FERTILIZER

INDUSTRY

Overview
Brief History
Classification, Uses and Process
Waste Production and Waste treatment
Prospect as a Chemical Engineer and the future of the industry

Reporters:
Elajah Mae Zaragoza
Annjanette Ayson
Easter Gloren Foronda
Jasen Emil De Leon

Fertilizers
- Any material of natural or synthetic origin that is applied to
soils or to plant tissues to supply one or more nutrients
essential to the growth of plants.

Three Macronutrients:
Nitrogen
Phosporus
Potassium

Fertilizers are classified in many ways. They are classified

according to whether they provide a single nutrient in which case
they are classified as "straight fertilizers." "Multinutrient fertilizers"
(or "complex fertilizers") provide two or more nutrients

BRIEF HISTORY
Ancient History
Egyptians, Romans, Babylonians, and early Germans all are recorded as using
minerals and or manure to enhance the productivity of their farms. The use of
wood ash as a field treatment became widespread.

1730
Viscount Charles Townshend(1674-1738) first studied the
improving effects of the fourcrop rotationsystem that he had
observed in use inFlanders.

Early 19th Century

Johann Friedrich Mayer(1719-1798) was the first to present
to the world a series of experiments upon it the relation
ofgypsumto agriculture

BRIEF HISTORY
Early 19th Century
The French agronomist Victor Yvart (1763-1831) believed that the action
of gypsum is exclusively the effect of the sulphuric acid, which enters
into its composition; and founds this opinion upon the fact that the ashes
of turf, which contain sulphate of iron and sulphate of alumina, have the
same action upon vegetation as gypsum
The French agronomist Charles Philibert de Lasteyrie (1759-1849),
observing that plants whose roots were nearest the surface of the soil
were most acted upon by plaster, concludes that gypsum takes from the
atmosphere the elements of vegetable life, and transmits them directly
to plants.
Louis Augustin Guillaume Boscintimates that the septic
quality of gypsum (which he takes for granted) best explains
its action on vegetation

Humphry Davyfound that, of two parcels of minced veal,

the one mixed with gypsum, the other left by itself, and
both exposed to the action of the sun, the latter was the
first to exhibit symptoms of putrefaction.

Early 19th Century

ChemistJustus von Liebig(1803-1873) contributed greatly
to the advancement in the understanding of plant nutrition.

John Bennet Lawes, an Englishentrepreneur began to

experiment on the effects of various manures on plants
growing in pots in 1837, and a year or two later the
experiments were extended to crops in the field. One
immediate consequence was that in 1842 he patented a
manure formed by treating phosphates with sulphuric acid,
and thus was the first to create the artificial manure
industry.
Joseph Henry Gilbert, who had studied under Liebig at
theUniversity of Giessen, as director of research at
theRothamsted Experimental Stationwhich he founded on
his estate.

BRIEF HISTORY

BRIEF HISTORY
Early 19th Century

Jean Baptiste Boussingault(1802-1887) pointed out

that the amount of nitrogen in various kinds of
fertilizers is important.

MetallurgistsPercy Gilchrist(1851-1935) andSidney

Gilchrist Thomas(1850-1885) invented theGilchristThomas process.

Early 20th Century

The Birkeland-Eyde Process
- It was developed by Norwegian industrialist and scientistKristian Birkelandalong
with his business partnerSam Eydein 1903, based on a method used byHenry
Cavendishin 1784.

The Haber Process

- In the early decades of the 20th century, theNobel prize-winning chemistsCarl
BoschofIG FarbenandFritz Haberdeveloped theHaber processwhich utilized
molecular nitrogen (N2) and methane (CH4) gas in an economically sustainable
synthesis ofammonia(NH3). The ammonia produced in the Haber process is the
main raw material of theOstwald process.

The Ostwald process

-TheOstwald processis achemicalprocessfor production ofnitric acid(HNO 3),
which was developed byWilhelm Ostwald(patented 1902).

