TVA Fertilizer Research
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Browsing TVA Fertilizer Research by Author "Hubert L. Balay"
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- ItemAdvantages of Producing and Using Monoammonium Phosphate(1980-10) Hubert L. Balay; Jeffery L. GreenhillThis document explores the advantages of producing and utilizing monoammonium phosphate (MAP) as a fertilizer ingredient. Since the 1960s, the production of ammonium phosphate has been primarily focused on granular diammonium phosphate (DAP). However, MAP has gained popularity due to its versatility and benefits as a fluid fertilizer base. The document highlights the advantages of MAP production in various aspects, including ammonium phosphate production plants, regional granulation plants, bulk blending plants, fluid fertilizer production, transportation, storage, and agronomics. The document discusses the advantages of using MAP over DAP in ammonium phosphate production, particularly in scrubbing processes. The MAP production process simplifies scrubbing and offers greater flexibility in acid concentration. Nongranular MAP production methods are also explored, emphasizing their simplicity and suitability for storage, handling, and transportation. The document further elaborates on the advantages of MAP in regional granulation plants. By adjusting the ammoniation ratio, regional granulation plants can increase the amount of phosphoric acid used, thereby improving granulation efficiency and product storage. The introduction of the pipe-cross reactor is highlighted as a development that enables the use of higher amounts of phosphoric acid in regional granulation plants. Additionally, the benefits of MAP in bulk blending and suspension fertilizers are discussed. MAP allows for a wide range of blending ratios without additional phosphate materials, offering logistical advantages. It is also favored in suspension fertilizers due to lower shipping costs and the absence of cold weather storage issues associated with fluid bases.
- ItemEffect of Granule Size on Application(1983-10) Broder, Michael F.; Hubert L. BalayThis study investigates the effect of granule size on the application of dry fertilizer using spinner spreaders, which are commonly used in the United States for broadcasting fertilizer. Previous research has emphasized the importance of particle size in maintaining uniform distribution within blends. However, the focus has been on smaller particles, discouraging using larger materials. This paper explores the advantages of broadcasting materials larger than typical granular products and examines the impact on spread patterns. The literature review reveals that particle size significantly influences the segregation of raw materials in blends. Small particles travel a shorter distance from the spinning discs than large particles, affecting the distribution pattern. Studies have also shown that irregularly shaped particles travel less distance than spherical particles due to their larger drag coefficients. However, recent research suggests that while median particle size is crucial, size variability has little effect on the spread pattern. The study conducts field spreading tests using a double-spinner spreader and a high-flotation applicator with a single spinner. Three different sizes of urea granules are used, with similar density, shape, and surface roughness. The spread patterns are analyzed using a computer program, and various spinner and chute adjustments are tested to determine the optimal settings. Results demonstrate that larger granules can be broadcasted more effectively when placed nearer to the centers of double spinners. Swath widths increase significantly, with improvements of up to 30 feet observed. The study also reveals that larger granules produce less dust and are less prone to drifting, making them advantageous in reducing environmental concerns.
- ItemHandling and Distributing Urea(1983) Hubert L. Balay; Slappey, George A.This document explores the handling and distribution of urea, a nitrogen fertilizer compound widely used in agriculture. It traces the history of urea, from its first organic synthesis in 1828 to its significant growth in production and market share over the years. The document highlights the advantages of urea over other nitrogen sources, including its lower pollution levels, transportation risks, and plant food content. It also discusses the challenges associated with urea, such as size segregation, mechanical strength, chemical compatibility, and the presence of biuret. Additionally, the document examines the production of urea-ammonium phosphate grades and the potential use of urea as a supplemental nitrogen source in liquid fertilizers. This document provides valuable insights into the importance and complexities of handling and distributing urea in the agricultural industry.
- ItemLatest Developments in Production of Suspension Mixtures(1982-09) Hubert L. Balay; Slappey, George A.This document discusses the advancements made in producing suspension mixtures for fertilizer applications. The authors highlight the historical background and challenges associated with the production and application of suspension mixtures. They emphasize the shift towards more efficient banding techniques due to economic factors impacting farmers. The article presents various methods for preparing suspension fertilizers, focusing on using different base solutions, including ammonium polyphosphate and ammonium orthophosphate. The Tennessee Valley Authority's (TVA) processes for producing these bases are described, including the pipe reactor process and a continuous process for ammonium orthophosphate suspension. The authors also explore the production of solid ammonium polyphosphate and its granulation process. They discuss the benefits of cooling techniques to control crystal growth and enhance suspension quality. The document also highlights the potential of a batch process for producing orthophosphoric acid-based suspension mixtures, offering a cost-effective alternative to existing continuous processes. The findings presented in this report contribute to the understanding and improvement of suspension mixture production, aiding farmers in achieving optimal fertilizer efficiency.
