EP3768417A1 - Divided perforated plate for fluid bed granulator or cooler - Google Patents

Divided perforated plate for fluid bed granulator or cooler

Info

Publication number
EP3768417A1
EP3768417A1 EP19711922.5A EP19711922A EP3768417A1 EP 3768417 A1 EP3768417 A1 EP 3768417A1 EP 19711922 A EP19711922 A EP 19711922A EP 3768417 A1 EP3768417 A1 EP 3768417A1
Authority
EP
European Patent Office
Prior art keywords
fluid
granulator
bed
perforated plate
cooler
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP19711922.5A
Other languages
German (de)
French (fr)
Inventor
Rüdiger GRABARSKI
Heinz Bernd ROTH
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ThyssenKrupp AG
ThyssenKrupp Fertilizer Technology GmbH
Original Assignee
ThyssenKrupp AG
ThyssenKrupp Fertilizer Technology GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ThyssenKrupp AG, ThyssenKrupp Fertilizer Technology GmbH filed Critical ThyssenKrupp AG
Publication of EP3768417A1 publication Critical patent/EP3768417A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/16—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by suspending the powder material in a gas, e.g. in fluidised beds or as a falling curtain
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
    • B01J8/34—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with stationary packing material in the fluidised bed, e.g. bricks, wire rings, baffles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
    • B01J8/36—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed through which there is an essentially horizontal flow of particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
    • B01J8/44—Fluidisation grids

Definitions

  • the invention relates to a fluid-bed granulator system comprising a divided perforated plate, a corresponding fluid-bed cooler system, a urea granulation plant comprising the respective inventive fluid- bed granulator system and/or fluid-bed cooler system and the use of the inventive fluid-bed granulator/cooler system for the production of fertilizer granules containing ammonia compounds.
  • fertilizers may contain nitrogen, phosphate, sulfur, potassium or micronutrients.
  • a common, widely used fertilizer contains urea as its main component.
  • the water soluble urea rapidly decomposes in the soil, providing ammonia and nitrate compounds.
  • the fertilizer may contain only urea or a combination of urea with one or more of the before mentioned components, e.g. phosphate, sulfur, potassium or micronutrients.
  • Urea can be produced on a large industrial scale by reacting ammonia with carbon dioxide via a (simplified) two-step reaction:
  • Urea fertilizers can be combined with ammonia sulfate or elemental sulfur, therefore providing both plant nutrients in one fertilizer.
  • Ammonia sulfur can be directly used by the plant, whereas elemental sulfur needs to be decomposed by soil microorganisms, thereby providing long-term plant nutrients. Examples of urea/sulfur granules can be found e.g. in US 4,330,319 A.
  • the fluid-bed granulation process is based on providing granulation seeds, which grow by absorbing very small droplets of a growth liquid. These small droplets can be provided via an “atomized” liquid urea melt.
  • the term“atomized” used in the description refers to a mixing process of the liquid urea melt (or other suitable fertilizer melts) with a pressurized medium like air. This mixing process creates a liquid/gas emulsion or an aerosol of small droplets.
  • the term“atomized” should therefore not be confused with a molecular separating process on an atomic scale.
  • the produced droplets may have a medium size distribution around 1 pm to 200 pm. These small melt droplets absorb on the surface of the granulation seeds, thereby creating “growing” granulation particles. These fresh “in-situ” produced granules may commonly exhibit temperatures around 100 °C and are relatively soft. The particles further cool down in the fluid-bed of the granulator and/or in separate cooling compartments.
  • the size of perforated plate of a fluid-bed granulator or fluid-bed cooler cannot be increased indefinitely.
  • the perforated plate will be integrated into the non-finished fluid-bed granulator or fluid-bed cooler by a crane, utilizing the open roof during construction.
  • the same method cannot be used to replace damaged perforated plates during the working-life of the fluid-bed granulator or fluid- bed cooler.
  • an increasing size of the perforated is related to an increasing weight of the perforated plate.
  • This increased weight results in an increased bending tendency of the perforated plate, prohibiting a planar arrangement of a very heavy perforated plate.
  • This bending tendency may result in an inhomogeneous temperature and flow profile in the fluid bed granulator, thus increasing the particle size distribution and lowering the product quality.
  • US 3,733,056 A discloses a perforated plate in a fluidized bed for treating granular material.
  • the perforated plate comprises sections with different openings.
  • WO 2013/165245 A1 discloses a plant for the production of urea. The plant comprises conventional sections for synthesis and recovery, for evaporation and condensation, for urea finishing, and for dust scrubbing.
  • GB 2 012 030 A discloses a fluidized bed equipment for use with coal fired boiler.
  • Preferred embodiments of the invention are subject to the corresponding dependent claims.
  • the object of the present invention is also solved by providing a urea granulation plant suitable for the preparation of urea containing granules according to claim 15.
  • the Fluid-bed granulator system according to the invention comprises at least a fluid bed granulator with a perforated plate located inside the granulator space.
  • the Fluid-bed granulator system according to the invention is suitable for the granulation of urea and nitrogen containing fertilizers.
  • the before mentioned perforated plate comprises at least two inner perforated plates and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar and wherein a central support tube is arranged between the middle part bar and a granulator ground floor. It was found, that non-divided perforated plates with a length above 3000 mm are very difficult (if at all) to handle.
  • middle part bar is located within the granulator space, parallel oriented to the granular particle flow direction, preferably in the main direction defined by the axis between the granulation seeds inlet and the granulator outlet opening.
  • parallel include deviations from an exact parallel placement of the middle part bar.
