FERTILIZER INDUSTRY

Chemical Fertilizer
• A chemical fertilizer is a
substance applied to
soils or directly onto
plants to provide
nutrients optimal for
their growth and
development.
 Fertilizers Types
• Straight fertilizer is a
fertilizer that contribute single nutrient
to the crops. urea, rock phosphate,
ammonia, ammonium sulfate etc
• Straight fertilizer can be used straight
to the crops.
• nutrients that have been supply are
incomplete.
• The advantage of this straight fertilizer
is because of the low price compare to
the other fertilizer. But, the effect to
the crops is not good enough
Nitrogen fertilizer – Nitrogen is one of the main elements which can be
found in most commercial fertilizer.
• nitrogen is a component in plant cells (chlorophyll) .
• Nitrogen function is to supply foods to the plant during
photosynthesis and enhance the plants growth.
• Lack of nitrogen will cause the leaf become yellowish and
consequence on the plant growth.

Phosphorus (P) – Phosphorus is a second ingredient in fertilizer.

• It will act to enhance root growth and flowering.
• The root will grow deep and tree becomes much stronger.

Potassium (K) –It is important in flowering and fruiting purpose.

• Lack of potassium will have an effect on the plants protein synthesis.
• Potassium will support in plant chemical process such as
carbohydrate, sugar, protein, and enzyme synthesis for plant growth.
2. Complex fertilizers: Complex fertilizers
contain two or three primary plant nutrients
which are in chemical combination.
eg. Diammonium phosphate, nitrophosphates
and ammonium phosphate.
3. Mixed fertilizers: are physical mixtures of
straight fertilizers.
• They contain two or three primary plant
nutrients.
• Mechanical or manual mixing of ingredients.
Read details about types of fertilizer from
agritech.tnau.ac.in/agriculture/agri_nutrientmgt_fertilizers.html
 The NPK ratio
• Fertilizer packaging contains a set of numbers, for example 6:1:5 .

• These numbers are called the NPK ratio, and they give the mass ratio of
nitrogen, phosphorus and potassium in the fertilizer.

• The NPK ratio expresses the content of each nutrient as a percentage of N, P

and K in this order. For Example

• 38% of the total fertilizer is nitrogen, phosphorus or potassium.

• % N: 3 in every 9 parts of the 38% contains nitrogen (N)
• % P: 1 in every 9 parts of the 38% contains phosphorus (P)
• % K: 5 in every 9 parts of the 38% contains potassium (K)
In some countries the ratios are expressed in compound form: N:P2O5:K2O.
Nitrogen still refers to the element nitrogen, but phosphorus and potassium
refer to the compounds phosphorus pentoxide (P2O5) and potassium oxide
(K2O).
Question
Calculate the mass of nitrogen (N), phosphorus (P) and potassium (K) that
is present in 500 g of industrial fertilizer with a NPK ratio of 5:2:3 (40).

Answer
Determine the mass of the total nutrients in the fertiliser sample.
40% of the sample contains nutrients, therefore:
40% of 500 g = 0,4 x 500 g = 200 g which contains nutrients.
Determine the mass of the specific component in the sample
For every 5 units of nitrogen there are 2 units of phosphorus and 3 units of
potassium so the total number of units is 10.
5 of the 10 units are nitrogen, therefore:
510× 200 g = 100 g will be nitrogen (N).
2 of the 10 units are phosphorus, therefore:
210× 200 g = 40 g will be phosphorus (P).
3 of the 10 units are potassium, therefore:
310× 200 g = 60 g will be potassium (K).
 SUPERPHOSPHATE
• Superphosphate is the fertiliser most commonly used to ensure that soil
has a sufficiently high phosphorous content.
• It is manufactured from the reaction between sulfuric acid and
'phosphate rock' (rock rich in the mineral fluorapatite, Ca5(PO4)3F)
2Ca5(PO4)3F + 7H2SO4 + 3H2O → 7CaSO4 + 3Ca(H2PO4)2.H2O + 2HF
The reactions occurring during the production of superphosphate are
complex and are usually summarised as follows:
Ca5(PO4)3F + 5H2SO4 → 5CaSO4 + 3H3PO4 + HF

Ca5(PO4)3F + 7H3PO4 + 5H2O → 5Ca(H2PO4)2.H2O + HF

• 2. Minor reactions.
• 2CaO+2F2 = 2CaF 2+ O2
• 3CaO + P2O5 = Ca3 (PO4) 2
• CaO+SO3 = CaSO 4
• MgO+H2SO4 = MgSO4 +H2
• Fe2O3+3H2SO4 = Fe2 (SO4) 3+3H2O
• 3. Pollution reaction.
• CaF2+H2SO4 = CaSO 4 +2HF
• 4HF+ SiO2 = SiF 4+H2O
• 3SiF4+2H2O = 2H 2SiF6+ SiO2
• All reactions occurring at the same time.

