•lOlRN ̂ L OF SCIENCE & TKCHNOLOGY 4 No 87 2012 GREENHOUSE GAS INVENTORY AND REFERENCE EMISSION LEVELS DETERMINATION FOR FERTILIZER SECTOR IN VIETNAM KlfeM KE KHi NHA KINH VA XAC DINH MUC PHAT THAI CO[.]
Trang 1GREENHOUSE GAS INVENTORY AND REFERENCE EMISSION LEVELS DETERMINATION FOR FERTILIZER SECTOR IN VIETNAM
KlfeM KE KHi NHA KINH VA XAC DINH MUC PHAT THAI CO S6
CHO NGANH SAN XUAT PHAN BON VII^T NAM
Vu Thi Minh Tliu Nguyen Thf Anh Tuyet
Vietnam Institute of Industrial Chemistry Hanoi University of Science and Technology
Received February 29.2012; accepted April 26, 2012
ABSTRACT
Fertilizer pmduction is becoming an intensive industry In Vietnam, meaning that greenhouse gases (GHG) emission of the sector will increase and contribute a significant proportion to a national GHG emission total Among domestic fertilizer types, nitmgenous fertilizer and DAP are most output-intensive production as well as COz-output-intensive emissions This paper determines total GHG amount as well as reference emission levels of fertilizer pmduction in Vietnam The study focuses on two intensive energy pmducts, those are urea (related to the NHj production) and DAP (related to the referred for developing strategic that objectives to mitigate the impacts of climate change and towards
a low carbon economy in service of sustainable development
TOM TAT
Sdn xuit phdn bdn dang tr& thdnh ngdnh cdng nghidp trong diim tai Vidt Nam diiu dd din t&i phdt thdi khi nhd kinh (KNK) cua ngdnh sd tdng vd gdp ty 1$ ddng ke trong tdng phdt thdi KNK qu6c gia Trong s6 cdc /o?/ phdn bdn dugc sdn xuit tat Vidt Nam, hai loai sin phim chidm ty trqng l&n nhit ding th&i cQng gdy phdt thdi CO2 l&n nhit Id phdn dam va DAP Bai bdo ndy xdc djnh phdt thdi KNK cho ngdnh sdn xuit phdn bdn Vi$t Nam t$p trung v^o 2 loai hinh tidu thu ndng luang vd phdt (lien quan t&i sdn xuit axit photphoric) Tren ca sa dd ddnh gid sa bd vi hidu qua sir di^ng nang luang cung nhu mirc phdt thdi ca sa cda ngdnh Ket qud co the duac sir dung true tiep eho cdng tdc kiim kd KNK qudc gia, ddng th&i Idm ca s& cho vide xdy dung cdc muc tidu chiin luoc nhdm gidm nhe tde
1 INTRODUCTION Up to 2010, there were about 400
fertilizer production plants in Vietnam According to the World Meteorological produced 6.6 million tons (Mt) of product Organization (WMO), the increasing rate of outputs include 4 types - N (urea), DAP, P greenhouse gases (GHG) concentration has (phosphate), and NPK [3] At the moment, reached a peak in 2010, of which the major more than 80% of this output total was contribution is CO2 Among industrial sectors, produced by 5 largest plants, among which two Ihe nitrogenous fertilizer production is one of nitrogenous fertilizer plants supply 100 % most intensive energy and GHG emission domestic urea demand According to the sectors Even though specific energy Vietnam Fertilizer Association (VFA) by the
end of 2012, the domestic production will reach consumption of Ihe modem nitrogenous
fertilizer plants is much reduced compared to 7.25 million tons include 2 million tons of urea ,2 million tons of phosphate 330.000 tons of the 60s-teehnology plants (28 GJ/ton of NH3 ^^p^ a^j 35 j^jnjon tons of \PK In the 2012 compared to 60 GJ/ton of NHj, respectively) 2015 period 1.5 million tons of urea will be
ni, energy use in fertilizer industry still added by neu and expansion projects occupies about 1.2% of the world energs p^^,„^^^ production ha al»ays been consumption More than 90% of this energy is considered as the most intensive energy and
Trang 2producing NHj, producing HjP04 and
producing HNOj (IFA) Tlie average specific
energy consumption in nitrogenous fertilizer
production in the world is about 41 GJ/ion of
NHj [4] In Vietnam, paralell with the
developing trend of domestic fertilizer
