacity incy monitors r.

e: es acid at 4

rock grindplus 98.5% sum an asshigh profit

e for AlF3 fepsum

grade cussed

nce

PROVEMENsultant

on succes

th free heades a 3rd stgas scrubbecrease recycle par

42% concening is needrecovery &

set rather tpotential eed

NTS

ssful projec

at from air letage of er.

rticle size a

ntration vsded. & clean gypthan liability

cts.

eaving

and

. ~27%

psum y

Session II

2

Abstrac IntroducEstimatProcess◦ Elimin◦ Reduc◦ Identif◦ RedireProcess1. Site s2. Open3. Close4. Proce5. High 6. Impro7. Non-C8. Calci

24th AFA I

Rich

ct:

ction - Peged Range s Changes ate off-site

ce phosphafy opportunect fresh was Alternativselection an Circuit Pred Circuit Pess Water Strength F

oved WashContact Evnation

nt’l. Te

Phard D. Ha

asusTSI Cof P2O5 Lto Reduce

e dischargeate flow to nities to recater make-

ves nd climate rocesses – Processes Recycling

Fluoride Rehing and/orvaporator C

chnical F

Phosphatearrison – Pr

Peg

Core Busineosses to Ge Phosphates gypsum st

cycle proce-up to gyps

conditionsno recove– some re

ecycle r Double FiCondenser

Fertilizers

e Plant Yielrocess SupasusTSI In

ess ActivitieGypsum State Losses:

tack ess water sum stack

s - typical pery of pore covery of p

iltration r Cooling

s Confere

ld Comparpervisor / Fnc. - USA

es acks

plants, Flormoisture P

pore moistu

ence

risons Fertilizer Co

rida and N.P2O5 ure P2O5

onsultant

Africa

Session II

Abstrac R&D Inadvancestock coproprietoffer staBy the (URECOTo be aindustryplants (ceffectiveThe key- Synthincludin - Urea mlosses a- Strippand pro� Submthe proc- Doubtechnolo - Simplifdifferentinvestm Innovatiunit as wfor it to increaseR&D Insfor urea

2

Novel LMr. R

ct:

stitute of Ued productosts, improtary licenseate of the a

present mON 2006®able to proy we’ve devcapacity oveness requy features oesis reactog Vortex M

melt separand increasing distillatlonging the

merged carcess internble-stage ogies.

fied equipmt pressure.

ment and co

ive R&D Inwell as forbe the moes up to 60stitute of U

a production

24th AFA

Large ScalRinat Ande

Urea is a tion technoove safetyes and “knart solutionsmoment w) and avera

ovide compveloped anver 2000 tpuirements. of our advaor operate

Mixer, Long

ation at sese the effiction in CO2e operatingrbamate coal heat to gmelt distil

ment lay-ou. Thus, theonstruction

nstitute of Ur the rehabost rational 0% and eneUrea univern providing

Int’l. Te

le Energy Eerzhanov, D

R&D Ins

leading enologies tha

y and ecolonow-hows” s to increae have deage-scale plete servin energy-efpd) that co

anced teches at 200 bgitudinal Se

everal stagciency of di2 flow at 9g period of ondenser ogenerate 3lation red

ut as a rese HP equip

and assem

Urea technbilitation of

investmenergy costs rsal technog perfect op

echnical F

Efficient TDeputy Tecstitute of U

ngineering at help ouogy efficie for the mse plant preveloped t(URECONce and to fficient tecrresponds

nology arebars and iectioning E

es during tistillation p90 bars allothe strippe

operating a3 Bar steamduces the

ult of the sment can bmbly costs

nology can an existing

nt there shdeplete su

ology for laperational

Fertilizer

Technologchnical DireUrea – Rus

company r customency. R&D

majority of uroductivity.technologie

N 2007®) ube on the

hnology foto the pres

e: s equippe

Element and

the syntherocess. ows achiever due to leat 90 bars m.

equipmen

synthesis abe positionfor the ere

be used fog plant witould be at

ufficiently (arge capacand econo

rs Confere

gy for Ureaector of Innssia

focused oers to cut t

Institute ourea techn es for conrea plants.

e edge of or constructsent enviro

d with a sd Trays.

esis reactio

ving higheess wearingprovides e

nt costs

and HP distned at a lowection of a

or the consh total liquleast 2 un

reaching 5city units isomical perfo

ence

a Productinoviations

on the devtheir energof Urea is nologies al

nstruction . modern tretion of largonment and

set of inter

on helps to

r process g service cefficient rec

compared

tillation uniwer height urea unit.

