The majority of ammonia is utilized as fertilizers in the agricultural sector. Liquid fertilizers typically contain ammonia, ammonium nitrate, urea, and aqua ammonia and are also used to produce ammonium and nitrate salts. Common areas in fertilizer plants and distribution sites that require ammonia detection include:
- Storage tanks
- Rail or truck loading/unloading
- Port shipping terminals
- Spray towers
- Plant perimeter monitoring
- Pumps and compressors
- Pipelines and valves
These areas are densely packed with equipment, making perimeter monitoring crucial for safeguarding both the entire plant and the surrounding community. To enhance ammonia gas detection in fertilizer plants, open path technology can be utilized across multiple process locations. Additionally, a multi-sensor layered approach, incorporating various types of fixed-point gas detectors and sampling systems, offers better redundancy to protect personnel and equipment.
Industrial Processing
A variety of industries use ammonia in their production processes. In the rubber and leather industries, ammonia is used to stabilize natural and synthetic latex to avoid early coagulation.
The pulp and paper industry uses ammonia for wood pulping and as a casein dispersant in paper coating processes.
Ammonia is also frequently employed in drug manufacturing, where it inhibits the growth and reproduction of certain bacteria. Additionally, it serves various roles in pharmaceutical production, including acting as a neutralizing agent.
These applications require manual and automated processes, and workers must oversee and manage production. Reliable and very low-level ammonia detection is critical for worker safety and health.
Refrigeration/Cooling Systems
Ammonia is a commonly used refrigerant in the beverage and food industry. Cooling systems are often situated in the following areas:
- Production areas
- Machine rooms
- Air Handlers
- Freezers
- Coolers
- Loading docks
Temperatures and humidity levels in refrigeration systems can rapidly change, affecting ammonia levels as well as the lifetime of standard sensors. Other gases and odors in the plant may trigger traditional electrochemical sensors, resulting in unnecessary and costly false alarms.
Therefore, selecting the appropriate and reliable technology that is resistant to changing conditions is crucial. The unique photoacoustic infrared sensor of the Chillgard 5000 meets these requirements effectively.
Ammonia Production and Storage
The majority of global ammonia production is based on the steam reforming of natural gas. During synthesis, natural gas molecules are converted to carbon and hydrogen. Ammonia is produced by reacting hydrogen with nitrogen at high pressures and temperatures.
Water electrolysis provides an additional source of hydrogen for ammonia synthesis. The technique uses electricity to split water into hydrogen and oxygen.
The processes involved in ammonia synthesis require gasses to be under high pressure, which increases the danger of gas leakage, and hydrogen is one of them. The ultrasonic technique considerably enhances traditional catalytic bead gas detectors for hydrogen detection, resulting in faster leak identification. Installed hydrogen flame detectors detect invisible fires and prevent subsequent explosions.
Another concern is outdoor ammonia exposure caused by leaks and spills at producing plants and storage sites. Open-path toxic gas detectors help mitigate risk by covering large areas where rapid dilution of leaking gas could pose a significant challenge.
Gas Detection Solutions
Chillgard® 5000 Ammonia Monitor
The patented photoacoustic infrared (PAIR) sampling method delivers the earliest detection of ammonia leaks across multiple sampling points in fertilizer production areas.
- Not impacted by temperature and humidity fluctuations
- The photoacoustic infrared sensor is specific to ammonia gas
- Operates for months with minimal zero drift
- Advanced sensor diagnostics and predictive maintenance provide worry-free operation
- Single calibration point for cost-effective and quick maintenance
ULTIMA® X5000 Gas Monitor
Image Credit: MSA - The Safety Company
The ULTIMA® X5000 Gas Monitor uses proprietary XCell® sensor technology to detect ammonia in high-risk installations that require point detectors for rapid leak detection.
- XCell sensor technology can endure substantial environmental fluctuations in humidity and temperature
- Stable indications and a quick response time when detecting ammonia leakage
- Utilizes non-consuming reactions, providing extended lifespan
- Dual sensing technique lowers CAPEX and installation expenses
Observer®i Gas Leak Detector
Image Credit: MSA - The Safety Company
An omnidirectional acoustic detector that uses ultrasonic technology. Instantly identifies pressured gas leaks during ammonia synthesis operations.
- ANN technology differentiates gas leak sounds from background noise, enhancing leak detection and reducing false alarms.
- Instantly detects gas leaks at the speed of sound.
- The patented Senssonic™ self-test ensures full acoustic integrity
- Maintenance is trouble-free, and one person can inspect and calibrate