- ItemMarketing Advantages of Using Solid Materials in Suspensions(1976-07) Hubert L. BalayThis material highlights the marketing advantages of utilizing solid materials in suspension fertilizers. The presentation by Hubert L. Balay, a chemical engineer from the Tennessee Valley Authority, discusses the benefits of solid materials over fluids in terms of cost-effectiveness and ease of transportation. Using solid materials in suspension fertilizers reduces transportation costs, especially considering the rising freight rates for dilute materials. The author explores various solid materials, including monoammonium phosphate, TVA ammonium polyphosphate, diammonium phosphate, solid urea, TVA granular urea-ammonium phosphate (UAP), calcium phosphate, red potash, and micronutrients. The presentation concludes by emphasizing the potential savings and future implications of adopting solid materials in suspension fertilizer production. This information is based on a presentation at the NFSA Round-Up conference in 1976 in St. Louis, Missouri.
- ItemNew 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.
- ItemProcess and Product Considerations of Fluid Lime(1980-08-26) Hubert L. Balay; Salladay, David G.This material provides an overview of fluid lime's process and product considerations, focusing on its various applications and the challenges associated with its production and use. It highlights the widespread use of limestone in construction, agriculture, metallurgy, and chemical processes. The report discusses the importance of limestone in agriculture for raising soil pH and improving crop yields. It emphasizes the significance of limestone's particle size and chemical composition in determining its effectiveness in soil neutralization. The publication further explores the concept of fluid lime, which involves applying finely-ground limestone as a suspension, thereby eliminating dust during handling and promoting rapid reaction in the soil. It describes the equipment and mixing procedures involved in producing limestone suspensions, including the use of combination mixing-storage systems to address storage and handling issues. The document also explores the potential use of byproduct sources of limestone, such as precipitated flue dust from cement plants and waste materials from sugar refining and pulp and paper industries, as alternative raw materials for fluid lime suspensions.
- ItemProducing and Marketing Suspension Fertilizers From Solids(1977-07) Hubert L. Balay; Salladay, David G.This material discusses the production and marketing of suspension fertilizers from solid materials, focusing on the advantages of fluid fertilizers over solid ones. The authors highlight the ease of mixing and uniform application of pesticides as a significant advantage of fluid fertilizers, along with other properties such as accuracy of application, low salt index, and the ability to mix and apply secondary and micronutrients uniformly. Traditionally, fluid fertilizers have been considered premium products due to their advantages and higher prices resulting from the costlier phosphate materials used in their production. However, in the face of rising costs and the need for cheaper raw materials, using solids to produce fluids has gained traction. The authors explore the use of monoammonium phosphate (MAP) and diammonium phosphate (DAP) as popular solid bases for fluid fertilizers, discussing their solubility and production methods. The potential use of triple superphosphate and ammonium polyphosphate (APP) as phosphate sources in fluid fertilizers is also mentioned. Overall, the material provides insights into the historical development and current practices of producing suspension fertilizers from solid materials.
- ItemQuality Control of Liquids and Suspensions(1984-12) Hubert L. BalayThe analysis and quality control of solid fertilizers has been extensively studied. In contrast, liquid and suspension fertilizers have often been assumed to be less prone to quality control issues due to their relatively homogeneous nature. However, control officials' reports indicate that such assumptions are unfounded. This publication investigates the impurities in raw materials, particularly phosphate sources, used in fluid fertilizer production and highlights their contribution to quality control challenges. The study draws upon research conducted by the Tennessee Valley Authority (TVA), revealing the presence of insoluble compounds derived from impurities in phosphate rock and wet-process phosphoric acid production in raw materials used for fluid fertilizer production. A profound understanding of the fundamental principles underlying liquid and suspension fertilizers is crucial to establish an effective quality control program. The publication clarifies the significance of a solubility curve representing the relative solubility of ammonium phosphates during fertilization. Furthermore, it emphasizes the importance of selecting appropriate potash grades for suspensions, considering criteria such as size specifications and impurity content. The publication also provides insights into preparing carriers for suspensions, focusing on the commonly used attapulgite clay as a suspending agent. It highlights the necessity of properly shearing and gelling the clay to prevent settling and crystal growth in suspensions. The recommended shearing process involves multiple passes through a centrifugal pump, ensuring optimal orientation of clay particles. Additionally, the publication explores the electrical charge characteristics of attapulgite clay, which contribute to its ability to prevent solids from settling. Sampling techniques for fluid fertilizers are addressed to ensure accurate chemical analysis. Proper sampling procedures are outlined, including the importance of recirculating the fertilizer through the pump to obtain representative samples. The publication suggests determining the optimal recirculation time experimentally or with assistance from control officials, ensuring reliable and consistent sampling.