  • the parallel deviations of the middle part bar include a deviation of ⁇ (plus/minus) 20° (degrees).
  • granular particle flow direction refers to the direction starting from granulation seeds inlet, passing the grow- and cooling zones of the perforated plate and ending near the granulator outlet opening.
  • the middle part bar is not to be confused with the connecting elements which link single perforated plate elements forming the final overall perforated plate. These connecting elements are oriented in an orthogonal or near orthogonal angle to the before mentioned granular particle flow direction and the axis between the granulation seeds inlet and the granulator outlet opening.
  • the overall perforated plate which closes and seals the room between the perforated plate and the granulator floor, comprises 15 to 50 inner perforated plates.
  • the Fluid-bed granulator system comprises at least a fluid bed granulator with a granulator space inside the fluid-bed granulator.
  • the fluid-bed granulator further comprises the perforated plate located inside the granulator space and spray nozzles located in, on or beside the perforated plate.
  • the spray nozzles are attached above the perforated plate.
  • a fluidization air inlet preferably located below the perforated plate, provides the necessary fluidization air for the fluid bed of fertilizer granules.
  • the term “fluidization air” includes air or inert gases like C0 2 , nitrogen, argon or mixtures thereof.
  • the spray nozzles are connected with supply lines for atomization air and supply lines for a liquid melt, preferably a liquid melt containing urea.
  • these supply lines for air and melt can be combined in one line or two adjacent lines.
  • the term“lines” includes hoses, tubes and pipes.
  • the term“melt” includes solutions with more than 50 wt. (weight) %, preferably more than 75 wt. %, urea or nitrogen containing fertilizer salts or compounds.
  • the fluid-bed granulator comprises a granulation seeds inlet.
  • the term“a granulation seeds inlet” comprises internal and external devices, lines and openings for the introduction of granular seeds, e.g.
  • the term“internal” refers to the production of granular seeds within the granulator.
  • the term “external” refers to the providing provision or production of granular seeds from outside the granulator, e.g. via sieves or crushers outside the fluid-bed granulator.
  • the fluid-bed granulator comprises a granulator outlet opening and an air vent opening.
  • the granulator space comprises separating walls with integrated openings. These separating walls may further alter and modify the speed of the fluid bed towards the granulator outlet opening. Dust, e.g.
  • the scrubber unit comprises at least a dust removing scrubber and an ammonia removing scrubber.
  • suitable scrubbers can be found in WO 2005/032696 A1 (figure 1) or W02010/60535 Al.
  • the perforated plate comprises at least two inner perforated plates and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar and wherein a central support tube is arranged between the middle part bar and a granulator ground floor.
  • middle part bar is located within the granulator space, parallel oriented to the granular particle flow direction, preferably in the main direction defined by the axis between the granulation seeds inlet and the granulator outlet opening.
  • parallel include deviations from an exact parallel placement of the middle part bar.
  • the parallel deviations of the middle part bar include a deviation of up to ⁇ (plus/minus) 20° (degrees).
  • granular particle flow direction refers to the direction starting from granulation seeds inlet, passing the grow- and cooling zones of the perforated plate and ending near the granulator outlet opening.
  • the middle part bar is not to be confused with the connecting elements which link single perforated plate elements forming the final overall perforated plate. These connecting elements are oriented in an orthogonal or near orthogonal angle to the before mentioned granular particle flow direction and the axis between the granulation seeds inlet and the granulator outlet opening.
  • the overall perforated plate which closes and seals the room between the perforated plate and the granulator floor, comprises 15 to 50 inner perforated plates.
  • a stiffener tube is arranged below the two inner perforated plates and/or below the middle part bar.
  • the stiffener tube increases the stability of the inner perforated plates and reduces deviations between connected adjacent perforated plates and inner perforated plates.
  • the inner perforated plates are arranged in two inner frames.
  • the inner frames increase the stability of the inner perforated plates.
  • the inner frames reduce the fluctuation, vibration and oscillation of the inner perforated plates in the granulator, especially during the granulation process.
  • partition plates are arranged below and/or above the perforated plate. Besides their general advantageous effects in regard to the granulation process (e.g. in regard to temperature and particle growing), the introduction of partition plates further increases the stability of the perforated plate.
  • the stiffener tube is connected with the partition plates, further increasing stability and reducing the vibration tendency of the perforated plate.
  • the two inner perforated plates the middle part bar, the central support tube and/or the tube support comprise metals and polymers, preferably steel, more preferably stainless steel.
  • the two inner perforated plates have a width of between 300 mm to 1000 mm, more preferably between 400 mm and 900 mm, and a length between 1500 mm to 2200 mm, more preferably between 1600 mm to 2000 mm.
  • the perforated plate comprises 15 to 50 inner perforated plates, more preferably 16 to 40 inner perforated plates.
  • the invention further includes a fluid-bed cooler system.
  • the fluid-bed cooler system comprises at least a fluid bed cooler with a cooler space inside the fluid-bed cooler and a perforated plate located inside the cooler space.
  • a fluidization air inlet preferably located below the perforated plate, provides the necessary fluidization air for the fluid bed of fertilizer granules.
  • the fertilizer granules are conveyed into the cooler via a product inlet.
  • the cooled fertilizer granules leave the fluid-bed cooler via a cooler outlet opening.
  • the fluid-bed cooler comprises an air vent opening. Dust, e.g. urea dust, and chemical vapors like ammonia, which are created or released during the granulation process, are removed in to a scrubber unit via the air vent opening.
  • the scrubber unit comprises at least a dust removing scrubber and an ammonia removing scrubber.
