Greater safety and efficiency in liquid ammonia sampling

Introduction

In the demanding world of the chemical industry, Yara Sluiskil, part of the global Yara International, is known for its commitment to operational efficiency and sustainability. Central to its production process is the sampling of liquid ammonia; a task that is essential with various challenges.

The challenge facing Yara Sluiskil was complex and multifaceted. As a major producer of fertilizer, the safe and efficient sampling of liquid ammonia, a crucial raw material, was a necessity.

This case study illustrates how Yara Sluiskil and Swagelok worked together to review the standards for safe and efficient ammonia sampling in the industry. It also takes a look at the impact of this successful partnership contributing to a chain reaction of innovation and improvement throughout Yara's organization.

Who is Yara Sluiskil?

Yara Sluiskil is the largest production site of the Norwegian company Yara International, with nearly 17,000 employees worldwide. Yara operates in 52 countries and has been selling its products in more than 160 countries since 1929. From its current location in the Ghent-Terneuzen Canal Zone, the company manufactures nitrogen fertilizer and industrial chemicals, such as Air1® and NOxCare® that capture harmful nitrogen oxides (NOx). In addition, Yara Sluiskil produces CO2 for the bubbles in soft drinks and beer, dry ice on which vaccines are stored, for example, or CO2 as a growth substance in greenhouse horticulture. The plants are among the most efficient and reliable in the world. Safety is a top priority.

The raw materials Yara uses are natural gas (methane), air and water. Solids such as dolomite rock and gypsum serve as fillers for the fertilizer granules. Yara's mission is simple but ambitious, namely: to responsibly feed the world and protect the planet.

The ammonia dilemma

The challenge facing Yara Sluiskil was complex and multifaceted. As a major producer of fertilizer, sampling liquid ammonia (a crucial raw material) was a necessity. However, the existing system for this sampling was outdated and inefficient.

Inefficiency: The old system was time-consuming and labor-intensive. Sample collection took a long time, leading to delays in the analysis process.

Safety risks: Working with liquid ammonia poses significant risks. The old system had multiple connections that had to be tightened manually, which increased the risk of leaks and exposure to hazardous substances.

Lack of visual control: The existing method offered little to no visual control over the sampling process. This lack of visibility made it difficult to ensure sample quality and consistency.

The solution

The Swagelok ammonia sampler minimizes operator exposure to potentially hazardous materials and environmental effects. The glass fixture design allows samples to be dispensed without operator exposure while still allowing visual confirmation of process steps. The enclosed fixture design controls the release of ammonia into the environment and the sampler can be installed at the sampling point.

Yara and Swagelok

The optimization of liquid ammonia sampling at Yara Sluiskil's began to take shape in 2019, when Swagelok Netherlands came into the picture through a report to Yara. The process of collaboration and innovation between the two companies unfolded as follows:

Initial discovery and demonstration

The initial introduction to Swagelok's technology began with a notification in 2019 that their liquid ammonia sampling solution had potential for Yara. Wilco Landkroon, Field Engineer & Trainer at Swagelok Netherlands, visited the site to demonstrate the product, originally developed for the U.S. market.

Test setup and pilot phase

Several sessions took place in 2021 to install a test setup. With the involvement of Swagelok Company and the Dutch distributor, the test setup was installed. For this, Matt Dixon, Technical Leader of Swagelok Company came specially flown in to personally demonstrate the operation of this innovative test setup. The pilot phase then began, comparing the new system with the old method of sample collection.

This allowed Yara to immediately see the benefits, such as the improved speed and safety in the sampling process.

Unique collaboration and development

Sampling liquid ammonia is a complex process where precision, safety and speed are key. The sampling system was originally only available in the United States. For this reason, Swagelok took the initiative to facilitate a prototype for the European market, in the form of a test rig. This started a unique pilot project aimed at further developing and refining the ammonia sampling system. This phase was crucial for adapting the system to Yara's specific needs. The collaboration was strengthened by the provision of a prototype by Swagelok, which gave Yara the opportunity to test the device in a real-life situation and provide valuable feedback.

Time, safety and innovation

Efficiency improvement: Swagelok's new sample collection system provided a faster method for collecting ammonia samples, significantly reducing the time required for sample collection and analysis. This led to a more efficient workflow and quicker responses to quality controls.

Increased safety: By focusing the design on minimizing exposure to ammonia and reducing manual connections, safety risks were dramatically reduced. The new system reduced the risk of leaks and other incidents, creating a safer working environment for employees.

Ease of use and visual control: With improvements in ease of use and the introduction of more effective visual control mechanisms, the sample collection process became more transparent and consistent. This provided better quality assurance and a more user-friendly experience for operators. With the improved system, Yara can now use residue tubes for further analyses in their laboratory in addition to moisture analyses, such as testing for oil or metals in the samples which contributes to better quality control of the medium. In addition, the collaboration between Yara and Swagelok gives room for sharing feedback and knowledge, improving efficiency, reducing risk and stimulates innovation. It is no longer a customer-supplier relationship, but a partnership of knowledge sharing.

The road to innovation opened at Yara

The cooperation between Swagelok and Yara is an impressive example of how shared expertise and focused collaboration can lead to significant improvements in industrial processes. The fruits of this collaboration extend beyond Yara's borders. Other Yara sites around the world, including Australia, Norway and Germany, have expressed interest in the innovative ammonia sampling system developed by Swagelok, inspired by its success at Yara Sluiskil.

This growing interest has led to the formation of a "community of practice" within Yara, where knowledge and experiences are shared via a specially set up SharePoint site. This community acts as a knowledge hub, where Yara's global locations can access the project's valuable insights and best practices. The impact of the collaboration between Yara and Swagelok Netherlands has thus initiated a chain reaction of innovation and improvement throughout Yara's organization.

This development not only highlights the effectiveness of the system, but also underscores the power of collaboration and knowledge sharing within a global network. The collaboration with Swagelok Netherlands has resulted in a solution that not only meets current needs, but also provides a future-proof strategy for the complex challenges of ammonia sampling. This is clear evidence that when organizations such as Yara and Swagelok join forces, they can not only improve their own operations, but also have a positive impact on the broader industry.