TVA Fertilizer Research
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- Item1966 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.
- ItemRecent 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.
- ItemThe Role of the Engineer in Providing Technical Information(1996-05-19) Achorn, Frank P.This material highlights the evolving role of engineers in the United States fertilizer industry, specifically in providing technical assistance and information regarding the production, marketing, and application of various fertilizer products. Over the past few decades, the industry has undergone significant changes, transitioning from a byproduct-focused approach to a more chemical-intensive and technologically advanced sector. This shift necessitated the expertise of engineers to supply technical guidance in areas such as product formulation, process design, equipment recommendation, and storage and handling procedures. The material emphasizes the instrumental role of engineering field personnel in developing newer fertilizer products, such as granular triple superphosphate, as well as the introduction of high-analysis grades and micronutrient incorporation techniques. Furthermore, it discusses the engineers' involvement in designing and operating bulk blending plants and liquid cold-mix plants, which have revolutionized fertilizer marketing systems. The material also highlights the engineers' contributions to developing liquid suspensions and their efforts in conducting demonstrations and providing technical support for applying these innovative fertilizers. Additionally, it mentions the importance of technical service groups within fertilizer companies and the division of the United States into regions to ensure effective consumer assistance and support. The material concludes by recognizing the potential for engineers to provide technical services internationally and overcome challenges related to fertilizer production, transportation, distribution, and application.
- 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.
- ItemUse of Byproducts in Suspensions(1984)This material discusses the utilization of byproducts and chemical waste in the fertilizer industry, focusing on their application in suspensions. Prepared by the Tennessee Valley Authority (TVA), the report highlights TVA's role in assisting chemical firms in developing uses for byproducts containing valuable plant nutrients. One such example is using spent phosphoric acid, a waste product from aluminum fabricators. This acid, when neutralized by ammonia, can be used to produce mixed liquids containing phosphate. By adjusting the pH, aluminum precipitation can be controlled, resulting in a clear solution suitable for soil application. The report also explores the increasing use of spent sulfuric acid, primarily in regions where it is readily available. Agricultural application is considered an efficient solution for the disposal of this material. Due to the corrosive nature of spent acids and the risk of iron salt crystal formation, precautions such as adding urea and clay suspending agents are recommended to prevent nozzle clogging and improve dissolution. Various sources of spent acid, including galvanizing companies and lead acid battery salvagers, are identified as potential suppliers. The material these companies provide can serve as a source of sulfur and zinc, although the final concentrations may vary. Handling challenges and properly characterizing byproducts to ensure the absence of hazardous substances are emphasized. The report highlights the importance of considering environmental and human safety when using byproducts in agricultural applications. Dilution or proper blending with other materials may be necessary to mitigate any potential risks associated with heavy metal content or toxic substances.