TVA Fertilizer Research

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Now showing 1 - 20 of 47

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.
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.
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.
Advantages of Producing and Using Monoammonium Phosphate
(1980-10) Hubert L. Balay; Jeffery L. Greenhill
This 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.
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.
Developments in Fertilizer Technology and Application Techniques
(1988-12) Broder, Michael F.; Mann, Horace C.; Culp, John E.
This material provides an overview of the National Fertilizer Development Center (NFDC), a key Tennessee Valley Authority (TVA) program dedicated to fertilizer research and development. Established in 1933, TVA aimed to foster the growth of the Tennessee Valley region and promote public-private cooperation in developmental programs. The NFDC, located in Muscle Shoals, Alabama, is the nation's only comprehensive fertilizer research and development program. The NFDC's primary objectives are to generate new technologies and products related to fertilizers, improve fertilizer use efficiency, and prevent environmental damage caused by fertilizer production and application. The center conducts basic research, developmental activities, and national technology transfer programs in collaboration with the fertilizer industry, land-grant universities, and farmers. It has the necessary facilities to develop and test new technologies, including laboratories, pilot plants, prototype production facilities, and greenhouses. The paper also highlights several recent and ongoing developments in fertilizer manufacturing. One notable innovation is the production of urea-nitric phosphate (UNP), a solid fertilizer with potential economic advantages over traditional methods. The NFDC's falling curtain-evaporative cooling process is also discussed, enabling urea granulation with superior product quality and low energy consumption. Additionally, the use of calcium lignosulfonate as a conditioning agent for granular urea, replacing formaldehyde, is explored due to its environmental safety and cost-effectiveness. The material further outlines advancements in sulfur-coated urea, nitrogen-sulfur fluid fertilizers, and phosphate-based products, including ammonium polyphosphate and urea phosphate. It highlights the NFDC's efforts to develop cost-effective fertilizers while considering environmental concerns and using lower-grade phosphate ores. It concludes by discussing recent progress in fertilizer application technology, including automatic rate controllers and fuel efficiency improvements in custom application equipment.
Effect of Granule Size on Application
(1983-10) Broder, Michael F.; Hubert L. Balay
This 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.
Feeding a World of 10 Billion People: The TVA/IFDC Legacy
(IFDC, 2003-03-14) Borlaug, Norman E.
This material contains information on Travis P. Hignett Memorial Lecture, given by a distinguished speaker, highlighting the role of science, technology, and fertilizer in improving food production over the past 50 years. The lecture explores the challenges of feeding a population of 10 billion by the end of the century. It discusses the history of the TVA's agricultural resource development program, which led to fertilizer science and technology advancements. It also explains establishment of the International Fertilizer Development Center (IFDC) and its contributions to global fertilizer sector development. The material emphasizes the importance of integrated soil nutrient management and innovative practices to achieve sustainable agricultural productivity and alleviate poverty. The document concludes with the projected population growth and the need to address the increasing demand for food.
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.
Handling 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.
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.
Latest 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.
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.
Marketing Advantages of Using Solid Materials in Suspensions
(1976-07) Hubert L. Balay
This 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.
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.

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