issue no. (73) september- december 2015 - arabfertilizer.org · issue no. (73) september- december...

Issue No. (73) September- December 2015

Editorial: Fertilizers and Waterfor SustainableAgriculture

22nd AFA Int’l. FertilizerForum & Exhibition

29th AFA Int’l. FertilizerTechnology Conference & Exhibition

2 - 4 February 2016 Cairo, EGYPT

11 - 13 October 2016 Tunis

Editorial

Publishing such an edition synchronizes with convening the 22nd AFA International Forum titled “Fertilizers and Water for Sustainable Agriculture”. As per the reports issued by the United Nations Organization, during the last fifty years, world population doubled three times and countries have been facing the chal-lenge of providing food for their people.

Food security is closely related to economic growth, social progress, stability and peace. Therefore, food security agenda must focus on agriculture and rural development via sus-tainable production enhancement, productivity promotion, rural development and water ratio-nalization fulfilled by using modern irrigation methods.

In this context, fertilizer industry is standing at crossroads in an attempt to maintain a sound balance between increasing fertilizer produc-tion and supporting rationalization in addition to achieving sustainable growth in production capacities. To deal with the huge rise in popu-lation rate, the food requirements from agricul-tural crops should consider doubling agricul-tural production in order to meet such a steady growth. This cannot be implemented except by widely expanding land reclamation activ-ities and combating desertification and fertile land trespassing. From another side, raising agricultural productivity efficiency by con-ducting more specialized researches should be considered to produce pests-resistant species, achieve water rationalization together with ap-plying wise use of mineral and other types of fertilizers.

Accordingly, it is concluded that the ideal

practice of fertilizer usage and the good gov-ernance of plant nutrients are implemented by applying the 4Rs Method (right fertilizer source at the right rate at the right time and in the right place). Also, providing farmers with guidelines, based on scientific foundations within an international framework to ensure fertilizer usage efficiently and effectively, will undoubtedly assist in achieving the targeted food security. This endeavor necessitated the publishing of the Manual of the 4Rs for Plant Nutrients Integrated Management to be includ-ed with the agricultural extension publications, which are published and distributed by AFA to fertilizers manufacturers and farmers.

AFA has been encouraging direct communica-tion with farmers for believing in the signifi-cance of highlighting the integrated and lead-ing role of promoting agricultural productivity for the sake of human being health, underscor-ing the fertilizer member companies’ role re-lated to social responsibility issues and devel-oping fertilizer industry, related materials and usages to achieve food security. This is being applied by launching agricultural caravans across the Arab region consistent with OCP similar activities, being an exemplary model in this regard. AFA seeks, through such cara-vans, to call for increasing the awareness-rais-ing and extension activities tackling the good usage of all types and (macro and micro) com-ponents of mineral fertilizers during different plant growth phases. Notably, this pursuit in-creasingly affect agricultural productivity by integrating AFA member companies and con-vening agricultural training programs for agri-cultural field stakeholders in the Arab region.

Editorial Board

Fertilizers and Water for Sustainable Agriculture

Editor-in- Chief

Mr. Mohamed Abdallah ZainSecretary General

Quality Control and Assurance

in Maintenance in Fertilizer Industry

Workshop

Workshop on «Fertilizers Awarenessand Soil Analysis» Agricultural

Caravans are practical implementation of social responsibility towards agricultural community

“Information Communication Skills” Training Program

Issue Report

With Member Companies

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• AFA is a non-profitable, Arab International Organization established in 1975. AFA is operating under the umbrella of Council of Arab Economic Unity.

• AFA comprises Arab institutions and companies working in the fields of fertilizers man-ufacturing, trading in addition to other related fields.

• AFA aims, generally, at coordinating and developing technical relations between mem-ber companies, together with all issues related to fertilizer industry. AFA represents a framework through which Arab companies work and get to know the latest technologi-cal developments in fertilizer industry. It further provides Arab companies’ representa-tives with the opportunity to strengthen relationships with international institutions, or-ganizations and companies working in the field of fertilizer industry, trade and usage.

Deputy Editor-in- Chief

Mrs. Mushira MoharamManager, Communication & PA

Members of Editorial Board

Eng. Mohamed M.AliStudies Manager

Mr.Yasser KhairyHead, Economic Section

Colour separation & printed by

All correspondences tobe addressed to:

Arab Fertilizer AssociationP.O. Box 8109 Nasr City 113719 Ramo bdg. Omar ben Khattab

St. Nasr Road - Nasr City Cairo, Egypt

Tel: +20 2 23054464Fax:+20 2 23054466 +20 2 23054465

E-mail: [email protected]

Tel : 02 3720 6007 - 0122 744 6308

SAFCO Wins King Khalid Award for“Responsible Com petitiveness”

JD 96 M Arab Potash Company’s net profit at end of 3rd Quarter of 2015, up 37% from last year

APC signs JD 4 Million Agreement with Ministry of Wa-ter to Finance Construction of Wadi Al Wadat Dam

ALKALI SCRUBBER SYSTEM IJC’s CSR Initiative – Protect your Environment

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Issue Number (73) September- December 2015

DR. JAWAHERY HAS BEEN CHOSEN AFA CHAIRMAN & MR. BENSARI VICE CHAIRMAN FOR 2016

FERTILIZER INDUSTRY REPRESENTATIVES ATTEND THE FAO COMMITTEE ON WORLD FOOD SECURITY

AFA SECRETARIAT DELEGATION HOSTED BY GPIC

MANAGEMENT OF OLIVE MILL WASTEWATER IN THE MEDITERRANEAN REGION

FERTILIZER AND WATER FOR SUSTAINABLE AGRICULTURE

NUTRI- FACTS

AFA Board of DirectorsChairman

H.E. Dr. AbdulRahman JawaheryBahrain

Board Members

H.E. Mr. Jamal Eddine BensariAFA Vice Chairman - Morocco

H.E. Mr. Hedhili KefiTunisia

H.E. Mr. Khalifa Al-SowaidiQatar

H.E. Mr. Abdallah AL- SwailemKuwait

H.E. Mr. Saad Abu Al Maaty Egypt

H.E. Mr. Abdel Karim ElBarasiLibya

H.E. Mr. Khaled Al-ManaSaudi Arabia

H.E. Mr. Hamed Al-HashmiOman

H.E. Mr. Adil kareem Kak

AhmedIRAQ

H.E. Mr. Ayoob M. SalehUAE

H.E. Dr. Shafik AshkarJordan

H.E. Mr. Miloud LouhichiAlgeria

MemberSyria

• The articles and all material contained herein do not necessarily represent the view of AFA unless the opposite clearly mentioned.

• The contributions of researchers, students, and experts in the field of fertilizer industry and trade are highly welcomed for free publication provided that they have not been published before. The General Secretariat is not obliged to return the articles which are not published.

• The Journal is providing the chance for publishing adverts for the companies involved in manufacturing and trade of fertilizer and other agricultural inputs. The arrangements for that should be discussed with the journal’s management.

Press Release

Fertilizers & Agriculture

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Studies & Research SELECTION OF SCREENING EQUIPMENT FOR FINAL PRODUCT QUALITY - OMIFCO’S EXPERIENCE IN UREA GRANULATORS

Helium Leak Detection in High PressureUrea Reactor

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Issue Report

Quality Control and Assurance in Maintenance in Fertilizer Industry

Based on the goals established by AFA performance development strategic plan, aiming at enhanc-ing productivity through technical development and qualification as well as expanding fertilizer fac-tories’ capacities, AFA organized in cooperation with AFA member Oman India Fertilizer Company a workshop titled “Quality Control and Assurance in Maintenance in Fertilizer Industry”, in Muscat, Oman, during the period 23 – 35 November 2015. AFA Secretary General, Engi-neer Abdallah Zain stated that the Workshop, via exchanging expertise and information, targets raising the awareness of and pro-viding knowledge to the partici-pants’ in the following fields:- Highlighting maintenance man-

agement, quality and productiv-ity fields;

- Setting electronic maintenance systems to ensure quality main-tenance results;

- Identifying methods and basics of performance efficiency eval-uation for maintenance process and team;

- Pinpointing the impact of engi-neering inspection and period-ical maintenance on fertilizer factories’ productivity;

- Communicating and exchang-ing expertise regarding mainte-nance best practices applied by AFA member companies.

Mr. Zain further added that the Workshop included a number of essential topics:

- Periodical maintenance and im-pact of preventive maintenance programs

- Integration of maintenance and production processes

- Predictive maintenance and im-pact on reliability

- Impact of effective preventive maintenance

- Maintenance of major rotating equipment

- Computerizing maintenance process management

- Failure mode effects analysis- Maintenance auditing process- Maintenance risk management- Maintenance Key Performance

Indicators (KPIs)- Erosion in high temperatures- Presentation of distinguished

Arab fertilizers companies ex-periences in maintenance field

23-25 November 2015, Muscat, Oman

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AFA Workshop

More than 60 attendants from AFA members participated, from Oman, UAE, Jordan, Bahrain, Al-geria, Egypt, Iraq, Kuwait, Libya, Morocco, Pakistan, Qatar, KSA and Tunisia.Also, the 103rd Board meeting held parallel to the Workshop. The meeting discussed a number of issues, important of which 2016 plan and budget, and followed up the implementation of strategic programs and plans concerned with the development of AFA per-formance efficiency. In this oc-casion, AFA would like to extend deep appreciation to Mr. Hamad Al Hashemi, AFA Board mem-ber and General Director, region representative in Oman. Also, we would like to express gratitude to Oman India Fertilizer Company staff for their support to such a technical workshop proceedings.

