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Specialized Chemical Handling Equipment

About the Chemical Industry

The chemical industry is a cornerstone of the global economy, transforming raw materials into an extensive array of products essential for industrial applications and everyday life. It encompasses a vast range of sub-sectors, including inorganic chemicals, organic compounds, ceramics, petrochemicals, agrochemicals, polymers, rubbers (elastomers), oleochemicals, explosives, flavors, and fragrances. These products underpin industries as diverse as agriculture, construction, energy, and healthcare.

Core Functions of the Chemical Industry

At its core, the industry processes raw materials such as hydrocarbons from oil and natural gas, atmospheric gases like oxygen (O₂) and nitrogen (N₂), water (H₂O), minerals like phosphates, and metals like iron (Fe) and aluminum (Al). These are converted through complex chemical reactions into commodity chemicals that serve as building blocks for higher-value products.

Wet Materials and Feedstocks

In fertilizer production and other sectors, handling challenging raw materials such as wet sand, bitumen, and tar sands is a key technical hurdle. These materials often contain moisture, cohesive particles, and impurities like silica (SiO₂) or organic residues, necessitating specialized equipment and chemical processes to ensure their effective integration into manufacturing cycles.

  • Bitumen and tar sands, rich in heavy hydrocarbons, are chemically refined using methods such as hydrocracking or pyrolysis, breaking long-chain hydrocarbons into lighter, more usable fractions.
  • Wet sticky materials, such as clay-rich sands, may require pretreatment processes such as calcination (thermal decomposition) or dispersion using surfactants to ensure flowability and consistency in downstream applications.


At WTW Americas, we specialize in the material handling of sticky, abrasive, and wet bulk materials, making difficult to handle material such as bitumen and tar sands, no challenge for our equipment.

Fertilizer Production: The Heart of Agrochemicals

The chemical industry plays a pivotal role in modern agriculture by producing fertilizers that enhance soil productivity. Fertilizers supply essential nutrients—nitrogen (N), phosphorus (P), and potassium (K)—to crops, commonly referred to as NPK fertilizers.

Nitrogen Fertilizers

Nitrogen is sourced from atmospheric nitrogen gas (N₂) using the Haber-Bosch process, a groundbreaking chemical reaction that combines N₂ and hydrogen gas (H₂) (typically derived from methane, CH₄) under high temperatures (~450°C) and pressures (~200 atm) in the presence of an iron (Fe) catalyst. This produces ammonia (NH₃), a precursor for nitrogen-based fertilizers like:

  • Ammonium nitrate (NH₄NO₃): A high-nitrogen fertilizer.
  • Urea [(NH₂)₂CO]: Widely used for its high nitrogen content and ease of application.

Phosphorus Fertilizers

Phosphorus, primarily obtained from phosphate rock (calcium phosphate, Ca₃(PO₄)₂), is treated with sulfuric acid (H₂SO₄) to produce phosphoric acid (H₃PO₄). This is a key intermediate for producing:

  • Triple superphosphate (TSP): Formed by reacting phosphate rock with phosphoric acid.
  • Ammonium phosphate [(NH₄)₃PO₄]: A popular NPK fertilizer component.

Potassium Fertilizers

Potassium, often derived from potash ores such as potassium chloride (KCl), is used in its raw form or combined with nitrogen and phosphorus to create balanced fertilizers. The solubility and bioavailability of potassium ions (K⁺) make it essential for plant health.

Sustainability in Fertilizer Manufacturing

The production of fertilizers, while essential, is energy-intensive and has significant environmental implications. Innovations in green chemistry aim to reduce the industry’s carbon footprint by:

  • Capturing and utilizing CO₂ emissions during processes like ammonia synthesis.
  • Employing renewable hydrogen sources, such as electrolysis of water powered by solar (Si) or wind energy, instead of methane reforming.
  • Recycling phosphorus from agricultural runoff and organic waste, creating a circular approach to nutrient management.

Petrochemicals and Polymer Production

While fertilizer production dominates the agrochemical subsector, the broader chemical industry also processes hydrocarbons into critical products like polymers (polyethylene, PE, and polypropylene, PP) and specialty chemicals. Through cracking of hydrocarbons, the industry generates ethylene (C₂H₄) and propylene (C₃H₆) for downstream applications in plastics, elastomers, and resins.

Geopolitical and Economic Considerations

The global distribution of raw materials influences chemical production centers. The United States, Germany, Japan, and Russia are among the largest chemical producers, leveraging their access to natural resources and technological advancements. For instance, tar sands in Canada and Venezuela represent vast reserves of hydrocarbons, while phosphate mines in North Africa underpin global phosphorus supply chains.

The Future of the Chemical Industry

The chemical industry is transitioning toward sustainable practices through the adoption of bio-based feedstocks, carbon-neutral processes, and enhanced recycling technologies. Fertilizer production is moving towards precision agriculture, integrating data-driven applications to minimize nutrient waste and maximize efficiency. Innovations like green ammonia, produced via renewable hydrogen, and slow-release fertilizers, which reduce leaching and environmental harm, highlight the industry’s potential for transformative change.

