Waste Minimization Waste Minimization in Fertilizer Industryin Fertilizer Industry

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ContentContent Introduction of fertilizer industry Challenges faced Sources and types of waste

generation Waste minimization Means of waste minimization Case Study Laws and regulation Conclusion

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IntroductionIntroduction

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Pre Liberalization

Post Liberalization

1950 -51: 1/4th of

Global Average

Public Sector

Companies

Co-operative

Sector

1977: Retention

Price Scheme

(Govt. to aid

Farmers)

1992: Reducing

Subsidy

1992: Decontrol

Phospatic and

Potashic Fertilizers

1992: Retention

Policy Confined

to Urea only

2000: Long Term

Fertilizer Policy

29 MM tons of

demand in 2010

35 MM tons of

demand forecasted

2012

More Projects in

Pipeline

Penetration in

Overseas Market

Gujarat to play

Key role

Future Trends

Fertilizer IndustryFertilizer IndustryPhase 1: 2000-01 and 2001-02

Evaluate existing capacity.

Increase in urea prices from time to time.

Evaluate the possibility of a coal based expertise.

Promote joint ventures.

Finalize policy on fertilizer pricing and capacity enhancement.

Eliminate distribution controls on urea and augment concession

scheme to bio fertilizers.

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Fertilizer IndustryFertilizer IndustryPhase II (2002-03 and 2003-04)

Finalize decision on feedback.

Long term strategy of increased capacity.

Decide on extent of protection to local industry.

Eliminate MRP and encourage productive investment.

Reorganize the association between the industry and farmers.

Judicious utilization of fertilizer and greater emphasis on

ecofriendly fertilizer.

Establish Fertilizer Policy Planning Board.

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Fertilizer IndustryFertilizer IndustryPhase III (2004-05 and 2006-07)

Removal of MRP

Define government's role in decontrol setup and with respect to policy

relating to LNG.

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Fertilizer IndustryFertilizer IndustryW T O Implications:

The restriction on quantity of fertilizers to be imported has been

eliminated from April 1, 2001.The proposed plan to establish a tariff rate

quota (TRQ) for the import of urea has been deferred.

The Government has planned to impose a higher tariff of 150-200 per

cent on imported urea in future. This would lead to increase in prices of

imported urea and be detrimental to the demand supply gap which is likely

augment in future.

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Challenges FacedChallenges Faced Retention Price Scheme Elimination

International Competition: WTO Implications

Inherent inefficiencies

Losses are born by govt.

Chemical fertilizers: Soil Degradation

Development of Bio-fertilizers

Shortage of Feed Stock: imports of potash, natural gas, urea etc

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Sources and types of Sources and types of wastagewastage

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RawMateria

ls

ManufacturingProcess

NitrogenFertilizers

PhosphorusFertilizers

AmmoniaProduction Nitric

Production

UreaProduction

Phosphogypsum

Phosphoric Acid

Green HouseEmissions

Land Degradation

Due to Mining Radium

Types of WastesTypes of Wastes

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Air EmissionAir Emission Green House Emissions Ammonia production:

SO2, NOx, CO, CO2, H2S, VOCs, PM, CH4, HCN, NH3 Nitric Acid production:

Nitric Oxide, Nitrogen Dioxide and trace amounts of Nitric Acid mist Urea Production:

Ammonia, Particulate matter

Originates from- Process condensate Closed-loop cooling tower blow down Closed-loop boiler blow down

Main contaminants from Nitrogen plants:

Ammonia, Nitrate Nitrogen & Organic Nitrogen

Waste WaterWaste Water

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Solid WasteSolid Waste Spent Catalysts- from ammonia & nitric acid production

Solid wastes or by-products can include pyrite ashes, calcium carbonate, sand & plastic

bags used to transport & packaging waste

Phosphogypsum stacks: TENORM

Ra-266

fig. Phosphogypsum Stacks

Stacks are constructed with little or no soil preparation

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Waste MinimizationWaste Minimization Waste minimisation aims to eliminate waste before it is

produced and reduce its quantity and toxicity. Prevention is the

primary goal, followed by reuse, recycling, treatment and appropriate

disposal.