production (in which production of urea,
phosphate and DAP will occupy about 65%,
18% and 10% respectively), GHG emissions
from the sector will increase significantly In
order to contribute to the national GHGs
inventory mission, this paper determines total
GHG amount as well as s base emission line of
fertilizer production in Vietnam The study
focuses on two intensive energy products, those
are urea (related to the NH, production) and DAP (related to the HjPO* production)
2 RESEARCH METHODS 2.1 Determining GHG emiwions in nitrogenous rciiilizcr produclion
Vietnam has 2 urea fertiiizer plants -those arc HaBac Nitrogenous Fertiiizer and Chemical Ltd Company (HANiCHEMCO) and Phu My Fertilizer Piani (PFP) They use different NHj-synthesIs leclmologies: HANICHEMCO applies China coal-based gasification technology (Fig 1) and PFP applies auto-thermal reforming technolt^ using natural gas (Fig.2) These produclion processes gcneftte COj
Fig I Coal-based NH3 produclion process
(CCS: Carbon Capture and Storage;
ASU: Air Separation Unit)
In principle, total CO: emissions of the
sector can be delermined by aggregating CO^
emissions from fertilizer plants In order to
determine CO: from plants, conventional
method is material balance This method
requires extremely detail input data which are
of the national GHG inventory programme, the
IPCC guidelines have been used for
determining total GHG emissions from
numbers of sectors such as electricity, and
cement production For nitrogenous fertilizer
production IPCC 2006 introduced three GHG
The formulations are as follows [5]:
Tier I •
Eco2 = AP • FR ' CCF * COF * 44/12 - R^QJ
where: E^-oj = CO, emissions kg: AP -• NIU
production, ion: FR = fuel requirement per unit
of output GJ/ton of Ml produced; CCF =
carbon content factor of the fuel, kg CO./ ;
'-IPI 181
Fig 2 Natural gas-based NH, prod Process
(SMR: Steam Methane Reformer)
Rco,=CO, recovered for downstream use (for produclion of urea CO' liquid and C0-> solid)
Tier 2 TFR,= 5:(AP„ • FR„)
E ^ i (TFR • c c r • COF • 44 12) - R^Q,
where TFR, = total fuel requirement for fuel i, GJ; AP,j = NH- production using fuel i in process y, tons; FR,^ = fuel requirement per unit
of output for fuel 1 in process j GJ/ton SHj produced
Tier 3 TFR, = V TFR,„
E , „ , = :L(TFR, • CCF* COF'44 12)-R<-o:
where TFR, = total fuel requirement for fuel/, GJ; TFR,,, = total fuel requirement for fuel i used by plant n GJ
2.2 Determining GHG emissions in DAP fertilizer production
Vietnam has only one DAP plant - that is
Trang 3DAP Vinachem Company Limited (DAPCo)
The company applies modem technology using
primary source of apatite ore (phosphate rock)
The main stage of DAP process is
manufacturing phosphoric acid (Fig 3), that
generates COi
Fig 3 H}P04 produclion process
Phosphoric acid produclion is not
addressed by the 2006 IPCC guidelines, but the
Inventory of U.S, Greenhouse Gas Emissions
and Sinks provides a method for estimating
process related C02 emissions from phosphoric
acid production Based on that, we can estimate
the emissions from Ihe production of DAP
The wet process - the phosphate rock
reacts with concentrated H,S04 to produce
H3PO4:
Ca3(P0Jj + 3 H,SO^ = 2 H;PO^ + 3 CaSO,
CO2 is emitted when the limestone
component (CaC03) of phosphate rock reacts
with the sulfiiric acid (H2SO4) [6] The
following reaction summarizes the emission
process:
CaCO ^ H3SO, + up = CaSO, 2H,0 - CO,
Process emissions were calculated by
multiplying a defeuh factor for inorganic
carbon content within phosphate rock by the
amount of phosphate rock used to produce
phosphoric acid There are three options as
follows [6]:
Qei/OTti simplified emission calculations:
Efoi = AD * EF
where- E^^^^ = CO, = process emissions of CO,;
AD = phosphate rock consumption; EF =
