DPSA: Assignment A3

Individual Report

Agrochemicals: Ammonium Nitrate

Amar Bhogal

Student ID: 1454157

Abstract
Ammonium nitrate is a high nitrogen content fertiliser used to increase plant
growth. It is commonly used in agriculture in order to increase the yield of crops
by supplying nitrogen, originally from the atmosphere, to the plants. However,
the use of ammonium nitrate does come with some issues. It is extremely
flammable and when applied incorrectly, can harm the environment due to
leaching of nitrates into water systems. Because of the hazards it poses, strict
guidelines have been put in place for its transportation and storage. However,
use of fertiliser such as ammonium nitrate is becoming ever more important with
global populations rising, putting more pressures on the agricultural industry to
produce the food the world needs. This paper looks at how this fertiliser works,
how it is produced, how to ensure correct application and some of the health and
safety hazards associated with it.

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Table of Contents

Abstract 1

Introduction 2

What makes ammonium nitrate suitable for use as a fertiliser?

2

Production and Manufacture

3

Application and Dangers of Over Application

5

Regulations and Guidelines on Storage and Transportation

6

Conclusions 7

References 8

Introduction
Ammonium nitrate is a chemical widely used as a high nitrogen fertiliser in order
to increase the productivity of various crops. Ammonium nitrate is the nitrate salt
of the ammonium ion, and has the chemical formula NH 4NO3. It is normally found
in a granular or a powder like form, but like sodium chloride, is a white crystalline
solid. For ease of use in the agricultural industry, ammonium nitrate is processed
into smaller prills, which allow for easier transportation and means the dosage is
more easily measured. Ammonium nitrate can also be used as an ingredient in
explosives, and because of this, has gained somewhat of a more negative
reputation in recent years.
The discovery of ammonium nitrate is widely accredited to Johann R. Glauber
(Foldvary, 2001). He first synthesised the chemical by simply mixing two
solutions of ammonium carbonate and nitric acid, allowing the ammonium ions
from ammonium carbonate to react with the nitrate ions from the acid, forming a
new nitrogen rich ionic compound.
As a fertiliser, ammonium nitrate is often used in conjunction with chemicals
containing phosphorous and potassium to create NPK fertilisers. These fertilisers
provide all of the essential elements, nitrogen, phosphorous and potassium, that
plants require to grow and so are widely used throughout the agricultural
industry.

What makes ammonium nitrate suitable for use as a fertiliser?

The most important feature of ammonium nitrate which makes it such an
effective fertiliser is the high nitrogen content in the actual ion itself. By
molecular weight, ammonium nitrate is 35% nitrogen, compared to 21% for
ammonium sulphate, another popular nitrogenous fertiliser. This high nitrogen

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percentage gives ammonium nitrate an advantage over other fertilisers as it can
deliver a much higher ratio of nitrogen to the plant per unit weight of fertiliser.
Plants require nitrogen mainly for the synthesis of nitrogenous amino acids.
Plants cannot use atmospheric nitrogen for this because it is very inert and
plants do not possess the necessary enzymes to facilitate the breakdown of the
triply bonded diatomic nitrogen molecule. Therefore, plants must absorb other
nitrogenous molecules in order for them to synthesise the required amount of
amino acids to allow the plants to grow. Relating this to agriculture, the more
nitrogen available to crops, the bigger they are likely to grow, which will mean
better yields for farmers and therefore more profit.
Nitrate ions (NO3-) can easily be absorbed by plants through their roots. Unlike
the ammonium ion, it is often readily available in the soil. Nitrates are highly
soluble in water and therefore travel quickly in the soil to reach plant roots.
Applying nitrogen as ammonium nitrate therefore provides an instant nutrient
supply. Ammonium (NH4+) is directly taken through the roots very slowly. Most of
the ammonium is transformed into nitrate by soil microbes. This process
depends on temperature due to enzyme catalysed reactions, and takes between
one and several weeks. All of the nitrogen in the fertiliser, whether ammonium or
nitrate, will become nitrates before the plant can absorb it through its roots. This
combination of ammonium and nitrate ions allows both an immediate uptake of
nitrogen and a more sustained source of nitrogen which means that the fertiliser
needs to be applied less regularly. (YARA, 2011)
There are two main types of ammonium nitrate fertiliser (HSE, 2004):
Straight ammonium nitrate fertiliser - contains ammonium nitrate to provide the
essential element nitrogen, although it may also contain inert fillers to bulk up
the fertiliser, such as sand, soil or ashes.
Compound fertiliser - contains ammonium nitrate mixed with salts that contain
water soluble potassium and phosphate to supply the essential elements;
nitrogen, potassium and phosphorus to plants. They are more commonly known
as NPK fertilisers.

