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FERTILIZER INDUSTRY Overview Brief History Classification, Uses and Process Waste Production and Waste treatment Prospect as a Chemical Engineer and the future of the industryReporters:Elajah Mae ZaragozaAnnjanette AysonEaster Gloren ForondaJasen Emil De LeonFertilizers- Any material of natural or synthetic origin that is applied to soils or to plant tissues to supply one or more nutrients essential to the growth of plants.Three Macronutrients: Nitrogen Phosporus PotassiumFertilizers are classified in many ways. They are classified according to whether they provide a single nutrient in which case they are classified as "straight fertilizers." "Multinutrient fertilizers" (or "complex fertilizers") provide two or more nutrientsAncient HistoryEgyptians, Romans, Babylonians, and early Germans all are recorded as using minerals and or manure to enhance the productivity of their farms. The use of wood ash as a field treatment became widespread.1730Viscount Charles Townshend(1674-1738) first studied the improving effects of the fourcrop rotationsystem that he had observed in use inFlanders.

Early 19th Century

Johann Friedrich Mayer(1719-1798) was the first to present to the world a series of experiments upon it the relation ofgypsumto agricultureBRIEF HISTORYEarly 19th Century The French agronomist Victor Yvart (1763-1831) believed that the action of gypsum is exclusively the effect of the sulphuric acid, which enters into its composition; and founds this opinion upon the fact that the ashes of turf, which contain sulphate of iron and sulphate of alumina, have the same action upon vegetation as gypsum

The French agronomist Charles Philibert de Lasteyrie (1759-1849), observing that plants whose roots were nearest the surface of the soil were most acted upon by plaster, concludes that gypsum takes from the atmosphere the elements of vegetable life, and transmits them directly to plants.

Louis Augustin Guillaume Boscintimates that the septic quality of gypsum (which he takes for granted) best explains its action on vegetation

Humphry Davyfound that, of two parcels of minced veal, the one mixed with gypsum, the other left by itself, and both exposed to the action of the sun, the latter was the first to exhibit symptoms of putrefaction.

BRIEF HISTORYEarly 19th Century

ChemistJustus von Liebig(1803-1873) contributed greatly to the advancement in the understanding of plant nutrition.

John Bennet Lawes, an Englishentrepreneur began to experiment on the effects of various manures on plants growing in pots in 1837, and a year or two later the experiments were extended to crops in the field. One immediate consequence was that in 1842 he patented a manure formed by treating phosphates with sulphuric acid, and thus was the first to create the artificial manure industry.

Joseph Henry Gilbert, who had studied under Liebig at theUniversity of Giessen, as director of research at theRothamsted Experimental Stationwhich he founded on his estate.

BRIEF HISTORYEarly 19th Century

Jean Baptiste Boussingault(1802-1887) pointed out that the amount of nitrogen in various kinds of fertilizers is important.

MetallurgistsPercy Gilchrist(1851-1935) andSidney Gilchrist Thomas(1850-1885) invented theGilchrist-Thomas process.BRIEF HISTORYEarly 20th Century

The Birkeland-Eyde Process It was developed by Norwegian industrialist and scientistKristian Birkelandalong with his business partnerSam Eydein 1903, based on a method used byHenry Cavendishin 1784.

The Haber Process- In the early decades of the 20th century, theNobel prize-winning chemistsCarl BoschofIG FarbenandFritz Haberdeveloped theHaber processwhich utilized molecular nitrogen (N2) and methane (CH4) gas in an economically sustainable synthesis ofammonia(NH3). The ammonia produced in the Haber process is the main raw material of theOstwald process.

The Ostwald processTheOstwald processis achemicalprocessfor production ofnitric acid(HNO3), which was developed byWilhelm Ostwald(patented 1902).

Erling Johnson- In 1927Erling Johnsondeveloped an industrial method forproducing nitrophosphate, also known as theOdda processafter hisOddaSmelteverk ofNorway

BRIEF HISTORY

KRISTIAN BIRKELAND

SAM EYDE

CARL BOSCH

FRITZ HABER

WILHELM OSTWALDClassification of FertilizersBased on CompositionStraight FertilizersClassification of FertilizersBased on Composition Fertilizers which supply only one primary plant nutrient, namely nitrogen or phosphorus or potassium. eg. Urea, ammonium sulphate, potassium chloride and potassium sulphate. Complex Fertilizers Fertilizers two or three primary plant nutrients of which two primary nutrients are in chemical combination. These fertilizers are usually produced in granular form.eg. Diammonium phosphate, nitrophosphates and ammonium phosphate.Mixed FertilizersFertilizers that are physical mixtures of straight fertilizers. They contain two or three primary plant nutrients. Mixed fertilizers are made by thoroughly mixing the ingredients either mechanically or manually.Classification of FertilizersBased on Composition11Classification of FertilizersBased on Physical FormSolid FertilizersSeveral formsviz.Powder (single superphosphate),Crystals (ammonium sulphate),Prills (urea, diammonium phosphate, superphosphate),Granules (Holland granules),Supergranules (urea supergranules) andBriquettes (urea briquettes).