  • suitable scrubbers can be found in WO 2005/032696 A1 (figure 1) or WO 2010/60535 Al .
  • the before mentioned perforated plate comprises at least two inner perforated plates and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar and wherein a central support tube is arranged between the middle part bar and a granulator ground floor.
  • the middle part bar is located within the fluid-bed cooler space, parallel oriented to the granular particle flow direction, preferably in the main direction defined by the axis between the product inlet and the cooler outlet opening.
  • the term“parallel” include deviations from an exact parallel placement of the middle part bar.
  • the parallel deviations of the middle part bar include a deviation of ⁇ (plus/minus) 20° (degrees).
  • the term “granular particle flow direction” refers to the direction starting from the product inlet, passing the cooling zones of perforated plate and ending near the cooler outlet opening.
  • the middle part bar is not to be confused with the connecting elements which link single perforated plate elements forming the final overall perforated plate. These connecting elements are oriented in an orthogonal or near orthogonal angle to the before mentioned granular particle flow direction and orthogonal to the axis between the product inlet and the cooler outlet opening.
  • the overall perforated plate which closes and seals the room between the perforated plate and the cooler floor, comprises 15 to 50 inner perforated plates.
  • a stiffener tube is arranged below the two inner perforated plates and/or below the middle part bar.
  • the stiffener tube increases the stability of the inner perforated plates and reduces deviations between connected adjacent perforated plates and inner perforated plates.
  • the inner perforated plates are arranged in two inner frames.
  • the inner frames increase the stability of the inner perforated plates.
  • the inner frames reduce the fluctuation, vibration and oscillation of the inner perforated plates in the granulator, especially during the granulation process.
  • partition plates are arranged below and/or above the perforated plate. Besides their general advantageous effects in regard to the granulation process (e.g. in regard to temperature and particle growing), the introduction of partition plates further increases the stability of the perforated plate.
  • the stiffener tube is connected with the partition plates, further increasing stability and reducing the vibration tendency of the perforated plate.
  • the two inner perforated plates the middle part bar, the central support tube and/or the tube support comprise metals and polymers, preferably steel, more preferably stainless steel.
  • the two inner perforated plates have a width of between 300 mm to 1000 mm, more preferably between 400 mm and 900 mm, and a length between 1500 mm to 2200 mm, more preferably between 1600 mm to 2000 mm.
  • the perforated plate comprises 15 to 50 inner perforated plates, more preferably 16 to 40 inner perforated plates.
  • the invention further comprises a urea granulation plant comprising an inventive fluid-bed granulator as described above and/or fluid-bed cooler as described above.
  • the invention further comprises an inventive fluid-bed granulator system as previously disclosed and/or fluid-bed cooler system as previously disclosed for the production of fertilizer granules containing ammonia compounds, nitrates, phosphates, urea, elemental sulfur, ammonia sulfate, UAS (urea - ammonia sulfate), and/or mixtures thereof.
  • Figure 1 shows a schematic view of the fluid-bed granulator system
  • Figure 2 shows a schematic view of fluid-bed cooler system
  • Figure 3 shows a schematic view of the perforated plate and Figure 4 shows a schematic top view of the perforated plate.
  • Figure 1 shows the schematic view of the fluid-bed granulator system according to the invention comprising a fluid bed granulator (9) with a granulator space (1) and a granulator ground floor (10) inside the fluid-bed granulator (9).
  • a perforated plate (2) is located inside the granulator space (1).
  • Spray nozzles (3) are located on or above the perforated plate (2), a fluidization air inlet (11) is located below the perforated plate (2).
  • Multiple supply lines for atomization air (4) and supply lines for a liquid melt (5) are connected to the spray nozzles (3).
  • these supply lines (4, 5) can be combined in one line.
  • the fluid-bed granulator (9) further comprises a granulation seeds inlet (6), preferably in connection with a not shown product sieve or crusher, a granulator outlet opening (7) and an air vent opening (8).
  • the fluid-bed (17) is formed by the corresponding granular particles (16) utilizing the fluidization air from below the perforated plate (2).
  • the fluidization air flow is indicated by arrows labeled (II)
  • the flow direction of the fluid bed granular particles (16) is indicated by arrows labeled (I).
  • the fluid-bed (17) is preferably divided by one or more partition plates (13).
  • the structure of the perforated plate (2) is shown in Figure 3.
  • FIG. 2 shows fluid-bed cooler system, preferably for the granulation of urea and nitrogen containing fertilizers, according to the invention.
  • the fluid-bed cooler system comprises at least a fluid bed cooler (14) with a cooler space (15) and cooler ground floor (12) inside the fluid-bed cooler (14), a perforated plate (2) located inside the cooler space (15), product inlet (19), fluidization air inlet (21), a cooler outlet opening (18) and an air vent opening (20).
  • the fluid-bed (17) is formed by the corresponding granular particles (16) utilizing the fluidization air from below the perforated plate (2).
  • the flow direction of granules is indicated by (I)
  • the flow direction of the fluidization air is indicated by (II).
  • the structure of the perforated plate (2) is shown in detail in Figure 3.
  • Figure 3 shows a schematic view of the perforated plate.
  • Figure 3 is a cut-out of the fluid-bed granulator (9) or the fluid-bed cooler (14) showing the lower part of the fluid-bed granulator (9)/fluid-bed cooler (14) from the granulator ground floor (10)/ cooler ground floor (12) up to the perforated plate 2.
  • figure 3 shows the elements of invention in a preparation state, indicating the single, partially unfinished elements.
  • the “minimum” elements of the inventive setup are shown in the area labeled (A).