Production and Manufacture

The nitrogen used to produce ammonia comes from the environment via the
Haber process. Therefore the nitrogen that will be used by the plants is
atmospheric nitrogen, which the plants had previously been unable to access.
All ammonium nitrate plants produce an aqueous ammonium nitrate solution
through the reaction of ammonia and nitric acid in a neutralizer as follows:

[NH4]++ [NO3] - NH4NO3

This reaction normally takes place in a neutralizer where water evaporates from
the heat produced by the reaction to increase the concentration of the solution.
Higher temperatures and pressures can be used to produce a higher
concentration of ammonium nitrate; however, the temperature of the neutraliser
should never exceed 120C to minimise the risk of explosions. Up to 99.5% of the
ammonia and nitric acid is fully converted to ammonium nitrate. This ammonium
nitrate solution is then used to manufacture the prills that ammonium nitrate is
transported in.

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To produce this solid product, the aqueous ammonium nitrate solution is
concentrated even further in an evaporator. The resulting liquid melt contains
about 95 to 99.8% ammonium nitrate at 149C. This melt is then processed to
make solid ammonium nitrate products.
Prilling or granulation can be used to produce solid ammonium nitrate. Prills are
small globules or pellets. In the production of prills, melt is sprayed in at the top
of a specialised prill tower. In the tower, melt droplets fall into a rising cool air
current that solidifies the falling drops into prills. The density of the prills is easily
varied by changing the density of the ammonium nitrate solution used to make
the melt. Low-density prills are formed from a 95 to 97.5% ammonium nitrate
melt, while high-density prills are formed from a 99.5 to 99.8% melt. Nearly all
fertilisers are made from higher density ammonium nitrate prills.
Granulated ammonium nitrate is produced by spraying the concentrated melt
(99 - 99.8%) onto smaller particles of ammonium nitrate in rotating cylindrical
drums. As the particles rotate in the drum, more and more layers of the
ammonium nitrate melt are sprayed on to the particles, adding layers and
forming granules. Additives like magnesium nitrate and magnesium oxide may
be added directly into the melt stream. Additives such as these serve three
purposes: to increase the density and strength of the final product, to act as a
drying agent, and to allow solidification of the granules to occur at reduced
temperature by reducing the freezing point of molten ammonium nitrate.

(Cheremisinoff, Nicholas P. 2011)

The temperature of the ammonium nitrate exiting the prilling or granulation

formation process is approximately 66 to 124C. To prevent deterioration and
clumping, the product must be cooled before it is stored and shipped. Typically,
rotary drums are used to cool granules and prills leaving the solids formation
process. Because low-density prills have a high moisture content, they also
require drying to remove excess moisture in rotary drums before cooling.
Since the solids are produced in a range of sizes, they must be screened for
similar sized prills or granules. Any irregularly sized prills are dissolved and
recycled back to the solution concentration process. Granules are screened
before cooling. Smaller particles are returned directly to the granulator and
larger granules may be either crushed and returned to the granulator or sent to
the solution concentration process. Following screening, products can be coated
with clay or earth in a rotary drum to prevent agglomeration during storage and
shipment. (Cheremisinoff, Nicholas P. 2011)

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To be able to design a manufacture process on this product, more information on
the synthesis of ammonia and nitric acid would be required. It would be optimal
to synthesise both of these chemicals in the same plant as the manufacture of
the fertiliser as this would reduce transport costs, and be more cost effective
than purchasing the ammonia and nitric acid from a third party. Because of this,
more information on the Haber process and the synthesis of nitric acid would be
required, including the equipment required and the parameters of the process,
such as flowrates, temperatures and pressures needed at each stage.
Cost and time would be the main aspects that would drive the process selection.
Obviously time and cost will be carefully considered, to be able to produce as
much fertiliser as is possible over short periods of time. For these reasons, a
continuous process would be more suitable for the production of ammonium
nitrate fertiliser than a batch process. Another consideration to take into account
is that it may be worth also building plants to produce phosphate and potassium
based fertilisers. This way, the three plants would be able to produce compound
fertilisers, which are more desirable as they contain all the essential elements
plants need to thrive in a single product.

