Introduction

Production of Nitrophosphate Fertilizer

Fertilizers go through many stages of a long handling chain before arriving at
the final customer. It is crucial that upon delivery the product is of
satisfactory quality such that it can be applied readily without affecting its
application or subsequently crop yield.
Fertilizers should have good storage properties and be free from dust, which
means good mechanical resistance to stresses usually occurring in the
handling chain.
To minimise deterioration in quality and to avoid safety problems in transport,
attention should be paid both to the initial fertilizer properties and correct
handling procedures at all stages from the factory to the field.
To minimise deterioration in quality and to avoid safety problems in transport,
attention should be paid both to the initial fertilizer properties and correct
handling procedures at all stages from the factory to the field.
 Composition of NPK and CN-Fertilizer

The complex fertilizer (NPK, Compound fertilizer) from Yara

normally consists of Nitrogen, Phosphorus and Potassium
(NPK) as the primary nutrients – or nitrogen with either
Phosphorus or Potassium (NP, NK). In addition the fertilizer
can contain secondary nutrients (Ca, Mg, Na, S) and micro-
nutrients (Fe, B, Mn Zn).
The Calcium Nitrate fertilizer consists of 18.9% water soluble Ca
and 15.5% Nitrogen as a minimum, of which 1.1% is NH4-N.
this product melts at 96oC and is highly water soluble. Calcium
Nitrate solutions are commonly used for fertigation and in
technical applications.
 Distinguishing characteristics of the
prilled NPK from Yara
Yara makes close to 2 million tonnes of prilled NPK. The prilled product has
some favourable characteristics that distinguish it from most granular NPK
products.
Prilled NPK:
• Dissolves quickly in soil even in dry climates
• Contains up to 75% water soluble P and 100% citric soluble P and approx
20% of total P as polyphosphates
• Contains low amounts of Cadmium
• Free flowing if well protected against humid air
• Normally a lower D50 and a broader particle size distribution.
These properties of prilled NPK ensure a rapid nutrient supply for plants. The
special P chemistry of the prills enhance plant growth through a very high
P availability and efficiency.
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 Physical properties of fertilizers
The physical quality of NPK, CN and fertilizers in general depends on:
• their physical properties
• the climatic storage conditions
• stress in the handling chain
A product’s physical properties are determined by its chemical composition and how it is
produced.
The most important properties for handling, storage and spreading are:
• Hygroscopicity
• Caking
• Particle shape and size distribution
• Particle strength and mechanical resistance
• Segregation
• Dust formation
• Bulk density
Coating systems are important for preserving the quality of products by protecting these against
moisture and physical damage under handling.
HYGROSCOPICITY
Air contains moisture as water vapour and therefore exerts a water vapour pressure (p H2O) that
is determined by humidity and temperature. Hot air can contain more water than cold air.
The water content is expressed by the relative humidity (RH).
When the air is saturated with water vapour the relative humidity is 100% and 50% RH if half
saturated.
Hygroscopicity is an important property enabling prills or
granules to dissolve quickly I the soil and thus supply nutrients
readily to the plants after fertilizer application.
All fertilizers are more or less hygroscopic which means that they
start absorbing moisture at a specific humidity or at a certain
water vapour pressure.
Some very hygroscopic fertilizers attract moisture much more
readily and at a lower humidity than others, eg Calcium
Nitrate. Water absorption takes place if the water vapour
pressure of the air exceeds the water vapour pressure of the
fertilizer.
Absorption of moisture during storage and handling will reduce
the physical quality. Knowing at which humidity the grades
start to absorb large quantities is very important.
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By knowing the air temperature and humidity and the surface temperature of
the fertilizer, it can be determined if water absorption will take place or
not.

Typically, a water absorption curve ascends slowly at low humidity (as

illustrated), but at a certain humidity or humidity range it starts to
increase steeply. This humidity is called the critical humidity of the
fertilizer. The critical humidity will vary with temperature.

A large water uptake will in general have some undesirable consequences on

fertilizer products:
• Particles gradually become soft and sticky
• Caking tendency increases
• Formation of dust increases
• Warehouse floors become damp and slippery
• Spreading rates could become affected.
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CAKING
Most fertilizers tend to sinter or cake during storage. Such caking arises due to the
formation of strong crystal bridges and adhesive forces between granules.
Several mechanisms can be involved; those of most importance seem to be:
• Post reactions (chemical reactions in the finished product).
• Dissolution and re-crystallisation of fertilizer salts on the particle surface.
• Adhesive and capillary forceds between surfaces.

Caking is affected by several factors:

• Chemical composition
• Air humidity
• Temperature and ambient pressure
• Moisture content
• Particle strength and shape
A product with low caking tendency can be produced if the parameters above are
controlled. In addition application of an appropriate anti caking agent is often
needed.