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Mr. Mohamed Zain

Mr. Hamad Hashimi

Mr. Muhammad Sajid

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Program• Total Productive Maintenance

Muhammad Sajid, Lecturer, University of Gujrat, Pakistan• Turnaround Management and Impact of Effective Preventive

Maintenance ProgramsMuhammad Sajid, Lecturer, University of Gujrat, Pakistan • Predictive Maintenance and Impact on Reliability

Muhammad Sajid, Lecturer, University of Gujrat, Pakistan• Life Time Extension Study of High Pressure Urea Piping

Omar Al- Mohammed, Inspection Engr. ALBAYRONI, S. Ara-bia

• Selection of Screening Equipment for Final Product Quality Omifco’s Experience in Urea GranulatorsT.P.Raju & Rashid Al Farsi, OMIFC, Oman

• Computer in Maintenace Muhammad Sajid , Lecturer, University of Gujrat, Pakistan

• Impact of Effective Maintenance Management on Mechanical System

Matrouk Al Enzi, Plants Mechanical Manager, APC, Jordan• IJC Predictive Maintenance Practices and Its Impact on Reli-

abilityMohammed Megdady, IJC,, Jordan

• Rub Detection in a Synthesis Gas CompressorChinmaya Kar & Waleed Al-Sallom

• Reliability Improvement and Failure Reduction of Cooling Tower FansChinmaya Kar & Abbas Abdullah Al-Hussain, SAFCO, S. Arabia

• Helium Leak Detection in High Pressure Urea ReactorAnkit Niranjan, OMIFCO, Oman

• Sharing of Maintenance Experiences in Major Rotating Equip-mentMuhammad Sajid, Lecturer, University of Gujrat, Pakistan

• Lesson Learn from Failures: Failure of Mixed Feed Coil in Pri-mary ReformerSaad M Al-Qahtani, RCA Specialist, Reliability, Process & Inspection ALBAYRONI,, S. Arabia

• High Temperature CorrosionAnkit Niranjan, Sr. Inspection Engineer, Peak Vue™ Tech-nology Detects Faulty Bearing at OMIFCO, Preventing Costly DowntimeSalim Baalwi, OMIFCO, Oman

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Workshop on «Fertilizers Awareness and Soil Analysis»

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Right rate, Right time and Right place

- Agricultural maps- Regional reports for some par-

ticipating Arab countries: Mo-rocco, Jordan and Saudi Arabia

- Basics of fertilizer needs calcu-lation

- Challenges facing Arab farmers, fertilizers usage in Kingdom of Saudi Arabia

tion to chemical analysts and lab-oratories technicians. The workshop program included various topics:- Ideal usage of fertilizers- Soil analysis- 4Rs: Right fertilizer source,

The three-day agricultural work-shop tackled a number of crucial issues related to the agricultural system. The workshop goal was to identify the challenges en-countering the agricultural sector, especially with reference to fer-tilizer field, and define adequate solutions and suggestions to over-come such challenges. It further aimed at improving and using fertilizers rationally and sustain-ably in a way increasing agricul-tural productivity, providing so-ciety with healthy and safe food, achieving suitable farmer income and fulfilling sustainable agricul-tural goals.

The workshop participants in-cluded agricultural and academic experts, representatives of Arab countries Ministries of Agricul-ture, number of AFA member companies› staff from sales and marketing departments in addi-

In collaboration with OCP Group, the proceedings of «Fertilizers Awareness and Soil Analysis» and «Information Communication Skills» workshops were hosted in Casablanca, Morocco.

Casablanca 28 – 30 October 2015

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- Ministry of Agriculture, Rural Development and Maritime pre-sentation on agriculture sector in Morocco and Green Morocco plan strategy

- Fertilization by irrigation: fertil-ization high efficiency technol-ogy

- Soil analysis as a method for rationalizing chemical fertilizer usage

- Approximation recommendation for crop fertilization in Morocco

- Nutrient management in olive orchards in North Africa

ProgramSession I : - Country Report - Morocco Mss. Ibtissam El Bakkali , Ministry of Agriculture, Morocco.- Country Report – Jordan Dr. Munir J. M. Rusan , Consulting Director, IPNI, Norcross, GA, USA & Jordan University of Science and Technology, Irbid, Jor-dan- Arab Farmers Challenges Mr. Ahmed Saeed Dajam, Scientist, Technology Management, SABIC, Saudi Arabia- Nutrient Management in Olive Orchards in North Africa: Achievements and Perspectives Dr. Elgharous, Consultant, IPNI North Africa- General Discussion and Concluding Remarks (for 1st day )

Session II :- Lessons learned from Caravan Visits and the Moroccan Farms ( General Discussion)- Soil Testing as a Tool for Optimizing Mineral Fertilizer Use Dr. Ghassan Hamdallah, Ex FAO Sr. Regional Land & Fertilizer Use Officer- Crop Fertilizer Recommendation Approaches in Morocco Prof. Lhoussaine Moughli, Institut Agronomique et Vétérinaire Hassan II, Rabat, Morocco

Session III :- Fertigation: Tool for Efficient Nutrient Management Dr. Munir J. M. Rusan , Consulting Director, IPNI, Norcross, GA, USA & Jordan University of Science and technology, Irbid, Jor-dan- Presentation by Dr. Adel Abdel Khalik, Technical Consultant, Evergrow, Egypt- Recommendations & Concluding Remarks

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Issue ReportIssue ReportAgricultural

caravans are practical

implementationof social

responsibilitytowards

agriculturalcommunity

per geographical areas. It is an in-teractive system, through which information can be analyzed us-ing the internet and user provided with adequate recommendations about the most significant crops; to ensure high productivity and best utilization of agricultural land in addition to rational fertil-izer usage in quantity and quality.During 2015, OCP launched in June the olive tree caravan, on four phases. 1400 farmers benefit-ed from such caravan, more than eight pilot fields were identified and 12 tons of fertilizers were dis-tributed free of charge. Another caravan has followed in Septem-ber, which is the citrus caravan. It was also implemented on four phases, benefited 1400 farmer and more than eight pilot fields were identified. With regard to the current third caravan, it is the grains caravan. 2800 farmers benefited from such a caravan, more than 32 pilot fields were identified and 24 tons of fertilizers were distributed free of charge. The caravan program included convening four work-shops for the Moroccan farmers, as follows:- Agriculture Workshop: it sen-

sitizes farmers concerning the significance of agricultural cy-cle, soil preparation, seeding timings and the best related methods.

ing smallholders’ income and liv-ing standards, supporting agricul-tural good practices, preserving the environment, managing effi-ciently the financial contribution program related to Morocco agri-cultural development, developing the south-south cooperation with regard to food security and estab-lishing strategic partnerships lo-cally and internationally.OCP essential projects include:• Following up with Morocco

smallholders in partnership with OCP fertilizers distribution through mainstreaming activi-ties (experimental fields, train-ing days)

• Providing agriculture extension service

• Accomplishing merged projects for agricultural development

• Organizing OCP caravans in Morocco and Africa

• Carrying out research and devel-opment activities

OCP contributes in developing the national agricultural sector via ambitious and fundamental scien-tific and practical programs, for instance the approval of soil fer-tility map by analyzing soil as a first step to ensure productive ag-riculture development. This pro-gram led to the establishment of soil information system, to tackle either soil main characteristics or natural resources classification as

Aiming at providing workshop with the practical and applied na-ture of agricultural experiments, it was agreed to allocate the work-shop second day for a field visit to the agricultural caravans, which is a successful initiative carried out by OCP in Morocco, 2015. OCP is considered to be the eminent partner of the Moroccan agricul-ture sector, through the “Green Morocco Plan”. OCP contribution emerges from the values of partic-ipation and openness adopted by OCP, working on improving the living conditions of thousands of people in Morocco and different areas of the world. OCP activities are related to five main themes:• Social development• Agricultural development• National and cultural heritage

protection• Training and research• Reflection and strategy settingOCP activities further exceed Mo-rocco borders to touch on foreign countries conditions. It is thus committed to promote the south-south cooperation and fulfill local people needs.The agricultural development pro-gram aims at setting and leading economic and social developmen-tal initiatives in the agricultural sector. This is applied by improv-

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- Fertilization Workshop: it guides farmers to the necessary nutri-tional elements for crops, fertil-ization methodology, specifying the most important signs for main elements shortage, esti-mating soil nutritional elements and timing of application.

- Protection Workshop: it rais-es farmer awareness of weeds problems in addition to means and time of combating, identi-fying diseases that may affect crops and commonly harmful insects and means of protection.

- Harvesting Workshop: it guides the farmer to the adequate time for harvesting and the ideal meth-od for harvesting and storage.

These caravans are accompanied also with health caravans for farmers’ children. Free medical clinics were established to carry out medical checks for children eyes and teeth. Eye glasses were provided free of charge for peo-ple with special needs. It is worth noting that around 6000 child has benefited from such medical car-avans. In the following pictures:Taking care of special needs – paying due attention to farmers’ children education – AFA Secre-tary General putting eye glasses for one of the farmers children.

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“Information Communication Skills” Training Program

From another side, the training program focused on developing a number of skills such as the delivery and drafting of media message effectively via differ-ent media means. This pursuit is sought taking in consideration the strategic role played currently by media means with regard to com-prehensive development and con-necting economy and institutions with consumers and community development stakeholders. Ac-cordingly, this program achieved great success through partici-pants’ contribution in the agricul-tural caravan event and knowing how to cover such an event on the media level. It is noteworthy that the participants have commended the topics tackled. In such a framework, AFA gath-ered distinguished lecturers with experience in the media field from Faculty of Information, British

Parallel to the agricultural workshop, AFA organized a training program titled “Information Communication Skills”. From one side, the program targeted the provision of required training, for people with special needs, on communication skills in order to be ca-pable of effectively dealing with media means when delivering their message to the targeted audience.

Casablanca 28 – 30 October 2015

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University in Egypt. The training program included the following items:- Introduction: Why Media is

Important? - Media Accessibility & Media

Outreach- Writing a Press Release- Media Interview- Press Conference In addition, a practical training in front of the camera on how to act an interact with it.The Training Program has proved its success from all par-ticipants.The attendance in both work-shops exceeded forty eight par-ticipants from member com-panies such as Jordan, Egypt, Qatar, UAE, KSA, Tunisia and Morocco.

ProgramSession I

* Overview and the workshop objectives * Media accessibility: How to build a good relationship with the

media? Dr. Adel Saleh, Vice Dean - Faculty of Communication & Mass Media

The British University in Egypt (BUE)Session II

* Create your tailored messages (working groups) * Practice your Skills: News release (working groups)

Dr. Adel Saleh, The British University in Egypt (BUE)Session III

Lessons learned: How to use such an event on media level (Working groups)Practice your skills: Media statement & Spokesman ((Role Playing) Dr. Adel Saleh, The British University in Egypt (BUE)

Session V Preparing your first newsletter: What was happened during this three day workshop? (work-ing groups) All participants & Trainers Practice your skills: Media interview (Role Playing) Dr. Adel Saleh, The British University in Egypt (BUE)

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investors. This success will be rooted in strategic planning, international standards, a committedworkforce that is inspired, engaged, creative and de-.livers, and sustainable social development SAFCO has invested in many expansion projects and become one of the largest industrial complexesin the Middle East. It is a major producer of agricultural nutrients, which are produced according to the highest quality and energy efficiency standards and help achieve the Kingdom’s economic, social and .environmental objectives

SAFCO received the fifth King Khalid award for “Responsible Competitiveness” at a ceremony held under the patronage of the Custodian of Two Holy Mosques, King Salman bin Abdul Aziz Al-Saud, in the presence of a distinguished prize committee onDec. 8. KKA Award reflects the vision towards sus-tainable development and corporate social responsibility and it is our privilege to be selected amongst the best companies under the King Khalid Award.criteria Ahmed Al-Jabr, SAFCO President, said that the prestigious award marks the company’s 50-year journey of success, demonstrates progress on the right path, and highlights continuing efforts to servethe community. He commended the Board of Direc-tors focus on expanding safely, sustainably to deliv- er value to shareholders and develop national talent.for SAFCO Al-Jabr extended his appreciation to all employees and thanked the Board of Directors for their supportand remarkable contribution to this great achieve- .ment He said the award signifies a promising future for

WinsKing Khalid Award for“ResponsibleCompetitiveness”

