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确保优质的产品质量Assuring Premium Product Quality
CNFIA技术交流会,中国 . 鄂尔多斯,2015年7月15日—18日CNFIA Technology Conference, ERDOS CHINA, July 15-18, 2015
Mark Brouwer
www.UreaKnowHow.com尿素工业领域技术信息交流的网络平台,以提高尿素装置的运行性能和安全性能为目的
The internet platform to exchange technical information within the urea industry with the target to improve the performance and safety of urea plants
E-library
Partnerships
超过3600位会员,代表98%以上的全球尿素装置>3600 Members representing
>98% of all urea plants worldwide
UreaKnowHow.com促使安全和生产工艺的改进UreaKnowHow.com catalyzes
Safety & PerformanceBiweekly a Technical paper
Round Tables> 1000 discussions
目录 Content
- 概述 Introduction
- - 现有技术 Finishing technologies
- - 尿素成型方式 Various forms of urea
- 尿素产品质量 Urea Product Quality
- - 结块 Caking
- - 强度 Strength
- - 粉尘 Dust
- - 产品污染 Contamination
- - 混合肥再分离 Segregation
- 结论 Conclusions
现有技术Finishing technologies
尿素成型方式Various forms of Urea
高塔造粒装置 (±80% 的工厂)Prilling urea plants (±80% of plants)
• 附近消费
Local consumption
• 较小尺寸Smaller (1.7-2.1 mm)
• 较低强度Lower strength (1 kg/cm2)
现阶段 Finishing sections
流化床造粒装置 (±20% 的工厂)Fluid Bed Granulation urea plants (±20% of plants)
• 出口型工厂Export oriented plants
• 混合肥料配制Mixed fertilizer applications
• 较大尺寸 (典型 3 mm)Large size (typically 3 mm)
• 较高强度Higher strength (3 kg/cm2)
现阶段 Finishing sections
转鼓造粒装置 (±3% 的工厂)Drum Granulation urea plants (±3% of plants)
• 出口型工厂 Export oriented plants
• 混合肥料配制 Mixed fertilizer applications
• 较大尺寸 (典型 3 mm) Large size (typically 3 mm)
• 较高强度 Higher strength (3 kg/cm2)
现阶段 Finishing sections
Bagging/storageE-motor
Product
Exha
ust a
ir
Steel belt (W=1.5 m, L=20-25 m)
CW in
CW out
125 T/D; 99.7 wt%
钢带造粒技术Steel belt granular technology
• 创新技术 Innovative technology
• 规格可选 Size can chosen (1-5 mm)
• 强度介于小颗粒和大颗粒之间 Strength between prills and granules
• 排放少 Less emissions
• 特殊通途 Specialties
现阶段 Finishing sections
专用尿素 Technical urea
• 脲醛树脂 UF resins
• 柴油车尾气处理液 (车用尿素) Ad Blue (SCR)
• 三聚氰胺 Melamine
饲料级尿素 对比 大颗粒 (深度施肥/国际化肥研发中心)Feed grade urea versus large sizes (UDP/IFDC)
现阶段 – 特殊用途 Finishing sections - specialties
尿素产品质量
Urea Product Quality
强度参数 Strength parameters
破碎强度Crushing Strength
抗冲击性能Impact Resistance
抗磨性能Abrasion Resistance
结块 Caking
什么是结块? What is caking ?
尿素结块是由颗粒间形成晶体键造成的Caking of urea is caused by formation of crystal bonds between particles
结块 Caking
架桥形成很快 Bridges are formed quickly
不同存储时间的架桥粒径尿素, 30℃, 相对湿度70%, 1.6mm, 7.5kPa
存储时间 [h]
架桥粒径
[mm
]
结块 Caking
架桥随时间变强 Bridges become stronger in time
不同存储时间的颗粒间粘合力尿素, 1.6mm, 30℃, 相对湿度70%, 7.5kPa
存储时间 [h]
颗粒间粘合力
[mN
]
结块 Caking
影响结块的因素 Factors influencing caking
产品水分含量 Moisture content (differences) in product
空气相对湿度 Relative humidity of air
温度 Temperature (differences)
游离氨 Free ammonia (differences)
甲醛含量, 颗粒内甲醛含量的变化 Formaldehyde content (differences), formaldehyde
content varies in granule itself
包裹 Coating
粒度分布, 尺寸范围, 均匀度指数 Size distribution, SGN, UI
粉尘含量 Dust content
储存压强 (堆高) Storage pressure
储存时间 Storage time
结块 Caking
相对湿度
[%]
温度 [℃]
■颗粒开始潮解▽结块
※不结块
结块 Caking
结块&粉尘的原因 Caking & Dust causes
wt% water
P
P
T
T free NH3 UF
T
nozzles
T
UF res. time
TVar
.
loadnozzle
T L
结块&粉尘的原因 Caking & Dust causes
物流过程logistic
Procedures
仓储条件conditionsWarehouse
结块&粉尘的原因 Caking & Dust causes
产品质量评定 Product Quality Assessment
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
BeforeAfter
Quality acceptable
Quality not acceptable
customerproducer
质量可接受
质量不可接受
以前现在
生产商 用户
产品污染 Contamination
混合肥的再分离 Segregation problems
装车(堆积效应)
运输(筛分效应)
卸车(撒播效应)
除尘技术 Dedusting Technology
最终解决方案 Final solution : Van Bommel Dedusting Technology
水分含量 : max 0.30% Moisture
缩二脲 : max 1% Biuret
氮含量 : min 46.0% Nitrogen氮含量 = (纯尿素中氮含量 + 缩二脲中氮含量 + 游离氨中氮含量)Nitrogen = (Nitrogen of pure urea + nitrogen from biuret + nitrogen of free NH3)
破碎强度 : 3kg on 3.15mm Crushing strength
粒度分布 Size distribution至少90%在客户/经销商要求的范围内。At least 90% should be in the range of the request of the client/trader. 同时小于1.25mm的颗粒不超过1%。Also max 1% may be smaller than 1.25mm.中国标准2-4.75的是不被国际所接受的。Product from 2-4.75 in Chinese Standard will not be accepted internationally.
甲醛: 自由, 如果客户未要求 Formaldehyde: Free, if not specified by the customer
不结块 / 流动性好 No caking / free flowing
游离氨 : max 150ppm Free ammonia
推荐的尿素产品质量Recommended Urea Granular Quality
结 论
Conclusions
- 尿素市场接近饱和- Urea market will become tighter
- 尿素生产商需优等质量的产品- Urea producers need to assure top quality product
- 水分含量是降低 / 避免结块的关键因素- Moisture content is key to minimize / avoid caking
- 好的质量才能有好的回报 – 价格更优, 损失更小- Top quality product pays back in premium prices and less losses
结论 Conclusions