CN and prilled NPK products from Yara have very low caking ability provided that
absorption of moisture is avoided.
CN and prilled NPK
products from Yara
have very low caking
ability provided that
absorption of
moisture is avoided.
PARTICLE SURFACE, SHAPE AND SIZE
Two types of fertilizer particles are made by Yara, granules and prills. Prills have a
smooth and glassy surface, whereas the surface of granules can vary a lot;
normally granules are more rough and uneven than prills. The colour of the partcle
surface can vary according to the raw materials applied in the process or due to
inorganic or organic pigments added to colour the particles.
NPK prills have a broad size distribution that has proved to enhance spreading
properties. Granular NPK is often larger than prills and the particle size distribution
is narrower.
PARTICLE STRENGTH AND METHANICAL RESISTANCE
The crushing strength of fertilizer particles differs greatly and with the chemical
composition. For nitrophosphate NPK products the average strength is around 5
kg. crushing strength measured for various fertilizer types is illustrated.
Water absorption of 1% will reduce particle strength by 10-20%. 3% water absorption
will have a very negative effect on NP and make the surface of NPK and CN very
sticky.
Mechanical resistance is the ability to resist the stresses of fertilizers imposed upon
them in the handling chain. The mechanical resistance depends on surface
structure and particle strength.
Provided correct handling, nitrophosphate NPK’s produced by Yara have high crushing-
strength and good mechanical resistance. Yara 7
SEGREGATION
Fertilizers consist of particles of varying size. When in motion or
vibrated, the smaller and larger particles tend to separate –
the fertilizer segregates.

This phenomenon can take place anywhere in the distribution

system and especially when the material is piled in big heaps.
The smaller particles will be enriched in the centre of the pile.

A good rule is for instance to build up heaps by using many small

ones.