Erling Johnson
- In 1927Erling Johnsondeveloped an industrial method forproducing
nitrophosphate, also known as theOdda processafter hisOddaSmelteverk
ofNorway

BRIEF HISTORY

KRISTIAN
BIRKELAND

SAM EYDE

FRITZ HABER

CARL BOSCH

WILHELM
OSTWALD

Classification of Fertilizers

Based on Composition
Fertilizers
Straight Fertilizers

Classification of Fertilizers
Based on Composition

Straight Fertilizers
Fertilizers which supply only one primary plant
nutrient, namely nitrogen or phosphorus or potassium.
eg. Urea, ammonium sulphate, potassium chloride and
potassium sulphate.

Complex Fertilizers

Fertilizers two or three primary plant nutrients of

which two primary nutrients are in chemical
combination. These fertilizers are usually produced in
granular form.
eg. Diammonium phosphate, nitrophosphates and
ammonium phosphate.

Classification of Fertilizers
Based on Composition

Mixed Fertilizers

Fertilizers that are physical mixtures

of straight fertilizers. They contain
two or three primary plant nutrients.
Mixed
fertilizers
are
made
by
thoroughly mixing the ingredients
either mechanically or manually.

Classification of Fertilizers
Based on Physical Form

Fertilizers
Solid Fertilizers

Classification of
Fertilizers
Based on Physical Form

Solid Fertilizers

Several formsviz.
Powder (single superphosphate),
Crystals (ammonium sulphate),
Prills (urea, diammonium phosphate,

superphosphate),
Granules (Holland granules),
Supergranules (urea supergranules)
and
Briquettes (urea briquettes).

Class

ificat
ion o
F
e
f
rtiliz
Base
ers
d on
Phys
ical F
orm

Liquid Fertilizers

Liquid form fertilizers are applied

with irrigation water or for direct
application.
Ease of handling, less labour
requirement and possibility of
mixing with herbicides have made
the
liquid
fertilisers
more
acceptable to farmers.

Uses of
Plants need sun, water and nutrients to grow. The
nutrients canFertilizer
be taken from air or soil. If there is
an ample supply of nutrients in the soil, crops are
more likely to grow well and produce high yields.
If even one of the nutrients needed is in short
supply, plant growth is limited and crop yields are
reduced.

Fertilizers are needed to obtain high yields

because they supply crops with the nutrients the
soil lacks. By adding fertilizers, crop yields can
often be doubled or even tripled. The UN Food and
Agriculture
Organization
(FAO)
Fertilizer
Programme undertook extensive demonstrations
and trials in 40 countries over a period of 25
years. The weighted average increase resulting
from the best fertilizer treatment for wheat was
about 60%.

f
o
s
Use
r
e
z
i
l
i
t
r
e
F ensure the most effective use of
Fertilizers
both land and water. Where rainfall is low
or crops are irrigated, the yield per unit of
water used may be more than doubled and
the rooting depth of the crop increased
through fertilizer application.

Every plant nutrient, whether required in

large or small amounts, has a specific role
in plant growth and food production. One
nutrient cannot be substituted for another.

SOIL PH EFFECT ON
PLANT ROOTS

N
n
e
g
o
r
t
i

Improves the growth and yield

of crops
Nitrogen is the motor of plant
growth. It is taken up from the
soil in the form of nitrates or
ammonium. As the essential
constituent of proteins, nitrogen
is involved in all the major
processes of plant development
and yield formation.

Phosphorus P (Phosphate)

Speeds up crop maturity and improves

quality
Phosphorous performs a key role in the
transfer of energy. It is essential for
photosynthesis
and
other
chemicophysiological. Phosphorous is indispensable
for cell differentiation, as well as for the
development of the tissues that form a
plants growing points. Most natural and
agricultural soils are phosphorus deficient.
When there are problems with phosphorous
fixation, this also limits its availability.

Potassium K

Helps
fight
crop
disease
and
improves quality
Potassium activates more than 60
enzymes, (the chemical substances
that govern life and play a vital part
in
carbohydrate
and
protein
synthesis). It improves a plants
water regime and increases tolerance
to drought, frost and salinity. Plants
that are well supplied with potassium
are less affected by disease.