struction ouid recycle nits at a pla50% for stes a competormance

ion

velopment gy and feean owner lowing us

of low-sca

ends in urge-scale urd operation

rnal device

reduce he

performanconditions. cuperation

with oth

ts working that reduc

f a new urprocess, b

ant. Capacam). titive soluti

of ed-

of to

ale

rea rea nal

es,

eat

ce of

her

at ces

ea but city

on

Session II

Gu

Abstrac Water anecessacorpora HoweveWho guWill my Project I need asure if I

Avanceunique absolute

The paguarantPakistan

Abstrac The use the usagesolar ponpotash). Satellite and depththe final Infrared the areasThe main1. Improv

2. Plan thlocatin

3. Locatidikes.

4. Locatipheno

2

uaranteed

ct:

and steam ary measute objectiv

er certain quarantees t

manufactuInvolves ha specific can mana

on, a US partnersh

ely no finan

per brieflyteed (no risn respectiv

Utiliza

ct:

of satellite ie of satellitends system

images wereh profiles wimages werelayer of the of any suspn benefits ofve the proce

he salt dredgng any close

ing any susp

ing the reveromenon.

24th AFA

(Risk FreeAvan

Mr

systems aures to mies of impro

questions dhe savingsuring proceigh capital ROI or IRRge it to ach

based syip to reduncial risk to

y describessk) savingsvely.

ation of Sa

images is wie imagery to at the Arab

e processed which used to

e saved in spimage was

pect sink holef processing ess control of

ging works ined area aroun

ected sinkho

rse flow of th

Int’l. Te

e) Energy nceon's Pr. Armagha

Ava

re big enernimize theoved qualit

do arise whs and what ess be distu

investmenR to investhieve my fi

ystem inteuce energo customer

s Avanceos, and det

atellite ImaMr. Zaid

idely used inimprove the

b Potash Co

using specio improve thpecial softwaused to checes. the satellite f the solar po

n the solar pnd high dens

ole (coordina

he brine in th

echnical F

Savings inroprietary n Yusuf – anceon – P

rgy cost cee energy ty, profitab

hile initiatin if savings urbed? nt!!! t; Energy onancial go

grator andgy consumrs.

on’s “iwatetails of proj

age to ImpHalaseh/ SAPC – Jo

n many appe efficiency

ompany that

al software he process coare as an arcck for seepa

images for tonds system

pond system sity brine an

ates) and the

he solar pon

Fertilizer

n Water an"iwater" &Business MPakistan

enters in a consumptiility and en

g energy sare not ac

optimizatiooals.

d energy mmption in w

er” and “ibjects at En

prove SolaSenior Cheordan

lications all of the contrused to pro

like Infograontrol and p

chiving and cage of the br

the Arab Potm.

by calculatinnd evaluate th

e risk of thes

nds system an

rs Confer

nd Steam & “iboiler”Manager

fertilizer plon in orde

nvironment

savings prochieved?

n is not my

managemewater and

boiler” pacngro Fertili

ar Ponds Pemist

around the rol and increoduce Carna

agh and Irdaspredict for fucomparison rine from the

tash compan

ng the salt ghe dredged a

se sinkholes

nd set the rig

ence

Systems t”

ant. Everyer to bettet sustainab

ojects, som

y business

ent compad steam s

ckages, thezer Limited

Production

world. Thisease the prodallite ( the

ss to have duture actionssystem (Arce solar pond

ny are:

growth in eacareas.

on the syste

ght solution

through

y facility taker align wility.

me are;

s and am n

any, offerssystems w

e concept d and Nes

n

s paper revieductivity of raw martial

density, therms. The data acMap GIS) ds and to loc

ch subarea,

em and the

for this

kes with

not

s a with

of stle

ews the of

mal and

cate

Session II

Chairp

1 ThFeMr

2 FSMr

3 CaMrDeMrSyn

4 IJCPhMr

5 RepUrMrSup

person:

