innovative tools, fertinagro nutrientes granulation process · 7 brussels january 27th, 2016 spire...

Innovative tools,

methods and indicators

for optimizing

the resource efficiency

in process industry

“This project has received funding from the European Union’s Seventh Programme for research, technological

development and demonstration under grant agreement No 604140”

FERTINAGRO NUTRIENTES

Granulation Process

Joaquin Romero

Chemical Process Department

SPIRE Workshop on Resource Efficiency Monitoring, Assessment and Optimization

Brussels 27th January 2016

FERTINAGRO NUTRIENTES 2

SPIRE Workshop on Resource Efficiency Monitoring, Assessment and Optimization Brussels January 27th , 2016

Ports and logistical centres 9. Bayonne 10. Valencia 11. Castellón 12. Montiijo 13. Huelva 22. Elche 23. Cigales

Offices 15. Teruel (Head Office) 16. Madrid 17. Zaragoza 18. Ragusa 19. Montijo 20. Misson 21. Montevideo

Plants 1. Teruel: Pellets 2. Sarrión: Pellets 3. Escucha: Organic minerals 4. Utrillas: liquids, specialities 5. Castellón: WSF, logistics 6. Avilés: SSP 7. Misson: Pellets 8. Huelva: WSF, Pellets



• Argentina

• Uruguay

• Brazil

• Mexico

• Senegal

• South Africa

• Portugal

• France

• UK

• Italy

• Ukraine

• Turkey

• Syria

• Cyprus

• Malta

• Lebanon

• Algeria

• Nigeria

• Angola

• Mozambique

• Sudan

• Kenya

• Egypt

• Saudi Arabia

• Pakistan

• Thailand

• Nicaragua

• Dominican

Republic

• Colombia

• Peru

• Brazil

• Bolivia

• Paraguay

• Ecuador

• Switzerland

• Poland

• Romania

• Bulgaria

• Greece

• India

• China

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Process Overview

In the Top-Ref project Fertinagro have been performing several

changes in their process in order to optimize energy

consumption.

The principal changes are:

1. Automatization: PLC and SCADA.

2. Pre-heater the air.

3. Reduction in the use of the sieve: currently, we use a frequency

converter with the mill to modify the size.

3


Process Overview

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1. Old SCADA 2. New SCADA

5


2. System to pre-heat the air inside the burner

6


Impact and outcomes

Our current situation without finishing the optimization:

1. Reduction of gas consumption 2% - 4%.

2. Reduction in power consumption 2% - 3%.

3. Reduction of the downtime due to some problems with the sieve.

4. Reduction of the downtime 10%.

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TOP-REF Benefits for FERTINAGRO

Identification and study of variables and situations not covered in reality but

feasible to happen and be solutions.

New and Improved Control Strategies.

Design and implementation of a soft sensor for continuous process improvement

and some time in advance

Identify new areas for improvement and possible remediation projects.

Continuous reduction of energy consumption by the design and implementation of

new methodologies

Possibility of implementing the methodology developed in the different production

plants that Fertinagro has all over the world

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Conclusions

The results obtained so far in the simulation have high accuracy with an error of

less than 15% on the final size of the particle.

Economic and energy studies have explained that energy losses are mainly the

outgassing of the rotary dryer and the high quantity of material recycle doubt out

of a irregular size. There are different possibilities of utilization and therefore a

reduction of more than 30% of energy consumption.

Some improvements ideas have been identified to reduce the energy consumption

and improve the quality of the final product

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1. Reduction of energy consumption 15%-20%. Simulation

2. Implementation in other plants (In Spain, France, Senegal and

Brazil). Extend the results

3. Implementation in other process.

Future goals

“This project has received funding from the European Union’s Seventh Programme

for research, technological development and demonstration under grant agreement No 604140”

THANK YOU VERY MUCH FOR YOUR ATTENTION

innovative tools, fertinagro nutrientes granulation process · 7 brussels january 27th, 2016 spire...

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