SAFCO

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economic conditions in Asian and Brazilian markets including a drop in their currencies rela-tive to the US Dollar. The mar-ket has stabilized in recent weeks and new demand through local tenders in Asia is surfacing. The estimates for global shipments in 2015 point toward 59-60 million tons, which would make this year the second highest year on re-cord. APC continues to ship out the contracted volumes to India and China where 2015 deliveries are expected to match 2014 lev-els.Mr. Al Sarayrah noted that the current market conditions em-phasized the importance of the annual sales agreements with our Chinese and Indian customers.Mr. Al Sarayrah highlighted the significant increase in expected payments to the national Trea-sury compared to last year. In-come tax increased to about JD 22.4 million at the end of Q3 compared to JD 8.7 million for the same period last year, and royalties increased to about JD 17 million at the end of Q3 com-pared to JD 4.8 million for the same period last year, reinforcing APC’s leading role in supplying the Treasury with revenues.APC also maintained its leading role in supporting local commu-

nity development and improving services to local communities, which is among APC’s most im-portant core values. The Board of Directors approved a budget rise from JD 7.5 million to JD 10 million for the Company’s CSR program 2015, which focuses on sustainable projects that bring long-term benefit to Jordanian citizens and introducing new projects that complement the ac-complishments of the past years.Mr. Jamal AL Sarayrah also re-vealed that APC’s future plans focus on investing in expanding the Company’s asset base in its plants located in the South of Jor-dan. About US $1 billion was al-located in future budget estimates for capital projects that will be completed over the next several years mainly expansion in potash production through increasing production capacity by 245,000 tons and raising the production capacity of granular potash by 250,000 tons per year. Also, KE-MAPCO (APC wholly owned subsidiary) approved plans to raise its production capacity of potassium nitrate from 135,000 tons to 175,000 tons per year.President and CEO Brent Hei-mann added that APC’s top pri-ority is to provide a safe working environment for its employees, and in July 2015 APC completed

Mr. Jamal AL Sarayreh

AL SARAYRAH: APC INCREASED EFFICIENCY OF OPERATIONS AND REDUCED FUEL PRICES REFLECTED

POSITIVELY ON PROFIT MARGINS

JD 96 M ARAB POTASH COMPANY’S NET PROFIT AT END OF 3RD QUARTER OF 2015, UP 37% FROM LAST YEAR

The Company produced 1.7 M tons of potash, sold 1.6 M tons until end of 3rd Quarter, reflect-ing its success in maintaining its alliances with key markets and customersFuture plans focus on expansion of production, downstream in-dustry projects, and alternative energy sourcesAmman - 01/11/2015: Arab Pot-ash” Company (APC) realized a net profit at the end of the third quarter (Q3) of 2015 of about JD 96 million after taxes, provisions and royalties, up 37% from the same period of the previous year 2014, when net profit amounted to JD 69.7 million.Chairman of the Board Mr. Jamal AL Sarayreh said that APC sig-nificantly reduced the production cost per ton by the end of Q3 through deferral of salt dredg-ing activities, efficiency of pro-duction, and cost management. These policies, coupled with the rise in the global sale price of potash, raised APC’s profit mar-gin from 23% last year to 40% in 2015, resulting in increased prof-its despite lower volumes and revenue of sales compared to the same period in 2014.Mr. Al Sarayrah pointed out that the global potash market was impacted in the third quarter by

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nity development and improving services to local communities, which is among APC’s most im-portant core values. The Board of Directors approved a budget rise from JD 7.5 million to JD 10 million for the Company’s CSR program 2015, which focuses on sustainable projects that bring long-term benefit to Jordanian citizens and introducing new projects that complement the ac-complishments of the past years.Mr. Jamal AL Sarayrah also re-vealed that APC’s future plans focus on investing in expanding the Company’s asset base in its plants located in the South of Jor-dan. About US $1 billion was al-located in future budget estimates for capital projects that will be completed over the next several years mainly expansion in potash production through increasing production capacity by 245,000 tons and raising the production capacity of granular potash by 250,000 tons per year. Also, KE-MAPCO (APC wholly owned subsidiary) approved plans to raise its production capacity of potassium nitrate from 135,000 tons to 175,000 tons per year.President and CEO Brent Hei-mann added that APC’s top pri-ority is to provide a safe working environment for its employees, and in July 2015 APC completed

Mr. Jamal AL Sarayrehone million working hours with-out lost time injuries. Last year APC completed 5 million work-ing hours without lost time inju-ries, which places it among the leading industrial companies in worker safety in Jordan and the region. Commenting on APC’s financial results, Mr. Heimann pointed out that Q3 results are very good, especially in light of the recent increases in taxes, royalties, and electricity tariffs, which coin-cided with the drop in the global price of fuel. He added that, to expedite handling at the export terminal in order to cope with the increase in production, work has started to build a new industrial port in Aqaba at an initial cost JD 118 million, financed equally by APC and the Jordan Phosphate Mines Company. Mr. Heimann added that APC’s management also focuses on completing the Company’s capital projects that include diversifying energy sources and increasing depen-dence on renewable energy. It was decided to proceed with a project to generate electricity from solar cells at a capacity of 33 MW, which will be complet-ed within two years. Studies are also ongoing for another project to generate electricity and steam using natural gas.

Minister of Water and Irri-gation Dr. Hazem Al-Nasser, and Chairman the Board of Arab Potash Company (APC) Mr. Jamal Al Sarayrah signed an agreement today, Sunday 8/11/2015 at the Ministry of Water and Irrigation by which APC would provide four mil-lion Dinars to fully finance the construction of Wadi Al Wa-dat Dam in Tafilah Governor-ate. The agreement follows a similar agreement signed in January 2014 to finance the construction of Wadi Ibn Hammad Dam to the value of JD 26 million.Dr. Al-Nasser stressed at the signing ceremony that “the Arab Potash Company is one of the Jordan’s leading com-panies in supporting govern-ment and local community organizations in all parts of the Kingdom.” Dr. Al Nasser added that “financing the con-struction of Wadi Al Wadat Dam to the value of JD 4 mil-lion by APC comes in response to citizens’ needs in the south-ern regions for such dams, which will provide water to the people of Tafilah. The min-ister expressed his pride “at the strategic partnership with the Arab Potash Company,

APC SIGNS JD 4 MILLION AGREEMENT WITH MINISTRY OF WATER TO FINANCE

CONSTRUCTION OF WADI AL WADAT DAM which contributed to many solutions for water challenges facing the South.”For his part, Mr. Jamal Al Sarayrah said that “financing the dam is in line with the vi-sion of His Majesty King Ab-dullah II Ibn Al Hussein that the first priority is a better life for all Jordanians. Wadi Al Wadat Dam and Wadi Ibn Hammad Dam will provide water for drinking and agri-culture to citizens in the larg-est concentration of pockets of poverty in the Kingdom, and they will address some of APC’s needs for water.” Mr. Al Sarayrah added that APC and the Ministry of Water and Irrigation work continuous-ly to find suitable solutions to the water problem in the south, in the context of APC’s corporate social responsibility (CSR) program. Construction of Wadi Al Wa-dat Dam will be carried out in cooperation between the Ministry of Water and Irri-gation and the Arab Potash Company, and it is expected to be completed in two to three years, after which rain water will be harvested in the dam at a capacity of 0.5 million cubic meters.

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surface renewal efficiently pro-vides acid gas absorption.Once the process gas exits the Froth Zone, the quenched gas and liquid will then enter the disen-gagement vessel. The liquid will fall to the sump while the gas will travel up to the chevron demisting device and the clean gas enters in to the stack.The benefits of the DynaWave in this application are:• Very high SO2 removal efficien-

cies can be obtained in a single vessel.

• Non plugging design.• High on-stream reliability.• Simple operation, low mainte-

nance and minimal operator at-tention required.

• Effluent tank with oxidation blower system to convert good oxidation of sulphites salt to sul-phate.

• Safe method of effluent disposal.• For the alkali scrubber system

project the Basic engineering package by Dupont Mecs – Bel-gium.

• Detailed engineering done by - Protech India.

• Alkali scrubber vessels fabrica-tion by Chemical process indus-tries India.

With a capital investment of US$ 1.80 million, the project was com-missioned on 14th October 2015 in the IJC Sulfuric acid plant com-plex. The performance of the sys-tem was found to be effective.

ALKALI SCRUBBER SYSTEMIJC’S CSR INITIATIVE – PROTECT YOUR ENVIRONMENT

IJC’s (Indo-Jordan Chemicals Co. Ltd.) continuous commitment to-wards CSR (Corporate Social Re-sponsibility) initiative, in order to reduce the S02 emission in the SA stack; we approached the MECS for the proposal of Basic Engineer-ing package of DynaWave Engi-neered Scrubbing System. During the Initial start up condition of the SA plant after the cold shut down the SO2 emission will be on high-er side of 4500 - 5000 ppm due to low temperature in the converter beds.This proposal presents the Dyna-Wave Engineered Scrubbing Sys-tem which is designed to remove sulfur dioxide from the sulfuric acid plant. FAT tower tail gas stream down to less than 600 ppm SO2 at stack at maximum condi-tion and less than 100 ppm SO2 to stack during minimum and nor-mal operating condition of the SA Plant.The DynaWave is designed to ac-complish gas quenching, and acid gas removal for normal operation and also for startup/shutdown op-eration. The DynaWave consist of one Reverse Jet stage in one inlet barrel with a disengagement ves-sel.The DynaWave scrubbing system - The heart of this system is the Reverse Jet, a gas-to-liquid con-tactor that creates a zone of intense mixing. The feed gas enters the top of a vertical duct and collides with the scrubbing liquid that is injected upward through a large bore injec-tor or Reverse Jet Nozzle.A standing wave of highly turbu-lent flow is created at the point where the liquid is reversed by the gas. These standing wave regions are called Froth Zones. In these zones, a very high rate of liquid

Issue 7316


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SANDVIK-fertilizer-ad-ART.indd 1 20/02/2015 15:58

FERTILIZER INDUSTRY REPRESENTATIVES ATTEND THE FAO COMMITTEE ON WORLD FOOD SECURITY

Press Release

A fertilizer industry delegation led by Chairman Abdulrahman Jawa-hery and Director General Char-lotte Hebebrand attended the 42nd session of the Committee on World Food Security (CFS) in Rome this week.The mission included a meeting with FAO Director General Gra-ziano da Silva. During this meet-ing, Dr. Jawahery reiterated the industry’s commitment to increas-ing access to inputs and technol-ogy by smallholders “We believe that it is of utmost importance to continue developing a broad range of practical programs to improve smallholder access to inputs. This includes financing, of course, but it also comprises services to farmers in form of technologies and knowl-edge transfer.” Mr. da Silva commended the pri-vate sector for playing a crucial role in achieving zero hunger and combatting malnutrition. The pri-vate sector’s commitment was also highlighted by the unprecedented attendance of over 140 delegates.The IFA delegation had several

bilaterals with country actors and participated in two side-events/ Charlotte Hebebrand spoke in a side-event on nutrition organized by the World Food Programme and the Scaling Up Nutrition (SUN) movement. Hebebrand presented several case-studies on micronu-trient fertilization concluding that “Micronutrient fertilization is a simple, affordable and sustainable solution to contribute to eradicating deficiencies globally. This makes it a viable program which can be tai-lored to regional and national needs and implemented worldwide.” In another event organized by the International Year of Soils Steering Committee, Hebebrand spoke to the merits of integrated soil fertility management and highlighted that “Soil testing is important so farm-ers can learn exactly how much of each nutrient is required to ensure balanced fertilization using local-ly available organic nutrients and mineral fertilizers. “ The voice of the fertilizer industry was also heard in Plenary where Dr. Jawahery delivered a compel-

ling statement on Action on Food Insecurity in Protracted Crises. He stressed that “The private sector, is the biggest engine of poverty reduction and economic growth in the developing world and thus stands ready to contribute to secur-ing food availability for people liv-ing in protracted crises”.The IFA Chairman also hosted the High-Level Dinner which brought together business leaders and am-bassadors, which provided a vi-brant forum for discussion among private and public actors. IFA and its members have been actively en-gaging in the CFS through the Pri-vate Sector Mechanism. Moreover, IFA has developed a longstanding relationship with the Rome-Based Agencies and currently sits on the Steering Committee of the Interna-tional Year of Soils.The fertilizer industry delegation also included the following mem-bers: Tip O’Neill (United States), Nina Khangaldyan (Russia), Bente Slaatten (Norway) and Antonella Harrison (United Kingdom).

