TVA Fertilizer Research

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1966 Survey of Continuous Ammoniator-Granulator
(1966-11) Achorn, Frank P.; Lewis, J.S. Jr.
This document summarizes the content of material presenting the results of a 1966 survey conducted on the continuous ammoniator-granulator used in the fertilizer industry. The study aimed to determine changes in ammoniator-granulator practices over the past five years. Questionnaires were sent to 142 companies, and replies from 57 companies concerning 122 ammoniator-granulators were received. The survey highlights several key trends, including an increase in the size of ammoniator-granulators and a shift toward producing different fertilizer grades, such as ammonium phosphates and granular superphosphates. The report provides detailed data on the grades and ratios produced by ammoniator-granulators and information on equipment specifications, construction materials, and granulation control methods. The findings offer valuable insights for operators using continuous ammoniator-granulators in the fertilizer industry, allowing them to assess their operations compared to industry trends and practices.
Ammonium Polyphosphate Fluid Fertilizers Made from Merchant-Grade Orthophosphoric Acid
Achorn, Frank P.; Mann, Horace C.; McGill, Kenneth E.
This article discusses developing and producing ammonium polyphosphate (APP) fluid fertilizers using merchant-grade orthophosphoric acid. The Tennessee Valley Authority (TVA) developed an energy-efficient process to produce these fertilizers, which can be stored, shipped, and marketed throughout the United States. The APP fluid contains polyphosphate, allowing it to be stored at low temperatures without freezing. A demonstration-scale plant was built, and approximately 10,000 tons of 9-32-0 grade APP suspension were produced and distributed to distributors in 13 states. The article describes the process flow, chemical and physical properties of the fertilizers, their uses in mixed-grade suspensions, and storage recommendations. The operating procedures, equipment, and polyphosphate content variables are also discussed. The findings indicate that APP fluid fertilizers offer a cost-effective alternative to suspension fertilizers, particularly in regions with sub-zero temperatures.
Cost Comparison between Clear Liquids and Suspensions Fertilizers
(1980-09-12) Achorn, Frank P.
The study compares the costs of producing and using clear liquid and suspension fertilizers. The authors address the potential cost savings of using suspension fertilizers due to their ability to be made in higher-analysis grades. The analysis considers factors such as raw material costs, investment costs, fixed and operating costs, transportation costs, application costs, and the cost of refilling nurse tanks and applicators. The study concludes that in most instances, the total cost of producing, transporting, and applying suspension fertilizers is lower than that of clear liquid fertilizers. The cost difference ranges from significant savings for certain ratios to minimal savings for others. While suspensions offer economic advantages, they require more complexity in handling and storage. The authors recommend employing personnel experienced in the mixing and applying fluid fertilizers for marketing suspension fertilizers. Additionally, precautions should be taken to agitate suspension mixtures in storage. The study notes that suspensions are particularly beneficial for operators facing challenges meeting sales requirements during the fertilizer season. Overall, the study highlights the economic desirability of using suspension fertilizers in most cases but emphasizes the need for expertise in their handling and storage.
Cost Comparison of Ocean Shipment of Anhydrous Ammonia and Solid Urea Versus Shipment of Urea-Ammonia Solution
(1966-12) Achorn, Frank P.; Walkup, Harold G.
This document presents a study comparing the costs of production and ocean shipment of solid urea and anhydrous ammonia with urea-ammonia solution. The study aims to determine the costs involved in providing solid urea and various grades of urea-ammonium phosphate materials to four destination countries. The production and shipment costs are analyzed for different destination points, including a direct shipment of finished products and the decomposition of urea-ammonia solution into solid urea and ammonia. The study focuses on the Gulf Coast area of the United States to analyze nitrogen-containing primary materials. The document outlines the production and shipment processes for solid urea, anhydrous ammonia, and urea-ammonia solution, considering shipping methods, storage, and handling costs. The destination countries and ports considered in the analysis are Santos, Brazil; Bombay, India; Lagos, Nigeria; and Istanbul, Turkey, which provide a range of conditions and factors such as length of haul, port facilities, and labor costs. The cost analysis is based on engineering cost estimates for modern plants and reliable sources for storage, handling, and shipping costs. The document assumes grassroots plants and accounts for the increased costs of constructing plants overseas. Various cost factors, including working capital, operating labor, maintenance, overhead costs, depreciation, local taxes, and insurance, are considered in the analysis. The estimated costs of manufacturing anhydrous ammonia, urea solution, and urea-ammonia solution are presented, including fixed and variable costs per ton. The analysis includes a breakdown of costs for raw materials, utilities, operating supplies, labor, maintenance, and overhead. The total manufacturing cost per short ton and metric ton is calculated for each product.