regional chemical composition factor of
phosphate rock
Q&ion 2 hybrid method, based on each
quantity of phosphate rock and the percentage
of inorganic carbon:
t r i 2 ^ "' 2205
where: Em = annual CO2 mass emissions from
a wet-process HjPO: process line m (metric tons); 44/12 = ratio of molecular weights, CO2
to carbon; ICn = inorganic carbon content of
the batch of phosphate rock used during month
n (percent by weight, expressed as a decimal fraction); Pn = mass of phosphate rock
consumed in month n by wel-process HjP04
process line m (tons); m = each wet-process
HjPO.i process line; z = number of months during which the process line m operates; 2000/2205 = conversion fector to convert Ions
to metric tons
Option 3 - by using Continuous Emission
Monitoring System (CEMS), GHG emissions contained within a stack or vent is directly measured Because of very high installing and operating costs of CEMS, there is not any fertilizer plant in Vietnam installed this system
3 RES EACH RESULTS 3.1 Sources of data Information and data related to fuels, materials and products of fertilizer plants are collected using questionnaires undersigned by the Vietnam National Chemical Group [7] and collected data (AP, Rcoz AD ) for nitrogenous fertilizer plants and DAP plants in Vietnam 3.2 Results and discussion
Based on total output of NHj produced in
plant (I) and plant (2), total equivalent CO2
(COieq.) emissions can be calculated using Tier
I However, due lo the difTerenliations in technological characteristics and material types between these two plants Tier 2 should be applied separately for each plant Tier 3 can not
be used in this study because of the lack of country-specific factor In the case of plant (3)
Trang 4Table I ColUcUtI data for uisa <S DAP plants Table I Calculation factors for COt tnvitiilory
( D - H A N I C H K M C O
M a i n
produclh
(limvi)
K a w
NM,
urea
l i q u i d
solid
C O
-a-;il
motcriuls i 4H
(KinyrI t,,.,]
N H ,
120.566
144.182
29,363
~w5.nn
.1111.706
1 sn.'i'^ 1
141
i i ' i t i ' ;
116,867 139.449 2«.033
" 5 5 3 0 2 7 "
271.74H
|.l').(.2(l
364 111,27*
113,200 143.879 30.339 5771)00
^'ihlh 1
1.17.IHS 11,'noil
M a i n
pri'iliicts
lion Mi
j M-ilcriaK
M l ,
urea
r
! nalural
' t;.is
1 M i ,
461.900
553.667
515.298
427.S33
488.300 591.873 540.217 457.357
469.509 5RH.')31 5l'i,'12K r><) 7S7
products H j P U i
5fi,4fil i
26.377 '
04 :,S7
J 5 ( \ l ' ) ( l _ 75.139 r,7 402.287 ,
COicq emissions because of limited data
sources Table 2 summarizes calculation
factors for CO^ inventory and table 3 presents
results calculaled in different choices
As shown in the results of plants ( I ) and
(2) there is a difference of about 2 0 % between
two calculation choices Obviously, if wc can
apply Tier 2 we can get belter results C O '
emission of plant (3) keeps doubling increase
year by year since the plant has started its
operation at the end of 2008 The plant's
produclion output is gradually stabilizing,
meaning that its emission is expected around
280.000 tons every year
4 CONC l l S l O N
The paper determines total GHG amounl
as well as reference emission levels fertilizer
Plant
TItrl
C S I I I |!|
FR
iQJ/ton)
42.5 53.0 37,5
Djiliim 1
CCF
tinC/OJ)
21.0 25.8
COF
1
1
EF
—r-0.672
Table 3 GHG emission of urea & DAP plants (choice 2) - Unit: thousand tons COjcq
Plml 1 (1) 1 (2) 1 (3) 1 T«ri
•tier I for total 11)^121: Option lfor(3)
20119
2010
2011
2.955.101 3.081.350 2.955.361
70.01
144 66
28112
3.025.182
3.226.009 3.237,184
Tier 2 for separate lt)A 12) Option I for (3)
2009
2010
2011
1.007.507 975.828
964 J 4 0
1.318.109 l,397JSI 1.323.938
70 08
144 66
28182
2.395.698 2.518.039 2.570.101
Table •/
(Unit: liu REis of urea and DAP produclion UMi'hl tons ('<)_• 11/ Ion ofproduci)
IMiint f h i n t
Tier 1
A v e r a g e of , ( l ) * ( 2 ) !
