dblue production

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insightbeyondnumbers

Diesel Emissions Conference& AdBlue® Forum Asia 2010

2010 AdBlue®

March 23 - 25, 2010. Westin Hotel, Beijing, China


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Measuring AdBlue® quality and understanding

requirements of AdBlue® infrastructure

Östen Andersson, Director Technical Support & HESQEnvironmental & Speciality Products

Diesel Emissions Conference & AdBlue Forum Asia 2010


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Östen Andersson

1. Short Introduction

2. Where does the contaminationrisk lie in the AdBlue supplychain

3. Anti-Contamination RiskMeasures Taken in

AdBlue production Bulk Logistics Filling of IBCs, Cans and

Drums Dispensing Equipment

4. VDA Quality Audit Programme


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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, ofdifferent sizes

– Telemetry and services


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4 Yara Production Plants centrallylocated 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 localclient needs, including dedicatedterminals

Over 120 distribution depotsacross Europe

1. Yara is the world’s largest AdBlue producer


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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.

Purico aims to be the leading AdBlue solution provider in China

through Air1 concept.

Yara’s experience,

know-how &

expertise in Europe

Sinofert’s production

capacity & distribution

network in China


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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.


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2. Multiple Contamination Risks in the AdBlue

supply infrastructure

AdBlue

productionPlant & Storage

Transport

Truck

Rail

Ship

Storage

Terminal

Intermediate

Storage

Land

Transport

Land

Transport

Road

Transport

Road

Transport

Road

Transport

Storage at

Customer

site

Filling of IBC,Drums & Cans

Customer

Possible Contamination Risk

X

X

X

X

X

X

X

X

X

X


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3.1 Anti- ContaminationMeasures in AdBlue

ProductionPrimary production fromUrea Hot melt

Secondary production bydissolving of solid Urea


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Static Mixer

Cooling Filtration(Optional)

Storage TankStorage Tank

Demineralised Water

Urea Hot melt

Loading PumpLoading station

Batch Control Batch Control

3.1 Principal Drawing AdBlue Production from

Urea Hot Melt

Quality ControlConductivity

Quality ControlExample:

ConcentrationPressureTemperatureFree Ammonia

Quality Control

DensityTemperature

Closed system

In principal nocontamination risk


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Yara’s Urea Plant, Brunsbüttel, Germany


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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


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Quality ControlConductivity

3.2 AdBlue Production from Urea Prills,

Dissolving increases the risk of contamination

UreaBig Bags1 000 kg

Hopper

Mixer

StorageTankAdBlue

StorageTankAdBlue

Transfer pump

Filter

Filter

Transfer pump

LoadingPump

LoadingStation

StorageTankDemin.Water

DemineralisedWater Production

BatchControl

BatchControl

ScrewConveyor

Control SystemConcentrationTemperature

BatchControl

X

X

X

XX

Possible Contamination Risk


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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


– 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


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3.3. AntiContamination

Measures for BulkLogistics


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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


– 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


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3.4 Anti ContaminationMeasures 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


– Not dedicated filling

equipment



– 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


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3.5 Anti ContaminationMeasures for

Dispensing Equipment


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3.5 Examples of IBC and Drum pumps


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3.5 Pumps for IBC and Drums risks of

contamination


– Not dedicated equipment

– also used for other liquids



– 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


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3.5 Examples of Customer Dispensing equipment

Dry Break Fillingconnection

http://www.blue1.be/en/commercial_pump_installations.htm


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3.5 Risks for Dispensing Equipment at

Customer sites




– 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


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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


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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


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Ö

Thanks for your attention

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