Mr. J

e major resrtilizers (JS

r. Yuri Cher

SA Neutralizr. Salah Albu

atalysts for Srs. Ayten Yevision r. Henrik Lanthesis

C Experiencosphoric Ac

r. AWINASH

placement orea Plant r. Bellary Mperintenden

ohn Win

search activSC “NIUIFrnenko – Ge

zation with ustami - Pr

Sulphuric AY. Wagner –

arsen - Gene

ce on Revamcid Plants

H PESHWE,

of High Pr

Muhammad Unt

g

Phospha

vities of the ”)

eneral Direc

Calcium Crocess Engin

Acid and Am– Arae Man

eral Manage

mping of Su

, PLANT HE

ressure Scru

Usman – Ma

S

ate Consu

Research In

ctor

Compoundsneer

mmonia Planager – Caty

er, Marketin

ulfuric Acid

EAD

ubber in SA

aintenance

Sessio

ultant– J

Institutes for

ants ylest

ng & Sales

d and

AFCO-II

on II

John Win

r JSC “N

JACOB

HaldorTopsoe

IJC

SAFCO

g P.E. - U

NIUIF” R

BS U

r e

D

Jo

O S.

USA

Russia

USA

Denmark

Jordan

S. Arabia

2

The m

Abstrac

The pap“NIUIF”Russian m

Abstrac As enviplant opphosphacooling precipitatreat fluneutralizscrubbecondenswith phused beseveral

24th AFA I

major resea

ct:

er describes”) and showsmineral ferti

ct

ronmental perators wate plantspond wate

ate as the uoride conzation prioers to remosers. If a mosphate roecause it icalcium co

nt’l. Te

arch activiM

s the main s technologiilizers plants

FSA NMr

regulationwill eventu currently er that is srecirculati

ntaminated or to dischove fluoridemarket canock to pros not profiompounds

chnical F

ities of theMr. Yuri Che

JSC

research acical processes and plants

Neutralizatr. Salah Alb

J

s continueally be reuse direc

saturated wng water cwater, ph

harging effes as fluosnnot be fouduce a weitable. Thissuch as ph

Fertilizers

e Researcernenko –C “NIUIF”

ctivities of es developedlocated in th

tion with Cbustami - JACOBS –

to restrict equired to ct contact with fluoridcools in lahosphate pfluent. A bilicic acid pund for theeak phosps paper dihosphate r

s Confere

h InstituteGeneral D- Russia

Russian Rd by this Inhe former So

Calcium CoProcess E

– USA

chemical pneutralizebarometri

de salts. Mrge coolingproducers better envprior to cone fluosilicic

phoric acidscusses Frock, lime a

ence

es for FertDirector

Research Inststitute that h

oviet Union s

ompoundsngineer

processinge fluoride wic condens

Most of thisg pond systypically u

vironmentandensing thc acid, it ca. This tech

Fluosilicic Aand limesto

tilizers (JS

titute for Fehave been imstates

s

g emissionswaste matsers with s fluoride istems. Whuse lime ol alternativhe vapors ian then behnique is Acid neutraone.

SC “NIUIF”

ertilizers (JSmplemented

s, phosphaterials. Morecirculati

is allowed hen forced or limestove is to uin baromete neutraliznot currenalization w

S

”)

SC d at

ate ost ng to to ne se tric ed

ntly with

Session III

24th AF

M

Abstrac The firsexperienFor maplant shbuild-upAn imprdust proprotectiothis uniqbetweenconsumsame ti1oday, 4are in oThe secof our 2AdvancHaldor change many teThis paoffered primary for amm

Variouconve

reformeachieve The HTunit hasresulted

FA Int’l.

CMr. Henrik

Mrs.

ct:

st Part of tnce we havny sulphur

hutdowns isp caused byroved proteotection caon catalystque VK38 n screening

ming and exme signific4 years latperating arcond part o5-mm dais

ced ReformTopsoe Afreforming

echnologiesper descrito the ammreformer a

monia produus options ective gas

er (HTER) ted, while th

ER teleolos been revad in a 33%

. Technic

Catalysts fk Larsen –

Ayten Y.

this paper ve gained ric acid plas the screey plugging ection agaiatalyst in tt in the shadust prote

gs comparxpensive shcant savingter, close toround the wof this papesy dust proming TechfS (Topsoe technologs such as sbes how thmonia induand due touction. are availabheated refo

technologye methane

gy has nowamped withincrease in

al Fertiliz

for Sulphu– General MWagner –

Haldor T

describeson VK69 aants the boening requi

by dust prnst pressuhe top of ape of a 2ection catared to the 1hutdowns fgs in blowo 80 installworld. er disclosetection inst

hnology foe) suppliesgy. The Hasyngas, hyhe HTER tustry. For ao high refor

ble for a caorming sta

effective y is a provee leakage is

w been in sh an HTERn reforming

zers Conf

uric Acid aManager , Area Man

Topsoe – D

s case storand VK-701ottleneck firement of resent in thure drop buBed 1. In 5-mm Dais

alyst result12 mm Daifor catalyst

wer energy lations with

s actual optallations.