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Why Waste Minimization?Why Waste Minimization?

Meeting the compliance

Saving resources and energy

Increasing the productivity

Reducing pollution

Increasing the efficiency of production

Means for waste Means for waste minimizationminimization

Waste Hierarchy

3R Concepts

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Solutions to Increase Efficiency Solutions to Increase Efficiency and Reduce Waste in Fertilizer and Reduce Waste in Fertilizer Manufacturing CompaniesManufacturing Companies Meter and control the quantities of active ingredients

Reuse by-products from the process as raw materials

Reuse by-products as raw material substitutes in other processes

Use automated filling to minimize spillage

Use nitrogen blanketing

Give preference to non halogenated and non aromatic solvents

Use high-pressure hoses for equipment cleaning

Use equipment wash down waters and other process waters (such as

leakages from pump seals) as makeup solutions for subsequent batches

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Use dedicated dust collectors to recycle recovered materials

Vent equipment through a recovery system

Maintain losses from vacuum pumps at low levels

Return toxic materials packaging to the supplier for reuse or

incinerate/destroy in an environmentally acceptable manner

Minimize storage time of off-specification products

Find productive uses for off-specification products

Minimize raw material and product inventory

Solutions to Increase Efficiency Solutions to Increase Efficiency and Reduce Waste in Fertilizer and Reduce Waste in Fertilizer Manufacturing CompaniesManufacturing Companies

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Promotion of Waste Minimization- Promotion of Waste Minimization- Some ExamplesSome Examples

Reuse of wasted material from acetylene production plant in Egypt

Production of Sodium Flu silicate from Wasted Material in single

super phosphate industry

Control and Recovery of Phosphorous Pentoxide Emission in a

Rodencide Production Plant

Reuse of phospho gypsum from phosphate fertilizer industry in

cement industry

Reuse of lime sludge from fertilizer industry for Lime Pozzolina

mixture

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Case StudyCase StudySolar water heating (SWH) system for

preheating boiler feed water To generate hot water for preheating boiler feed water In order to reduce the fuel consumption in the boiler, it was

decided to install SWH system

Benefits: Reduction in 80-100 tons of LSHS per year Reduction in SO2 emission levels

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System specification

Installed capacity 1, 20,000 litres / daySolar collectors 1305 (2 m^2 absorber area each)storage tanks 4 (60,000 lit)Total investment Rs. 155 lakhsSavings achieved Rs. 14.4 lakhs/yearDepreciation benefits Rs. 54.6 lakhPayback period (after considering subsidies & depreciation benefits

Less than 3 years

The Case Study Booklet on Renewable Energy by Published by Confederation of Indian Industry

Production of Sodium Flu silicate from Wasted Material

The company produced single super phosphate fertilizer and sulphuric

acid as main products and ferrous sulphate as a by product

Waste water discharged directly into the Nile River is a very acidic

waste and contains fluoride (3257 mg/l), silicate (3480 mg/l) and

phosphate (110 mg/l)

Waste water produced was utilized to produce sodium Flu silicate (Na2

SiF6), a preservative for Portland cement

Benefits:

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Design, construction and implementation of a full scale unit for the

production of Na2SiF6 were carried out and put into operation.

Reduced the pollution load by 40% and saved 2 million L.E/y the

payback period was 0.6 month

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Proceedings of International Symposium on Environmental Pollution Control and Waste Management 7-10 January 2002, Tunis (EPCOWM’2002), p.229-235.

Laws and regulationLaws and regulation

Government Policies and Support for

Cleaner Technology National Environment Policy of 2006, which incorporates the

concept of the 3Rs- Reduce, Re-use, Recycle

Charter on Corporate Responsibility between the Government

and 17 major polluting industries

A registration scheme for recycling of wastes has been

established

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ConclusionConclusion

Fertilizer industry being chemical process

industry, naturally produces waste which are harmful

for all the stakeholders. Though there are efforts from

government bodies and industry, still there is a scope

to reduce waste by new technology and innovation.

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