Fertilizer Application Equipment
Achorn, Frank P.; Ray Diamond
This material provides an overview of fertilizer application equipment, specifically focusing on ground-operated dry fertilizer distributors. Different fertilizer application systems are discussed, including broadcast application equipment, spinner and boom-type spreaders, and full-width distributors. The material describes the features and mechanisms of these equipment types, highlighting their usage, design variations, and performance characteristics. Factors affecting distribution patterns, such as particle size, density, and segregation, are also discussed. The accuracy and variability of application rates for different feed mechanisms are examined, emphasizing the importance of considering fertilizer density in adjusting application rates. The document concludes with the findings of performance tests conducted on various distributors, indicating the variability in application rates across a hypothetical field.
Fluid Fertilizer Application Equipment
(1967-10) Achorn, Frank P.
This document provides an overview of fluid fertilizer application equipment, focusing on metering and pumping systems used in various agricultural applications. The material examines different types of equipment, their operational principles, and their effectiveness in delivering liquid fertilizers accurately and uniformly. The discussion begins with exploring two common methods of metering anhydrous ammonia, utilizing variable orifice meters and piston-type metering pumps. Details are provided on their functioning, including the maintenance of constant pressure and the role of diaphragms and springs. The document then explores different approaches for broadcasting non pressure solutions. It describes a truck-mounted system with a flooding-type nozzle, where application rates are adjusted based on pressure and air agitation. Another technique uses multiple nozzles and a recirculating pump, highlighting the challenges of achieving uniform application rates due to overlapping. Additionally, a slinger-type applicator is presented as an effective solution for suspensions. Row and pre-plant applications of nonpressure solutions are addressed, focusing on gravity-flow systems and constant head metering. The latter involves converting a drum into a metering system, ensuring airtightness, and utilizing an orifice disk for rate control. The material also discusses positive displacement pumps, such as piston-type pumps suitable for liquid fertilizers and aqua ammonia. It introduces squeeze pumps for row applications, where a liquid is drawn into rubber tubes and expelled through variations in roller speed. Internal gear pumps and roller-impeller pumps are examined as alternative positive displacement options. It also provides a concise overview of various fluid fertilizer application equipment, outlining their mechanisms, functionalities, and application suitability. It is a valuable resource for agricultural professionals seeking to understand and select appropriate equipment for precise and efficient fluid fertilizer application.
Fluid Fertilizers
(1986) Achorn, Frank P.
This material summarizes the content of Chapter 6 on fluid fertilizers, focusing on the term "fluid fertilizer" and its various forms, such as anhydrous ammonia, aqua ammonia, nitrogen solutions, liquid mixed fertilizers, and suspensions. The chapter primarily discusses the production and use of fluid fertilizers in the United States, although other countries are also identified. It highlights the increasing popularity of fluid fertilizers, particularly nitrogen solutions, and their advantages, such as low-cost raw materials, ideal fertilizer placement, micronutrient and pesticide-carrying capabilities, and ease of handling. The material also uses anhydrous ammonia, including its production, storage, dealer operations, and application methods. Safety considerations and precautions associated with handling ammonia are outlined. Additionally, the document mentions aqua ammonia as a safer alternative to anhydrous ammonia and describes its production, storage, and application. Finally, it discusses the growing use of nonpressure nitrogen solutions in the US and their preference over anhydrous ammonia.
Fluid Fertilizers - 1967
(1967-12-14) Achorn, Frank P.
