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Eden Jack 19 May 2011
Omnia Fertilizer LtdNitrous Oxide Reduction Project
(UNFCCC Reg No. 0752)
CDM Awareness Raising Workshop
Presentation Outline
• Introduction Omnia• Nitric Acid Plant• Project Evaluation• Project Execution• EnviNox• CDM Process• Summary
Omnia Group
Fertilizers
•
Bulk Fertilizers (eg)•
LAN
•
4:3:4 / 2:3:2•
Greensulph
•
Speciality Products (eg)•
CN (FBG Technology)
•
MgNO3
•
Liquid Fertilizer (eg)•
UAN
Explosives /Chemicals
•
Ammonium Nitrate based explosives•
Detonators
•
Protea Chemicals•
Zetachem
•
JV Nalco
Omnia
Responsible Care SignatoryISO 9001ISO14001
OSHAS 18001ISO 17025
Omnia
•
Process of building New Facilities:•
Ammonia Logistics
•
Nitric Acid Plant•
Ammonium Nitrate
•
Solution•
Porous
•
Estimated cost R1.4bn•
Fertilizer and Explosives Market
•
Commissioning 2012
2008
Nitric Acid Plant
•
Ostwald Technology•
Built 1982
•
UHDE Process•
Dual Pressure Technology•
Low pressure NH3
Conversion•
High pressure Absorption
•
650 tpd, re-rated 750tpd, 100% acid
Converter Primary Reactions
•
4 NH3
+ 5 O2
→ 4 NO + 6 H2
O
•
4 NH3
+ 3 O2
→ 2 N2
+ 6 H2
O
•
4 NH3
+ 4 O2
→ 2 N2
O + 6 H2
O
Reactions Downstream of Converter
•
Oxidation of NO•
2NO + O2
2NO2
N2
O4
•
Absorption•
3NO2
+ H2
O 2HNO3
+ NO
•
N2
O4
+ H2
O HNO2
+ HNO3
•
3HNO2
HNO3
+ H2
O + 2NO
Reactions Downstream-
Converter
•
2 NH3
+ 8 NO → 5 N2
O + 3 H2
O
•
4 NH3
+ 4 NO + 3 O2
→ 4 N2
O + 6 H2
O
•
Nitric Acid Plant Basis
•
Combustion of NH3, over Pt/Rh
catalyst •
NOx
94-96%•
N2O 4-6%
Study
•
Kyoto Protocol•
Methodology AM0028 was completed 2005
•
GWP 310•
Specific to Selective Catalytic Reduction (SCR)
•
Feasibility 2005
Basis for EnviNOx
Installation
•
Reduce Greenhouse Gas Emission (GHG)•
Legislation
•
South Africa non Annex 1 Country
Project Evaluation•
UHDE technology•
Primary, Secondary or Tertiary
•
Primary Abatement
•
Secondary/Tertiary Abatement•
Capital cost
•
Catalyst Leased/ Own•
Efficiency Guarantees
•
Retrofit Design •
Installation Process
•
Plant Availability•
Approved Methodologies
Tertiary Abatement (considerations)
•
Capital Cost•
Analyser
•
Delta-V•
Structure and Reactor
•
Catalyst•
Plant Availability
•
Lower Tail Gas Temperature
Tertiary Abatement
•
Superior Product-
Guarantees•
Proven Technology
•
Does not hamper the process-
end of pipe design•
Retrofit design
•
CDM UNFCCC considerations
Nitric Acid Plant Basis
•
Combustion of NH3, over Pt/Rh
catalyst •
NOx
94-96%
•
N2O 4-6%•
UHDE technology•
Primary, Secondary or Tertiary
•
Economics•
Social Responsibility
Project Execution
•
Project initiated 2006•
UHDE
•
Omnia Project Department•
Emerson
•
Management (CDM)
Project Boundary for N2O Destruction Facility at Omnia’s Nitric Acid Plant
heatexchanger
Ammonia
nitric acid
N20destruction
facility
Tail gas turbine
To atmosphere
Natural gas
Clean tail gas
tail gas
Process Water
coolingwater
AmmoniaOxidationReactor
Air
Ammonia Gas
Heat exchanger
Boiler
N2O2H2O
AmmoniaOxidationcatalyst
process gaswith N2O, NO2 & NOx
N2O destruction facility
Project Boundary
absorptiontower
Project Boundary For N2O Destruction Facility at Omnia’s Nitric Acid Plant Fig.2
