Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance Neville Jordison Solex Thermal Science Inc. Canada 6 th to 10 th of May AGADIR MOROCO

A Brief History o Indirect Heat Exchanger introduced to the fertilizer industry approximately 25 years ago o Today more than 100 coolers installed in fertilizer plants round the world o Equipment operating successfully in every type of fertilizer - Urea (prills & granules), AN, CAN, LDAN, NPK, MAP, DAP, AS o Company History creation of Bulkflow Heat Exchangers – a technology division within Cominco Engineering Services Ltd BULKFLOW TECHNOLOGIES is incorporated with headquarters in Calgary, Canada Rebranded as Solex Thermal Science Inc to enhance profile as a world leader in the science of heating and cooling bulk solids

Advantages compared to Air Cooling (Rotary or Fluid Bed) o Low energy consumption o No air usage – eliminates chillers, fans ducts and scrubber o Compact design o Lower installed capital cost

Principle of Operation Combines the science of mass flow with indirect heat transfer Product flows slowly by gravity between water cooled plates Product flows in uniform velocity mass flow Water flows counter-current inside plates Heat Exchange by conduction

The Secret to Long Term Operating Performance What causes Caking ? HYGROSCOPIC PRODUCT WATER COOLED PLATES HUMIDITY IN VOID SPACE CONDENSATION CAKING ON PLATES ×

The Secret to Long Term Operating Performance Preventing the Caking Mechanism ADD PURGE AIR TO LOWER DEWPOINT CORRECT WATER TEMP PROFILE ELIMINATE CONDENSATION NO CAKING PURGE AIR

The Secret to Long Term Operating Performance The CRH Curve

The Secret to Long Term Operating Performance Thermal Modelling – Process Input Conditions

The Secret to Long Term Operating Performance Thermal Modelling – Output Temperature Profile

The Secret to Long Term Operating Performance Ensuring Water Temperature is above the Dew Point Water temperature must be to right of dewpoint line to prevent condensation mechanism

The Secret to Long Term Operating Performance Complete System o Tempered Water Module to provide controlled cooling water temperatures o Purge air system controlled flowrate and dewpoint o Instrumentation and Control System

Pilot Testing at OCP Jorf Lasfar o DAP o Product Inlet Temperature 65 – 75°C o Maintain discharge temperature below 50°C o Demonstrate long term run capability without caking

Pilot Testing at OCP Jorf Lasfar Test Set-up o Double Bank Exchanger o Controlled Cooling Water Temperatures o Purge Air system o Demonstrate long term run capability without caking PURGE AIR PRODUCT IN PRODUCT OUT

Pilot Testing at OCP Jorf Lasfar ProductWater Purge Air Steady-State Averages for each run: T° in T° out Rate TOP BANK T° in BOTTOM BANK T° out Run 1 (July 17)66-74°C44-58°C180 kg/h65-72°C43-58°Cyes Run 2 (July 18) °C45-46°C kg/h61°C44-45°Cyes Run 3 (July 20)63-72°C39-44°C200 kg/h °C40-45°Cyes Results

Pilot Testing at OCP Jorf Lasfar Plate Banks checked after each run o Removable Plexiglas plate o Plate surfaces stayed clean throughout testing

Typical DAP Cooler o Product Flowrate:100 t/h o Product Size: 1 – 4 mm o Product Temperature in: 85C o Required Product Temp. out: < 50C o Cooling Water: Cooling Tower at 28C o Purge Air: Required A = B = 1650 C = 1580 E = 150 F = 1800 G = 2470 J = 1390

Typical DAP Cooler o Water Temperature Control Module o Primary water supply can be cooling tower or sea water – use 254SMO or titanium plate heat exchanger o Purge Air Supply o Unit typically installed immediately following the screens

Recent Fertilizer Projects CompanyLocationProductCapacity Yara FertilizersPorsgrun, NorwayNPK210 t/h Gemlik GubreGemlik, TurkeyAmm. Nitrate 80 t/h National Fertilizers Jagdishpur, India Urea Prills 2 x 155 t/h Zuari Fertilizers and Chem. Zuarinagar, India NPK 75 t/h JPMCJordan DAP2 x 70 t/h

Large urea prill cooler during installation in India

Long Term Operating Performance “This campaign the CAN Plant started up on 5 th of June and until now The Solex Cooler hasn’t needed cleaning yet and is operating perfectly”. Quote from Alp Bulent GULES Gemlik Gubre Sanayii A.S. Sept 26 th 2010 Thank you for your attention