This material summarizes material presented by Frank P. Achorn at the 1967 Maine Plant Food Society meeting. The material focuses on the growing interest in fluid fertilizers, including clear liquids and suspensions, among manufacturers and consumers. It highlights the increasing consumption of liquid mixed fertilizers and their significant role in the fertilizer industry. The material provides insights into the classification and operation of hot-mix and cold-mix plants for fluid fertilizer production. It discusses the use of different raw materials, such as phosphoric acid, ammonia, and potash, and their effects on manufacturing. The document also explores suspensions' production and potential advantages, particularly in addressing the need for micronutrients. It also touches on economic considerations and the future outlook for clear liquids and suspensions in the fluid fertilizer market.
How To Prevent Segregation in Granular Bulk Blends
(1982-01) Achorn, Frank P.
Bulk blending is a widely adopted marketing system for granular mixtures in the United States and many other countries. This publications summarizes key findings and recommendations on preventing segregation in granular bulk blends based on a study of bulk blend plants and mixing equipment. The research identifies various equipment configurations and operational efficiencies, such as automated systems and mixers. It explores the challenges associated with mixer design, particle size distribution, and the impact of other materials on blend uniformity. The importance of using particle size analysis and implementing appropriate precautions during handling and application is emphasized. The study highlights the use of newer materials, such as granular monoammonium phosphate (MAP) and urea-ammonium phosphate (UAP) blends, which offer compatibility and storage stability advantages. Practical recommendations are provided to enhance the quality and uniformity of granular bulk blends, contributing to efficient and effective fertilizer application.
Low-Pressure Suspensions
(1984-08) Achorn, Frank P.; Broder, Michael F.; Cole, Carl A. Jr.
This document presents research on low-pressure suspensions, specifically focusing on their production, handling, and application in agriculture. The authors, Carl A. Cole Jr., Frank P. Achorn, and Michael F. Broder, discuss the advantages of low-pressure suspensions regarding cost, raw material versatility, and increased concentration compared to solution fertilizers. The study explores the use of ammonia as a nitrogen source and its similarities to aqua ammonia. Various laboratory tests and plant-scale demonstrations are described, highlighting the ease of production, storage, and application of low-pressure suspensions. Additionally, the document discusses the design of mixing plants, mixing procedures, and application techniques. Cost comparisons between low-pressure suspensions and conventional solutions show potential savings for fertilizer dealers and farmers. The research emphasizes the benefits and feasibility of low-pressure nitrogen suspensions as an alternative fertilizer option.
Minimizing the Cost of Mixed Fertilizers and Location of Bulk Blending Plants - Part A
(1967-08) Achorn, Frank P.
This material presents a study on minimizing the cost of mixed fertilizers and the optimal location of bulk blending plants. It is divided into two parts, with Part A focusing on the fundamentals of bulk blending plants and their role in producing dry-mixed granular fertilizers. The material outlines the flow of materials in the bulk blend marketing system, involving basic producers and their production of various nitrogen, phosphate, and N-P products. The blending plant is typically situated within a 50-mile radius of the farms it serves. Each phase of the bulk blend marketing system incurs costs, and it is the responsibility of the blender to determine the most cost-effective combination of these costs to deliver and apply plant nutrients on the farm. The material introduces a least-cost linear program developed by Mr. Walker to assist blenders in making informed decisions. It highlights the transportation and handling costs of the bulk blend marketing system and explores the impact of higher-analysis materials on reducing these costs. The benefits of using higher-analysis materials include decreased transportation costs and the ability to produce mixtures of higher nutrient analyses. The production of high-analysis grades is advantageous for blenders as it lowers their fixed and handling costs per unit of plant food. The material emphasizes the importance of considering delivered costs, fixed and operating costs, and finding the least-cost mixtures to deliver to the farm at the lowest price. Blenders can enhance their sales programs and improve their economic viability by optimizing these factors. The material concludes by mentioning how the Tennessee Valley Authority (TVA) supports blenders in determining the least-cost mixtures based on the materials available to them.
New Developments in Fluid Fertilizer Manufacture
(1982-02) Achorn, Frank P.