EnviNox Structure
Empty Envinox Reactor
Tail Gas Flow Measurement
EnviNox
EnviNox
EnviNox UnitNOx
0.0
50.0
100.0
150.0
200.0
250.0
300.0
350.0
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58Day
ppm
Nox inNox out
EnviNox
EnviNox UnitN2O
0.0
200.0
400.0
600.0
800.0
1000.0
1200.0
1400.0
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58
Day
ppm
N2O InN2O Out
EnviNox
EnviNox Efficiency
92.0
93.0
94.0
95.0
96.0
97.0
98.0
99.0
100.0
sep
nov jan
mar
may jul
sep
nov jan
mar
may jul
sep
nov jan
mar
Months 2008 - 2011
%
Nitric Acid Plant Stack
Process
•
Omnia Project•
Prior Consideration Form
•
Project Identification Note (PIN)•
Letter of Approval (LoA) South African DNA
•
Project Design Document•
Validation
•
Registered May 2007•
Plant commissioned February 2008
CDM Process
•
Safety and training•
Completed a preliminary verification audit•
Successful Audit
•
400k t CER’s
delivery,
CDM Process
Table 9: Estimated Ex-ante Emissions Reduction during the first 7-year crediting period (tCO2 e)
Year (1) Project Emissions Leakage Baseline Emissions Emissions Reduction
2008 32,797 0 512,188 479,391
2009 33,417 0 521,872 488,455
2010 53,284 0 512,188 458,904
2011 52,389 0 503,580 451,191
2012 33,417 0 521,872 488,455
2013 32,797 0 512,188 479,391
2014 54,292 0 521,872 467,580
Total 292,391 0 3,605,759 3,313,368
Notes:
(1) Year is defined as the time period between April 1 and March 31 of subsequent year
CDM ProcessVerification
Reports
Number From To Audit CER's Issuance
1 26/02/2008 17/03/2008 Jul-08 26276 Mar-09
2 18/03/2008 08/07/2008 Jul-08 157285 Jan-09
3 09/07/2008 31/01/2009 Feb-09 321234 Sep-10
4 01/02/2009 31/05/2009 Nov-09 151795
5 01/06/2009 31/10/2009 Nov-09 169105
6 01/11/2009 31/05/2010 Aug-10 251999
7 01/06/2010 30/11/2010 Feb-11 204089
8 01/12/2010 31/04/2011 Jun-11 191359
Total 1473142
CDM Process
•
Verification 1 –
3•
Installation didn’t match Methodology
•
Installation did not match PDD•
Preliminary audit did not pick up either
•
DOE’s
were pedantic about process•
Monitoring report and plan were sophisticated and complex
•
Reports generated from the system•
Communication and back ups
CDM Process
•
Unable to change PDD•
Unable to change installation retrofit
•
Process -
Request for Deviation from UNFCCC•
Process took approximately 6 months
CDM Process
•
Verification 4 –
6•
New DOE appointed
•
New Criteria•
New criteria from EB
•
Request for deviation does not apply•
Re-submit Request for Revision
•
Change Hardware•
Change PDD
•
Change Monitoring Report and Monitoring Plan•
Revision completed 14 months April 2011
•
Verification 4 Completeness check
CDM Process
•
Verification 7 onward•
Template change for Monitoring Report
•
EB requirements change•
DOE requirements change
•
Process change and focus
Summary
•
Achieved Greenhouse Gas Reduction•
Stack Emissions clear
•
Omnia Social Responsibility/ Responsible Care
•
Kyoto and Post 2012•
CDM and UNFCCC
•
CER prices and market•
Methodology
•
DOE requirements•
Africa not capitalized on the framework effectively
Concerns /Comments
Thank Youwww.omnia.co.za
ejack@omnia.co.za
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