During the AFA 103 Board Meeting held in Muscat, Oman, on Tuesday, the 24th of Novem-ber 2015, the Board Members decided to re-se-lected Dr. Abdulrahman Jawahery President of Gulf Petrochemical Industries Company as AFA Chairman and Mr. Jamal Bensari vice Chairman for 2016 cycle for the second term.It is worth mentioning that Dr. Abdulrahman Jawahery holds a master's degree in Chemical Engineering from London, and doctoral degree from the London South Bank University and

the fellowship of the British Institute of Chem-ical Engineers, and has a track record super-vising as one of the prominent and influential figures in the petrochemical industry on a glob-al scale. Dr. Jawahery held many important positions on the regional and international organiza-tions. He is Chairman of the International Fer-tilizer Industry Association (IFA) and Board Member of Gulf Petrochemicals & Chemicals Association (GPCA).

Dr. Jawahery has been chosen AFA Chairman & Mr. Bensari

Vice Chairman for 2016

Issue 7318

AFA SECRETARIAT DELEGATION HOSTED BY GPIC

Dr. Jawahery and AFA Team

Responding to a gen-erous invitation from Gulf Petrochemical Industries Company (GPIC), a delegation from AFA Secretari-at has paid a visit to GPIC to be informed with the facets of de-velopment and to get to know the myriad potentials possessed by Bahrain in the industrial sector, already witnessing remarkable progress. This visit is taking place within the frame-work of AFA Secretariat channels of communication with member companies.During this visit, the delegation met GPIC Chairman Engineer Abdul Rahman Gawahry, and expressed all thanks and appreci-ation to such a kind gesture. The delegation members affirmed that this visit is an opportunity to know about the development and progress witnessed by GPIC in all technical, environmental and vo-cational fields as well as to benefit from the different experiences of GPIC staff.Then, the delegation visited the in-dustrial compound, social club and

training academy. The academy director has clarified the pillars on which GPIC is based, which assist in applying the Company strategy and carrying out training programs to raise Company staff profession-al skills and capacities. He fur-ther added that GPIC is proud of striking records in the safety field. Moreover, he presented the com-pany philosophy, operational strat-egy and HSE standards applied during such operations.The delegation members then posed questions and inquiries re-lated to company leadership and management aspects and nature. Subsequently, the delegation held a field visit that included the Company factories and facilities, during which the delegation knew

about the manufac-turing and exporting phases as well as the environmental proj-ects surrounding the Company; highlight-ing the remarkable attention provided by the GPIC to environ-mental issues and the significant efforts ex-erted in this regard.The delegation ex-tended deep appre-

ciation to GPIC Chairman, exec-utive management members and staff for hosting and introducing them to the Company nature of work. AFA delegation also ad-mired the developed operational processes and factories, compris-ing state-of-the-art equipment and machines, and commended GPIC efforts exerted to train and devel-op its national staff. The delegation members further praised the Company remarkable attention paid to the environmental aspects, whether by establishing green projects inside the industrial compound or by supporting differ-ent activities and proceedings held by the community to raise people awareness of environmental pres-ervation.

Issue 73 19

Most countries of the Mediterra-nean region are suffering from scar-city of water resources. Therefore, untraditional water resources such as municipal and industrial waste-water can be a valuable additional water resource if properly man-aged. It has been documented that more than half of the municipal and industrial wastewater are disposed untreated to the environment.

Wastewater management (treat-ment and re-use) therefore remains a crucial issue to the sustainability of the environment with impli-cations and challenges in the so-cio-economical development in this region. In December 2008 the Mediterranean Ministerial Confer-ence on Water held in Jordan called for the need to develop and imple-ment strategies to achieve appropri-ate wastewater management with the need to conserve water quality including appropriate treatment of various types of wastewater for far-ther sustainable reuse in agriculture.

Wastewater can be generated from municipal, industrial and/or agri-cultural activities. The olive mill wastewater (OMW) is generated from olive Mills during the process of extraction of olive oil. It was estimated that the Mediterranean region accounts for 97% of the world›s olive production. About 11 million tons of olives are produced each year out of which nearly 2 million tons of olive oil is extract-ed. The estimated olive mill waste-water (OMW) generated annually by olive oil processing is 9 million tons. OMW is highly resistant to biodegradation and can potentially cause serious environmental and health hazard problems harm if not properly disposed.

In general, OMW is composed from about 80% water, 18% organ-ic matter, and 2% mineral matter. The organic matter of OMW con-tains oils, fats, phenols, proteins, or-ganic acids, and carbohydrates. The phenolic compounds are phytotoxic to living organisms including plants and microorganisms. High organic load of OMW deteriorate water quality when disposed untreated to water bodies. OMW emits odorous volatile compounds and create odor nuisance when disposed into the soil and water bodies causing dete-rioration of soil water quality.

On the other hand, OMW can be beneficial and be used as water for irrigation, soil conditioner, biomass fuel, fertilizer and compost. OMW contains valuable plant nutrients such as N, P, K and micronutrients as well as organic compounds that can enhance soil fertility and pro-ductivity. Moreover, OMW can also be a source of valuable products such as antioxidants, enzymes and beneficial phenolic compounds.

Currently, most of the generated OMW either use only basic treat-ment methods (evaporation) or they just dispose the OMW in the areas surrounding their facilities. Such management imposes serious threats to the environment and pub-lic health. Therefore, proper man-agement including both treatment and reuse is crucial in this region where water resources are scarce in both the quantity and quality

Since OMW is not biodegradable, its treatment by chemcal and physi-cal methods suc as photooxidation, membrane micro and ultrafiltration, are expensive and currently is eco-nomically non feasible. Therefore, most countries allowed conditional

and controlled application of un-treated OMW to agricultural lands. These conditions in general are as follow:1. OMW can be spread on the non

cultivated lands two months be-fore planting any field crops and soil then has to be plowed and the OMW be mixed with the soil through soil plowing

2. OMW can be spread between fruit tree rows but not directly under the tree

3. OMW not to be applied to the land with slope more than 7%

4. OMW spreading to the land should not be allowed in sites close to the surface and ground water or recreation and urban areas

5. The maximum rate of OMW ap-plication to the soil is no more than 80 cubic meter per hectare

Management of Olive Mill Wastewaterin the Mediterranean Region

Prof. Munir RusanJordan University of Science

and TechnologyConsulting Director of

the International Plant Nutrition Institute in the Middle East

[email protected]; [email protected]


Issue 7320

6. Land and plants receiving OMW should be monitored periodically for quality parameter

7. Land application of OMW should be managed on a site-specific ba-sis considering all environmental and soil factors in each site and avoid any generalized recom-mendations for OMW use.

In a study to evaluate the phyto-toxicity of OMW and possible re-use of OMW as a soil amendment and source of irrigation water, an experiment was conducted in a greenhouse environment. Untreat-ed (100%omw), diluted OMW (25%omw, 50%omw) and fresh water (W) as a control were used for irrigating corn crop grown in calcareous soil. The characteristics of OMW used and the soil are given in Table 1 and Table 2, respectively.

The following main results and findings obtained from this experi-ment are as follow:Plant growth (Fig 1):

1. The undiluted OMW resulted in the lowest plant dry weight indi-cating the phytotoxic effect on the plant growth

2. Dilution of untreated OMW at a ration of 3:1 (3 water and 1 OMW) was adequate to signifi-cantly reduce OMW phytotox-icity

3. Plant growth was improved with the soil application of the high-est dilution of OMW with fresh water (25%OMW), followed by the control treatment where fresh water alone was used (W)

4. The relative plant dry weight obtained by the 25%OMW was 23% more than that obtained by the control (W) and three times more than that obtained by the application of undiluted OMW (100%OMW)

5. The decrease in OMW phytotox-icity following OMW dilution could be attributed to the reduc-tion of the levels of the phenols

and other phytotoxic compounds6. Plant growth enhancement with

application of diluted OMW could be attributed to the bene-ficial organic substances and es-sential nutrients provided to the soil with OMW application

Plant Uptake of macronutri-ents(Table 3):1. The plant contents of N, P

and K were the highest for the 25%OMW treatment followed by the W

2. The increase in the plant N, P and K with the 25%OMW com-pared with the control treatment (W) indicates the soil is defi-cient in these nutrients and that the OMW provided the soil with these nutrients or enhanced the original unavailable soil nutri-ents resulting in a an increase in their uptake by the plant

3. The lowest plant contents of N, P and K was obtained by the ap-plication of the undiluted OMW and tended to increase with dilu-tion of OMW

4. The higher the dilution was the higher the contents of plant nu-trients

5. The decreasing trend in plant up-take of nutrients with dilution of OMW followed the trend of the effect of the same treatments on the plant dry weight

6. Obviously the lower the dilution of the OMW is the lower is the plant dry weight

7. Although the OMW contains considerable amounts of N, P and K which simultaneously would be added to the soil upon OMW application [54-55], their uptake by the plant irrigated with undiluted and diluted OMW re-mained low due to the low plant dry weight

Soil characteristics after plant har-vest (Table 4):1. Soil pH at the end of the growing

period was significantly lower in

Issue 73 21

the soil where undiluted OMW was applied

2. Other treatments of diluted OMW did not decrease the soil pH. The decrease in soil pH could be attributed to the acidic nature of olive mill wastewater. It should be pointed out that the soil is calcareous with high buf-fer capacity.