  • This inventive setup at least comprises two inner perforated plates (2a, 2a’) connected via a middle part bar (2c).
  • a central support tube (2d) is arranged between the middle part bar (2c) and a granulator ground floor (10)/ cooler ground floor (12).
  • the inner perforated plates (2a, 2a’) are preferably arranged in two inner frames (2b, 2b’) ⁇ The setup comprising the inner perforated plates is repeated (not shown in figure 3, c.f. figure 4) alongside the middle part bar (2c) forming and closing the final perforated plate (2).
  • Stiffener tubes (2e) are arranged below the two inner perforated plates (2a, 2a’) and below the middle part bar (2c). These stiffener tubes (2e) increase the stability. In addition the stiffener tubes (2e) reduce the vibration and bending tendency of the perforated plate (2).
  • the stiffener tubes are connected with partition plates (13), which further regulate the temperature and gas flow in the granulator.
  • Figure 4 shows a schematic top view of the perforated plate.
  • The“minimum” elements of the inventive setup comprising two inner perforated plates (2a, 2a’), two inner frames (2b, 2b’), middle part bar (2c) and the central support tube (2d) are shown in the area labeled (A).
  • Stiffener tubes (2e) are arranged below the inner perforated plates (2a, 2a’) and/or between the partition plates (13) and the perforated plate (2), further increasing the stability of adjacent elements comprising the two inner perforated plates (2a, 2a’).

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Fertilizers (AREA)
  • Glanulating (AREA)

Abstract

The invention relates to a fluid-bed granulator system at least comprising a fluid bed granulator (9) with a perforated plate (2) located inside the granulator space (1), wherein the perforated plate (2) comprises at least two inner perforated plates (2a, 2a') and wherein the two inner perforated plates (2a, 2a') are connected via a middle part bar (2c) and wherein a central support tube (2d) is arranged between the middle part bar (2c) and a granulator ground floor (10) and wherein the fluid bed granulator (9) comprises a granulator space (1) inside the fluid-bed granulator (14), the perforated plate (2) located inside the granulator space (1), spray nozzles (3) located in, on or beside the perforated plate (2), fluidization air inlet (11), supply lines for atomization air (4) connected to the spray nozzles (3), supply lines for a liquid melt (5) connected to the spray nozzles (3), a granulation seeds inlet (6), a granulator outlet opening (7) and an air vent opening (8).

Description

DIVIDED PERFORATED PLATE FOR FLUID BED GRANULATOR OR COOLER
The invention relates to a fluid-bed granulator system comprising a divided perforated plate, a corresponding fluid-bed cooler system, a urea granulation plant comprising the respective inventive fluid- bed granulator system and/or fluid-bed cooler system and the use of the inventive fluid-bed granulator/cooler system for the production of fertilizer granules containing ammonia compounds.
Due to a continuous world population growth, there is an ongoing need in providing reliable, easy producible and cheap fertilizers. These conventional fertilizers may contain nitrogen, phosphate, sulfur, potassium or micronutrients.
A common, widely used fertilizer contains urea as its main component. The water soluble urea rapidly decomposes in the soil, providing ammonia and nitrate compounds. Based on the application, the fertilizer may contain only urea or a combination of urea with one or more of the before mentioned components, e.g. phosphate, sulfur, potassium or micronutrients.
Urea can be produced on a large industrial scale by reacting ammonia with carbon dioxide via a (simplified) two-step reaction:
2 NH3 + C02 H2N-COONH4 (1)
H2N-COONH4 (NH2)2CO + H20 (2)
The absorbance of water based on the hygroscopic nature of urea easily results in uncontrolled aggregation, quality degradation and caking of fine, untreated urea particles. This process can negatively affect the solubility, bulk storage, durability or chemical stability of the urea fertilizer. In addition, the uncontrolled gain in weight by absorbing water increases the transport weight and costs. Therefore, further post synthesis process steps are necessary in order to provide a transportable and storable urea fertilizer. Common technical processes include diverse granulation technics like prilling, drum granulation or fluid-bed granulation. Especially prilling processes suffer from some critical drawbacks like relatively soft particles and sometimes deformed inhomogeneous particles.
These problems can be avoided by using a fluid-bed granulation process, which results in harder, more stable and homogeneous granules. The resulting granular urea is particularly suitable for bulk blending operations. Furthermore, there is reduced segregation or mechanical damage during mixing and transporting of the urea based fertilizer. Examples of fluid-bed granulation process of urea can be found in WO 2010/060535 Al, e.g. in paragraphs [0025H0035], figure 1 or in US 4,701,353 A, DE 31 16 778 Al and US 4,219,589 A.
Urea fertilizers can be combined with ammonia sulfate or elemental sulfur, therefore providing both plant nutrients in one fertilizer. Ammonia sulfur can be directly used by the plant, whereas elemental sulfur needs to be decomposed by soil microorganisms, thereby providing long-term plant nutrients. Examples of urea/sulfur granules can be found e.g. in US 4,330,319 A.
The fluid-bed granulation process is based on providing granulation seeds, which grow by absorbing very small droplets of a growth liquid. These small droplets can be provided via an “atomized” liquid urea melt. The term“atomized” used in the description refers to a mixing process of the liquid urea melt (or other suitable fertilizer melts) with a pressurized medium like air. This mixing process creates a liquid/gas emulsion or an aerosol of small droplets. The term“atomized” should therefore not be confused with a molecular separating process on an atomic scale. The produced droplets may have a medium size distribution around 1 pm to 200 pm. These small melt droplets absorb on the surface of the granulation seeds, thereby creating “growing” granulation particles. These fresh “in-situ” produced granules may commonly exhibit temperatures around 100 °C and are relatively soft. The particles further cool down in the fluid-bed of the granulator and/or in separate cooling compartments.
