Omnia Fertilizer Ltd
Nitrous Oxide Reduction Project
(UNFCCC Reg No. 0752)
Eden Jack
19 May 2011
CDM Awareness Raising Workshop
Presentation Outline
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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 Signatory
ISO 9001
ISO14001
OSHAS 18001
ISO 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
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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 H2O
• 4 NH3 + 3 O2 → 2 N2 + 6 H2O
• 4 NH3 + 4 O2 → 2 N2O + 6 H2O
Reactions Downstream of Converter
• Oxidation of NO
• 2NO + O2
• Absorption
• 3NO2 + H2O
• N2O4 + H2O
• 3HNO2
2NO2
N2O4
2HNO3 + NO
HNO2 + HNO3
HNO3 + H2O + 2NO
Reactions Downstream- Converter
• 2 NH3 + 8 NO → 5 N2O + 3 H2O
• 4 NH3 + 4 NO + 3 O2 → 4 N2O + 6 H2O
• Nitric Acid Plant Basis
• Combustion of NH3, over Pt/Rh catalyst
• NOx 94-96%
• N2O 4-6%
Study
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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
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UHDE technology
• Primary, Secondary or Tertiary
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Primary Abatement
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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
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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
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Project initiated 2006
UHDE
Omnia Project Department
Emerson
Management (CDM)
Project Boundary for N2O Destruction Facility at Omnia’s Nitric Acid
Plant
heat
exchanger
Project Boundary
To atmosphere
tail gas
Air
Ammonia Gas
Process
Water
N2
O2
H2O
cooling
water
Ammonia
Ammonia
Oxidation
catalyst
Ammonia
Oxidation
Reactor
Natural gas
Tail gas
turbine
absorption
tower
N20
destruction
facility
Boiler
Clean tail gas
N2O destruction facility
process gas
with N2O, NO2
& NOx
Heat
exchanger
nitric acid
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 Unit
NOx
Nox in
Nox out
350.0
300.0
ppm
250.0
200.0
150.0
100.0
50.0
0.0
1
4
7
10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58
Day
EnviNox
EnviNox Unit
N2O
N2O In
N2O Out
1400.0
1200.0
ppm
1000.0
800.0
600.0
400.0
200.0
0.0
1
4
7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58
Day
EnviNox
EnviNox Efficiency
100.0
99.0
98.0
96.0
95.0
94.0
93.0
Months 2008 - 2011
m
ar
ja
n
no
v
se
p
ju
l
m
ay
m
ar
ja
n
no
v
se
p
ju
l
m
ay
m
ar
ja
n
no
v
92.0
se
p
%
97.0
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 (tCO2e)
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
292,391
0
3,605,759
3,313,368
Total
Notes:
(1) Year is defined as the time period between April 1 and March 31 of subsequent year
CDM Process
Verification
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
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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
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Kyoto and Post 2012
CDM and UNFCCC
CER prices and market
Methodology
DOE requirements
Africa not capitalized on the framework effectively
Concerns /Comments
Thank You
www.omnia.co.za
[email protected]