3. This could explain the small decrease in the soil pH with un-diluted OMW while the diluted OMW was not affecting the soil pH. In addition

4. On the other hand, the soil salini-ty (EC) was increased drastically by the application of undiluted and diluted OMW

5. The highest increase in soil EC was obtained by the undilut-ed OMW and then the EC de-creased with decreasing the dilu-tion of the OMW. The increase in EC with OMW application is obviously attributed to the high salt concentration in the OMW that would accumulate in the soil with continuous application

6. Compared to the soil application of water with and without fer-tilizer, the soil contents of both organic matter and total poly-phenols were the highest for the undiluted then by diluted OMW. Besides improving the soil fertil-ity of the soil with OMW appli-cation, increasing the soil organ-ic matter tends to enhance soil structure by enhancing the soil aggregation

Soil nutrients after plant harvest (Table 5):1. Soil N, P, K, Ca, Mg and Na

drastically increased with undi-luted and diluted OMW appli-cation in comparison with the control treatments where water applied

2. The highest values for all these nutrients were obtained when undiluted OMW was applied (Table 6). The increase in soil N,

P and K contents with OMW ap-plication can be attributed to their high content in the OMW used (Tables 2). Such enrichment of the soil with organic matter and macronutrients would improve the soil fertility and productivity levels.

ConclusionsBased on the results obtained

from this study it can be conclud-ed that soil application of undiluted OMW had phytotoxic and prohib-iting effect on plant growth. On the other hand, and due to high levels of organic matter, phenols and nu-trients in the OMW, the soil fertil-

ity was improved following soil application of OMW. Dilution of OMW with potable water at water to OMW ratio of 3:1 (25%OMW) is recommended before soil appli-cation to eliminate its phytotoxicty and to enhance plant growth. Such dilution can be adopted without any further treatment as an inexpen-sive technology before application. Finally, the enhancement of soil OM, N, P and K and improving soil fertility is of particular impor-tance for the poor soils of the arid and semi-arid region. Thus, OMW in this region has the potential to be used as an organic soil amendment.


Fig. 1. Plant dry weight (DWT) as g plant-1 and relative to the control (W)Different letters in each column indicate significant difference at p < 0.05

Issue 7322

Agriculture, a source of food for both man and cattle, is as old a profession as the dawn of mankind. The ancient Egypt – etymologically black land (kemet): rich soil deposited by the Nile – thrived for thousands of years as Egyptian civilization, which the Greek historian Herodotus called “the gift of the Nile”. Thus, fertile soils and water are the vital components of any sustainable agricultural production systems. The subject being important has, therefore, been attempted by the people of all ages, from Columel-la’s Husbandry1 in AD 60 to the recent publications of 20152. And one is confounded to charter a new course of discourse in the face of vast and volumi-nous contributions available on the components of the subject. The current scenario, the sustainability of the system, implying producing more with less and yet compatible with the dictates of economic, eco-logical and social considerations, makes the matters worse: a daunting tall order! Nevertheless one has to wade through water, plough through soils and mud-dle through the maze of plants to find a way out.Water – That sustains lifeThat water is life, is the word of God: From the Qur’an: There are numerous verses on the

subject, for example:− And We made from water everything living (21:30)− And you see the earth barren. But when We send

down (rain) water upon it, it quivers and swells, and brings forth plants of every joyous kind (22:5).

− Let man consider his food! How We pour the wa-ter down in torents and cleave the land asunder to produce thereby grains, and vines and vegetables, and olives and palms, and dense gardens, and fruits and fodders, all for you and your cattle to relish.

From the Bible − He makes springs flow in the valleys, and rivers

run between the hills. They provide water for the wild animals; there the wild donkeys quench their thirst. In the trees near by, the birds make their nests and sing.From the sky he sends rain on the hills, and the

earth is filled with His blessings.He makes grass grow for the cattle and plants for us

to use, so that we can grow our crops and produce wine to make us happy, olive oil to make us cheerful, and bread to give us strength (Psalms 104: 10-15)

Water being vital for life, the history of man is linked with water. Consider the ancient civilizations: the Babylonian and the Assyrians in Mesopotamia, the Nile valley, the Indus valley, the Greeks, the Chi-nese, etc., they were all dependent upon water; Mo-henjo-Daro built extensive water works, including irrigation canals; Egypt built the world’s oldest dam, Solomon, about 950BC, directed the construction of aqueducts for men, beast and field; Hippocrates recognized the dangers of polluted water for human health and recommended filtration and boiling, and the Romans used poorer waters for irrigation3.

Water is essential component of all human and plant cells. Water’s role in metabolism, in regulat-ing body temperature, and in nourishing the tissues, explains why life cannot sustain without water. The water molecule is simple: two atoms of hydrogen (H) and one of oxygen (O2), expressed as H2O, which is one of the simplest compound. And yet, it is so complex (Figure 1) the latest research reveals4:

Fertilizer and Water for Sustainable AgricultureDr. Muhammad Tahir Saleem, Editor of Farming Outlook is the only English

quarterly magazine in Pakistan

Fig 1The complexityof water molecule

Issue 73 23

Water is nature’s greatest miracle. Consider the hydrological cycle: vapours rising high from the ocean, streams, plant transpiration, forming clouds in the air, falling as rain of the soil, soaking in the soil for use by plants, and access running off back to streams and ocean. This is a never-ending circula-tion process known as water cycle (Figure 2). By the sky of the returning rain, and by the land splitting (86:11-12)Agriculture is the biggest user of water. While 2 litres of water are often sufficient for daily drinking purpos-es, it takes about 3,000 litres to produce the daily food needs of a person, and agriculture makes use of 70 per cent of all water withdrawn from aquifers, streams and lakes5. And yet water is scarce, warranting effi-cient management for producing food supply for the burgeoning population. Water applied in traditional system is considerably lost and consequently the ap-plication efficiency is low such as shown in Table-16:

Thus, it is important that water application is as much efficient as possible. Besides, we should re-sort to approaches to improving and sustaining pro-ductivity under water-scarce conditions7:a) Modifying the soil environment by providing ir-rigation and reducing water loss, and b) Modifying plants to suit the environment through genetic improvements.Soil – That support and nourishes the plantFig 3 Soil as foothold and source of nutrient supply to the plantSoil both serves as foothold and a source of nutri-ents for the plant (Figure 3). Its definition differ ac-cording to various perceptions: soil morphologist visualizes soil in terms of the various horizons and chemical and physical properties while a farmer thinks of soil in terms of its ability to produce crops

in order to meet his needs of food and fibre. Soil is made up of mineral matter, air, water and organic matter in approximately 49, 25, 25, 1 per cent re-spectively. Plant growth is largely dependent on the various physical and chemical properties of soils. However, soil is a ‘living’ entity and it includes bac-teria, algae, protozoa, fungi, insects, earthworms, etc. There is an average of five million N-fixing microor-ganisms like azotobacter and clostridium, plus fifty million other living beings like fungi per gm soil. These microorganisms weigh between 500 and 1000 kg/ha within the arable layer. They form 15 per cent of soil’s humus. Increasing organic matter improves soil health. Healthy soils are porous, which allows air and water to move freely through them besides nourishing plants adequately. One has to unlock the potential of a healthy soil in order to obtain sustainable crop production.Fig 4 Photosynthesis processPlant growth is yet another miracle of the Creator: the process of photosynthesis by which plants convert car-bon dioxide of the air via sunlight. ‘All our food comes from this process, either di-rectly or indirect-ly. We eat green plants and their grains and fruits as well as the an-imals that feed such plants’8. Plants take car-bon dioxide from air, hydrogen from water and their chlorophyll

traps energy from sunlight and transforms it into chemical energy used fro the pro-duction of sugar (Figure 4). The photosynthesis equation is given below:

Table-1: Efficiency of applied irrigation water


Issue 7324

Pants are made up of 80 per cent of water and the rest, 18 per cent constituting carbon, hydrogen and oxygen, and the remaining two per cent of mineral constitu-ents, of which there are at least 16 essential elements required for plant growth. Among the essential el-ements there are primary or major, secondary and micronutrients with specific functions in plant life. Plants take up nutrients from soil, air, and water (Figure-5).The growing crops while absorb nutrients from soils, they deplete them overtime from one or more nutrients with the result that the crop yields are lim-ited by the deficient nutrients. In due course of time deficiency symptoms appear. Soil and plant testing are generally the diagnostic tools to assess the nutri-ent status of soils. Fertilizer - That replenishes the depleted nutri-entsThe story of fertilizers dates back to the dawn of scientific agriculture in the beginning of seven-teenth century when J.B van Helmont (1577-1644) conducted the first quantitative experiment to un-ravel the mystery of plant growth. The ‘principle of vegetation’ was a mystery and various research-ers thought of different substances: J. R. Glauber (1604-1668) as saltpeter, Francis Home (1775) as humus and de Saussure (1767-1845) as ashes of plants when Boussingault (1802-1887) was the one who initiated field experiments. However, finally it was von Liebig (1803-1873) who gave the min-eral theory of fertilizers and stated the ‘law of the minimum’ which enunciates that growth of plants is limited by the plant nutrient element present in the smallest relative amount. When soil gets depleted of its nutrients, they are re-plenished through the application of chemical com-

pounds known as fertilizers. Fertilizers are plant foods and used to supplement the soil supply of the essential plant nutrients. A fertilizer is, thus defined as a sub-stance used for the purpose of supplying one or more of the elements essential for plant growth (Figure 6). There are different kinds of fertilizers depending on the nutrient content. There are straight, such as urea, single superphosphate (SSP) / triple superphosphate (TSP), muriate / sulphate of potash which contain a single nu-trient, and compound fertilizers, such as diammonium phosphate (DAP) and NPKs also called complete fer-tilizers which contain two or more nutrient elements. Fertilizer products and their application is by itself a subject and the efficiency of the applied fertilizer de-pends on a host of factors, including the nature of soil and the kinds of crops. However, fertilizer efficiency is a complex matter. The applied nutrients in the form

of fertilizers have low efficiency: only 40 to 65 per cent of nitrogen (N), 15 to 25 per cent of phosphorus (P) and 30 to 50 per cent of potash (K)9. 4R nutrient stewardship concept, which implies the right source,

rate, time, and place for plant nutri-ent application is the latest approach in fertilizer efficiency.Fertigation – That optimizes water and fertilizer applicationWater use efficiency led to the devel-opment of such techniques as sprin-klers around 1920s and lightweight steel pipes in the 1930s, trickle ir-rigation in the late 1950s and early 1960s. (Keller and Bliesner, 1990). Scarcity of irrigation in Israel led in 1960 to the development of drip ir-rigation (Kafkafi, U. and J. Tarchitz-ky, 2011). However, drip irrigation was for the first time commercially used only in 1980 in corn and cotton fields (Patricia. J. and M. Ron Price, 2008). Fertigation was now a step

Issue 73 25

soon to follow. The practice of supplying crops in the field with fertilizer via the drip irrigation water is called Fertigation (Figure 7).