Fertilizer Manufacturing Process

- Fully integrated factories have been designed to produce
compound fertilizers. Depending on the actual composition
of the end product, the production process will differ from
manufacturer to manufacturer.

Basic Fertilizer
Manufacturing

Nitrogen fertilizer
component

Ammonia is one nitrogen fertilizer

component that can be synthesized
from in-expensive raw materials.
Since nitrogen makes up a significant
portion of the earth's atmosphere, a
process was developed to produce
ammonia from air.

Haber process

In this process, natural gas and steam are pumped

into a large vessel. Next, air is pumped into the
system, and oxygen is removed by the burning of
natural gas and steam. This leaves primarily
nitrogen, hydrogen, and carbon dioxide. The carbon
dioxide is removed and ammonia is produced by
introducing an electric current into the system.
Catalysts such as magnetite (Fe 3 O 4 ) have been
used to improve the speed and efficiency of
ammonia synthesis. Any impurities are removed
from the ammonia, and it is stored in tanks until it
is further processed.

Haber process

Ostwald process

Phosphorous fertilizer
Extraction
component

To isolate phosphorus from phosphate rock, it is treated

with sulfuric acid, producing phosphoric acid. Some of this
material is reacted further with sulfuric acid and nitric acid
to produce a triple superphosphate, an excellent source of
phosphorous in solid form.
Some of the phosphoric acid is also reacted with ammonia
in a separate tank. This reaction results in ammonium
phosphate, another good primary fertilizer.

Potassium fertilizer component

Potassium chloride is typically supplied

to fertilizer manufacturers in bulk. The
manufacturer converts it into a more
usable form by granulating it. This
makes it easier to mix with other
fertilizer components in the next step.

Granulatin
g

To produce fertilizer in the most usable form, each of the

different compounds, ammonium nitrate, potassium
chloride, ammonium phosphate, and triple
superphosphate are granulated and blended together.
One method of granulation involves putting the solid
materials into a rotating drum which has an inclined
axis. As the drum rotates, pieces of the solid fertilizer
take on small spherical shapes. They are passed
through a screen that separates out adequately sized
particles. A coating of inert dust is then applied to the
particles, keeping each one discrete and inhibiting
moisture retention. Finally, the particles are dried,
completing the granulation process.

n
i
d
n
Ble
g

The different types of particles are

blended together in appropriate
proportions to produce a composite
fertilizer. The blending is done in a
large mixing drum that rotates a
specific number of turns to produce the
best mixture possible. After mixing, the
fertilizer is emptied onto a conveyor
belt, which transports it to the bagging
machine.

FERTILIZERS ADDITIVES
CONDITIONERS

These are low grade organic materials like peat soil, paddy husk,
groundnut hulls etc., which are added to fertilizer mixtures during
their preparation for reducing hygroscopicity and to improve their
physical
condition.

FILLER

A filler is a weight make material like sand, soil,

coal powder etc, added to the fertilizer ingredients
so as to produce a mixture of the desired grade.

NEUTRALIZERS OF RESIDUAL ACIDITY

These are the materials like dolomite, lime stone

etc, added in fertilizer mixtures to counteract the
acidity of nitrogenous fertilizers.

Bagging

Fertilizers are typically supplied to farmers in large

bags. To fill these bags the fertilizer is first
delivered into a large hopper. An appropriate
amount is released from the hopper into a bag that
is held open by a clamping device. The bag is on a
vibrating surface, which allows better packing.
When filling is complete, the bag is transported
upright to a machine that seals it closed. The bag
is then conveyed to a palletizer, which stacks
multiple bags, readying them for shipment to
distributors and eventually to farmers.

Quality Control

To ensure the quality of the fertilizer that is produced,

manufacturers monitor the product at each stage of
production. The raw materials and the finished products
are all subjected to a battery of physical and chemical
tests to show that they meet the specifications
previously developed. Some of the characteristics that
are tested include pH, appearance, density, and melting
point. Since fertilizer production is governmentally
regulated, composition analysis tests are run on samples
to determine total nitrogen content, phosphate content,
and other elements affecting the chemical composition.
Various other tests are also performed, depending on the
specific nature of the fertilizer composition.