Application and Dangers of Over Application

Ammonium nitrate is most commonly applied in prills, small globules that can be
applied directly to the soil of the crop. The fertiliser is evenly spread out over the
crop and allowed to rest on top of the soil, where the prills break down and the
ammonium and nitrate ions are be able to mix into the soil itself. The fertiliser is
applied directly to the crop from a disc or spout that
is directly behind a tractor.
As shown on the above graph, the optimum
nitrogen application (in terms of grain yield) for
crops is 175 kilograms newtons per hectare with a
residual amount 30 kilogram newtons per hectare
of nitrogen. Combining these two pieces of data, to
maximise grain yield in crops, 205 kilogram
newtons per hectare of nitrogen should be in the
soil of the crop. The residual quantity of nitrogen
in the soil can be analysed so that farmers
(YARA, 2011)
know the amount of ammonium nitrate
fertiliser to apply so that they can reach a
total of 205 kilogram newtons per hectare and maximise their crop yield (YARA,
2011). It is important than grain yield is maximised, especially with the current
predicament the world is facing. The population of Earth is rising rapidly, and
more food is required to fuel this ever growing population. By increasing grain
yield, more food is being produced per unit area, and crops are becoming more
productive. If humans can continue to maximise grain yield, combining the use of
fertilisers with other methods, there will be enough food for the growing
population to thrive.
Nitrates are extremely soluble in the soil solution and, unlike ammonium, do not
cling on to soil particles. Once the soil becomes wet, nitrates may leach into field
drains or into nearby water systems as the drainage water moves through the
soil. Leaching is more rapid on light sandier soils which drain very quickly and
have a low water retention. This means the level of rainfall after application of

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the fertiliser hugely affects the amount of nitrate leached to the environment and
the next rainfall should be taken into consideration when fertiliser is being
applied. Although ammonium ions normally cling to soil particles and is much
less likely to leach than nitrate, as under normal conditions ammonium is
converted to nitrate by soil microbes. In practice, sources of nitrogen such as
ammonium will have a similar risk of leaching as sources containing nitrate when
used in excess of the requirement of a crop.
During and following heavy rainfall, nitrogen in the soil can move along surface
and enter waterways disrupting natural ecosystems. The amount of nitrogen lost
from soil in this way will vary widely in different fields and depending on the
amount of rainfall. Because of this, it is important that the amount of ammonium
nitrate being applied onto a crop is controlled.
The main time that nitrates are leached from the soil is during winter when there
is increased rainfall. The overall objective is therefore to minimize soil nitrate
concentrations when the crop has been harvested. Further steps to reduce
leaching include analysing the nitrgoen content of soil on a regular basis, keping
a porous soil structure to allow water to penetrate soil fully, and applying
ammonium nitrate at interval to assure rapid take up by plants (YARA, 2011).
Nitrate leaching should be controlled as if nitrates get into the water system,
they can affect marine ecosystems. For example if the nitrate level rises above
420mg of NO3 per litre, the environment becomes toxic to fish and they will
either move away from the are or die. Aquatic invertebrates are more tolerant to
changes of nitrate level, but even they will be affected at 555mg of NO 3 per litre.
(CF Industries Sales, 2013)

Regulations and Guidelines on Storage and Transportation

Because ammonium nitrate can combust violently or even explode when it
comes into contact with a heat source, there are some regulations that have
been put in place regarding its manufacture and storage. With ammonium nitrate
fertilisers that contain more than 28% nitrogen, the risks of explosions are
increased by any of the following; heat, contamination or even whilst in
confinement, such as drains or closed off parts of equipment.
Ammonium nitrate fertilisers should be stored in dedicated, well-ventilated
buildings that are made inflammable materials, like steel or bricks and concrete.
To reduce contamination, it is recommended the store be cleaned thoroughly
before ammonium nitrate is stored there. However, when the stores are located
close to inhabited areas, it is often better to store the ammonium nitrate outside,
provided it is in a protected area away from any combustible materials. Outdoor
storage such as this highly reduces the risk of fires due to electrical equipment.
However, if ammonium nitrate is stored outdoors, it is necessary to ensure the
fertiliser cannot come into contact with sunlight or water, both of which would
deteriorate the fertiliser, for example, covering the fertiliser with shrink wrap
plastic. The storage area should be distanced from possible sources of heat, fire
or explosion, such as oil storage and wooded areas. Faulty electrical equipment is
a major risk factor for warehouse fires. Regular inspection and maintenance of