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Segregation should be minimised through correct handling since it has an adverse effect on
fertilizer bulk density and consequently spreading.
Segregation does not affect the distribution of nutrients in the complex fertilizers produced
by Yara, since they are homogenous and each particle has the same composition.
DUST FORMATION
Fertilizer dust is not hazardous to health, but will cause discomfort at the work place and
reduce working pleasure. Therefore , in most countries dust emission from handling
operations is restricted by law.
Dust normally arises from:
• Poor surface structure and particle strength, low mechanical resistance
• Mechanical stress in the transport line
• Wear and tear from equipment (scrapers, screw feeders, grain trimmers etc.)
• Water absorption during storage and handling
Yara products have high mechanical resistance and have coating systems that suppress dust
formation. Dust can still be experienced occasionally mainly due to water absorption
and abrasion in the transport line.
BULT DENSITY
Bulk density or volume weight (kg/m3) may differ slightly between products. Variations in
particle distribution due to segregation will influence the bulk density. For mechanical
spreading it is important that variations within a specific product are minimal.
Correct handling will ensure an even bulk density for Yara NPK and CN.
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YARA COATING SYSTEMS
Yara R&D has developed efficient coating systems for the various grades to substantially:
• Reduce water absorption when exposed to humid air
• Reduce caking tendency
• Reduce dust formation
In addition, a pigmented coating is often used to give a cetain colour to the product.
Most fertilizers are surface treated to obtain all or one of the above-mentioned effects.
Coating agents used to improve the quality of fertilizers are benign to plants, soil and
human beings.
PROTECTION AGAINST WATER ABSORPTION
Soil-degradable coating systems have been developed that greatly reduce the rate of
water absorption. These are distributed evenly on the particle surface by means of a
coating drum. The effect can to some extent be changed by varying the amount of
coating.
Calcium Nitrate is a very hygroscopic fertilizer with a critical humidity below 40%,
meaning that it easily starts to dissolve if exposed to humid air.
For Calcium Nitrate Yara has developed a unique coating that can reduce the rate of
water absorption by 99%. Most CN grades shipped in bulk today have this unique
coating on the granule surface.
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ANTI CAKING AGENT
Fertilizers and salt products generally tend to agglomerate during transport
and storage. This property has been of major concern to fertilizer
manufacturers and considerable research has been devoted to solve the
problem.
In order to prevent caking, fertilizers are treated with various agents that
normally include a surface active compound and a fine inert powder. The
surface active compound influences crystal formation such that strong
bridges are not formed, and the powder reduced the surface content area.
PREVENTING DUST FORMATION
The dust released from fertilizer products depends on several physical
properties like particle strength and shape, ways of handling and the
coating system applied.
Coating systems developed by Yara can reduce dust release up to 90% in a
bulk handling chain.
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 Handling and storage of fertilizers
Most of our fertilizers are handled in bulk. To preserve top quality throughout the entire
handling chain it is important to train operators to follow correct handling routines and
procedures.
Focus areas for preserving fertilizser quality are listed below:
LOADING OF VESSELS AND BARGES
• Clean and dry holds (free of remnants, rust).
• Tight hatch covers (sealings, seal-bars, fittings). Look for rust stripes on hatch coamings.
If in doubt the hatches should be sealed with marine tape, foam or silicone.
• Bulkheads of wood should be covered with plastic.
• Cargo should be covered completely with plastic sheeting and fastened with wooden
sticks.
• Loading must not occur during heavy fog or precipitation.
DISCHARGING
• Inspect the cargo before start of discharge, check the hatch coamings and the cargo
surface. If the product is damaged, call for surveyors and inform the master about the
findings.
• Ensure that water damaged cargo and contaminants are separated from sound product.
• Do not discharge during heavy fog or precipitation.
• Do not mix spilled material on the quay or deck of the vessel with sound product.
• When cleaning holds, put the bobcat into the hold as alte as possible. Minimise driving
into the product to reduce formation of dust and fines.
DISCHARGING AND STORAGE EQUIPMENT
• Grabs, hoppers, conveyor belts and transfer points should be clean and dry.
• Empty the hoppers and conveyor belts before breaks. Clean if necessary.
WAREHOUSE
• Fertilizers must be stored on clean and dry floors.
• Doors should be tight fitting and other openings closed.
• Bulk walls of wood must be covered with plastic if not impregnated.
• Blends or urea and products containing ammonium nitrate (eg NP, NPK, CAN) are very hygroscopic.
• Traces left on the floor will soon form a solution when exposed to air.
• Follow the FIFO-rules; First in – First out, if possible.
• If spillage, sweep and clean immediately
BULK STORAGE AND LOADING OFF
• Bulk products should be covered with plastic sheets or other covering immediately after completed
discharge.
• Coverings should overlap by at least 0.5m.
• The covering should be fastened with wooden sticks.
• When removing product from the pile do not unnecessarily expose the product to air.
• Re-cover immediately when the operation is completed.
• Avoid spillage when re-building the pile with a front end loader; do not overfill shovel, do not drive into
the pile.
• If lumps are observed in the pile, the product must be sieved on delivery or before dispatch.
USE OF PAYLOADERS
A payloader is convenient to use when moving bulk material. However, to avoid damaging the material, it s
advised that the following precautions are taken:
• Keep a correct angle between the bucket and the floor to minimise crushing. Do not keep it flat.
• Avoid spilling on the floor.
• Do not drive the wheels into the pile.
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Examples of quality deterioration when handling
fertilizers
 Bags and bagging – storage of bags
Bags protect the product against humidity and mechanical stresses. Bags made of
polyethylene (PE), polypropylene (PP), paper or combinations of these materials are
available (valve bags, fully “open” bags for melt sealing and stitching).
Bags are made after given specifications:
• Weight of paper, layers of paper
• Thickness of plastic foil (PE)
• Fabric weight (woven PP)
• Strength and elongation
• Dimension
• Additives like UV stabilisers
UV-protection is important in areas with high temperature and strong sun.