This paper presents an overview of the developments in fluid fertilizer manufacturing in the United States over the past 30 years. The study examines the fluid fertilizers utilized in 1980, including anhydrous ammonia, aqua ammonia, nitrogen solutions, and fluid mixtures. While there has been a significant increase in the use of fluid fertilizers during the last two decades, recent data from the United States Department of Agriculture (USDA) suggest a minimal growth in their usage in the past year. The findings reveal that approximately 61 percent of the total nitrogen applied in the U.S. is in fluid form, with anhydrous ammonia accounting for a significant portion. Additionally, 16 percent of the phosphorus (P2O5) and 8 percent of potassium (K2O) are applied as fluids. Among the various fluid fertilizers, fluid mixtures represent 20 percent of the total mixtures employed in the U.S. The paper highlights the lack of recent innovations in using anhydrous ammonia and emphasizes the focus on this aspect throughout the discussion.
New Developments in Manufacture and Use of Liquid Fertilisers
(1973-02-15) Slack, A.V.; Achorn, Frank P.
This document provides an overview of the developments in the manufacture and use of liquid fertilizers over the past five years. While using liquid fertilizers on a large scale is relatively new, spanning only about 20 years, it has proven to be an area ripe with opportunities for innovation. The paper explores the historical context of liquid fertilizer use and highlights significant advancements and trends in the field. It discusses the objectives of liquid fertilizer production, such as cost efficiency, high nutrient concentration, product quality, low pollutant emission, and uniform application. The challenges and advantages associated with liquid fertilizers are examined, with a focus on nutrient concentration and the use of polyphosphates. The paper summarizes recent polyphosphate chemistry and hydrolysis research, offering insights into improving liquid fertilizer production and addressing associated issues.
New Processes and Products--Present and Future
(1966-03-04) Achorn, Frank P.
This document highlights the importance for manufacturers to stay updated on new fertilizer technology and how the Tennessee Valley Authority (TVA) field program aims to address this need. It presents statistics on the consumption of primary nutrients in Florida and predicts a continued rapid increase in their usage. The TVA program focuses on developing cost-effective methods for manufacturing, marketing, and distributing plant nutrients and improving fertilizer processes and products to lower overall costs. The document showcases examples of TVA's achievements, such as developing diammonium phosphate and ammonium polyphosphate-based suspensions, which offer lower prices and improved efficiency compared to conventional fertilizers. It also discusses the incorporation of micronutrients into fertilizer blends to minimize segregation issues and increase solubility. Additionally, the document explores the production of solid urea-ammonium phosphate and other potential products, addressing concerns related to nitrogen volatilization and introducing sulfur-coated formulations. TVA's research and development efforts in liquid fertilizers are outlined, highlighting the progression toward higher-analysis grades and the successful incorporation of micronutrients in suspension mixtures. The document concludes by emphasizing TVA's commitment to collaborating with fertilizer companies in Florida, offering technical assistance and expertise to support their operations.
Recent Developments in Granulation I
(1965-11) Achorn, Frank P.; Lewis, J.S. Jr.