By combining elemental science, engineering innovation, and environmental stewardship, the chemical industry continues to be a vital force in modern civilization, driving progress in agriculture, energy, and materials science.

WTW Americas Industry Experience

WTW Americas delivers world-class material handling solutions specifically tailored for the demanding environments of the chemical industry, with a strong focus on fertilizer production.

Material receival is a critical first step in the chemical industry, particularly for fertilizer production, where efficient unloading systems ensure smooth and reliable operations. WTW Americas  Truck Discharge Machine (TDM) serves as the ideal machine to receive raw materials. The TDM is specifically engineered to speed the unloading of materials into a processing facility, without the need for costly excavation, and requiring minimal civil work. The complete unloading facility can receive bulk material from trucks, front-end loaders, barges, and railcars. For example, WTW Americas has a number of installations in Potash plants, where materials is unloaded from railcars. The TDM will accept a full truck load of material and can be discharged from 0 to 1,200 t/h at constant or variable rates.

Our portfolio of advanced machines, including the Silo Discharge Machine (SDM) and Bunker Discharge Machine (BDM), provides innovative methods to handle raw materials and intermediate products efficiently, ensuring seamless integration into complex chemical production processes.

In fertilizer production, managing materials like ammonium nitrate (NH₄NO₃), urea (CO(NH₂)₂), potassium chloride (KCl), and phosphates requires systems capable of dealing with fine powders, wet and sticky materials, and abrasive substances. WTW Americas’ Silo Discharge Machine (SDM) is engineered for versatility and reliability, featuring a rotating discharge arm that uniformly extracts materials such as wet sands, clays, and mineral inputs directly from silos. With sizes ranging from 1.5 to 6 meters in diameter and capacities up to 1,000 t/h, the SDM ensures consistent flowability, preventing issues like bridging or ratholing—common challenges in handling bulk fertilizers.

Similarly, the Bunker Discharge Machine (BDM) offers exceptional performance for reclaiming materials from stockpiles, domes, or hoppers. The BDM is particularly effective in managing tough-to-handle inputs like phosphate rock and wet potash, operating on rails to ensure uniform material extraction and transport to downstream processes. Its high reclaim rates, ranging from 10 to 2,500 t/h, make it ideal for scaling production in large fertilizer manufacturing plants. The system integrates seamlessly with our TKF Chain Conveyors for efficient transfer to blending or processing units.

WTW America’s TKF Chain Conveyors can be configured in a variety of widths and lengths. They can be used to distribute, discharge, and transport material in nearly every direction and orientation. They are frequently employed to move materials that would not normally convey on belt conveyors, such as CKD, alternative fuels, cement or other dusty materials.

Standard or specifically designed, WTW Americas TKF Chain Conveyors are self-cleaning, can run horizontal, inclined, and even vertical with widths from 0.25 to 2 meters. Our Chain Conveyor solutions have been rigorously tested to ensure success once installed in the field.

The combination of the chain material, the method of manufacturing the links, the yield strength, hardening of the chain as well as the material of the fastening equipment such as bolts, pins and trough tolerances transform our chain into a long-lasting trouble-free system. All connectors and pins are made of high-quality alloy steel that is subjected to special treatments to enhance their duration and resistance to wear and tear.

WTW Americas’ material handling solutions are built with durability and chemical resistance in mind, using specialized materials like stainless steel, high-nickel alloys, and corrosion-resistant coatings to endure the harsh environments of fertilizer production. The equipment is designed to operate efficiently with precision metering capabilities, ensuring accurate delivery of inputs such as sulfuric acid (H₂SO₄) and anhydrous ammonia (NH₃)—essential components in creating nitrogen-based fertilizers.

By incorporating WTW Americas’ advanced systems into fertilizer production lines, chemical manufacturers can enhance operational efficiency, minimize waste, and ensure safety. The integration of sustainable design features, such as energy-efficient motors and dust-tight sealing mechanisms, supports compliance with stringent environmental standards while contributing to a circular economy by reducing emissions and material losses.

WTW Americas’ focus on innovation, reliability, and sustainability empowers fertilizer producers to meet growing global demand while addressing modern challenges such as resource scarcity and climate impact. With a proven track record of success in the chemical industry, WTW equipment is the ideal choice for optimizing fertilizer production from raw material handling to finished product distribution.

By integrating WTW Americas’ advanced conveyor, discharge, and handling systems, cement producers can achieve a high level of process reliability, ensuring uninterrupted production and contributing to overall energy efficiency in the highly demanding chemical manufacturing process. All of our equipment can be modified to meet specific industry needs.

For more information about our equipment, please visit our equipment page.

Learn More

To learn more about WTW Americas equipment and experience in the Chemical Industry email info@wtwamericas.com or call +1705-749-3544.

Contact Us

Email
info@wtwamericas.com

Phone
705-749-3544

Address
159 King St. Suite 208
Peterborough, ON, Canada
K9J 7H7

WTW Americas specializes in handling sticky, wet, hot (up to 750°C), abrasive and non-free-flowing bulk materials.

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