1

EKORLimited Liability CompanyResearch & Engineering Enterprise

The system for monitoring and control of neutralization processes in ammonium nitrate

production

Director Dovgalov Leonid +380503287217 ISO 9001:2008

2

The system for monitoring and control of neutralization processes in ammonium nitrate production is a complex of equipment and sensors for measurement and control of the following parameters:

nitric acid concentration in the reactors;

ammonia concentration in the neutralizers;

ammonia concentration in the buffer tanks.

3

System for monitoring and control of neutralization processes in ammonium nitrate production. Block diagram.

4

External view of instrument board, sensor and operator’s workplace.

5

The operation of the system is based on the following relationships:

redox potential of fluid as a function of nitric acid and ammonia concentration; redox currents as a function of nitric acid and ammonia concentration

6

Plot of redox potential of ammonium nitrate solution as a function of ammonia and nitric acid concentration at 160оС

300

400

500

600

700

800

900

1000

Концентрация избыточной азотной кислоты или аммиака, г/л

Пот

енци

ал о

тнос

ител

ьно

хлор

сере

брян

ого

элек

трод

а ср

авне

ния,

мВ

0 кислотааммиак 512 9

Pote

ntia

l rel

ativ

e to

silv

er c

hlor

ide

refe

renc

e el

ectr

ode,

mV

ammoniaConcentration of excess nitric acid or ammonia, g/l

acid

7

Plot of redox currents of ammonium nitrate solution as a function of ammonia and nitric acid concentration at 160оС

-4000

-3000

-2000

-1000

0

1000

2000

-300 -100 100 300 500 700 900 1100 1300 1500

потенциал относительно хлорсеребряного электрода сравнения, мВ

ток

(усл

овны

е ед

иниц

ы)

нейтральная среда избыток азотной кислоты 5 г/лизбыток азотной кислоты 10 г/л избыток азотной кислоты 15 г/лизбыток аммиака 0,4 г/л

Область определения кислоты Область определения аммиакаОбласть определения терморазложения

neutral environmentexcess of nitric acid 10 g/lexcess of ammonia 0.4 g/l

excess of nitric acid 5 g/lexcess of nitric acid 15g/l

Define area of acid Define area of thermal decomposition Define area of ammonia

Cur

rent

(con

vent

iona

l un

its)

Potential relative to silver chloride reference electrode, mV

8

The design of the concentration sensor gives a possibility to operate it under the following conditions:

at high temperatures (up to 190оС) at high pressures (up to 8 atm) in aggressive serviceA special feature of the

concentration sensor is that it can be located directly in process solution stream inside the equipment or piping.

Concentration sensor

9

Software

monitors the excess nitric acid and ammonia measurement process

controls the nitric acid and ammonia supply displays the process parameters as numeric values displays the process parameters as trends allows to store data and view the process history

10

Program text window view

The current value of concentration, measured by the System

The current value of concentration, measured by the System

Recalculation coefficient

Current date

Current time

Data file name

Free disk space

Status bar

Information window

Control of regulation indicator Cursor Indicator of the work of program

11

Program graphic window viewThe position of the unit in which the sensor is installed

Color of the diagram point

Name of the diagram point

Column diagram

Value of parameters in time

Percentage lines

Current date

Current hour Time axis Marker of current time Control of regulation indicator

Indicator of the work of program

12

Picture of graphic window of operator’s workplace.

13

The system for monitoring and control of neutralization processes in ammonium nitrate production is operated at the following plants: JSC “Severodonetsk Azot Association” (Ukraine) JSC “Concern “Stirol” (Gorlovka, Ukraine) JSC “Rovnoazot” (Ukraine) JSC “Azot” (Cherkassy, Ukraine) JSC “Azot” (Rustavi, Georgia) JSC “Cherepovets Azot” (Russia) JSC “KuibyshevAzot”(Toliatti) JSC “Azot” (Novomoskovsk) JSC “Farg’onaAzot” (Uzbekistan) Chemical Complex “KazAzot” (Aktau, Kazakhstan) JSC “Achema” (Jonava, Lithuania) HIP Azotara (Panchevo, Serbia) Complex “Alzofert” (Algeria) ZA «Pylawy» (Poland) JSC «Azot» (Russia)

14

The introduction of the system enabled to run the process optimally at different ammonium nitrate production stages

15

16

The Patent of Ukraine and Permission for system application in Russian Federation are available.

17

The proposed system enables to:

improve the neutralization process control quality optimize the ammonium nitrate production process enhance the process safety reduce emissions to atmosphere improve the final product quality

18

The economic benefit from the introduction of the system is achieved owing to the following:

reduced emissions of ammonia, acid and ammonium nitrate to the atmosphere

decreased energy consumption for evaporation of ammonium nitrate solution

reduced costs for waste water treatment decreased corrosion damages to process equipment less number of operating personnel improved ammonium nitrate quality and reduced

quantity of off-spec product

19

The economic benefit from the introduction of the system achieved due to reduction of emissions at 500000 tpy capacity is about 700 thousand USD.

0

1

2

3

4

5

6

7

8

a b a b a b

a- before installation of the system b- after installation of the system

NH3 NH4NO3 HNO3

Concentration, g/l

20

The scope of supply includes: complete set of the system; erection supervision of sensor connection units; erection of sensors and instruments of the system; adjustment of the system; preparation of technical description and operating manual; operating personnel training; performance test run and commissioning of the system.

The erection of sensor connection units and cable routing are in Customer’s scope.

The proposed system is introduced into production during 4 months.