This document provides an overview of recent advancements in granulation technology, specifically focusing on granulation plants and their conversion processes. The granulation industry has witnessed an increase in the number of plants as companies previously producing pulverized mixtures have switched to batch granulation methods. This transition involves modifying batch mixers, installing ammonia and acid distributors, and utilizing rotary coolers for product cooling. Producers with medium-sized granulation plants have adopted pre neutralizers and scrubbers to enhance their production capabilities, leading to the manufacturing of diammonium phosphate granules and higher annual production volumes. The shift towards complete-grade handling stations has been observed among these companies. Additionally, some producers have transformed their batch ammoniators into continuous ammoniator-granulators to meet higher production demands. Various strategies have been employed to improve the efficiency and performance of granulation equipment. Operators have experimented with different materials for sparger pipes, with stainless steel and Hastelloy being preferred due to their longer lifespan and improved distribution of ammonia and acid within the granulator. Removing internal rings in ammoniator-granulators has been found to have no negative impact on granulation efficiency, while longer distributors have helped minimize nitrogen loss during the process. Several techniques have been implemented to prevent material caking, including rubber linings, flaps, knockers, and oscillating or spiral scrapers. These mechanisms effectively remove buildup from the walls of the ammoniator-granulator, ensuring smooth operation. Furthermore, a patented device for cleaning and positioning sparger bars has been introduced, enabling their rotation without equipment shutdown and facilitating maintenance. Integrating pre-neutralizers and scrubbers have allowed manufacturers to utilize larger quantities of phosphoric acid and ammonia to produce diammonium phosphate grades. The TVA process, involving partial ammoniation in a pre-neutralizer and complete ammoniation in the ammoniator-granulator, has shown promising results with high ammoniation levels and increased fluidity. This process allows for significant phosphoric acid consumption, resulting in high-quality fertilizers. Bulk handling stations have gained popularity among companies producing high-analysis grades, such as 8-24-2, 10-20-30, 12-24-24, and 20-10-10. These stations optimize transportation costs and enable the marketing of products over longer distances. Typical bulk handling stations consist of storage buildings with multiple bins or elevated storage tanks, utilizing conveyor systems for material unloading, storage, and loading onto bulk trucks. Cost studies indicate that constructing bulk handling stations alongside granulation plants is a competitive alternative to bulk blending, especially for high-analysis grades. However, the economic viability of this system relies on a high material movement, preferably exceeding 70,000 tons. At this scale, the cost-effectiveness of granulation with bulk handling stations approaches that of bulk blending. Collapse
Recent Developments in Granulation II
(1967-09) Achorn, Frank P.
This material discusses developments in granulation techniques in the fertilizer industry, presented by Frank P. Achorn at the Seminar for Latin American Fertilizer Executives in September 1967. The number of granulation plants in the United States and abroad has been steadily increasing. Many companies that previously produced pulverized mixtures have converted their batch ammoniators to granulators to produce granular products. Large-scale granulation plants have incorporated pre-neutralizers to manufacture diammonium phosphate grades. The Tennessee Valley Authority (TVA) ammoniator-granulator has been widely utilized for the production of diammonium phosphate and triple superphosphate grades by major granular fertilizer producers. These products are often marketed through blending plants, where they are mixed with potash to create different nitrogen, P₂O₅, and K₂O ratios. The conversion of small pulverized-mix plants into granulation plants has involved modifying the batch mixers by installing ammonia and acid distributors. Sketches and flow diagrams illustrate these modifications and the operation of batch granulation plants. Rotary coolers are used to rapidly cool the granular products, with some producers choosing to screen and recirculate the cooled material to the granulator for improved quality control. Certain companies have further converted their ammoniators into continuous granulators by enlarging the discharge and operating continuously. However, due to production limitations, some companies plan to construct conventional ammoniator-granulation plants to achieve higher production rates.
Recent Developments in Granulation III
(1968-05) Achorn, Frank P.
This document presents developments in granulation techniques discussed at the Management Seminar for Indian Fertilizer Executives by Frank P. Achorn, Head of the Process and Product Improvement Section at the Division of Agriculture Development, Tennessee Valley Authority. The document highlights the increasing number of granulation plants in the United States and abroad, with companies converting their small pulverized-mix plants to produce granular products. Various advancements are discussed, such as using TVA ammoniator-granulators, installing pre-neutralizers and scrubbers, and converting batch ammoniators to continuous granulators. The use of superphosphoric acid in small granulation plants to produce high-analysis grades is also explored. Additionally, the document describes different types of granulation plants, including small batch plants, conventional ammoniation-granulation plants, and up-to-date continuous ammoniator-granulators, along with their operational processes and benefits. Implementing innovative strategies to prevent material buildups on the ammoniator-granulator surfaces, such as rubber lining and flaps, is also addressed. These developments aim to improve granular fertilizer production's efficiency, productivity, and quality.