Classification of FertilizersBased on Physical FormLiquid FertilizersLiquid form fertilizers are applied with irrigation water or for direct application.Ease of handling, less labour requirement and possibility of mixing with herbicides have made the liquid fertilisers more acceptable to farmers.

Classification of FertilizersBased on Physical FormPlants need sun, water and nutrients to grow. The nutrients can be taken from air or soil. If there is an ample supply of nutrients in the soil, crops are more likely to grow well and produce high yields. If even one of the nutrients needed is in short supply, plant growth is limited and crop yields are reduced.

Fertilizers are needed to obtain high yields because they supply crops with the nutrients the soil lacks. By adding fertilizers, crop yields can often be doubled or even tripled. The UN Food and Agriculture Organization (FAO) Fertilizer Programme undertook extensive demonstrations and trials in 40 countries over a period of 25 years. The weighted average increase resulting from the best fertilizer treatment for wheat was about 60%.

Uses of FertilizerFertilizers ensure the most effective use of both land and water. Where rainfall is low or crops are irrigated, the yield per unit of water used may be more than doubled and the rooting depth of the crop increased through fertilizer application.

Every plant nutrient, whether required in large or small amounts, has a specific role in plant growth and food production. One nutrient cannot be substituted for another.

Uses of Fertilizer

Soil pH effect on plant rootsImproves the growth and yield of cropsNitrogen is the motor of plant growth. It is taken up from the soil in the form of nitrates or ammonium. As the essential constituent of proteins, nitrogen is involved in all the major processes of plant development and yield formation.

Nitrogen NPhosphorus P (Phosphate)Speeds up crop maturity and improves qualityPhosphorous performs a key role in the transfer of energy. It is essential for photosynthesis and other chemico-physiological. Phosphorous is indispensable for cell differentiation, as well as for the development of the tissues that form a plants growing points. Most natural and agricultural soils are phosphorus deficient. When there are problems with phosphorous fixation, this also limits its availability.

Helps fight crop disease and improves qualityPotassium activates more than 60 enzymes, (the chemical substances that govern life and play a vital part in carbohydrate and protein synthesis). It improves a plants water regime and increases tolerance to drought, frost and salinity. Plants that are well supplied with potassium are less affected by disease.

Potassium KFertilizer Manufacturing Process- Fully integrated factories have been designed to produce compound fertilizers. Depending on the actual composition of the end product, the production process will differ from manufacturer to manufacturer. Basic Fertilizer ManufacturingNitrogen fertilizer component Ammonia is one nitrogen fertilizer component that can be synthesized from in-expensive raw materials. Since nitrogen makes up a significant portion of the earth's atmosphere, a process was developed to produce ammonia from air.

Haber processIn this process, natural gas and steam are pumped into a large vessel. Next, air is pumped into the system, and oxygen is removed by the burning of natural gas and steam. This leaves primarily nitrogen, hydrogen, and carbon dioxide. The carbon dioxide is removed and ammonia is produced by introducing an electric current into the system. Catalysts such as magnetite (Fe 3 O 4 ) have been used to improve the speed and efficiency of ammonia synthesis. Any impurities are removed from the ammonia, and it is stored in tanks until it is further processed.

Haber processOstwald process

Phosphorous fertilizer component ExtractionTo isolate phosphorus from phosphate rock, it is treated with sulfuric acid, producing phosphoric acid. Some of this material is reacted further with sulfuric acid and nitric acid to produce a triple superphosphate, an excellent source of phosphorous in solid form. Some of the phosphoric acid is also reacted with ammonia in a separate tank. This reaction results in ammonium phosphate, another good primary fertilizer.

Potassium fertilizer component Potassium chloride is typically supplied to fertilizer manufacturers in bulk. The manufacturer converts it into a more usable form by granulating it. This makes it easier to mix with other fertilizer components in the next step.

GranulatingTo produce fertilizer in the most usable form, each of the different compounds, ammonium nitrate, potassium chloride, ammonium phosphate, and triple superphosphate are granulated and blended together. One method of granulation involves putting the solid materials into a rotating drum which has an inclined axis. As the drum rotates, pieces of the solid fertilizer take on small spherical shapes. They are passed through a screen that separates out adequately sized particles. A coating of inert dust is then applied to the particles, keeping each one discrete and inhibiting moisture retention. Finally, the particles are dried, completing the granulation process.

The different types of particles are blended together in appropriate proportions to produce a composite fertilizer. The blending is done in a large mixing drum that rotates a specific number of turns to produce the best mixture possible. After mixing, the fertilizer is emptied onto a conveyor belt, which transports it to the bagging machine.

BlendingFERTILIZERS ADDITIVESCONDITIONERSThese are low grade organic materials like peat soil, paddy husk, groundnut hulls etc., which are added to fertilizer mixtures during their preparation for reducing hygroscopicity and to improve their physical condition.

