dblue production
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insightbeyondnumbers
Diesel Emissions Conference& AdBlue® Forum Asia 2010
2010 AdBlue®
March 23 - 25, 2010. Westin Hotel, Beijing, China
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Measuring AdBlue® quality and understanding
requirements of AdBlue® infrastructure
Östen Andersson, Director Technical Support & HESQEnvironmental & Speciality Products
Diesel Emissions Conference & AdBlue Forum Asia 2010
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1. Short Introduction
2. Where does the contaminationrisk lie in the AdBlue supplychain
3. Anti-Contamination RiskMeasures Taken in
AdBlue production Bulk Logistics Filling of IBCs, Cans and
Drums Dispensing Equipment
4. VDA Quality Audit Programme
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1. Yara’s AdBlue solution : Air1
The leading AdBlue producer in the
world
We offer a complete solution to meet the
fleet operators, OEMs and oil majors
individual requirements under the brand Air1 around the world, covering:
– Reagent under the name AdBlue or
DEF
– Storage and handling equipment, ofdifferent sizes
– Telemetry and services
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4 Yara Production Plants centrallylocated for the core markets
Germany (Brunsbüttel)
The Netherlands (Sluiskil)
France (Le Havre)
Italy (Ferrara)
Unique back-up position and“safe harbor” for product
availability
Strategic Air1 locations for localclient needs, including dedicatedterminals
Over 120 distribution depotsacross Europe
1. Yara is the world’s largest AdBlue producer
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1. Joint Venture between Yara and
Sinofert – Purico in China
Yara and Sinofert formed a joint venture, Purico, to provide
DeNOx solutions, including AdBlue, in China.
Based in Qingdao, Purico will spearhead Air1 marketing in
China.
Purico aims to be the leading AdBlue solution provider in China
through Air1 concept.
Yara’s experience,
know-how &
expertise in Europe
Sinofert’s production
capacity & distribution
network in China
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1. Sinofert – a strong partner
Major businesses include the production, import, export,
distribution, wholesale and retail of fertilizer raw materials and
products, as well as research and development and services in
the field of fertilizer-related business and products.
With 2010 distribution centers spanning across 26 provinces,
Sinofert is the largest integrated supplier of fertilizers in China.
Sales volume 16 mill mt, Sinofert owned stakes in 13 fertilizer
manufacturers with a total capacity of 10 million tonnes, of which
more than 2.5 million tons are urea.
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2. Multiple Contamination Risks in the AdBlue
supply infrastructure
AdBlue
productionPlant & Storage
Transport
Truck
Rail
Ship
Storage
Terminal
Intermediate
Storage
Land
Transport
Land
Transport
Road
Transport
Road
Transport
Road
Transport
Storage at
Customer
site
Filling of IBC,Drums & Cans
Customer
Possible Contamination Risk
X
X
X
X
X
X
X
X
X
X
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3.1 Anti- ContaminationMeasures in AdBlue
ProductionPrimary production fromUrea Hot melt
Secondary production bydissolving of solid Urea
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Static Mixer
Cooling Filtration(Optional)
Storage TankStorage Tank
Demineralised Water
Urea Hot melt
Loading PumpLoading station
Batch Control Batch Control
3.1 Principal Drawing AdBlue Production from
Urea Hot Melt
Quality ControlConductivity
Quality ControlExample:
ConcentrationPressureTemperatureFree Ammonia
Quality Control
DensityTemperature
Closed system
In principal nocontamination risk
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Yara’s Urea Plant, Brunsbüttel, Germany
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3.1 There is low risk of contamination with
AdBlue produced from Urea Hot melt
Main contamination risks
– Unstable Urea production
Control Measures
– Control of process
parameters
– Stop of AdBlue production
at unstable conditions
– Batch analysis
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Quality ControlConductivity
3.2 AdBlue Production from Urea Prills,
Dissolving increases the risk of contamination
UreaBig Bags1 000 kg
Hopper
Mixer
StorageTankAdBlue
StorageTankAdBlue
Transfer pump
Filter
Filter
Transfer pump
LoadingPump
LoadingStation
StorageTankDemin.Water
DemineralisedWater Production
BatchControl
BatchControl
ScrewConveyor
Control SystemConcentrationTemperature
BatchControl
X
X
X
XX
Possible Contamination Risk
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Dissolving, Mixers and Hopper
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Dissolving; Storage of Urea Big Bags and IBC
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3.2 Multiple contamination risks for AdBlue
produced from Dissolving of solid Urea
Main contamination risks
– Solid Urea quality
– Demineralised water quality
– Not dedicated equipment
– Cross contamination with
other products or ambient
conditions
Control Measures
– Incoming control of solid
Urea
– On line control of water
quality
– Control of process
parameters
– Dedicated equipment
– Batch analysis – Routines to handle off spec.
