Ten technologies regarding nitrogen fertilizers

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1. Technical name: Composite High-Efficiency Foam Collector. Technical description: It integrates multiple separation technologies to completely address the issue of secondary entrainment of aerosols caused by large gas volumes and high flow rates. It is suitable for gas-liquid separation in absorption towers and regeneration towers, as well as for aerosol separation in various cooling and condensation processes. The processing capacity is 50% to 100% higher than that of traditional separators. To date, 4 companies have adopted this technology for aerosol separation. 2. Technical name: Advanced control technology 　　Technical overview: This technology reduces the standard deviation of key process variables by more than 50%, increases the processing capacity by 1%–5%, boosts the yield of target products by 1%–5%, and reduces specific energy consumption by 3%–5%. Two companies within Sinopec Group have adopted this system and have passed the acceptance inspection. 3. Technical name: Two-tower in-series process for urea synthesis tower 　　Technical overview: This process involves adding a premixer ； Second, add a synthesis tower of the same volume or a different volume, as well as a temperature-controlled connecting pipe between the two towers. The urea synthesis unit of Sichuan Jinxiang Chemical Co., Ltd. uses this process, and it has been operating well since its commissioning in 2003; the ammonia consumption per ton of urea has decreased from 605 kilograms to an average of 584 kilograms. 4. Technical name: High-pressure liquid-gas rapid tubular reactor for urea synthesis. Technical overview: The core of this technology lies in atomizing large-volume, high-pressure liquids into particles with sizes of 100–350 microns within a small space, where they mix with gaseous media to form a mixture similar to a homogeneous mixture. After the renovation of the urea production process system using the aqueous solution full-circulation method with an annual output of 100,000 tons, the carbon dioxide conversion rate can be increased by more than 3%, resulting in annual savings of 1.5 to 2 million yuan in steam costs. 5. Technical name: Unpowered ammonia recovery process and device. Technical description: This device enables the complete recovery of ammonia from the exhaust gases in synthetic ammonia systems, which not only increases production and reduces costs but also ensures that the emitted exhaust gases are free of ammonia pollution. The Mianyang branch of Sichuan Meifeng Chemical Company has adopted this technology, and a synthetic ammonia plant with an annual production capacity of 100,000 tons can recover 1,500 to 2,500 tons of liquid ammonia per year. 6. Technical name: Energy-saving and consumption-reducing process technology for methanol distillation systems. Technical overview: This technology improves the separation efficiency of each distillation tower, reduces the operating reflux ratio, and saves 20% in energy consumption. This technology has been successfully applied to the design and renovation of multiple methanol distillation systems, resulting in methanol quality meeting American AA grade or national premium standards. It increases yield by 1% and reduces production costs by 40 yuan per ton. 7. Technical name: Ash-polymerized fluidized bed coal gasification technology. Technical overview: This process utilizes a unique gas distributor and an ash agglomeration separation device, which improves the carbon conversion rate in the fly ash recycling system. It features wide compatibility with different types of coal, high reliability in continuous operation, and a simple process flow. The Jinshi Chemical Fertilizer Factory in Shijiazhuang, Hebei, has installed a 0.6MPa gasification unit, which has been put into operation. 8. Technical name: New process for potassium sulfate compound fertilizer 　　Technical overview: This process addresses the major issues associated with traditional processes, such as high steam consumption, high conversion temperatures, and heavy loads on the systems used to absorb the exhaust gases generated during conversion. It features low reaction temperatures, short processing times, and reduced energy consumption; it also effectively prevents scaling in coolers that use circulating water as a cooling medium. Shandong Shikefeng Chemical Co., Ltd. has built a 100,000-ton capacity potassium sulfate compound fertilizer production line using this process. 9. Technical name: Dual-pressurization *AO acid process technology. Technical overview: This technology solves the problem of insufficient steam available for internal use in domestic plants operating at full capacity, enabling self-sufficiency in steam production. The amount of by-product steam that can be exported amounts to around 3.6 tons per hour, and this alone generates an additional profit of about 5 million yuan per year. This technology has been applied to the *ao acid plants of relevant enterprises in Huai’an, Jiangsu, and Hangzhou, Zhejiang. 10. Technical name: New type of catalyst for natural gas-based ammonia synthesis. Technical overview: This catalyst enables the water-to-carbon ratio in the gas used for ammonia synthesis to be reduced from the current 3.5 to 2.7, resulting in a reduction of energy consumption for ammonia synthesis by nearly 20%. Five core catalytic technologies have been developed, including pre-conversion, single-stage conversion, two-stage conversion, high-temperature shift, and low-temperature shift. Catalysts for conversion at low water-to-carbon ratios in each of these stages have been put into industrial use.