2 M
Plant i
1.24 0.93
1 20
l->HKfui.inMi in Viemam to^uMni: on two mlciiMM- CIK'IL;\ piodiicl- lliosc arc urea (related lo the M h produclion) and DAP (related to the H ; P ( ) | production)
For « h o l e sector, it is estimated that total GHG emission of fertilizer production in Vietnam has a significant contribution to total CiHG emissions from industrial production in will not only slabili/e at this level but continues
to grow rapidly (increase twice, up to Ilie end
2015, increase three times, up to the early 2020) when new and expansion fertilizer production projecis operated
Furthermore COicq, emission per ton of product so-called reference emission levels (RELs) for fertilizer production in Vietnam are
Trang 5It is seen that REL of plan (1) is much larger
than REL of plant (2) - this reflects the
difference in production technology as well as
raw material used between two plants (Fig, 1
and 2) In general, RELs of Vietnam
coal-based nitrogenous fertilizer plant are still high
If we average values of specific GHG emission
in 2009, 2010 and 2011, the REL of
HANICHEMCO is 4.26 tons of COjeq per ton
of NH3 which is slightly higher than the REL of
Chinese corresponding plants (3.9 Ions COjcq
per ton of NH3) Because the production line of
HANICHEMCO was installed
ineomprehensively efficiency of using raw
materials and fuel energy of the plant is now
under designed Similarly, if we average values
of specific GHG emission in 2009, 2010 and
2011, the REL of DAPCo is 1.12 tons of
COjcq per ton of HjP04 which is also higher
than the REL of USA phosphoric acid
production (I.O tonof C02eq per ton of HjPO^)
[8] In the ease of PFP the company has
installed a CO2 recovering system using
KM-CRD technology (by Mitsubishi Japan) in order
to recover CO2 exhausted from reforming processes - this can mitigate about 240 tons of smaller than the corresponding number of the world (2.9 tons COjeq./Ion of NH3) [9] The study findings can be directly used for national GHGs inventory mission and indirectiy referred for developing strategic that objectives to mitigate the impacts of climate change and towards a low carbon economy in service of sustainable development Due to high REL of coal-based nitrogenous fertilizer production, energy efficiency solutions such as (before gasification step), CO2 recovering must
be considered in Vietnam
Acknowledgements The work presented in this paper is a part
of the 2012 Project sponsored Ministry of Industry and Trade
REFERENCES Chaudhary, T.R., 2001: Technological measures of improving productivity: Opportunities and constraints Presented at the Fertilizer Association of India Seminar "Fertiliser and Agriculture Future Directions," New Delhi, India 6-8/12/ 2001
Swaminathan, B and K.E Sukalae, 2004: Technology transfer and mitigation of climate change: The fertilizer industry perspective Presented at the IPCC Expert Meeting on Industrial Technology Development, Transfer and Diffusion, Tokyo, Japan, 21-23/9/2004
Ministry of Agriculture and Rural Development February Report 2011
UNIDO Global Industrial Energy Efficiency Benchmarking 11/2010
IPCC (2006) 2006 IPCC Guidelines for National Greenhouse Gas Inventories The National Greenhouse Gas Inventories Programme The Intergovernmental Panel on Climate Change, H.S Eggleslon, L Buenida, K Miwa, T Ngara, and K Tanabe (eds.) Hayama, Kanagawa, Japan U.S Environmental Protection Agency Technical Support Document for the Phosphoric Acid Production Sector: Proposed Rule for Mandatory Reporting of Greenhouse Gases 20/2/2009 Vietnam National Chemical Group Questionnaire collecting information, 2/2012
U.S Environmental Protection Agency Inventory of U.S Greenhouse gas emissions and sinks: 1990-2009 15/4/201!
The Worid Bank (WB) Energy Intensive Sectors of the Indian Economy Intensive Sectors, 11/2011
Author's address: Nguyen Thi Anh Tuyet - Tel (+84)904.861.412
Email: tuyetnta-inest@maiI.hut.edu.vn
Hanoi University of Science and Technology
No 1 Dai Co Viet Str., Ha Noi Viet Nam