Dr. T. M. Sami

All rights reserved © 2005, Alcatel

Technology Profile & Market Analysis For

Reduction Of Nitrous Oxide

At Egyptian Fertlizers Facilities

Dr. T. M. Sami

Cairo 5-6 April 2005

F2RC/TIMS/EEAA Workshop For Fertilizer In Egypt CD4CDM


F2RC/TIMSEEAA Workshop For Fertilizer In Egypt CD4CDM



F2RC/TIMS/EAA Workshop For Fertilizer In Egypt CD4CDM





CO2

CH4

N2O

CO2 = 72% CH4 = 19% N2O = 9%

Figure (1) GHG Emission In Egypt




All energy 61% Agriculture 36% Industry 3%

Figure (2) N2O Emission by Sector

Industry

Agriculture

All energy




Nitric acid Plant = 100%Figure (3) N2O Emission From Industrial Process

Nitric acid plant




Company Location Products Raw materials

Abu Qir fertilizersAnd chemicals

Alexandria AmmoniaNitric acidUrea (periled and granulated)Ammonium Nitrate granulated AN

Natural gas

Delta fertilizers &Chemicals

Talkha AmmoniaNitric acidUrea (prilled)Ammonium Nitrate MethanolUreaAmmonium nitrate solution

Natural gas

Egyptian Chemical Industries (KIMA)

Aswan AmmoniaNitric acidAmmonium Nitrate (prilled)Ferrosilicon Alloy (up to 75%% Silicon content

Water and air Coke, Quartz (SiO2) and Iron turnings

El Nasr Fertilizers &Chemicals (SEMADCO)

Suez AmmoniaNitric acidSulphuric AcidAmmonium Nitrate granulated ANAmmonium Sulphate crystallineCalcium Nitrate Solution CN

Natural Gas




Technology Advantages Disadvantages cost Efficiency

New Plant Retrofit

Extended reactorchamber

Simple process optimizationNo consumption of utilitiesNo catalyst useOperating experience available in commercial scale plant

Possible nitric acid production due to NOx

decomposition in extended reactors chamberHigh investment costSevere retrofit imitations for existing plants, including down line during constructionLimited N2O conversion (70%)

0.8 – 2.5 1.9 – 4.4

Catalytic decomposition in reactor chamber

Retrofit in existing reactor chamber possible (replacement catalyst support)Less catalyst required due to increased reaction kinetics at high temperaturesFirst tests on commercial scale have been completed

Possible nitric acid production losses due to NOx

decompositionRetrofit might be limited or impossible due to lack of available space for catalyst placement and design of the burnerUnknown thermo-stability of catalyst and effects of fouling due to platinum deposition

0.3 – 1.6 0.5 – 1.8

NSCR Proven technologyCombined NOx/N2O reductionNo influence on production capacity

Consumption and slip of fuelProduction of CO/CO2Heat productionLifetime of catalystNo suitable as end-of-pipe option

3.5 – 4.1 4.1 – 5.5

SCR upstream expander Suitable for lower tail gas temperature (300C)Possible combined NOx/N2O reductionNo influence on production capacityCatalyst is exposed to milder conditions compared to 4.1.2 resulting in expected higher stability and lower catalyst cost

Consumption of reducing agentRetrofit limitationsSlip when using natural gas as reducing agentIncreased pressure drop and surplus steam production due to steam cooler if compared with 4.2.3Not yet proven on commercial scale

3.1 – 5.4 4.1 – 5.5




Technology Advantages Disadvantages cost Efficiency

New Plant Retrofit

Decomposition (upstream expander)

No consumption of utilitiesSimple process set-upNo influence on production capacityCatalyst is exposed to milder conditions compared to 4.1.2 resulting in expected higher stability and lower catalyst cost

Relatively high tail gas temperature required. Tail gas temperature <400C required preheatingRetrofit limitationsNot yet proven on commercial scale

0.7 – 0.9 0.9 – 2.2

SCR downstream expander Simple end-of-pipe use existing plantsPossible combined NOx/NO reduction No influence on production capacityCatalyst is exposed to milder conditions compared to 4.1.2 resulting in expected higher stability and lower catalyst cost

Consumption of utilities/reducing agent (LPG)\Pressure dropNot yet proven on commercial scale

Not applicable

3.0 – 3.4

Decomposition downstream expander

Simple end-of-pipe use existing plantsNo influence on production capacityCatalyst is exposed to milder conditions compared to 4.1.2 resulting in expected higher stability and lower catalyst cost

Fuel consumption required for preheating (ignition temperature >400C)Increased reactors size compared to 4.2.3 (increased catalyst costs and pressure drop)Not yet proven on commercial scale

Not applicable

3.0 – 3.6




Project Profile 2

Project name N2O Reduction – Nitric Acid Production

CDM priority High

Location Delta Fertilizers & Chemicals Company - Nile Delta in Dakahlia

Best available techniques

First Project ID Best available techniques Yamaguchi Nitric Acid plant Japan 2001 Antwerp Nitric Acid plant 3 Europe 2003

Project Scope N2O emission reduction using high temperature selective catalytic reduction extra

catalyst bed install in the ammonia burner in the process chain

Technology to be employed BASF high temperature selective catalyst reduction

Second Project ID AMI Agrolinz Melamine International Gmb Hinlinz/Austria in 2003

Project Scope N2O emission reduction using low temperature selective catalytic reduction through an

extra reactor installation in off-gas of nitric acid production process

Technology to be employed Krupp Uhde low temperature selective catalyst for decomposition of N2O

