Innovative tools, methods and indicators for optimizing the resource efficiency in process industry. FERTINAGRO NUTRIENTES Granulation Process

Transcription

1 Innovative tools, methods and indicators for optimizing the resource efficiency in process industry FERTINAGRO NUTRIENTES Granulation Process Joaquin Romero Chemical Process Department Brussels 27 th January 2016 This project has received funding from the European Union s Seventh Programme for research, technological development and demonstration under grant agreement No

2 FERTINAGRO NUTRIENTES 2 Plants 1. Teruel: Pellets 2. Sarrión: Pellets 3. Escucha: Organic minerals 4. Utrillas: liquids, specialities 5. Castellón: WSF, logistics 6. Avilés: SSP 7. Misson: Pellets 8. Huelva: WSF, Pellets Ports and logistical centres 9. Bayonne 10. Valencia 11. Castellón 12. Montiijo 13. Huelva 22. Elche 23. Cigales Offices 15. Teruel (Head Office) 16. Madrid 17. Zaragoza 18. Ragusa 19. Montijo 20. Misson 21. Montevideo

3 FERTINAGRO NUTRIENTES 2 Argentina France Turkey Angola Thailand Bolivia Greece Uruguay UK Syria Mozambique Nicaragua Paraguay India Brazil Italy Cyprus Sudan Dominican Ecuador China Mexico Ukraine Malta Kenya Republic Switzerland Senegal Lebanon Egypt Colombia Poland South Africa Algeria Saudi Arabia Peru Romania Portugal Nigeria Pakistan Brazil Bulgaria

4 FERTINAGRO NUTRIENTES 2

5 Process Overview 3 In the Top-Ref project Fertinagro have been performing several changes in their process in order to optimize energy consumption. The principal changes are: 1. Automatization: PLC and SCADA. 2. Pre-heater the air. 3. Reduction in the use of the sieve: currently, we use a frequency converter with the mill to modify the size.

6 Process Overview 3

7 New Old SCADA

8 5 2. System to pre-heat the air inside the burner

9 6 Impact and outcomes Our current situation without finishing the optimization: 1. Reduction of gas consumption 2% - 4%. 2. Reduction in power consumption 2% - 3%. 3. Reduction of the downtime due to some problems with the sieve. 4. Reduction of the downtime 10%.

10 TOP-REF Benefits for FERTINAGRO 7 Identification and study of variables and situations not covered in reality but feasible to happen and be solutions. New and Improved Control Strategies. Design and implementation of a soft sensor for continuous process improvement and some time in advance Identify new areas for improvement and possible remediation projects. Continuous reduction of energy consumption by the design and implementation of new methodologies Possibility of implementing the methodology developed in the different production plants that Fertinagro has all over the world

11 7 Conclusions The results obtained so far in the simulation have high accuracy with an error of less than 15% on the final size of the particle. Economic and energy studies have explained that energy losses are mainly the outgassing of the rotary dryer and the high quantity of material recycle doubt out of a irregular size. There are different possibilities of utilization and therefore a reduction of more than 30% of energy consumption. Some improvements ideas have been identified to reduce the energy consumption and improve the quality of the final product

12 7 Future goals 1. Reduction of energy consumption 15%-20%. Simulation 2. Implementation in other plants (In Spain, France, Senegal and Brazil). Extend the results 3. Implementation in other process.

13 THANK YOU VERY MUCH FOR YOUR ATTENTION This project has received funding from the European Union s Seventh Programme for research, technological development and demonstration under grant agreement No