TVA Fertilizer Research

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Browsing TVA Fertilizer Research by Author "Cole, Carl A. Jr."

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    A Versatile Source of Nitrogen
    (1987-09-01) Kachelman, Donald L.; Cole, Carl A. Jr.
    The document focuses on the use of urea in solution and suspension forms. It highlights the temperature requirements and production rates for different nitrogen concentrations in urea solutions, emphasizing the cooling effect of urea dissolution and the need for external heat sources. It also discusses the production of urea-ammonium phosphate and urea-ammonium sulfate granules using solid urea as a feedstock. Additionally, the report explores the production of nitrogen-phosphate (NP), nitrogen-potassium (NK), and nitrogen-phosphate-potassium (NPK) solutions using urea, ammonium nitrate, orthophosphoric acid, polyphosphoric acid, and potassium chloride. It mentions the importance of maintaining proper N-to-P2O5 ratios and the role of supplemental nitrogen. The document highlights the challenges and recommendations for producing urea suspensions, including the need for periodic agitation during storage and the benefits of rapid cooling to achieve desirable crystal formation.
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    Acid Fertilizer Solution Production
    (1988-06-06) Kachelman, Donald L.; Cole, Carl A. Jr.; Waters, Joe A.
    The production and utilization of acid fertilizer solutions have increased interest in recent years. Typically characterized by a pH less than 2.5, these solutions are commonly derived from urea, urea-ammonium nitrate (UAN) solution, wet-process phosphoric acid, potassium chloride, and sulfuric acid. This material explores the solubility systems of various acid fertilizers, including urea-phosphoric acid, ammonium nitrate-phosphoric acid, UAN solution-phosphoric acid, ammonium sulfate-phosphoric acid, urea-sulfuric acid, phosphoric acid-potassium chloride, and sulfuric acid-potassium chloride. These acid solutions' production methods, equipment, handling, storage, and application, are discussed. The advantages and disadvantages of acid solutions, such as higher analysis grades, increased micronutrient solubility, improved compatibility with hard water, and enhanced phosphorus availability, are explored. The corrosive nature of acid solutions and their impact on steel materials is also addressed. Furthermore, the potential benefits of acid-suspension fertilizers, which allow for higher analyses and novel grade combinations, are highlighted. The paper concludes with a summary of acid solutions' physical, chemical, and agronomic advantages and their potential implications for fertilizer production and application.
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    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.
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    New Materials for Fluid Fertilizers
    (1978-07) Hubert L. Balay; Cole, Carl A. Jr.; Wright, Eugene B. Jr.
    This material discusses new materials and approaches for fluid fertilizers, focusing primarily on nitrogen products, and briefly mentioning phosphate compounds. The paper highlights the shift from the direct application of aqua ammonia to anhydrous ammonia due to cost considerations. However, there is renewed interest in aqua ammonia solutions, particularly 41-percent nitrogen aqua ammonia, as a compromise between low-cost, non-pressure aqua and high-nitrogen anhydrous ammonia. The paper describes converting anhydrous ammonia to aqua ammonia using low-cost equipment and explores the benefits and considerations of using 41-percent nitrogen aqua ammonia. The authors also discuss utilizing heat of solution for dissolving urea in aqua ammonia. By leveraging the heat generated during mixing anhydrous ammonia and water, urea can be dissolved efficiently, and urea solutions can be used as direct application fertilizers or as supplementary nitrogen in mixed liquid fertilizers. Different methods and devices for dissolving urea are presented, including utilizing heat transfer in a heat exchanger or employing preheated water. Furthermore, the material discusses using fluid clay, specifically attapulgite-type clay, as a suspending agent in suspension fertilizers. The advantages of using predispersed fluid clay over dry clay are highlighted, such as easier handling, reduced dust, and improved product consistency. The production process for fluid clay is explained, along with considerations for preventing contamination from fertilizer salts. Finally, the authors describe how the plant used for producing nitrogen fluid clay can be modified to produce urea-ammonium nitrate (UAN) suspension fertilizers. The modifications involve incorporating a second centrifugal pump and a feedline to add ammonium nitrate to the dispersed clay slurry. The UAN suspension can serve as a supplemental nitrogen source in plants producing high nitrogen suspensions from base grades.
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    Status of NPKs Ammoniation-Granulation Plants and TVA Pipe-Cross Reactor
    (1980-10) Salladay, David G.; Cole, Carl A. Jr.
    This document provides an overview of the status and prospects of NPKS (nitrogen, phosphorus, potassium, sulfur) ammoniation-granulation plants and TVA (Tennessee Valley Authority) pipe-cross reactors in the fertilizer industry. The study conducted surveys and interviews with plant production supervisors to gather data on the number of operating plants, annual tonnage produced, and the use of pipe-cross reactors. The results indicate that 107 granulation plants operated by 37 companies had 8.5 million tons of homogeneous NPKS granular fertilizers in the last year. The most popular grades produced include 6-24-24, 10-10-10, and 13-13-13, among others. Additionally, the installation and operation of pipe-cross reactors are discussed, highlighting design features, operating parameters, and significant results. Using pipe-cross reactors has led to savings in fossil fuel heat input for drying, increased production rates, and improved product quality. The document also presents specific cases, such as the production of MAP (monoammonium phosphate) 11-53-0-2S and using byproduct sulfur sources in the 16-8-8-XS grade. Finally, the economic aspects of retrofitting pipe-cross reactors into existing plants are explored, demonstrating that the investment costs are relatively small, and the payback period is usually less than one year.