Due to an ongoing demand for a further increase of the daily output of granulated urea, the size of a new designed fluid-bed granulator or fluid-bed cooler has to increase, too. This size increase is connected with a upscaling of the fluid-bed granulator or fluid-bed cooler components.
However, the size of perforated plate of a fluid-bed granulator or fluid-bed cooler cannot be increased indefinitely. Usually, the perforated plate will be integrated into the non-finished fluid-bed granulator or fluid-bed cooler by a crane, utilizing the open roof during construction. However, the same method cannot be used to replace damaged perforated plates during the working-life of the fluid-bed granulator or fluid- bed cooler. Depending on the size of the perforated plate elements and available openings, it may be impossible to replace and/or repair a perforated plate element without destroying it. In addition, an increasing size of the perforated is related to an increasing weight of the perforated plate. This increased weight results in an increased bending tendency of the perforated plate, prohibiting a planar arrangement of a very heavy perforated plate. This bending tendency may result in an inhomogeneous temperature and flow profile in the fluid bed granulator, thus increasing the particle size distribution and lowering the product quality.
US 3,733,056 A discloses a perforated plate in a fluidized bed for treating granular material. The perforated plate comprises sections with different openings. WO 2013/165245 A1 discloses a plant for the production of urea. The plant comprises conventional sections for synthesis and recovery, for evaporation and condensation, for urea finishing, and for dust scrubbing.
GB 2 012 030 A discloses a fluidized bed equipment for use with coal fired boiler.
It is therefore an objective of the present invention to provide a fluid-bed granulator with a perforated plate, wherein the perforated plate exhibits a low bending tendency and allowing an easy removal or replacement of its elements during maintenance or repairs, especially without destroying or damaging the perforated plate.
The object of the present invention is solved by a fluid-bed granulator according to claim 1. Preferred embodiments of the invention are subject to the corresponding dependent claims.
In a further aspect it is another object of the present invention to provide a fluid-bed cooler wherein the perforated plate exhibits a low bending tendency and allowing an easy removal or replacement of its elements during maintenance or repairs, especially without destroying or damaging the perforated plate. Preferred embodiments of the invention are subject to the corresponding dependent claims.
The object of the present invention is also solved by providing a urea granulation plant suitable for the preparation of urea containing granules according to claim 15.
In a further aspect it is another object of the present invention to provide the use of the fluid-bed granulator system or the fluid-bed cooler system for the production of fertilizer granules.
The Fluid-bed granulator system according to the invention comprises at least a fluid bed granulator with a perforated plate located inside the granulator space. Preferably the Fluid-bed granulator system according to the invention is suitable for the granulation of urea and nitrogen containing fertilizers. The before mentioned perforated plate comprises at least two inner perforated plates and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar and wherein a central support tube is arranged between the middle part bar and a granulator ground floor. It was found, that non-divided perforated plates with a length above 3000 mm are very difficult (if at all) to handle. In addition, perforated plates with a length above 3000 mm tend to bend, negatively affecting the performance of the perforated plate in the granulation process. Without to be bound to theory, it is believed that the own weight and dimension of a large (as described above) perforated plate prohibits a meaningful use. The before mentioned middle part bar is located within the granulator space, parallel oriented to the granular particle flow direction, preferably in the main direction defined by the axis between the granulation seeds inlet and the granulator outlet opening. The term “parallel” include deviations from an exact parallel placement of the middle part bar. Preferably, the parallel deviations of the middle part bar include a deviation of ± (plus/minus) 20° (degrees). The term “granular particle flow direction” refers to the direction starting from granulation seeds inlet, passing the grow- and cooling zones of the perforated plate and ending near the granulator outlet opening. The middle part bar is not to be confused with the connecting elements which link single perforated plate elements forming the final overall perforated plate. These connecting elements are oriented in an orthogonal or near orthogonal angle to the before mentioned granular particle flow direction and the axis between the granulation seeds inlet and the granulator outlet opening. Preferably, the overall perforated plate, which closes and seals the room between the perforated plate and the granulator floor, comprises 15 to 50 inner perforated plates.