or Ammons a full ranaldor Topsydrogen. mtechnologya new ammrming temp

apacity incrands out asperspectiven revamp s retained

successful R installed dg capacity.

ference

and AmmoMarketing

nager – CaDenmark

ries disclos1 LEAP5TMfor prolongBed 1 due

he feed gasuild-up can

2007 Topsy. Installats in a dousy. Conseqt screeningresult from

h 25 mm D

perating ex ia Plantsnge of refosoe Exchan

methanol, any .is adoptemonia planperature st

rease in thes an attractve. The Hal

option what a low le

commercidownstream

onia Plantsg & Sales Satylest Dev

sing someM. ged operate to increass. be obtaine

psee introdation of a 1ubling of thquently, thg is reducem the lowe

Daisy dust p

xperience o

orming tecnge Reformnd ammoned in an at, implemetill retains a

e front-endive option ldor Topsiehere a capvel.

al operatiom of an Au

s Synthesisvision

e of the op

ting time bsed pressu

ed by the uduced a ne15 cm top he operatine number d and at ther pressurprotection c

obtained fro

chnologies mer (HTERnia. mmonia pl

enting the Ha low meth

d of an ammfrom both a

e exchangeacity incre

on since: eauto thermal

Session

s

perating

between ure drop

use of a ew dust layer of ng time of time-

he re drop. catalyst

om one

which alsoR) technolo

lant and wHTER reduhane slippa

monia coma technicae ase of 20 -

arly 2003. Al Reformer

n II

Mr. Henr

Mrs.Ayten

o includesogy is app

what benefiuces the siage, which

mplex. Out ol as well as

-25 % can

A full size (ATR), thi

rik Larsen

n Y. Wagner

s heat ex-plicable to

ts can be ize Of the is crucial

of these s a cost

easily be

industrial s has

2

IJC E

AbstracFrequecontinuAfter sto operIn orderthe equiManufactime to 1. OBJEC2. PROJE3. CHAL

of any pro Our IJC’sproposal

Abstrac The Indoperatiophospho IJC is hDouble Agri’s scapacity NormallWe seeoptimizaonly it re Debottleof any p Our IJCrestrictioimprove

24th AFA I

EXPERIEN

ct: ent failureuous prodeveral shrate the pr to overcompment with

cturing of nput the plaCTIVE ECT SCOPE

LLENGE IN H

ocess is limit

s experiencesof capacity e

ReplaMr.

ct

do Jordan onal and oric acid pl

having 200Absorption

single stagy since its c

ly the proce lots of ation. Debequires cor

enecking isprocess is l

C’s experieons, inadeed efficienc

Int’l. Te

CES ON R

Mr

e of High Pduction losut downs

plant at deme the chalh upgraded ew Scrubbent back in o

E HAND

ted by the low

s on debottleenhancemen

cement of. Bellary M

Chemicalssafety fiellants.

00 MTPD n process ge hemihydcommissio

cess plantsplants areottleneckinrrect evalu

s like remolimited by t

ences on equacy in cy are discu

echnical F

REVAMPIN

r. AWINAS

Pressure ss. and repaesigned pllenge on pmaterial in

er, Air liftinoperation.P

west capacity

enecking like t with improv

f High Preuhammad

SA

s Companyld at its

sulfuric aand 700 Mdrate proc

oning.

s will have e expandeng for increation studi

oving the wthe lowest

debottlenecooling s

ussed.

Fertilizers

NG OF SULPLANT

SH PESHWIJC – Jor

Scrubber

airs equipparameterlant reliabiln May 2011g of 65 T n

Paper Conte

y steps in the

waste heat bved efficiency

essure ScrUsman – M

AFCO - S.

y is commiEshidiya c

acid plant MTPD of P2cess. Both

10-15% eed to highemental caes.

weakest lincapacity st

ecking likesystems &

s Confere

LFURIC ACTS WE, PLANTrdan

in SAFCO

pment relirs.ity, SAFCO. ew Scrubbe

ent ( not lim4. 5. 6. 7.

e process.

boiler limitatioy are discuss

rubber in MaintenanArabia

itted for itscomplex c

based on 2O5 phosp

h the proce

xtra margiher capacitapacity co

k in a chateps in the

e waste h& proposal

ence

CID AND P

T HEAD

O-II Urea

ability co

Manageme

er and replamited to thePRE-SD PREXECUTIONSUCCESS VSUCCESS S

on, sulfur flowsed.