- ItemRecent Developments in the Production and Use of Monoammonium Phosphate(1976-10) Hubert L. Balay; Salladay, David G.This document provides an overview of the recent developments in the production and utilization of monoammonium phosphate (MAP). The versatility of MAP has contributed to its growing popularity as a granular bulk blend material and a replacement for superphosphates in granulation plants. The low delivery cost of MAP compared to other ammonium phosphate products has further increased its appeal. The document explores various grades of MAP being produced and the processes involved in its production. The use of MAP in bulk blending is examined, highlighting its advantage over diammonium phosphate in achieving a wide range of blend ratios without the need for additional phosphate materials. The document discusses the need for additional nitrogen when using MAP and the availability of local nitrogen suppliers. Formulas for common grades blended from MAP, and diammonium phosphate are provided. Furthermore, the document explores the use of powdered MAP in granulation plants, particularly as a replacement for normal superphosphate and triple superphosphate. The cost-effectiveness, convenience in shipping, and compatibility with existing equipment make MAP a preferred choice in granulating high nitrogen grades. Operational experiences from a plant using MAP in the granulation process are shared, including challenges encountered and successful formulations. The document also discusses the use of MAP in fluid fertilizers and its contribution to suspension fertilizers. Factors such as impurity content, mole ratios, and the need for high-intensity mixing equipment are considered. Additionally, the production of ammonium polyphosphate from wet-process phosphoric acid is addressed, highlighting its storage and handling characteristics. Collapse
- ItemSelecting Equipment and Materials of Construction for Fluid Fertilizer Plants(1977-10) Kimbrough, Homer L.; Hubert L. BalayThis paper discusses the selection of equipment and materials for construction of fluid fertilizer plants. With the growing popularity of fluid fertilizer production, many new manufacturers are seeking guidance on equipment selection. The paper emphasizes the importance of considering factors such as the type of liquid fertilizer, production rate, fertilizer season length, and equipment usage. Projection of production needs over 5 to 10 years is recommended to avoid selecting inadequate equipment. The authors recommend selecting pumps, pipes, storage tanks, and mix tanks based on the characteristics of the fertilizers and operational requirements. The paper also highlights the significance of proper support, ventilation, and maintenance practices for maximizing the lifespan of the equipment. Overall, the information presented aims to assist prospective fluid fertilizer plant owners in making informed decisions about equipment selection and construction materials.
- ItemSuspensions by Cold Mixing(1968-07) Achorn, Frank P.; Hubert L. BalayThe 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.
- ItemTrends in Fertilizer Use(1986-01) Hubert L. BalayThe material explores trends in fertilizer use within the United States, with a focus on engineering aspects and their implications for the fertilizer industry. The author examines changes in fertilizer production and distribution, specifically highlighting the shift from granulated fertilizer to bulk blends and fluids. Bulk blending, facilitated by imported urea and cost-effective handling equipment, has gained market share due to its convenience and versatility in providing customized fertilizer formulations at lower prices. However, challenges related to analysis accuracy and micronutrient integration persist in bulk blends. Additionally, the decline in the number of NPK granulation plants is noted, with a shift towards ammonium phosphate (MAP) as a phosphate source for fluid fertilizers, offering stability, lower N:P2O5 ratios, and improved blending properties. The potential use of ammonium polyphosphate (GAPP) as a granular alternative is also explored. Fluid fertilizers, particularly suspensions, are gaining competitiveness with dry blends due to cost advantages and the utilization of low-cost nitrogen sources such as urea and ammonia. The material discusses various techniques for producing liquid fertilizers, including the use of ammonia in closed systems and the production of slow-release formulations. Furthermore, the study addresses the emerging trend of utilizing industrial waste products containing plant nutrients as fertilizers, emphasizing the need for appropriate treatment and evaluation. The role of computer programs in fertilizer formulation and plant design is briefly mentioned, along with the growing concerns regarding pollution and runoff from fertilizer plants. Finally, advancements in application equipment are highlighted, including the development of "boomed dry spreaders" and specialized applicators for banding fertilizers in reduced tillage systems.