THE TAN PROJECT
What is the TAN Project?
BNPL is proposing to construct and operate a TAN production facility to manufacture and supply TAN, the main raw material for ANFO (Porous Ammonium Nitrate + Fuel Oil). ANFO is the most widely used and economical civil explosive currently on the market. The TAN will be used in the Australian mining industry.
What does the plant consist of?
The production facility will be located adjacent to the existing BFPL ammonia plant in the Burrup industrial estate and will include:
- Process plants;
- Utilities area;
- Storages for finished product; and,
- Several buildings including a workshop, central control room, laboratory, safety and security gatehouse, administration office and staff amenities.
What are the guidelines for the project?
The TAN production facility is being developed using international technology, design and safety guidelines:
- All facilities will be designed and operated according to Yara's Technical and Operational Standards (TOPS). The Yara TOPS have been developed to ensure the safety of plant personnel;
- All equipment will be designed to Australian statutory requirements for this type of industry. This applies in particular to protection of plant personnel, pollution control, pressure vessels, machinery, electrical, instrumentation and civil works;
- Best available, leading-edge technology will be applied to process operations; and,
- Early input/comments/consultation will be invited.
Where will the plant be built?
Regulatory approval has been requested for Site D within King Bay/Hearson Cove Industrial Precinct on the Burrup Peninsula, approximately 13km northwest of Karratha Western Australia (WA).
When will the project begin?
Construction is currently planned to commence in the last quarter of 2010 with the TANPF expected to be fully commissioned by the last quarted of 2013.
Project Phase |
Commencement |
Completion |
Environmental Approvals |
October 2008 |
August 2010 |
Construction |
Last quarter 2010 |
July 2013 |
Commissioning |
June 2013 |
Last quarter 2013 |
Operation |
Last quarter 2013 |
Plant life of 20 plus years |
Decommissioning |
4-6 months after the plant’s end of life |
|
During the peak construction period, about 650 persons will be on site while the average construction work force will be approximately 400 persons. The operation of the TANPF will require 60 full time (direct) personnel.
What is the Product?
The product is TAN which is comprised of 34.5% nitrogen. There are two grades of ammonium nitrate; fertilizer-grade ammonium nitrate which is virtually non-porous and technical grade ammonium nitrate (also referred to as low density or porous grade ammonium nitrate), which is made to be porous for better absorption of fuel and higher reactivity.
This technical grade ammonium nitrate, or TAN, is the main raw material for ANFO (Porous Ammonium Nitrate + Fuel Oil), a porous ammonium nitrate and fuel oil explosive mixture, which is the most widely used and economical civil explosive currently on the market. This site will only be producing TAN, which will be sold to customers in the mining industry, for use in their mining operations.
What is the Process?
The basis for manufacturing involves two main raw materials: oxygen and ammonia. A visual illustration of the TAN process is set out below.
Step one of the production process involves combining oxygen (air) and ammonia to form nitric acid. This is done through a number of reactions. Step two involves combining the nitric acid and ammonia to form the ammonium nitrate solution. The final step of this process involves concentration of the ammonium nitrate solution, and further processing to form droplets of crystallised ammonium nitrate. These solidified droplets, referred to as prills are then dried and cooled to form the end product of TAN.
Technical Ammonium Nitrate Prills
How will the final product be stored?
Two types of storage facilities will be used for TAN: a bagged product storage facility and a bulk storage facility. Product that is to be bagged will be conveyed to an intermediate bulk storage silo, that provides a buffer between production and bagging. In the event that the buffer is full or the bagging operation is stopped for any reason, the product will be diverted to the bulk storage facility.
Forklifts will be used to transport bagged product to the product storage building. Bagged product will be transported to customers using trucks.
Bulk material will be transported to the consumers by trucks, which will be loaded using front end loaders, bucket elevators and silos in combination with a truck weighing system.