SAFCO-II ce Superin

s continualcomprising

Monsantophoric acidesses are

n than theties througsts less th

in, maximu process.

heat boiler of capac

PHOSPHO

Plant cau

uld not be

ent decided

acement wae below, fewEPARTIONSN (SD PHASVALUE STORY

w restrictions

Urea Planntendent

improvem of sulfur

o’s Doubled plant bas in operat

e nameplatgh modernhan the ne

um produc

limitationcity enhan

ORIC ACID

used

e achieve

d to take the

as done sucw more poinS SE)

s, inadequacy

nt

ments in boric acid a

e Conversised on Hydtion with f

e capacitienization aew plant a

ction capac

, sulfur flocement w

Se

D

ed

e challenge

ccessfully innts may be

y in cooling s

oth nd

on dro full

es. nd nd

city

ow with

ession II

e to replace

n short added)

systems &

e

Chairp

1 MeeFluMr.

2 RevMr.

3 BesConMr.(De

4 HeaStorof LMr.

2

person:

Mr. S

eting envirouid –bed Gra. Harald Fra

vamping of . Narayansa

st-practice oncept to Imp. salah Abduesignated).

alth, Safety ry behind A

LTI-s . Sami Amar

24th AFA I

Saed BOK

P

U

onmental isanulation wanzrahe – P

f a Conventiamy Selvaraj

on RBI drivplementatioulaziz Zaina

and EnviroAPC Succes

rneh/ QES M

nt’l. Te

KISHA

Plant Ma

UAE

ssues facingwith Plants Process Man

ional Total Raj – Head of

ven Integrityon aldin - Senio

onment in Fss in achievi

Manager

chnical F

Se

anager -

g new and e

nager

Recycle Uref Urea -1 Pl

y Assurance

or Inspectio

Fertilizer Ining 4000000

Fertilizers

essio

Ruwais F

existing urea

ea Plant lant

e from

n Engineer

ndustry 0 MHW Fr

s Confere

n III

Fertilizer

a Uhde FTechno

QAFC

GPIC

ree

ence

Industrie

Fertilizer ology B. V.

CO

APC

es (Fertil)

Netherlan

Qatar

Bahrain

Jordan

)

nds

S

ession IIII

Meetin

Abstrac In recebodies. ammonwith theWhile thefficiencammonindustryIn NPK without and the from theevaporaThe blevarious In accorfor achieWith UFintegratIn this pespeciaTechno

ng environ

ct:

nt years mThis has leia and ure

e demands he reductiocy, reducinia reductio

y. or AN planany difficuproduct. F

e acidic scation plant eed from thways. rdance witeving ammFT's Ammoed into the

paper varioally UFT´s plogy, which

nmental is

MrUhde F

many envied to a signa dust for from their

on of dust ng ammoniaons can b

nts the resulty, as in thFor a urea crubber conand which he ammon

h our commonia emisonia Convee granulatioous availabproprietaryh combines

ssues faci

. Harald FrFertilizer T

ronmental nificant rednew urea environmeemissions

a emissionbe achieve

sulting bleehese plantfluid-bed gntains comuntil now a

nia scrubbe

mitment tosion reducert Technoon processble and indy Ammonia s minimize

ing new anwith Pla

ranzrahe –Technolog

regulationduction in tfluid-bed g

ental authos can be ans in a ureaed by insta

ed stream fts the bleedgranulation mponents ware usuallyer must be

o improve octions from ology the a. ustrially prConvert

ed ammonia

nd existingnts Process My B. V. – N

ns have behe permissgranulationorities to redachieved ba granulatioalling acid

from the acd contains plant the s

which canny not part oe processe

our fluid-beurea fluidb

acidic bleed

roven optio

a emission

g urea Flu

Manager Netherland

een amensible emissn plants. Buduce their

by using scon plant is ic scrubbi

cidic scrubcomponen

situation isnot be procof the produed in som

ed granulabed granulad from the

ons for gran

ns with redu

uid –bed G

ds

nded by thsion levels ut existing emissions crubbing smore com

ng system

bber can bents which as more comcessed in uct specifice way. Th

ation proceation plantsammonia

nulation pla

uced produ

Granulation

he regulatofor plant operto the env

systems wimplicated. Inms well kn

e reintroduare already

mplicated. Ia standardcation. his process

ss UFT has. scrubber

ant operato

uction cost

n

ory

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24

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24

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24

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