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Cold spherodizers
Drum granulation
Pugmill
Pan granulation
These processes are used for products containing up to 34.5%N. For products that contain
up to 33.5% N, the pugmill, drum and cold spherodizers are used also [30,31]. These processes
operate the same way as for CAN. However, the ammonium nitrate melt concentrations (wt. %)
are different:
Drum
96-96.5
Pugmill
95.5-96
Pan granulation
99.5
99
97.5
With all methods, additives are obligatory for granulation and for improving storage
properties.
Dry recycled material is fed at a controlled rate to the inclined rotating pan
granulator. In the granulator a hot melt, which is virtually moisture free, is sprayed onto the
moving bed of solids and solidifies on the cool particles. Round granules are formed by
agglomeration, and, as their size increases, they move upwards in the rotating pan, finally
rolling over the rim. The granulation temperature is controlled by the rate at which solids are
fed to the pan. An optimum temperature range for agglomeration , within which a high
growth rate of the particles is obtained, is 5-25C below the temperature at which the
fertilizer melt solidifies. The recycle ratio under these conditions is about 0.5/0.7:1 for
ammonium nitrate. Granules leaving the pan are plastic and have a somewhat irregular
surface. They enter a polishing drum where they are exposed to mild mechanical forces and
smoothed. A certain amount of cooling also occurs. Cooling to the desired product
temperature is then performed in normal cooling equipment, such as fluidized bed or a rotary
drum. Depending on the climatic conditions at the plant site and the desired product
temperature, the cooling air may be conditioned. Cooled granules are conveyed to a screen.
Oversize material from the screen is fed to a crusher and the crushed material, undersize
granules, and dust from the cyclones, are recycled to the pan.
Because of the high melt concentration and temperature, a blue fume of submicron
ammonium nitrate- similar to the fume during prilling of high-density ammonium nitrate
has to be recovered for treatment. However, the air flow from the pan and polishing drum is
relatively small. A wet scrubber may be used for recovery; this is not usually practical in a
prilling process with a high rate of air flow from the top of the prilling tower. The air from
the product cooler is treated in wet or dry cyclones.
Pollution Control
As in all industrial operations, pollution control requirements for AN and CAN plants
have become more stringent in recent years. This has posed a difficult problem for highdensity AN prilling because of the large volume of air exhausted from prill towers and
because of the very small particle size of the fume in the air. Fuming is much more severe in
high-density prilling because the AN melt must be at higher temperature (about 180C) to
keep it from freezing. At this temperature there is an appreciable vapor pressure of NH3 +
HNO3 resulting from dissociation of AN, according to the equation:
SC-3
+
SC-4
AN-melt
Additive
Lime
GR-1
D-5
G-6
AN/CAN
G-2
Pan granulation of CAN has proven difficult because the pan is very sensitive to heat and
material balance factors. The product shape is irregular. The spherodizer processes and all
other processes need additives:
ammonium
Fluid bed:
98%-99% wt.
Pug-mill:
94.5%-95.5% wt.
Drum:
93.5%-94.5% wt.
In the Hydro-Agri fluid bed granulation process, dedusting of the airstreams from the
granulator and fluidized bed cooler is done by scrubbing with acidified weak AN solution. The
scrubbing solution is mixed with the lime/AN mixture prior to final evaporation.
In pug-mill granulation, the AN melt and the lime are proportioned in ratio control to the pugmill. Dust, undersize product, and crushed oversize are recycled to the pug-mill. The fresh, damp
granules pass to a drying drum, and the granules are screened hot. For drying, the off-gas from
the cooler is used. At full plant load the air heater for the dryer is turned off, and the plant
operates auto-thermally. The drying air is dedusted in dry cyclones; final dedusting is performed
in scrubbers. The on-size product is cooled in a fluidized bed cooler with conditioned air. Before
storage or bagging the product is coated. Spilled product is returned to the granulation loop.