FILLERA filler is a weight make material like sand, soil, coal powder etc, added to the fertilizer ingredients so as to produce a mixture of the desired grade.

NEUTRALIZERS OF RESIDUAL ACIDITYThese are the materials like dolomite, lime stone etc, added in fertilizer mixtures to counteract the acidity of nitrogenous fertilizers.

Fertilizers are typically supplied to farmers in large bags. To fill these bags the fertilizer is first delivered into a large hopper. An appropriate amount is released from the hopper into a bag that is held open by a clamping device. The bag is on a vibrating surface, which allows better packing. When filling is complete, the bag is transported upright to a machine that seals it closed. The bag is then conveyed to a palletizer, which stacks multiple bags, readying them for shipment to distributors and eventually to farmers.

Bagging

Quality Control To ensure the quality of the fertilizer that is produced, manufacturers monitor the product at each stage of production. The raw materials and the finished products are all subjected to a battery of physical and chemical tests to show that they meet the specifications previously developed. Some of the characteristics that are tested include pH, appearance, density, and melting point. Since fertilizer production is governmentally regulated, composition analysis tests are run on samples to determine total nitrogen content, phosphate content, and other elements affecting the chemical composition. Various other tests are also performed, depending on the specific nature of the fertilizer composition.

fertilizer's manufacturing waste and treatmentWATERAgricultural run-off is a major contributor to the eutrophication of fresh water bodies. For example, in the US, about half of all the lakes are eutrophic. The main contributor to eutrophication is phosphate, which is normally a limiting nutrient; high concentrations promote the growth of cyanobacteria and algae, the demise of which consumes oxygen. Cyanobacteria blooms ('algal blooms') can also produce harmfultoxinsthat can accumulate in the food chain, and can be harmful to humans.

fertilizer's manufacturing waste and treatmentNitrate pollutionOnly a fraction of the nitrogen-based fertilizers is converted to produce and other plant matter. The remainder accumulates in the soil or lost as run-off. High application rates of nitrogen-containing fertilizers combined with the high water-solubility of nitrate leads to increased runoffintosurface wateras well asleachinginto groundwater, thereby causinggroundwater pollution

fertilizer's manufacturing waste and treatmentSOILNitrogen-containing fertilizers can causesoil acidificationwhen added.This may lead to decreases in nutrient availability which may be offset byliming.

Accumulation of Toxic ElementsCadmiumThe concentration ofcadmiumin phosphorus-containing fertilizers varies considerably and can be problematic

FluoridePhosphate rocks contain high levels of fluoride. Consequently, the widespread use of phosphate fertilizers has increased soil fluoride concentrations.

fertilizer's manufacturing waste and treatmentRadioactive elementsThe radioactive content of the fertilizers varies considerably and depends both on their concentrations in the parent mineral and on the fertilizer production process. Uranium-238 concentrations range can range from 7 to 100 pCi/g in phosphate rockand from 1 to 67 pCi/g in phosphate fertilizers

Other MetalsSteel industry wastes, recycled into fertilizers for their high levels ofzinc(essential to plant growth), wastes can include the following toxic metals: leadarsenic,cadmium, chromium, and nickel. The most common toxic elements in this type of fertilizer are mercury, lead, and arsenic.

Changes in soil biologyHigh levels of fertilizer may cause the breakdown of the symbioticrelationships between plant roots andmycorrhizalfungi

fertilizer's manufacturing waste and treatmentfertilizer's manufacturing waste and treatmentContribution to Climate ChangeThegreenhouse gasescarbon dioxide, methaneandnitrous oxideare produced during themanufactureof nitrogen fertilizer. The effects can be combined into an equivalent amount of carbon dioxide.

fertilizer's manufacturing waste and treatmentRegulationsIn Europe problems with high nitrate concentrations in run-off are being addressed by the European Union's Nitrates Directive.Within Britain, farmers are encouraged to manage their land more sustainably in 'catchment-sensitive farming. In the US, high concentrations of nitrate and phosphorus in runoff and drainage water are classified as non-point source pollutants due to their diffuse origin; this pollution is regulated at state level.Oregon and Washington, both in the United States, have fertilizer registration programs with on-line databases listing chemical analyses of fertilizers.

Importance of Chemistry In Fertilizers Perfection of acid phosphate manufacture Harmful materials rendered useful Supply of nitrogen increased

Fertilizer Companies in Philippines AzAgri Products Corporatin Jcv Worldwide Traders Agricultural Greenhouses Natural Filipinas Corporation Rav Angel Intertrading Inc. TexiconAgri Ventures Corp. Fertilizer Philippines

The Future of the Industry Fertilizer research is currently focusing on reducing the harmful environmental impacts of fertilizer use.

Finding new, less expensive sources of fertilizers.

Yield increase

Fertilizer use efficiency

Private/public partnerships.

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