product
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3.3. AntiContamination
Measures for BulkLogistics
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3.3 AdBlue Tanks and Loading area for Trucks
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3.3 Ship loading Tank and loading area
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3.3 Loading and unloading of AdBlue is an area
with potential risks of contamination
Main contamination risks
– Not dedicated transport
vehicles
– Not dedicated transfer
equipment
– Materials in contact with
AdBlue not compatible
– Open handling of AdBlue
Control Measures
– Dedicated transport
vehicles
– Inspection before loading
and unloading
– If not dedicated, a certificate
of cleaning is mandatory
including information about
3 last products
– Inspection after loading
– Retention samples
– Sealing of all openings
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3.4 Anti ContaminationMeasures for Filling of
IBC, Drums and Cans
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3.4 Types of Packaged Product
IBC,1000 liter
Drum, 200 liter
Can, 5-10-20 liter
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3.4 Filling of IBC, Drums and Cans hold also
contamination risks
Main contamination risks
– Not dedicated filling
equipment
– Materials in contact with
AdBlue not compatible
– Returned IBC – Not cleaned
– Reconditioned
– Mix with off-spec product
– Mix with wrong product
– Filled in “uncontrolled conditions”
– Emptying with dirty equipment
Control Measures
– Dedicated filling equipment
– Drums and Cans always
one way package
– Closed IBC with CDS or
Micro Matric coupling and
dip tube
– Inspection procedures for
returned IBC
– Sealing of openings after
filling
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3.5 Anti ContaminationMeasures for
Dispensing Equipment
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3.5 Examples of IBC and Drum pumps
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3.5 Pumps for IBC and Drums risks of
contamination
Main contamination risks
– Not dedicated equipment
– also used for other liquids
– Materials in contact with
AdBlue not compatible
– Wrong handling by operator
– Filling in wrong truck tank
Control Measures
– Dedicated equipment
– Equipment designed for
AdBlue use
– Closed IBC with CDS or
MicroMatic coupling and dip
tube
– Warning signs, pictograms
– Operating manuals – Training of operators
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3.5 Examples of Customer Dispensing equipment
Dry Break Fillingconnection
http://www.blue1.be/en/commercial_pump_installations.htm
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3.5 Risks for Dispensing Equipment at
Customer sites
Main contamination risks
– Materials in contact with
AdBlue not compatible
– Contamination during filling
– Wrong handling by operator
– Filling in wrong truck tank
Control Measures
– Equipment designed for
AdBlue use
– Magnetic Filling nozzle
– Dry Break Filling coupling
– Warning signs, pictograms
– Operating manuals
– Training of operators
– Regular Maintenance
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4. What is the VDA Audit Programme?
Verband der Automobileindustrie e.V. (VDA) is the owner of the name
AdBlue® and to use the name you need a license
VDA has together with the main AdBlue producers and distributors in
Europe developed an Audit Programme
Minimum requirements on Management Systems
in AdBlue® production and distribution chain,following the ISO standards 22241, part 1 – 3
The audits has just started in Europe and Yara is one of the first licensees
that has been audited
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4. The VDA Audit Programme
The Audit Programme are divided in 7 sections
– Basic Requirements
– Production process
– Production equipment – Sampling and testing
– Documentation of test results and certification
– Administration, tracking, batch traceability and labelling
– Handling, transport and storage
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5. Summary
There are multiple contamination risks in the AdBlue supply infrastructure
The contamination risks could be reduced by relevant control measures
– Follow the guidelines and recommendations in ISO 22241 part 1 to 3 – Written procedures for all steps in the supply chain
– Training of all parties involved in the supply chain
– Use the right materials for all equipment in contact with AdBlue
– Use dedicated equipment for production, transport and dispensing
– Audit all parts of the supply chain at regular intervals
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Ö
Thanks for your attention
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