Some Agronomic Implications on Use of Low-Grade Phosphate Rock
(1980-10) Achorn, Frank P.; Jeffery L. Greenhill
This document explores the agronomic implications of utilizing low-grade phosphate rock in various agricultural applications. With reports of impending shortages of high-grade phosphate rock in Central Florida, many regional companies have turned to low-grade alternatives containing 62 to 68 BfL (bone phosphate of lime) for their phosphoric acid plants. However, this shift has resulted in increased phosphoric acid impurities due to the rock's nature and the different operating conditions required for its use. Consequently, meeting the tolerances needed for products such as diammonium phosphate (DAP) and triple superphosphate (TSP) has become challenging for many producers. Chemical analyses of commercial DAP samples reveal that a significant portion fails to meet the total P205 and nitrogen requirements. The reduced quality of DAP is attributed to excessive calcium sulfate levels in the phosphoric acid used during production, as well as high iron content and extended retention times in the preneutralizer. The document suggests solutions such as utilizing TVA's pipe-cross reactor (PCR) to eliminate the formation of citrate-insoluble P20s-Fe203 compounds and reduce sulfur content by optimizing reactor operation. Similarly, triple superphosphate (TSP) quality has also declined due to increased impurities in the rock and acid used during production. The impurities, including calcium, iron, sulfur, and aluminum, negatively affect the physical characteristics of TSP, making it difficult to achieve the desired screening results. Some producers reduce the acidulation ratio to address this, lowering P205 availability. Additionally, the use of ammonium sulfate solutions in TSP production raises the sulfur content of the product. While both ammonium phosphates and TSP contain significant amounts of sulfur and iron, their sulfur content is not typically sufficient to correct sulfur-deficient soils. However, it is suggested that they should still be considered as potential sources of sulfur. The document concludes that the availability of P205 will likely continue to be limited in DAP and TSP, emphasizing the importance of accounting for the unavailable P205 introduced through these products. Furthermore, it highlights the decreased water-soluble P20s in TSP and sulfur and iron's minor yet notable contribution to these fertilizers.
Some Liquid and Bulk Blending Fertilizer Facilities Now in Existence
(1963-09) Achorn, Frank P.
The establishment of liquid and bulk-blending fertilizer plants has increased significantly over the past decade. These plants, with capacities ranging from 2,000 to 5,000 tons of fertilizer per year, offer low investment and operating costs, making them attractive to nitrogen, P2O5, and K2O producers. This presentation provides a general discussion of the equipment used in manufacturing liquid and bulk-blended fertilizers, focusing on plants currently in use. Liquid fertilizer plants can be classified as liquid hot-mix or liquid cold-mix plants. Liquid hot-mix plants neutralize phosphoric acid with aqua ammonia or anhydrous ammonia, generating chemical heat. Liquid cold-mix plants mix high-phosphate liquid base solutions with urea-ammonium nitrate and potash. The presentation describes the equipment and processes involved in these types of plants. Bulk blending plants, which have gained popularity in the Midwest and other regions, involve dry-mixing solid raw materials to create customized mixtures with different nutrient contents. The raw materials are weighed, mixed, and conveyed to bulk trucks or bagging machines. The various types of mixers used in bulk blending plants, such as rotary mixers, mixing screw conveyors, ribbon mixers, and gravity-flow mixers, are discussed. The presentation also touches on materials handling systems, weighing devices, and different mixing techniques used in these fertilizer manufacturing facilities. While other types of liquid plants and blending systems are available, the focus is on the plants currently in general use.
Suspensions by Cold Mixing
(1968-07) Achorn, Frank P.; Hubert L. Balay
The document explores the process of cold mixing as a method for producing fluid fertilizers. Cold mixing combines clear liquid base solutions with clay, urea-ammonium nitrate, potash, and other additives to create high-analysis suspensions. The document discusses the equipment and procedures involved in the cold mixing process, including plant setup, mixing tanks, agitation techniques, and storage considerations. It also examines various materials used in cold mixing, such as clear liquids (10-34-0, 11-37-0), ammonium polyphosphate, potash, and micronutrients. The advantages and challenges of cold mixing suspensions and potential developments in the field are discussed. The report concludes by emphasizing the growing popularity of suspension fertilizers and the need for cost-effective production methods like cold mixing.

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