• virtually all the HF reacts with other silica minerals

associated with the fluorapatite (silicates, quartz)
to form silicon tetrafluoride.

• These gaseous emissions are recovered as

hydrofluosilicic acid (H2SiF6) in the scrubbing
system.

• Carbonates in the rock also react with sulfuric acid.

 MANUFACTURING PROCESS
Step#1
• The first unit operation in the SSP production is
the Ball mill.
• In the ball mill the rock phosphate is crushed
about 96% is passing through 100 mesh, which
requirement of the process.
• Fine rock phosphate particles are collected
through pulse jet collector of bags of rock grinding
system, we have provided cyclone separator system
attach with blower and pulse jet dust collector.
STEP#2
• Dryer the rock phosphate containing moisture
which dried up to 1 % through the co- current
operation with hot air.
• The inlet temperature of the hot air is 300
deg. And outlet temperature is 60
deg.Centigrade.
• The diameter of the dryer is about 2.5 meter
and length is about 15 meters.
Step#3 ACIDULATION
• The ground rock and sulfuric acid are reacted in a horizontal mixer. The feed rates are approximately:

• Phosphate rock - 25 tonnes/hour

• 98% Sulfuric acid - 14.5 tonnes/hour

• Water - 6 tonnes/hour

• A continuous flow of the sloppy mix drops out of the mixer into the Broadfield Den.

• The den consists of a slowly moving floor (approx. 300 mm/min) to enable setting of the ‘cake’ and reciprocating
sides, which prevent the superphosphate adhering to the walls.

• The partially matured superphosphate cake is cut out of the den with a rotating.

• cutter wheel after a retention time of approximately 30 minutes.

• Additives such as limestone, potassium chloride (potash) and ammonium sulphate may be added to the
superphosphate before it is worked further in the conditioner.

• The conditioner consists of a set of rotating paddles which break-up and knead the product. Water is usually added to
improve the product consistency for granulation.
Step#4 Granulation
• The granulation process is important in producing superphosphate of the
required physical properties.
• The granulation circuit consists of a pulveriser, granulation drum and classifier.
The pulveriser breaks up any lumps in the product before it is fed to the
granulation drum.
• The granulation drum rolls and agglomerates the superphosphate to form
granules. determine the retention time and bed depth.
• The granules are passed out of the end of the drum and through a classifier (wire
screen). Oversize granules (>6 mm) are recycled through the drum via the
pulveriser while the finished product is conveyed to the product stores.
• The superphosphate continues to cure in the store for about two weeks and the
product is “dressed” (oversize is passed
• The incline of the drum and the feed rate through a hammer mill after screening)
before dispatch.
• Trace elements and other nitrogen or potassium-containing compounds can be
dry-blended with superphosphate to give complete fertilisers to meet different
requirements.
 Triple Superphosphate
 
Chemical formula: Ca(H2PO4)2•H2O

Fertilizer analysis: 45% P 2O5 (0-45-0)

 
15% Ca
 
Water-soluble P: Generally >90%
 
Solution pH 1 to 3
•Triple superphosphate (TSP) was one of the first high Phosphorous containing
fertilizers.
• Technically, it is known as calcium dihydrogen phosphate and as monocalcium
phosphate, [Ca(H2PO4)2 .H2O].
•It is an excellent Phosphate source.
 
 Manufacturing Process
CaF2. 3Ca3 (PO4)2 + 14H3PO4 → 10Ca (H2PO4)2 + 2HF

• rock or limestone is reacted with phosphoric acid in 1 or 2 reactors in

series.
• phosphoric acid used in this process is appreciably lower in concentration
(40 percent P2O5) .
• The lower strength acid maintains the slurry in a fluid state during a
mixing period of 1 to 2 hours
• . A small sidestream of slurry is continuously removed and distributed
onto dried, recycled fines, where it coats the granule surfaces and builds
up its size.
• Pugmills and rotating drum granulators have been used in the granulation
process.
• A pugmill is composed of a U-shaped trough carrying
twin counter-rotating shafts, upon which are mounted
strong blades or paddles.