The Fluid-bed granulator system according to the invention comprises at least a fluid bed granulator with a granulator space inside the fluid-bed granulator. The fluid-bed granulator further comprises the perforated plate located inside the granulator space and spray nozzles located in, on or beside the perforated plate. Preferably, the spray nozzles are attached above the perforated plate. A fluidization air inlet, preferably located below the perforated plate, provides the necessary fluidization air for the fluid bed of fertilizer granules. The term “fluidization air” includes air or inert gases like C02, nitrogen, argon or mixtures thereof. The spray nozzles are connected with supply lines for atomization air and supply lines for a liquid melt, preferably a liquid melt containing urea. Optionally, these supply lines for air and melt can be combined in one line or two adjacent lines. Within the meaning of the invention, the term“lines” includes hoses, tubes and pipes. Within the meaning of the invention, the term“melt” includes solutions with more than 50 wt. (weight) %, preferably more than 75 wt. %, urea or nitrogen containing fertilizer salts or compounds. In addition, the fluid-bed granulator comprises a granulation seeds inlet. The term“a granulation seeds inlet” comprises internal and external devices, lines and openings for the introduction of granular seeds, e.g. urea or nitrogen containing fertilizers. The term“internal” refers to the production of granular seeds within the granulator. The term “external” refers to the providing provision or production of granular seeds from outside the granulator, e.g. via sieves or crushers outside the fluid-bed granulator. Furthermore the fluid-bed granulator comprises a granulator outlet opening and an air vent opening. Optionally, the granulator space comprises separating walls with integrated openings. These separating walls may further alter and modify the speed of the fluid bed towards the granulator outlet opening. Dust, e.g. urea dust, and chemical vapors like ammonia, which are created or released during the granulation process, are removed in a separate scrubber unit. Preferably, the scrubber unit comprises at least a dust removing scrubber and an ammonia removing scrubber. Examples of suitable scrubbers can be found in WO 2005/032696 A1 (figure 1) or W02010/60535 Al. As mentioned above, the perforated plate comprises at least two inner perforated plates and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar and wherein a central support tube is arranged between the middle part bar and a granulator ground floor. It was found, that non-divided perforated plates with a length above 3000 mm are very difficult (if at all) to handle. In addition, perforated plates with a length above 3000 mm tend to bend, negatively affecting the performance of the perforated plate in the granulation process. Without to be bound to theory, it is believed that the own weight and dimension of a large (as described above) perforated plate prohibits a meaningful use. The before mentioned middle part bar is located within the granulator space, parallel oriented to the granular particle flow direction, preferably in the main direction defined by the axis between the granulation seeds inlet and the granulator outlet opening. The term“parallel” include deviations from an exact parallel placement of the middle part bar. Preferably, the parallel deviations of the middle part bar include a deviation of up to ± (plus/minus) 20° (degrees). The term“granular particle flow direction” refers to the direction starting from granulation seeds inlet, passing the grow- and cooling zones of the perforated plate and ending near the granulator outlet opening. The middle part bar is not to be confused with the connecting elements which link single perforated plate elements forming the final overall perforated plate. These connecting elements are oriented in an orthogonal or near orthogonal angle to the before mentioned granular particle flow direction and the axis between the granulation seeds inlet and the granulator outlet opening. Preferably, the overall perforated plate, which closes and seals the room between the perforated plate and the granulator floor, comprises 15 to 50 inner perforated plates.
Preferably, a stiffener tube is arranged below the two inner perforated plates and/or below the middle part bar. The stiffener tube increases the stability of the inner perforated plates and reduces deviations between connected adjacent perforated plates and inner perforated plates.
Preferably, the inner perforated plates are arranged in two inner frames. The inner frames increase the stability of the inner perforated plates. In addition the inner frames reduce the fluctuation, vibration and oscillation of the inner perforated plates in the granulator, especially during the granulation process.
In a further embodiment partition plates are arranged below and/or above the perforated plate. Besides their general advantageous effects in regard to the granulation process (e.g. in regard to temperature and particle growing), the introduction of partition plates further increases the stability of the perforated plate.
Preferably, the stiffener tube is connected with the partition plates, further increasing stability and reducing the vibration tendency of the perforated plate.
In a further embodiment the two inner perforated plates the middle part bar, the central support tube and/or the tube support comprise metals and polymers, preferably steel, more preferably stainless steel. Preferably, the two inner perforated plates have a width of between 300 mm to 1000 mm, more preferably between 400 mm and 900 mm, and a length between 1500 mm to 2200 mm, more preferably between 1600 mm to 2000 mm.
In a preferred embodiment, the perforated plate comprises 15 to 50 inner perforated plates, more preferably 16 to 40 inner perforated plates.
The invention further includes a fluid-bed cooler system. The fluid-bed cooler system comprises at least a fluid bed cooler with a cooler space inside the fluid-bed cooler and a perforated plate located inside the cooler space. A fluidization air inlet, preferably located below the perforated plate, provides the necessary fluidization air for the fluid bed of fertilizer granules. The fertilizer granules are conveyed into the cooler via a product inlet. The cooled fertilizer granules leave the fluid-bed cooler via a cooler outlet opening. Furthermore the fluid-bed cooler comprises an air vent opening. Dust, e.g. urea dust, and chemical vapors like ammonia, which are created or released during the granulation process, are removed in to a scrubber unit via the air vent opening. Preferably, the scrubber unit comprises at least a dust removing scrubber and an ammonia removing scrubber. Examples of suitable scrubbers can be found in WO 2005/032696 A1 (figure 1) or WO 2010/60535 Al . The before mentioned perforated plate comprises at least two inner perforated plates and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar and wherein a central support tube is arranged between the middle part bar and a granulator ground floor. The middle part bar is located within the fluid-bed cooler space, parallel oriented to the granular particle flow direction, preferably in the main direction defined by the axis between the product inlet and the cooler outlet opening. The term“parallel” include deviations from an exact parallel placement of the middle part bar. Preferably, the parallel deviations of the middle part bar include a deviation of ± (plus/minus) 20° (degrees). The term “granular particle flow direction” refers to the direction starting from the product inlet, passing the cooling zones of perforated plate and ending near the cooler outlet opening. The middle part bar is not to be confused with the connecting elements which link single perforated plate elements forming the final overall perforated plate. These connecting elements are oriented in an orthogonal or near orthogonal angle to the before mentioned granular particle flow direction and orthogonal to the axis between the product inlet and the cooler outlet opening. Preferably, the overall perforated plate, which closes and seals the room between the perforated plate and the cooler floor, comprises 15 to 50 inner perforated plates.
Preferably, a stiffener tube is arranged below the two inner perforated plates and/or below the middle part bar. The stiffener tube increases the stability of the inner perforated plates and reduces deviations between connected adjacent perforated plates and inner perforated plates. Preferably, the inner perforated plates are arranged in two inner frames. The inner frames increase the stability of the inner perforated plates. In addition the inner frames reduce the fluctuation, vibration and oscillation of the inner perforated plates in the granulator, especially during the granulation process.