Task Manager




Project Profile 2CDM Small Scale Project Type Reduce emission by source and directly emit less than 15 kt of CO2

GHG targeted N2O

CDM Methodology NM 0061 “N2O Emission Reduction in onsan South Korea” Approved in CDM-EB-18

2005 requested to reformatted version of this methodology as in AM 0021 “Decomposition of N2O from existing adipic acid production plant”

Project Type N/A

Implementation time Frame Estimate 2 years with ongoing reduction

IBRD/IAD Commitment($ Millions)

N/A

Potential ERs Potential ER generation ≈ 5.53 million tCO2-e until 2012

Social & Environmental Benefits

Attract foreign investment. Global environment emission reduction. Contributed to environmental protection fund in fertilizer industry

Status/Issue Company awareness is addressed by CDM capacity development project, PIN and PDD in phase preparation in cooperation with the Abu Qir fertilizers company staff

Barriers to project Development

None




Project Profile 3Project name N2O Reduction – Nitric Acid Production

CDM priority High

Location El Nasr Fertilizers & Chemicals Company (SEMADCO) Suez Egypt Creusot-Loire Plant

Project ID Yamaguchi Nitric Acid plant Japan 2001 Antwerp Nitric Acid plant 3 Europe 2003

Project Scope N2O emission reduction using high temperature selective catalytic reduction extra

catalyst bed install in the ammonia burner in the process chain

Technology to be employed BASF high temperature selective catalyst reduction

Task Manager

CDM Small Scale Project Type Reduce emission by source and directly emit less than 15 kt of CO2

GHGs targeted N2O




Project Profile 3CDM Methodology NM 0061 “N2O Emission Reduction in onsan South Korea” Approved in CDM-EB-18

2005 requested to reformatted version of this methodology as in AM 0021 “Decomposition of N2O from existing adipic acid production plant”

Project type Investor equity



N/A

Potential ERs Potential ER generation ≈ 2.22 million tCO2-e until 2012



Status/Issue Company awareness is addressed by CDM capacity development project, PIN and PDD in phase preparation in cooperation with the En Nasr Fertilizers & Chemicals

Barriers to project Development

None




Project Profile 5Project name N2O Reduction – Nitric Acid Production

CDM priority High

Location Egyptian Chemicals Company (KIMA) Aswan Egypt

Project ID AMI Agrolinz Melamine international Gmb Hinlinz / Austria 2003

Project Scope N2O emission reduction using low temperature selective catalytic reduction through

an extraction reactor installation in off-gas of nitric acid production process

Technology to be employed Krupp Uhde low temperature selective catalyst for decomposition of N2O

Task Manager

CDM Small Scale Project Type Reduce emission by source and directly emit less than 15 kt of CO2

GHGs Target N2O

CDM Methodology NM 0061 “N2O Emission Reduction in onsan South Korea” Approved in CDM-EB-

18 2005 requested to reformatted version of this methodology as in AM 0021 “Decomposition of N2O from existing adipic acid production plant”




Project Profile 5Project Type N/A



N/A

Potential ERs Potential ER generation ≈ 5.56 million tCO2- e until 2012



Status / Issues Company awareness is new addressed by CDM capacity development project, PIN and PDD in preparation in cooperation with the Abu Qir fertilizers company staff

Barriers to project Development Non




General conclusions and Recommendation

1- MarketThe market is promising but depends strongly on the speed of implementation of climate policy.

2- TechnologyThe overall evaluation for best available techniques for nitrous oxide reduction catalysts results in the following ranking

• Norsk Hydro• Basf• Krupp Uhde• Grande Paroisse• ECN – SCR

•The cost of implementing the reduction methods vary from 0.83 to 3.77 Eur per ton 100% - nitric acid produced. The Norsk Hydro method has the lowest nitric acid price increase if this method is implemented.




3- For Egyptian Nitric acid PlantMost likely selected N2O reduction technology are Basf and Krupp Uhde technologies.

4- Egyptian Potential Market Volume

Company Location Plant capacityKton Nitric Acid

N2O emission

Kton N2O/year

N2O emission

(CO2 – equivalent)

Kton/year

Abu Qir Fertilizers / Alexandria

600 8.6 2666

El Nasr Fertilizers & Chemicals / Suez

198 1.69 524

Delta Fertilizers and Chemical / Dakahlia

264 2.976 922

Egyptian Chemicals Industries (KIMA) Aswan

264 3 933

1326 16.266 5045




Recommendations

• Comparison of the different N2O-reduction methods is difficult because of lack of data and insufficient comparable data. To improve the comparability of test results, the tests should be performed in the same ranges. These conditions are :

Inlet concentration N2O

Gas flow in the reactor

Internal diameter of the reactor

Bed height of the catalyst bed

Residence time in the catalyst bed

N2O-reduction




•The parameters for the calculation of the cost effectiveness and the reduction cost per ton HNO3 produced should be set as well and these data are :

Material cost for the construction of the catalyst bedProcurementConstituenciesExtra reactor for N2O-reduction (if applicable)Catalyst costCatalyst installation and production costsLost production due to catalyst installation/changeInsuranceMaintenancePropane or other aiding components used (if applicable)Extra heat exchanger (if applicable)Other costs

•Nitrous oxide emission data from nitric acid plants data need to be measure in more accurate method to obtain right profile for Egyptian market volume

Dr. T. M. Sami

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