• The blades agitate, shear, and knead the liquified mix

and transport the material along the trough.

• The basic rotary drum granulator consists of an open-

ended, slightly inclined rotary cylinder, with retaining
rings at each end and a scraper or cutter mounted inside
the drum shell.

• A rolling bed of dry material is maintained in the unit

while the slurry is introduced through distributor pipes
set lengthwise in the drum under the bed
• Slurry-wetted granules are then discharged onto a
rotary dryer.
• excess water is evaporated and the chemical reaction
is accelerated to completion by the dryer heat.
• Dried granules are then sized on vibrating screens.
• Oversize particles are crushed and recirculated to the
screen, and undersize particles are recycled to the
granulator.
• Product-size granules are cooled in a countercurrent
rotary drum, then sent to a storage pile for curing.
• After a curing period of 3 to 5 days, granules are
removed from storage, screened, bagged, and shipped.
 USES
• popular Phosphorous source .
• Over 90% of the total P in TSP is water soluble, so it becomes rap-idly available for plant uptake.
•TSP also contains 15% calcium (Ca), providing an additional plant nutrient.

•A major use of TSP is in situations where several solid fertilizers are blended together for
broadcasting on the soil surface or for application in a concentrated band beneath the surface.

•Monocalcium phosphate is an important ingredient in baking powder. The acidic monocalcium

phosphate re-acts with an alkaline component to produce carbon dioxide, the leavening for many
baked products.

• Monocalcium phosphate is commonly added to animal diets as an important mineral

supplement of both phosphate and Ca.
 UREA
PHYSICAL PROPERTIES OF UREA

Urea is a white, odorless, hygroscopic solid.

It is non-corrosive.
Molecular weight 60.05
Maximum Nitrogen content 46.6 %
Specific gravity 1.335
Bulk density 0.74 gm/cc
 Urea Manufacturing
The two main reactions involved are:

1)
CO2 + 2NH3↔NH2COONH4 H= -37.4 Kcal/gm mol

2)
NH2COONH4↔NH2CONH2 + H2O H= + 6.3 Kcal/gm mol

Undesirable side reaction taking place is:

3) 2NH2CONH2↔NH2CONHCONH2 + NH3
(Biuret)
•Both 1st & 2nd reactions are equilibrium reactions.
•The 1st reaction almost goes to completion at 185-190
oC & 180-200 atms.

•2nd reaction (decomposition reaction) is slow and

determines the rate of the reaction.
•Unconverted CO2 & NH3, along with undecomposed
carbamate, must be recovered and re-used.
• The synthesis is further complicated by the formation
of a dimer called biuret, NH2CONHCONH2, which must
be kept low because it adversely affects the growth of
some plants.
• Ammonia & CO2 are compressed separately and fed to the high
pressure (180 atms) autoclave as shown in ,which must be water
cooled due to the highly exothermic nature of the reaction.
• A mixture of urea, ammonium carbamate, H2O and unreacted
( NH3+CO2) is produced.
• This liquid effluent is let down to 27 atms and fed to a special flash-
evaporator containing a gas-liquid separator and condenser.
Unreacted NH3, CO2 & H2O are thus removed & recycled.
• An aqueous solution of carbamate-urea is passed to the atmospheric
flash drum where further decomposition of carbamate takes place.
The off gases from this step can either be recycled.
• The 80 % aqueous urea solution can be used as it is, or sent to a
vacuum evaporator to obtain molten urea containing less than 1 %
water.
• The molten mass is then sprayed into a prilling tower.
• To avoid formation of biuret and keep it less than 1 %, the
temperature must be kept just above the melting point for processing
times of 1-2 seconds in this phase of the operation.
Although the production of urea is high at high pressure and high
temperature, the

reaction is not operated at maximum temperature and pressure because:

Increased pressure increases capital & operating costs of compression and

reaction equipment.

Increased temperature accelerates decomposition of urea to biuret, a compound

that adversely affects the growth of some plants.

The above stipulated conditions produce intolerable corrosion rates, and a

compromise design must be chosen.
USES OF UREA

About 56 % of Urea manufactured is used in solid fertilizer.

About 31 % of Urea manufactured is used in liquid fertilizer.

Urea-formaldehyde resins have large use as a plywood

adhesive.

Melamine-formaldehyde resins are used as dinnerware & for

making extra hard surfaces.

Urea is used in manufacturing of textile chemicals.