In a further embodiment partition plates are arranged below and/or above the perforated plate. Besides their general advantageous effects in regard to the granulation process (e.g. in regard to temperature and particle growing), the introduction of partition plates further increases the stability of the perforated plate.
Preferably, the stiffener tube is connected with the partition plates, further increasing stability and reducing the vibration tendency of the perforated plate.
In a further embodiment the two inner perforated plates the middle part bar, the central support tube and/or the tube support comprise metals and polymers, preferably steel, more preferably stainless steel.
Preferably, the two inner perforated plates have a width of between 300 mm to 1000 mm, more preferably between 400 mm and 900 mm, and a length between 1500 mm to 2200 mm, more preferably between 1600 mm to 2000 mm.
In a preferred embodiment, the perforated plate comprises 15 to 50 inner perforated plates, more preferably 16 to 40 inner perforated plates.
The invention further comprises a urea granulation plant comprising an inventive fluid-bed granulator as described above and/or fluid-bed cooler as described above.
The invention further comprises an inventive fluid-bed granulator system as previously disclosed and/or fluid-bed cooler system as previously disclosed for the production of fertilizer granules containing ammonia compounds, nitrates, phosphates, urea, elemental sulfur, ammonia sulfate, UAS (urea - ammonia sulfate), and/or mixtures thereof.
The invention is further described in the following figures. The figures are meant for illustrative purpose only and do not restrict the scope of protection. The figures are not true to scale.
Figure 1 shows a schematic view of the fluid-bed granulator system,
Figure 2 shows a schematic view of fluid-bed cooler system,
Figure 3 shows a schematic view of the perforated plate and Figure 4 shows a schematic top view of the perforated plate.
Figure 1 shows the schematic view of the fluid-bed granulator system according to the invention comprising a fluid bed granulator (9) with a granulator space (1) and a granulator ground floor (10) inside the fluid-bed granulator (9). A perforated plate (2) is located inside the granulator space (1). Spray nozzles (3) are located on or above the perforated plate (2), a fluidization air inlet (11) is located below the perforated plate (2). Multiple supply lines for atomization air (4) and supply lines for a liquid melt (5) are connected to the spray nozzles (3). Optionally, these supply lines (4, 5) can be combined in one line. The fluid-bed granulator (9) further comprises a granulation seeds inlet (6), preferably in connection with a not shown product sieve or crusher, a granulator outlet opening (7) and an air vent opening (8). The fluid-bed (17) is formed by the corresponding granular particles (16) utilizing the fluidization air from below the perforated plate (2). The fluidization air flow is indicated by arrows labeled (II), the flow direction of the fluid bed granular particles (16) is indicated by arrows labeled (I). The fluid-bed (17) is preferably divided by one or more partition plates (13). The structure of the perforated plate (2) is shown in Figure 3.
Figure 2 shows fluid-bed cooler system, preferably for the granulation of urea and nitrogen containing fertilizers, according to the invention. The fluid-bed cooler system comprises at least a fluid bed cooler (14) with a cooler space (15) and cooler ground floor (12) inside the fluid-bed cooler (14), a perforated plate (2) located inside the cooler space (15), product inlet (19), fluidization air inlet (21), a cooler outlet opening (18) and an air vent opening (20). The fluid-bed (17) is formed by the corresponding granular particles (16) utilizing the fluidization air from below the perforated plate (2). The flow direction of granules is indicated by (I), the flow direction of the fluidization air is indicated by (II). The structure of the perforated plate (2) is shown in detail in Figure 3.
Figure 3 shows a schematic view of the perforated plate. Figure 3 is a cut-out of the fluid-bed granulator (9) or the fluid-bed cooler (14) showing the lower part of the fluid-bed granulator (9)/fluid-bed cooler (14) from the granulator ground floor (10)/ cooler ground floor (12) up to the perforated plate 2. For illustrative purpose only, figure 3 shows the elements of invention in a preparation state, indicating the single, partially unfinished elements. The “minimum” elements of the inventive setup are shown in the area labeled (A). This inventive setup at least comprises two inner perforated plates (2a, 2a’) connected via a middle part bar (2c). A central support tube (2d) is arranged between the middle part bar (2c) and a granulator ground floor (10)/ cooler ground floor (12). The inner perforated plates (2a, 2a’) are preferably arranged in two inner frames (2b, 2b’)· The setup comprising the inner perforated plates is repeated (not shown in figure 3, c.f. figure 4) alongside the middle part bar (2c) forming and closing the final perforated plate (2). Stiffener tubes (2e) are arranged below the two inner perforated plates (2a, 2a’) and below the middle part bar (2c). These stiffener tubes (2e) increase the stability. In addition the stiffener tubes (2e) reduce the vibration and bending tendency of the perforated plate (2). The stiffener tubes are connected with partition plates (13), which further regulate the temperature and gas flow in the granulator.
Figure 4 shows a schematic top view of the perforated plate. The“minimum” elements of the inventive setup comprising two inner perforated plates (2a, 2a’), two inner frames (2b, 2b’), middle part bar (2c) and the central support tube (2d) are shown in the area labeled (A). Stiffener tubes (2e) are arranged below the inner perforated plates (2a, 2a’) and/or between the partition plates (13) and the perforated plate (2), further increasing the stability of adjacent elements comprising the two inner perforated plates (2a, 2a’).
