Energy Conservation in Fertilizer Production

An energy efficient fertilizer production device called the Pipe Cross Reactor (PCR) was developed by the National Fertilizer Development Center (NFDC) of the Tennessee Valley Authority (TVA). The PCR uses the heat of reaction of ammonia with phosphoric acid and sulfuric acid to replace fossil fuel heat used in granulating and drying fertilizer. The device has been installed in about 30 fertilizer plants across the U.S.A. resulting in current annual energy savings equivalent to approximately 11 million gallons of fuel oil. In six years of cooperation with the TVA, the DOE spent about one million dollars on the PCR technology transfer effort. This TVA project is a notable success based upon demonstrated energy savings and industry acceptance of the technology. The technology is applicable to producing NPKS, DAP and MAP types of fertilizer. This paper discusses the technology with emphasis on the technology transfer work conducted by TVA and supported by DOE-OIP.