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electrical equipment and fittings should be ensured, and damage from animals
should be restricted by introducing a pest control system. (HSE, 2004)
Stacks of ammonium nitrate are limited to 300 tonnes as keeping the ammonium
nitrates in larger stacks increases the risk of the whole stack detonating in a fire.
This limit can be raised at purpose-built facilities for storage at manufacturing
sites, provided the material complies with the quality specification in the
Fertilisers Regulations 1991. To prevent fires and other heat sources from
affecting ammonium nitrate, and to allow access to the stacks in emergencies,
spaces of at least 1 metre between stacks and between the stack and the walls,
roof or any electric lights or heating pipes should be maintained. (HSE, 2004)
To prevent spillage and contamination, bags should be checked to see if they
have been correctly sealed on filling. The packaging must be made of an
inflammable material impermeable to water and oil, and strong enough to
withstand damage during normal storage and transportation.
It is imperative that no smoking is allowed anywhere in proximity to the
ammonium nitrate. The fire brigade should also be informed that ammonium
nitrate is being stored locally and plans should be made for giving early warning
of a fire, providing suitable access to the site and ensuring that an adequate
supply of water is available, or can be made available, to tackle any accidents.
The direct effects of the inhalation of the fumes of ammonium nitrate may not be
evident immediately, so if anyone is suspected of having inhaled such fumes,
they must be removed to a safe area where they should be kept warm and
rested, ideally lying down. Immediate medical help must then be sought.
Ideally, fertilisers should be transported in and out of buildings by a conveyor
system. The machinery used in the transportation of ammonium nitrate, such as
conveyor belts, should be made of inflammable materials to remove the risk of
fire or explosions. The equipment must be well maintained to avoid potential
heat sources and contamination. Where it is unpractical to use a conveyor
system, and a vehicle must be introduced into the store for transportation, it is
important that the vehicle is inspected for any oil and fuel leaks. Good
maintenance of vehicles is essential to prevent contamination. (HSE, 2004)
Regulations require anyone in Great Britain producing, importing or storing
certain specifications of ammonium nitrate to obtain a certificate to indicate that
the fertiliser has successfully passed a detonation resistance test (DRT). A DRT
certificate is required for material containing ammonium nitrate (including
mixtures) in which the nitrogen content exceeds 28% by weight. Quantities less
than 500 kilograms and material which is classified as explosives are exempt.
(AIC, 2007)

Conclusions
Ammonium nitrate is a highly effective fertiliser that is proven to increase the
yield of crops and aid plant growth. This is mainly down to its high nitrogen
content (35%), which allows plants to synthesise more amino acids, and
therefore leads to increased growth.
The production of ammonium nitrate is fairly simple (reacting ammonia with
nitric acid), but processing this ammonium nitrate into prills or granules, to allow
for easier transportation and application to crops is a far more complicated
process. To be able to design a process such as this, more information is

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required, such as the exact conditions, i.e. temperature, pressure, flowrates and
equipment, for the reaction between nitric acid and ammonia. All of the
chemicals required to produce ammonium nitrate could be synthesised on site
from raw materials to reduce costs. Phosphate and potassium fertilisers could
also be synthesised on site to create a complete compound fertiliser.
Ammonium nitrate use however does come with some issues. Leaching of
nitrates from the soil to the environment is a main concern as high nitrate levels
are toxic to marine life, and this can have a great consequence on ecosystems.
Because of this reason, ammonium nitrate should be avoided on sandier soils,
and be applied when no rain is predicted, as to prevent the washing away of the
fertiliser into nearby waterways.
Like all fertilisers, ammonium nitrates use is regulated. Ammonium nitrate is
especially hazardous due to its risk of combustion when in contact with heat.
Because of this, there are many guidelines on its storage and transportation.
However when these guidelines are followed, it is a safe fertiliser to use.
In conclusion, ammonium nitrate is an extremely useful fertiliser when it comes
to increasing grain yield. It is fairly simple to manufacture, and although its use
does come with certain hazards, both to the environment and in its storage, its
application is a highly effective method in increasing crop yields. This will be
especially important in the future. With populations rising, and more land being
used for housing, crops will have to produce increased yields in order to fuel the
growing population, and ammonium nitrate could be one of the most important
chemicals in allowing that to happen.

References
AIC (2007) Guidance Note for Manufacturers, Importers, Blenders, Transporters,
Store Keepers and Suppliers of Ammonium Nitrate Based fertilisers. Online
version available at:
https://www.agindustries.org.uk/latest-documents/guidance-note-ammonium-
nitrate-based-fertilisers

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Cheremisinoff, Nicholas P. Rosenfeld, Paul E.. (2011). Handbook of Pollution
Prevention and Cleaner Production, Volume 3 - Best Practices in the
Agrochemical Industry. Elsevier. Online version available at:
http://app.knovel.com/hotlink/toc/id:kpHPPCPVBB/handbook-pollution-
prevention/handbook-pollution-prevention
CF Industries Sales (2013) Material Safety Data Sheet Ammonium Nitrate. Online
version available at:
http://www.cfindustries.com/products_ammonium-nitrate.html
Foldvary, Fred. E (2001) Ammonium Nitrate: Regulate It. Online version available
at:
http://www.progress.org/tpr/ammonium-nitrate-regulate-it-2/
HSE (2004) Storing and Handling Ammonium Nitrate. Online version available at:
http://www.hse.gov.uk/explosives/ammonium/index.htm#storing-handling
YARA (2011) Nitrate fertilizer: Optimizing yield, preserving the environment.
Online version available at:
http://www.yara.com/doc/33521_Nitrate_-_Pure_Nutrient.pdf