Farmers in Pakistan first evolved fertigation in its crude from in the 60s who placed fertilizer, particu-larly ammonium sulphate, in the water outlet to the field (nakka) during irrigation. However, uneven ap-plication of fertilizer in the field, more in the nearer and less in the far ends, besides nitrogen losses, ob-viated the spread of this techniques.

The Gravity Irrigation System is the simplest form of Fertigation as it applies to an irrigation system working at atmosphere pressures in which water flows in open channels. The fertilizer solution drip into the irrigation channel as the fertilizer tank is above the level of the channel (Figure 8).Fertigation, a modern agro technique, provides an excellent opportunity to maximize yield and mini-mize environmental pollution (Hagin et al, 2002) by increasing fertilizer use efficiency, minimizing fer-tilizer application and increasing return on the fer-tilizer invested. Besides, timing, amounts and con-centration of fertilizer applied are easily controlled. Following are the pre-requisites for fertigation:• Equipmento Pressurized irrigation systemo A filter to prevent dripper from cloggingo A back-flow preventive valve• Fertilizerso Solubility in water sourceo The degree of acidity of fertilizer solution with re-gard to corrosiveness of the irrigation system com-ponents.However, for details on the use of Fertigation in alkaline soils, nutrients reactions with soil, plant physiological considerations fertigation as applica-ble to field crops, fruits and vegetables, ornamental

plants, etc. are in standard publications easily avail-able (Kafkafi U. and J. Tarchitzky, 2011; Hagin, J., M. Sneh and A. Lowengart-Aycicegi, 2002; Patri-cia, I. and M. Ron Price, 2008).

Sustainable agriculture – That is environmental friendlyThe Green Revolution of the mid 60s was a tremen-dous development towards meeting food security for a bourgeoning population. However, it suffered from myopic outlook: it lacked concern for envi-ronmental preservation and for future generations to feed themselves. As a consequence soil health got deteriorated and environmental polluted. These considerations helped emerge the concept of agri-cultural sustainability comprising the components as shown in Figure 9.

Sustainable agriculture, thus, implies a system of cropping which produces food, fibre and other plant / animal products while protecting soil health, envi-ronmental quality and human / animal (social) wel-fare. This approach of practising agriculture enables to produce healthier foods without compromising future generations ability to produce enough for them.Continuous agriculture using resource-intensive in-puts (fertilizers and chemical pesticides) robs soil of its health and ultimately leads to soil degrada-tion and erosion. Soil management that leads to conservation agriculture is the key component of sustainability. It implies minimum tillage, rational and wise management of inputs, appropriate crop rotation and returning of crop residue to the field (Lumpkin and Sayre, 2009). Crop rotations, which include legume crops in cereal systems, help reduce the pest populations through disruption of the pest life cycle, increase biological N-fixation, slow-re-lease of nutrients from complex organic substances, redistribute soil nutrients from lower soil depths to the root zone, etc. (Kassam and Friedrich, 2009).In brief, the use of fertilizer and water though such efficient techniques as Fertigation and the integrat-ed use of chemical-biological sources of nutrient supply besides improved crop husbandry in farm-


Issue 7326

ing systems approach are the measures that lead to the development of sustainable agriculture: Produce more with less.However, it is long way and arduous task to shift from traditional agriculture to the sustainable eco-system farming approach. The small-holding farm-er, who is constrained by resources, has neither the education and training nor the will and option to adopt sustainable farming which by its very defini-tion is a slow-moving approach requiring a massive public and private sectors confined efforts in provid-ing farmers the requisite education, training and the wherewithal.

The way forward – We seek; we learn We have moved from wild gathering and hunting of food in ancient times to the present-day precision farming, albeit in slow moving pace in contrast to other scientific disciplines. It has been a process of seeks and learns. So let us not slacken our pace if we have to achieve progress in eco-farming sustainable approach in leaps and bounds. Produce information in concrete terms, embark on education training of farmer, and make resources available to him for this vital noble task of feeding our generation with healthier foods, protecting environment and ensur-ing food security.

Bernard Frank. 1955. The Story of Water as the Story of Man. USDA, Water, the Yearbook of Agriculture 1955.Charles E. Kellogg. 1957. We Seek; We Learn. The USDA, Soils: The Year Book of Agriculture 1957.Food and Agriculture Organization, Rome http://www.fao.org/docrep/t7202e/t7202e08.htm Hagin, J., M. Sneh and A. Lowengart Aycicegi. 2002. Fertigation – Fertilization through irrigation, IPI Re-

search Topics No. 23. Ed. By A.E Johnston, International Potash Institute, Switzerland.Kafkafi, U. and J. Tarchitzky. 2011. Fertigation: A Tool for Efficient Fertilizer and Water Management. Interna-

tional Fertilizer Industry Association (IFA) and International Potash Institute (IPI), Paris, France.Kassam, A., and T. Friedrich. 2009. Perspectives on Nutrient Management in Conservation Agriculture. In 4th

World Congress on Conservation Agriculture”, New Delhi, India, 4-7 February.Keller, J. and R.D. Bliesner. 1990. Sprinkle and trickle irrigation. Van Nostrand Reinhold. New York.Lumpkin, T.A., and K.D. Sayre. 2009. Enhancing resource-productivity and efficiency through conservation

agriculture. In “Innovations for Efficiency, Equity and Environment. 4th World Congress on Conservation Agriculture”, New Delhi, India, 4-7 February.

Mcgrath, A. Kimberley. 1999. Word of Scientific Discovery. Gale Research, USA.Patricia, Imas and M. Ron Price. 2008. Fertigation Proceedings: Selected papers presented at the joint IPI-NA-

TESC-CAU-CAAS International Symposium on Fertigation Optimizing the utilization of water and nutri-ents, Beijing, 20-24 September, 2005. International Potash Institute, Switzerland.

Pay Drechsel, et al. 2015. Managing Water and Fertilizer for Sustainable Agricultural Intensification. Interna-tional Fertilizer Industry Association (IFA), International Water Management Institute (IWMI), International Plant Nutrition Institute (IPNI) and International Potash Institute (IPI), France.

Pay Dreschsel, et al. 2015. Managing water and nutrients to ensure global food security, while sustaining eco-system services, In Managing Water and Fertilizer for Sustainable Agricultural Intensification. IFA, IWMI, IPNI and IPI, France.

Science AAAS, At the Smallest Scale, Water Is a Sloppy Liquid, http://news.sciencemag.org/science-now/2010/10/at-the-smallest-scale-water-is-a.html?ref=hp

References

Issue 73 27

3500 PARKWAY LANE, SUITE 550PEACHTREE CORNERS, GEORGIA 2844-30092 USA

PHONE (0335-447 (770 | WWW. IPNI.NET

This Nutri-Fact is one of a series of fact sheets written by scientific staff of the International Plant Nutrition Institute (IPNI) that is focused on essential plant nutrients and their use. This series is available as PDF files at www.ipni.net/nutrifacts.

N u tr i -Fa c tsAgronomic fact sheets on crop nutrients

I ro n

Iron (Fe) is a nutrient required by all organisms, including microbes, plants, animals, and humans. It was first recognized

as a necessary plant nutrient in the mid 19th century when Fe-deficient grapes were successfully treated with foliar applications of Fe salts. Iron is a component of many vital plant enzymes and is required for a wide range of biological functions. It is common in the earth’s crust and as a result, most soils contain abundant Fe, but in forms that are low in solubility and sometimes not readily available for plant uptake.

Iron in SoilsIron is abundant in many rocks and minerals and as soils develop there can be either enrichment or depletion of Fe. Depletion commonly leads to deficiency and enrichment can cause toxicity in unique conditions. The main source of Fe in soils for use by plants comes from secondary oxide minerals that are adsorbed or precipitated onto soil mineral particles and organic matter. Although Fe is very abundant, it’s availability for plant uptake is quite low .

Iron in PlantsPlant roots absorb Fe from the soil solution most readily as (ferrous) Fe +2 but in some cases also as (ferric) Fe +3 ions. The chemical nature of Fe allows it to play an essential role in oxidation and reduction reactions, respiration, photosynthesis, and enzyme reactions. For example, Fe is an important component of the enzymes used by nitrogen-fixing bacteria.

The Fe concentration in plant leaf tissues varies between plant species, but is generally between 50 and 250 ppm (dry weight basis). If the Fe concentration is less than 50 ppm there are usually signs of deficiency, and toxic effects may be observed when the concentration exceeds 500 ppm.

The solubility of Fe oxide minerals in soil is very low, so plant roots have two general ways to access the Fe +2 or Fe +3 ions. The first strategy occurs in dicot species, and non-grass monocot species where Fe +3 ions are reduced to Fe +2 ions before moving into the root across selective membranes. This process involves the root excreting a variety of organic compounds and acids into the soil. In the second strategy, roots of grass species acquire Fe by excreting an organic chelate (siderophore) that solubilizes Fe from the soil, allowing enhanced uptake.

Soil Factors and Iron DeficiencyMost soils contain adequate Fe for plant nutrition, but chemical and environmental factors restrict plant uptake. Iron deficiencies are commonly observed in soils with elevated pH (>7.5), especially where there is abundant calcium carbonate (lime). Iron solubility is greatly increased as soil pH drops into the acidic range.

Soils containing abundant calcium carbonate can form bicarbonate ions (HCO 3

-) if the soils become overly wet, and bicarbonate interferes with Fe uptake by plants. This inhibition is usually only temporary and Fe deficiency symptoms disappear when the soil drains and warms up.

When soils become saturated, Fe +3 becomes converted to Fe +2 by microbial action. The Fe +2 form is much more soluble and can even result in toxicity for some rice varieties in flooded soils under strongly acid conditions.

NO. 12

North American Edition

Iron deficiency in soybean (left), sorghum (middle), and wheat (right).

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Plants growing in soils with low organic matter content are generally more susceptible to Fe deficiency than with abundant organic matter. Humus compounds are effective at binding and releasing Fe ions into soil solution. Portions of a field that are eroded (low soil organic matter) tend to be more susceptible to Fe deficiency.

Since many soil and environmental factors combine to regulate the Fe supply to plants, there is no widely accepted method of testing soils to predict the need for supplemental fertilization.

Deficiency and Toxicity SymptomsIron deficiency symptoms are universal among plant species, with general stunting and yellowing of younger leaves. Young Fe-deficient leaves develop chlorosis (yellowing) between the leaf veins, while the veins initially remain green. As the deficiency becomes more severe, the younger leaves become pale yellow to white in color. The young tissue is impacted first because Fe is poorly mobile within plants and does not readily translocate from older to younger tissues.

Iron toxicity is relatively rare, but the symptoms include bronzed and striped leaves. These effects are the result of excess Fe-hydroxyl radicals disrupting cellular functions. Due to the importance of maintaining Fe concentrations within safe ranges in plant tissues, the whole process of Fe uptake into roots (i.e., the movement from roots to shoots, and storage and release within plant cells) is highly regulated.