FERTILIZER'S MANUFACTURING WASTE AND TREATMENT

WATER

Agricultural
run-off
is
a
major
contributor
to
the
eutrophication of fresh water bodies. For example, in the US,
about half of all the lakes are eutrophic. The main contributor
to eutrophication is phosphate, which is normally a limiting
nutrient; high concentrations promote the growth of
cyanobacteria and algae, the demise of which consumes
oxygen. Cyanobacteria blooms ('algal blooms') can also
produce harmfultoxinsthat can accumulate in the food chain,
and can be harmful to humans.

Nitrat
e

p o llu t
io n

Only a fraction of the nitrogen-based

fertilizers is converted to produce and
other plant matter. The remainder
accumulates in the soil or lost as run-off.
High application rates of nitrogencontaining fertilizers combined with the
high water-solubility of nitrate leads to
increased runoffintosurface wateras
well asleachinginto groundwater,
thereby causinggroundwater pollution

FERTILIZER'S MANUFACTURING WASTE AND TREATMENT

FERTILIZER'S MANUFACTURING WASTE AND TREATMENT

SOIL
Nitrogen-containing fertilizers can causesoil
acidificationwhen added.This may lead to decreases in
nutrient availability which may be offset byliming.

Accumulation of Toxic Elements

Cadmium
The concentration ofcadmiumin phosphoruscontaining fertilizers varies considerably and can be
problematic
Fluoride
Phosphate rocks contain high levels of fluoride.
Consequently, the widespread use of phosphate
fertilizers has increased soil fluoride concentrations.

Radioactive elements
The radioactive content of the
fertilizers varies considerably and
depends
both
on
their
concentrations in the parent mineral
and on the fertilizer production
process. Uranium-238 concentrations
range can range from 7 to 100 pCi/g
in phosphate rockand from 1 to 67
pCi/g in phosphate fertilizers

FERTILIZER'S MANUFACTURING WASTE AND TREATMENT

FERTILIZER'S MANUFACTURING WASTE AND TREATMENT

s
l
a
t
e
M
r
e
Oth
Steel industry wastes, recycled into fertilizers for their
high levels ofzinc(essential to plant growth), wastes
can include the following toxic metals:
leadarsenic,cadmium, chromium, and nickel. The most
common toxic elements in this type of fertilizer are
mercury, lead, and arsenic.

Changes in soil biology

High levels of fertilizer may cause the breakdown of the
symbioticrelationships between plant roots
andmycorrhizalfungi

FERTILIZER'S MANUFACTURING WASTE AND TREATMENT

Contribution to Climate Change

Thegreenhouse gasescarbon
dioxide, methaneandnitrous
oxideare produced during
themanufactureof nitrogen fertilizer.
The effects can be combined into an
equivalent amount of carbon dioxide.

s
n
o
i
t
a
Regul
In Europe problems with high nitrate
concentrations in run-off are being addressed by
the European Union's Nitrates Directive.Within
Britain, farmers are encouraged to manage their
land more sustainably in 'catchment-sensitive
farming. In the US, high concentrations of nitrate
and phosphorus in runoff and drainage water are
classified as non-point source pollutants due to
their diffuse origin; this pollution is regulated at
state level.Oregon and Washington, both in the
United States, have fertilizer registration
programs with on-line databases listing chemical
analyses of fertilizers.

FERTILIZER'S MANUFACTURING WASTE AND TREATMENT

Importance of Chemistry In Fertilizer

Perfection of acid phosphate

manufacture
Harmful materials rendered useful
Supply of nitrogen increased

Fertilizer Companies in Philippines

AzAgri Products Corporatin

Jcv Worldwide Traders
Agricultural Greenhouses
Natural Filipinas Corporation
Rav Angel Intertrading Inc.
TexiconAgri Ventures Corp.
Fertilizer Philippines

The Future of the Industry

Fertilizer research is currently
focusing on reducing the harmful
environmental impacts of fertilizer
use.
Finding new, less expensive
sources of fertilizers.
Yield increase
Fertilizer use efficiency
Private/public partnerships.

End of
Report