• Bags should always be stored on a dry floor, preferably inside a warehouse or on pallets
placed on dry ground with good drainage. They should be well-covered with plastic or
tarpaulin that can withstand windy and unpleasant weather.
• For outside storage, place pallets on top of the covered fertilizer to protect against
damage caused by birds to tarpaulins or bags.
• For stability and safety big bags should be stored in the form of a pyramid. Pallets
should be stacked no higher than 3-pallets high. For shorter periods, 4-pallets high is
acceptable.
 Spreading - safety
The correct setting of a spreading machine is determined by the physical properties of the
fertilizer. Particle size distribution, bulk density and flow rate particularly influence the
setting. A wide granulometric spread has proved to be beneficial for even spreading of
homogenous fertilizers, which is the case for prilled NPK’s
Spreading tables from the manufacturers of spreading machines. These tables are based on tests
under ideal conditions in spreading stations, and give information on how to set the spreader
for optimum even spreading and the desired application rate (kg/ha) at a specific working
width. The settings vary between spreading machines and types of fertilizers. If spreading
tables are not available, it is recommended to use field trial equipment to give an estimation
of the spreading, although this is a less accurate method.
LEGISLATION
Over the years ammonium nitrate based fertilizers have been involved in several accidents that
have influenced the legislation of transport and handling. Decompositions during transport
and in storages have caused release of toxic gases and hazardous situations.
The international UN ‘Recommendation for the transport of Dangerous goods’ (Orange Books,
ref. www.unece.org/trans) is adopted in international fertilizer transport legislation by IMO
(shipping), ADR (road), RID (rail), and IATA (air) regulations. National legislation applies for
storage, and EFMA has issued a general ‘handbook for safe storage of fertilizers’ that gives
practical advice (ref. www.efma.org).
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NPK
Ammonium nitrate in NPK-fertilizers can decompose at high temperatures,
Exothermic reactions caused evolution of heat and gases from the
fertilizer after an initial period with decreasing pH.
The decomposition rate accelerates in the presence of chloride, organic
substances and some metal ions – particularly copper (Cu2+), andis
retarded in the presence of phosphate, carbonaceous material and high
pH.
For transport of NPK-fertilizers by sea and air the international IMO trough
test distinguishes between C-grades (Non-hazardous) and B-grades
(Hazardous, Class 9), according to the potential for self-sustaining
decomposition (SSD). SSD can be initiated by accidental heating (>120oC)
over time for some fertilizers, and such decomposition will continue after
the heat source has been eliminated. The decomposition is normally not
dangerous in itself, but the released gas contains toxic components (eg Cl2,
HCl, Nox), and the decomposition ca be extremely difficult to extinguish.
For safety reasons all NPK fertilizers containing ammonium nitrate shall be
handled as if they have the potential for SSD.
Prior to placing the fertilizer in storage, the operational personnel must
ensure that the storage facility is clean and free from contamination that
can initiate or accelerate decomposition, and that no heat sources (eg
lamps, electrical cables, conveyors, transport machinery, exhaust outlet)
can come in direct contact with the product. Do not overfill the storage
area.
Any decomposition must be extinguished with large amounts of water at the
area of decomposition. Use respiratory protective equipment.
CN-Fertilizer
CN contains approx 15% crystal water that minimises the oxidising properties
of the material. Consequently, CN-fertilizer is not classified under
international transport regulations as dangerous goods. According to
criteria set by EU-legislation Yara does not label the CN fertilizer in the EU
or in any other country as hazardous. No severe accidents have ever
occurred with CN-fertilizer.
HANDLING OF SPILLS AND REJECT MATERIAL
The warehouse floor should be kept clean and dry by absorbing moisture with
eg lavastone powder, sand, limestone, dolomite or phosphate rock.
Sawdust is combustible material and should not be used for any kind of
AN-based fertilizer.
Spills from conveyor belts or from bags should be collected, handled and sold
as normal product if free from contamination and meeting the
requirement of the fertilizer regulations. If not, the material should be
recirculated in the fertilizer process depending on the degree of
contamination/off-spec conditions), be dissolved or be made inert if the
AN-content is high. Polluted product and spills should be treated as a
waste material.
TRIMMING OF CARGO
When a mass of solid fertilizer is tilted, the surface particles will start sliding
when a given angle to the horizontal floor is reached (dynamic Angle of
Repose). According to IMO-safety regulations (BC-code) the fertilizer cargo
must be trimmed reasonably level to the boundaries of the cargo space.
The dynamic Angle of Repose (angle of slide) can be measured by the
tilting box method (IMO).
 GLOSSARY
Additive Substance intended to improve the properties of a fertilizer
Angle of repose (dynamic) The angle of slide when tilting a mass of solid fertilizer
Angle of repose (static) The angle obtained when falling on a horizontal base-plate
Bulk density The mass per volume of a material tipped into a container
Complex fertilizer Compound fertilizer, obtained by chemical reaction
Compound fertilizer Fertilizer, obtained chemically or by blending or both
Caking Agglomeration of particles
Citrate soluble P Phosphate soluble in citric acid (eg MAP/DAP/Ca-phosphate)
Exothermic reaction Chemical reaction generating heat
Granulation Particle formation by agglomeration or layering
Handling Production, supply, delivery, spreading
Hygroscopicity The ability to absorb water from the air
Nitrophosphate Fertilizers from dissolution of phosphate rock in nitric acid
Prilling Solidification of melt droplets when falling in cold fluid
Relative humidity Humidity relative to max obtainable humidity at spec. temp
Segregation Separation of particles due to motion or vibration
Water soluble P Phosphate soluble in water (eg MAP/DAP)
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 Fertibor
Hi Dadang,
I do not have such presentation, but maybe
you can consider using some of the points in
attached handling datasheet for reference.
Besides, other points likes:
1. Storing the product in its original bags on
pallet,
2. Do not expose to sunlight,
3. Store at dry area, indoor.
4. For bags which can't finish in 1 time use,
they need to seal / tie it well and not let it
open and expose to air/ moisture. Of
course, we encourage them to minimize
such incident.
5. For 25kg bags pallets : max 3 layers
stacking, IBC bags : max 2 layers stacking.
This is for safety purpose, and also helping
to minimize risk of bottom stack product
cake due to compaction.