Tissue analysis for Fe can be complicated since any dust that may be present on the leaf surface will also contain Fe. Rinsing or washing plant leaves is recommended prior to Fe analysis. Most tissue analyses rely on sampling the young leaves, since they are generally the first to show deficiency symptoms.

Fertilizing for Iron DeficiencyWhen inorganic Fe fertilizers are added to soil (e.g., ferric sulfate, ferrous sulfate, ferrous ammonium phosphate, ferrous ammonium sulfate, and oxides of Fe), they are rapidly converted to insoluble forms and provide minimal benefit for plant nutrition. Iron fertilizers protected with an organic chelate can be effectively applied to soils to correct plant deficiencies. For example, chelated fertilizers such as Fe-EDDHA and Fe-EDTA have been used with reasonable effectiveness ( Table 1 ), but their cost is often prohibitive for large-scale application. Foliar sprays containing Fe salts or chelates are effective at correcting plant Fe deficiencies during the growing season, but they may require repeated applications to prevent reoccurrence of deficiency.

Crop ResponseSeveral remedies are used to compensate for plant Fe deficiency. Depending on local conditions, some of these solutions may be more practical than others.

• Grow plant varieties and cultivars specifically adapted to the local conditions that are tolerant of low-Fe conditions. Large genetic differences exist among cultivars and a variety change is often effective for dealing with challenging soil conditions. ( Figure 1 ).

• Apply a Fe-containing fertilizer in the form of an inorganic salt or a chelated material to the soil.

• Spray a Fe-containing solution onto plant leaves to prevent or correct deficiencies. This does not correct any underlying soil problems preventing uptake of adequate Fe, but it can assist with eliminating growth limitations from Fe deficiency.

• Add an acidifying material to soils with elevated pH to improve the solubility of Fe. This acidification can be done for the entire field or spot treatment of a portion of the root zoneis often sufficient to improve Fe availability.

• Improve Fe availability by growing two plant species together. The ability of one crop to solubilize and acquire Fe sometimes results in sharing with a companion crop that has lesser capacity to extract Fe ( Table 1 ).

Ref. 15058# 12#

References1. Goos, R,J. and B.E. Johnson. 2000. Agron. J. 1139-92:1135.

2. Kaiser, D.E., J.A. Lamb, P.R. Bloom, and J.A. Hernandez. 2014. Agron. J. 1974-106:1963.

Oatcompanion

crop

Fe-chelate fertilizer

Fe chlorosis susceptible

variety

Fe chlorosis tolerant variety

Relative yield, %

No No 48 e 82 c

No Yes 71 d 87 bc

Yes No 73 d 76 cd

Yes Yes 87 bc 93 ab

Table 1. Relative grain yield of two soybean varieties, one susceptible and one tolerant to Fe deficiency, compared with the tolerant variety grown on a Fe-sufficient site (%100) 2.

Treatments include addition of a Fe-chelate fertilizer, or the presence of an oat companion crop on severely Fe-deficient soils. Letters following relative yields indicate significance at p ≤ to 0.10 for both varieties.

Figure 1. Grain yield of three soybean varieties grown in calcareous soil. The Glacier variety, susceptible to Fe deficiency, responded to foliar Fe application while no yield response was observed for more tolerant Council and Traill varieties 1. Error bars denote an LSD (0.05).

Issue 73 29

Studies & Research

Introduction:Oman India Fertilizer Company S.A.O.C. (OMIF-

CO) was set up as a joint venture project under the initiative of Government of Sultanate of Oman and Government of India. OMIFCO is owned 50% by Oman Oil Company, 25% by Indian Farmers Fer-tilizer Cooperative Ltd.(IFFCO) and 25% by Krish-akBharathi Cooperative Ltd.(KRIBHCO). OMIFCO was registered in the Sultanate of Oman as a closed joint stock company in year 2000.

The Ammonia Urea Complex comprises two trains, each with a design capacity of 1750 MTPD Ammo-nia and 2530 MTPD Granulated Urea and 0.25 mil-lion tonnes of surplus liquid Ammonia annually for export using natural gas as raw material. Storage fa-cilities for Urea(2X75000 MT) and Ammonia (2 X 30000 MT) as well as jetty with ship loaders are part of the project.

The project has two service Boilers of capacity 2 x 70 MT/hr and two HRSG Boilers of capacity 2X110 MTPH. Also the complex has its own captive power plant with two 30MW Frame 6B Gas turbine Gener-ators and import power connectivity with the nation-al grid for backup power.

UFT Fluid bed granulation Process Description The feed solution, typically a 97% urea solution,

is dispensed to the injection heads and finely atom-ized upwards into the bed of moving particles. This spraying is assisted by air.

Fluidization air delivered by a fan under the per-forated plate, flows through the product layer and is exhausted at the granulator top.

Granular urea flows out of the granulator at a con-trolled rate to a fluid bed cooler. After cooling, the granules are lifted by means of a bucket elevator to the screening section.

The fines fraction is recycled directly to the granu-lator whereas the coarse material is first crushed and thereafter sent to the granulator as seeding particles. The on-size product is sent to the warehouse after fi-nal cooling at the required storage temperature. The cooling of urea to a constant and sufficiently low storage temperature is one of the most significant

parameters to avoid caking. The air from the granulator and coolers contains

some urea dust which is easy to catch in standard scrubbing equipment. With industrially proven scrub-bers, efficiencies of more than 99.5% are easily ob-tained.

Therefore dust outlet concentrations of less than 0.1 kg per ton of urea produced can be achieved.

Operation of the fluid bed granulation plant is sim-ple and very reliable, guaranteeing a high on-stream factor. The granulator itself contains no moving parts, and its design is optimized to limit down time for cleaning to a strict minimum.

Product characteristicsUrea granules produced in the UFT fluid bed gran-

ulation have a well-rounded shape and are very hard. They resist particularly well to crushing and abrasion and hence are dust free, non-caking and completely free flowing, even after long storage and numerous handling and shipment operations.

SELECTION OF SCREENING EQUIPMENT FOR FINAL PRODUCT QUALITY - OMIFCO’S EXPERIENCE IN UREA GRANULATORS

T.P.RAJURASHID AL FARSI

Issue 7330

Process Parameters (normal operations)Urea Solution: temperature : 132 – 135 Deg.C. Pressure : 2 bar (g) (at granulator header) Concentration : 96%±0.5%(at granulator header)Atomization Air: temperature : 135 Deg.C. Pressure : 0.45 bar (g) (at granulator header) Flow rate : 66240 kg/h dry airFluidization air: temperature : around 52 Deg.C at granulator inlet Pressure : around 700 mmWC (after dampers) Flow rate : 389124 kg/h dry airFluid bed: temperature : 104°-108°C in granulator chambers height : around 1.0 m respectively 500-600 WC gRecycle solution: concentration : approx..45% urea Temperature : around 40°-50°CSolids temperature :granulator outlet : 95°C First fluid bed cooler outlet : 70°C Final fluid bed cooler outlet : 45°C

The Solids Recycle circuitThe granulated product is extracted from the gran-

ulator by two parallel operated H-150A/B vibrating extractors, which are followed by the S-150A/B safe-ty screens. The latter gauzes retain agglomerates or lumps larger than 10 mm for standard size production. Those lumps are directed to recycle tank T-153.

Having passed the safety screen, the urea granules fall down in to the L-151 First Fluid Bed Cooler and thereafter are taken up to the screening section by two parallel operated H-151 A/B Bucket elevators/

At each elevator discharge the granul stream is split in to two and directed to two parallel operat-ed screens S-151 A/B & S-151 C/D respectively, in which the fractionating of granules occurs. Either screen can be bypassed using the splitter valve.

Proper distribution of the product over the two screen inlets is catered by feeders H-157 A/B & H-157 C/D respectively.

Three fractions are separated:a) . The on-size (end product)Under normal operating conditions the on-

size material flows via diverter box H-156 A/B to Final Fluid Bed CoolerL-159.

Furthermore, it can be redirected to either the prouct belt conveyor, the start-up bin or the granulator itself.

b) The undersize(fines)Under normal operating conditions, the

fines flow back in to the granulator via di-verter box.

The flow can also be diverted to the start-up bin or to the dissolution tank.

c) The oversize fraction is normally sent to the roll crushers Z150 A/B before feeding it back to the granulator as seed material.

VIBRATING SCREENS INSTALLED IN OMIFCO PROJECT FOR SEPARATION OF FRACTIONS OF UREA GRANULES

Product Screening Machine Model : 90 HVSM2Make: CHAUVINDimensions per deck : 2000X4000No. of Decks : 2Screening area per deck : 32 m2Total weight when empty : 8800 kgWeight of vibrating body : 4400 kgSlope : 6°No. of screening machines installed per granulator : 4Capacity of each screening machine : 40 t/hSpare screening machine available : NoMOTION CHARACTERISTICSAcceleration :2 gSpeed :200 rpm

CHAUVIN Screen in OMIFCOProblems facing with the CHAUVIN make

screens in OMIFCO:These product screening machines have been run-

Issue 73 31

Studies & Research ning since commissioning ie. from Aug.2005 with frequent breakdowns. •Suspension cables • Stabilizing rods • LHS & RHS cradle beams • Gear box bearings(each gear box consisting of 7 bearings) •Top bearing •Repair/replacement of screen mesh is tough •Wiremesh life is hardly one year • Declogging balls life is around one yearThe very frequent failures of the above parts made maintenance team their life miserable and most of the cases down time of screen failure used to be 10-12 hrs. As there is no spare screening machine avail-able the granulator loads had to bring down to 25%.To eradicate this huge maintenance on CHAUVIN screens, OMIFCO started checking for suitable, less maintenance and more reliable screening machines in the market which have been proven in Urea Granulators.To select the suitable screening machines, the follow-ing bench marks were set in selection of machines. • No Gear box • No ropes • No couplings • Higher Capacity ( each screen capacity=3 times to CHAUVIN screen) •Replacement of screen mesh shall be easy •Weight of the screen shall not be more than 10 TOMIFCO team has visited different fertiliser units in Europe and Canada and found the following Vibrat-ing screening machine suitable for our Granulators.

OMIFCO has purchased 2 nos. Rotex Megatex XD-5300 screening machines with the following techni-cal specifications and installed one in each Granula-tor replacing the existing CHAUVIN Screen.

Technical Specifications of Rotex Megatex ScreensModel: Megatex –XD-5300-2Make: Rotex, EuropeNo.of Decks : 2 DeckScreening area of each deck : 28 m2Capacity of the screening machine: 2300 (final product)Screen frame size: 1219 X 2286 mmNo.of screen frames per screen: 20 Nos.Weight of the screen: 8210 KgSpeed of the drive mechanism: 1000 rpmPower: 15 KWROTEX MEGATEX XD-5300-2 Machine installed in OMIFCO

The above screening machines have been running since more than 5 years and their performance is excellent.

