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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Acid Plant Database  August 18, 2016

Owner Ravensdown Fertiliser Co-operative Limited

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Location Main South Road
New Zealand
Background Formerly
- Kempthorne Prosser and Co.

Ravensdown Fertiliser Co-operative Limited was established after a series of takeovers during 1977/78 by the amalgamation of the five fertiliser works formerly owned by Kempthorne Prosser & Co Ltd and Dominion Fertiliser Company.  Sixty per cent of its shares were held by Ravensdown Corporation Ltd, a farmer-owned co-operative whose members were farmers in the regions supplied by our three works. In 1987 Ravensdown merged with East Coast Fertiliser Co., a co-operative that owned and operated a single fertiliser works at Napier.  In July 1997 the New Plymouth operation of Farmers Fertiliser was purchased by Ravensdown.

Website www.ravensdown.co.nz
Plant Hornby Site
Coordinates 43° 32' 32" S, 172° 32' 14" E
Type of Plant Sulphur Burning
Gas Source Elemental Sulphur - Bulk Solid
Plant Capacity 250 to 280 MTPD
SA/DA 4 bed SA
Emissions Consent to Discharge to Air (CRC 921764)
Sulphur Compounds: < 1.5% of sulphur burned
SO2: < 0.13% v/v at any plant load
SO2: < 0.5% v/v for 1 hour after sulphur ignition during a cold start
Acid Mist/SO3: < 150 mg/Nm3 as SO3 for 1 hour after sulphur ignition during a cold start
Opacity: clear stack within 2 hours from sulphur ignition during a cold start
Status Operating
Year Built -
Technology -
Remarks -
Pictures   Ravensdown - Hornby 2.JPG (52879 bytes) 
General Ravensdown is the largest supplier of fertiliser in New Zealand, directly supplying more than half of all the fertiliser used in New Zealand agriculture.  We are 100% owned by New Zealand farmers, providing them with sound technical advice and a comprehensive range of key farming inputs, all at the lowest sustainable cost.  Less than a decade ago we were mainly a solid NPKS fertiliser supplier. Today we offer a comprehensive range of inputs – from soil testing through to anthelmintics, from lime through to agrochemicals – all backed by highly skilled technical specialists.  We use the ‘ground-up’ approach.  This involves working with farmers to test their soils, herbage and animals and then using the expertise of our Field Officers and technical representatives to analyse and interpret the results to provide recommendations to meet the exact needs of the farm.  It is about adding value to our farmers’ agri-businesses and helping them maximise their productivity.  The ground-up approach encompasses research, analysis, highly qualified field staff, an extensive product range, a Customer Centre which is always available to take queries and orders and a national distribution network.
References -

April 30, 2012 - Ravensdown’s Hornby fertiliser manufacturing facility has been awarded the prestigious ‘Return on Environment (ROE)’ award by GE Corporation (Water and Process) for making significant improvements to the cooling water quality at its sulphuric acid plant over the past three years.  The farmer-owned co-operative makes sulphuric acid on the 14 ha site. This acid is needed by farmers to make phosphate rock ready to spread on their soil for plants and clover to use.  “Turning sulphur into acid generates a lot of heat and steam which can be used for electricity generation,” explains Peter Hay, Works Manager at Hornby. “We use water to cool the acid plant and the turbine steam. But wherever there is water and warmth, there is a risk of bacteria. So we work with GE to ensure our bacterial control is the best it can be and this award is an acknowledgement of that commitment,” said Peter.  “Three years ago we invested in new cooling towers which, being made of PVC and fibreglass, are more resistant to bacteria and easier to clean. This meant less costly interruption to the plant and that we could use chlorination products like those used in swimming pools, but at a higher level, to control bacteria. We work in partnership with GE on best practice and some automation tools that scan for chlorine residuals. Clear colour-coded daily testing is carried out by plant operators and GE’s own expert visits each month.”  “The cooling tower water is a virtually-closed system. We use our own well but the pipe is 30 metres from the plant and we chlorinate the water before it even goes into the cooling system,” added Peter.  Ivan Rodrigues from GE said, “Established in 1992, the GE ROE Award recognises a select group of customers whose environmental and health and safety achievements, along with cost reductions while balancing industrial demands, clearly demonstrate that environmental responsibility and improved profitability are perfectly compatible goals. The Proof not Promise award is only given to companies who have documented how their system works.”  “We’re very proud of this award as it is the culmination of a huge amount of teamwork and investment in terms of time and money. Special mention should be made of the teams at our other acid plant in Awatoto near Napier who also put in a huge amount of effort into their bacteria control,” concluded Peter Hay.

MTPD - Metric Tonne per Day           STPD - Short Ton per Day
MTPA - Metric Tonne per Annum      STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption

* Coordinates can be used to locate plant on Google Earth