Reference siqns
(1) granulator space
(2) perforated plate
(2a) inner perforated plate
(2a1) inner perforated plate
(2b) inner frame
(2b1) inner frame
(2c) middle part bar
(2d) central support tube
(2e) stiffener tube
(3) spray nozzles
(4) supply lines for atomization air
(5) supply lines for a liquid melt
(6) granulation seeds inlet
(7) granulator outlet opening
(8) air vent opening
(9) fluid-bed granulator
(10) granulator ground floor
(11) fluidization air inlet
(12) cooler ground floor
(13) partition plates
(14) fluid bed cooler
(15) cooler space
(16) granular particles
(17) fluid-bed
(18) cooler outlet opening
(19) product inlet
(20) air vent opening (fluid-bed cooler)
(21) fluidization air inlet (fluid-bed cooler)
(I) flow direction of the granules
(II) flow direction of fluidization air

Claims

Claims
1. Fluid-bed granulator system at least comprising a fluid bed granulator (9) with a perforated plate (2) located inside the granulator space (1),
wherein the perforated plate (2) comprises at least two inner perforated plates (2a, 2a’) and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar (2c) and wherein a central support tube (2d) is arranged between the middle part bar (2c) and a granulator ground floor (10) and wherein the fluid bed granulator (9) comprises a granulator space (1) inside the fluid-bed granulator (14), the perforated plate (2) located inside the granulator space (1), spray nozzles (3) located in, on or beside the perforated plate (2), fluidization air inlet (11), supply lines for atomization air (4) connected to the spray nozzles (3), supply lines for a liquid melt (5) connected to the spray nozzles (3), a granulation seeds inlet (6), a granulator outlet opening (7) and an air vent opening (8).
2. Fluid-bed granulator system according to claim 1, wherein a stiffener tube (2e) is arranged below the two inner perforated plates (2a, 2a’) and/or below the middle part bar (2c).
3. Fluid-bed granulator system according to any one of claims 1 to 2, wherein the inner perforated plates (2a, 2a’) are arranged in two inner frames (2b, 2b’)·
4. Fluid-bed granulator system according to any one of claims 1 to 3, wherein partition plates (13) are arranged below and/or above the perforated plate (2).
5. Fluid-bed granulator system according to claim 4, wherein the stiffener tube (2e) is connected with the partition plates (13).
6. Fluid-bed granulator system according to any one of claims 1 to 5, wherein the two inner perforated plates (2a, 2a’), the middle part bar (2c), the central support tube (2d) and/or the tube support (2e) comprise metals and polymers, preferably steel, more preferably stainless steel.
7. Fluid-bed granulator system according to any one of claims 1 to 6, wherein the two inner perforated plates (2a, 2a’) have a width of between 300 mm to 1000 mm, preferably between 400 mm and 900 mm, and a length between 1500 mm to 2200 mm, preferably between 1600 mm to 2000 mm.
8. Fluid-bed cooler system at least comprising:
a fluid bed cooler (14) with a cooler space (15) inside the fluid-bed cooler (14), a perforated plate (2) located inside the cooler space (15), product inlet (19), fluidization air inlet (21), a cooler outlet opening (18), an air vent opening (20),
wherein the perforated plate (2) comprises at least two inner perforated plates (2a, 2a’) and wherein the two inner perforated plates (2a, 2a’) are connected via a middle part bar (2c) and wherein a central support tube (2d) is arranged between the middle part bar (2c) and a cooler ground floor (12).
9. Fluid-bed cooler system according to claim 8, wherein a stiffener tube (2e) is arranged below the two inner perforated plates (2a, 2a’) and/or below the middle part bar (2c)
10. Fluid-bed cooler system according to claim 8 or 9, wherein a wherein the inner perforated plates (2a, 2a’) are arranged in two inner frames (2b, 2b’).
11. Fluid-bed cooler system according to any one of claims 8 to 10, wherein partition plates (13) are arranged below and/or above the perforated plate (2).
12. Fluid-bed cooler system according to claim 11, wherein the stiffener tube (2e) is connected with the partition plates (13).
13. Fluid-bed cooler system according to any one of claims 8 to 12, wherein the two inner perforated plates (2a, 2a’), the middle part bar (2c), the central support tube (2d) and/or the tube support (2e) comprise metals and polymers, preferably steel, more preferably stainless steel.
14. Fluid-bed cooler system according to any one of claims 8 to 13, wherein the two inner perforated plates (2a, 2a’) have a width of between 300 mm to 1000 mm, preferably between 400 mm and 900 mm, and a length between 1500 mm to 2200 mm, preferably between 1600 mm to 2000 mm .
15. Urea granulation plant comprising a fluid-bed granulator system according to any one of the claims 1 to 7 and/or fluid-bed cooler system according to any one of the claims 8 to 14.
16. Use of the Fluid-bed granulator system according to any one of the claims 1 to 7 or the fluid-bed cooler system according to any one of claims 8 to 14 for the production of fertilizer granules containing ammonia compounds, nitrates, phosphates, urea, nitrogen containing fertilizers, elemental sulfur, ammonia sulfate, UAS (urea - ammonia sulfate), and/or mixtures thereof.
EP19711922.5A 2018-03-23 2019-03-22 Divided perforated plate for fluid bed granulator or cooler Pending EP3768417A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP18163512 2018-03-23
PCT/EP2019/057181 WO2019180186A1 (en) 2018-03-23 2019-03-22 Divided perforated plate for fluid bed granulator or cooler

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EP3768417A1 true EP3768417A1 (en) 2021-01-27

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JP4455643B2 (en) 2007-10-30 2010-04-21 東洋エンジニアリング株式会社 Granulating apparatus and granulating method using the same
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