ROTEX MOTION – Why it is effective?Gyratory motion at inlet end: quickly spreads & strat-ifies the materialElliptical motion at centre section: provides gentle conveyingLinear motion at discharge end : for effective near size separationWe have achieved the following benefits from the in-stalled Rotex Megatex screens. • Higher capacity and now spare screen is available • Screen cleaning frequency is 40-50 days • Life of screen mesh is more than 2 Years • Life of PU balls is more than 2 Years • No major failures experienced • Highest reliability achieved

Issue 7332

منظمـة عـربـيـة دولـيـة

11–13 October, 2016 Tunis

29 AFA Int’l. 29 AFA Int’l. th

Conference & ExhibitionConference & ExhibitionFertilizer TechnologyFertilizer Technology

In collaboration with AFA Tunisian Member companies, the Arab Fertilizers Association (AFA) is pleased to invite you to participate to the 29th AFA International Fertilizer Technology Conference & Exhibition which will take place in Tunis during the period: 11 – 13 October, 2016.

The event o�ers the chance to network over 3 days with the industry’s most senior executives from across the world and provides the ideal international forum for operations personnel to meet with industry experts, share experiences and exchange best practices.

Even more, the conference assist in learning about the latest technological and process advancements, technical innovations and new equipment and materials that enable stakeholders to meet the challenges of maintaining and improving plant operations and develop practical solutions to operational problems, through detailed case studies.

Sponsored By:

Studies & Research

Helium Leak Detection in High Pressure Urea Reactor Ali Al Siyabi & Ankit Niranjan

HLD_PressurePfeiffer_Asm_310_Leak_Detector

Oman India Fertilizer Company

Oman India Fertilizer Company was commissioned in April 2005. The performance in the first ten com-mercial years of operation has been very good and the entire envisaged project target has been accom-plished.This paper discusses high pressure reactor liner leakage issue in Urea-I unit. Leakage location could not traced by conventional methods until OMIFCO strove for helium leak detection.

INTRODUCTION: OMAN INDIA FERTILISER COMPANY S.A.O.C (OMIFCO) was set up as a joint venture project under the initiative of Government of Sultanate of Oman and Gov-ernment of India. OMIFCO is owned 50% by Oman Oil Company, 25% by Indian Farmers Fertilizer Co-Operative Ltd (IFFCO) and 25% by Krishak Bharati Co-Operative Ltd (KRIBHCO). OMIFCO was registered in the Sultan-ate of Oman as a closed joint stock company in the year 2000. The Ammonia Urea complex comprises two trains, each with a design capacity of 1750 MTPD Ammonia and 2530 MTPD granulated Urea, along with all sup-porting Utilities. It is designed to produce 1.65 mil-lion tones of granulated Urea and 0.25 million tones of surplus liquid ammonia annually for export, using natural gas as the raw material. Storage facilities for Urea (2X 75000 MT) and Ammonia (2X30000 MT) as well as jetty with ship loaders are part of the proj-ect. The complex has two service Boilers of capacity 2 X 70 MT/hr and two HRSG boilers of capacity 2X 110 MT/hr. Also the complex has its own captive power plant with two 30 MW Frame 6B Gas turbine Generators and import power connectivity with the national grid for backup power.

DESCRIPTION OF THE SYSTEM: OMIFCO owns and operates two Urea Plants designed by M/S SAIPEM, Italy (Previously Snamprogetti). The Urea manufacturing technology used at OMIFCO is based on the Ammonia Stripping Process.As per the process steps involved for producing Urea, feed Ammonia is fed to the reactor at elevated pres-sure. In the Urea plant the liquid Ammonia at about 15!.C (59!.F) and 23.5 Bar G (340.84 psig) pressure is initially received in an Ammonia receiver (V-105). Later by using an Ammonia booster pump (P-105-A/B), liquid Ammonia is pumped to the suction of the high pressure Ammonia feed pumps (P-101-A/B). The high pressure feed Ammonia pump transfers liq-uid ammonia to the Urea reactor through an ejector

where the liquid Ammonia acts as a propellant for the high pressure Ammonium carbamate solution. CO2 gas from compressor discharge at 158 bar and at 104!C temp enters into the Reactor.(Figure-02) Fig. 2: (Urea HP Process Diagram) INCIDENT SCENARIO OF HP REACTOR LEAKGE: In Urea-11 unit during the plant shutdown inspection

on 9th May 2014, a crystallized urea product is observed at the end of weep hole No.-56. This was the clear sign of leakage of the liner in progress during the operation of the plant. Also the same is confirmed by the lab reports. It was decided to as-certain the leakage location. No in-dication noticed on C-seam, L-seam & cleat joints by visual inspection & D.P.Testing corresponding to weep holes. (#55, 56, 23 & 24)

Fig. 1: (OMIFCO Image) Issue 7334

REACTOR DETAILS: Make: L&T Design Code: AD-MERKBLATT 2000 Design Pressure: 167 Kg/cm2 Design Temp: 218 o C Operating Pr: 152 kg/cm2 Operating Temp: 188 o C Hydro test Pr: 238.91 Kg/cm2 Corrosion Allowance: Nil (5 mm thk liner) Radiography: Full Empty weight: 230650 Kg PWHT: Yes Shell Material: SA533 Gr. B Cl2 Shell Head (Top/Bottom): SA537 Cl2 Liner/Internals/Trays Material: SA240 Gr.316L MOD Internal Bolting: 25.22.2 INVESTIGATION AND OBSERVATIONS: Since the leakage was not traced by the visual inspec-

tion and dye penetrant testing, it was decided to per-form conventional leakage detection test such as Soap solution test & Ammonia vapor leak test. Therefore the passage connection these weep holes were cleaned us-ing steam from outside & subsequently by LW.

CONVENTIONAL TESTING’S: First of all soap solution test was performed. In this

test, air at 0.5 Kg/cm2 g pressurized through weep hole no. 55 & 56. Weep hole no. 23 & 24 kept plugged. No time given as soaking period. Soap solution was applied on inner surface of the liner. No leakage indication ob-served.

Further it was decided to perform ammonia vapor leak test as recommended by Saipem. In this test, ammonia at 0.5 Kg/cm2 g pressure is injected through weep hole no. 55 & 56. Weep hole no. 23 & 24 kept plugged. 6 hrs soaking time is given. Paper wetted in phenolphthalein solution was envel-oped on the inner surface of liner. But no change in color is noticed.

Suspected Reason for No Detection may be low Test Pressure and Restriction in Air Flow

After getting gloomy results by above two tests, it was decided to start up the plant, but unfortunately

leakage observed again from the same place (weep hole no. # 56). For few days plant was kept running in this condition. But after few days of plant running it is decided to stop the plant to pinpoint the leakage. Soap solution test & ammonia vapor leak test were performed again using same procedure but no posi-tive indication came.

Now it is decided to perform helium leak testing. A vendor was called against the existing contract. On 10th Aug; Helium leak detection was performed.

HELIUM LEAK DETECTION: Description Helium Leak detection is based on mass spectrom-

etry technique employing mass spectrometer sensi-tive to helium gas. It is commonly referred as Mass Spectrometer Leak Detector (MSLD). It is used to locate and measure the size of leaks into or out of a system or containing device. In this testing helium is used as tracer gas, and is introduced to a test part that is connected to the leak detector. The helium leaking

through the test part enters in the helium leak detector. The amount of the helium is directly proportional to the leak rate of the part. The partial pressure of helium is measured by the leak detector and the measured value is converted to display the leak rate of the part. Presence of helium is detected by MSLD. Depending on the test methods, qualitative or quantitative information about leak and leakage rate is determined. Helium is the best choice of tracer gas to find leaks for number of reasons. It is non-toxic, inert, non-condensable, non-flammable and not normally present in the atmosphere (< 5 ppm). Helium is the smallest molecule which is inert. Due to its small atomic size, helium passes easily through leaks.

COMMON METHODS OF HELIUM LEAK TESTING:

Mainly there are two methods to leak test parts using helium: Vacuum Testing (outside-in) and Pressure Test-ing (sniffer technique). The detection method should be selected based on the working conditions of the part to be tested. It is important to maintain the same pressure conditions during the test as they will exist during the actual use of the part. Vacuum systems should be tested with a vacuum inside the chamber. A compressed air cylinder should be tested with high pressure inside the cylinder.

Vacuum Testing (Outside-in) In vacuum testing, the part is evacuated with a

separate pumping system for larger volumes, or by detector itself for smaller volumes. To locate a leak, helium is sprayed to the suspected leak sites of the part using a spray probe with an adjustable flow.

Fig. 3: (Leakage through Weephole)

Issue 73 35

Studies & Research Pressure Testing (Inside-out/Sniffer method) In Pressure Testing, the part is pressurized with helium

or a mixture of helium and air. To Locate a Leak, the potential leak sites of the part are scanned using a Sniffer Probe connected to the inlet of the leak detector.

PROCEDURE USED IN REACTOR: It was decided to perform helium leak detection us-

ing Sniffer probe method. Suspected area circumfer-ential seam # 7, 8, interconnecting long seam & cleat joints are masked with polythene sheet divided into a number of segment and edge of polythene sheet is sealed with suitable tape. This polythene envelope over leak susceptible area segment acted as a reser-voir for accumulating leaking helium. Thus helium concentration in the envelope would increase with holding period and probability of detection of

minute leakages is increased. Instrument air is in-jected to dry the annular space then Helium was in-stilled through weep hole no. # 55 & 56 (weep hole no. # 23 & 24 kept plugged).

The annular space between inner lining and shell is pressurized with helium gas. Pressure is maintained around 0.5 Kg/Cm2 g. Since gas/air is already present in the annular space, concentration of helium gas re-duces in the annular space. Four hour holding time was given. Presence of any helium under polythene sheet was checked by inserting tip of detector probe. Leak-age is identified by Helium test in the 8th tray’s circum-ferential liner weld joint. It was observed in the upper side wall of the weld approximately at 240 ! (Referred 0! from the internal overflow pipe clockwise).

REPAIR & REHABILITATION: The suspected area (approx 150 mm weld length) was

grinded and the area is checked by DP Testing which revealed a defect indication. It was arrested by welding and followed by DP test for root and final run. Repaired portion was checked with detector probe and no further indication was observed by Helium Leak testing.

CONCLUSION: It was the first incidence of any HP vessel liner

leakage in OMIFCO history. Conventional testing’s were failed to identify the

leakage location. This was the first time when any company in Mid-

dle East & India region used Helium leak detection for detecting such type of leakage.

Repair & recommendation procedure followed as per Saipem recommendation.

After OMIFCO experience, few companies in In-dia tried helium leak testing for detecting such type of leakage and thrived.

OMIFCO used helium leak detection used again successfully in June, 2015 for detection of liner leak-age in HP Carbamate Condenser.

OMIFCO is planning to buy above instrument in year 2016.

Figs. 4&Fig 05: (Testing Machine)

Fig. 6: (Liner Weld Area)

Figs 7 & 8: (Test in Progress) & (Polythene sheet masked by sheet)

Figs. 9 & 10: (Leakage Area) & (Pinpoint Location)

Figs.11 & 12: (Repaired area) &( Repaired Weld)

Issue 7336

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