Grupa Azoty S.A. (Tarnów, Poland) has commissioned the fifth line of its nitric acid installation, marking the completion of a key phase of the plant’s startup process. The fifth line is part of a major modernization and construction project for nitric acid production and related facilities, valued at PLN 300 million (around $74 million). The project improves the efficiency of nitric acid production, enhances the economic feasibility of nitric acid-based fertilizers, and aims to reduce environmental emissions.
The fifth line has a production capacity of 1,000 tons per day (calculated at 100% acid concentration), and the fourth neutralization line, with a capacity of 1,300 tons per day, is set to begin its technological startup later this month. These developments will ultimately increase the capacity for producing high-quality granular fertilizers (macro) for modern fertilization technologies and fully load two mechanical granulation lines. The launch of the fifth nitric acid line also facilitates the smooth modernization of the existing four nitric acid lines (with the first line already 80% modernized).
The new line utilizes the EnviNOx system for catalytic reduction of N₂O and NOx, enabling significant emission reductions: a 98% reduction in NOx emissions and a 96.6% reduction in N₂O emissions. Additionally, production efficiency and consumption indicators will improve: ammonia usage by 3%, electricity by 26%, and steam by 18%.
“We have completed an important stage of an investment whose concept—encompassing the construction of a new nitric acid line, modernization of the four existing lines, and expansion of fertilizer production potential, including two mechanical granulation lines for ammonium nitrate—was developed between 2012 and 2014. Key decisions in this regard were made as early as 2015. Unfortunately, the implementation of this investment sequence leaves much to be desired—the completion and commercialization were initially planned for 2019–2021. In addition to significant delays, a decision was made in 2022 to suspend certain aspects of this investment, including the new fertilizer production line and modernization of the fourth nitric acid line. We remain committed to this project, recognizing its significant potential for Grupa Azoty. We are already commercializing its assumptions, as demonstrated by the introduction of the megAN 33.5 fertilizer in July this year. A few days ago, we expanded our product portfolio with eNpluS, a product enriched with sulfur and calcium,” emphasized Hubert Kamola, Vice President of the Management Board of Grupa Azoty S.A. and President of the Management Board of Grupa Azoty Puławy.
The expansion of nitric acid production will allow Grupa Azoty Puławy to avoid plant downtime and the associated losses in fertilizer production. It will also eliminate production bottlenecks (in absorption and cooling nodes) and enable full production integration with other installations, utilizing the complete infrastructure and existing production potential.