Turnkey Solutions for Fertilizer Plants

Waste Heat Recovery Boilers for Fertilizer Industry

Fertilizer is an essential component of modern agriculture. The fertilizer industry transforms millions of tons of air, natural gas and mined ores into plant nutrition products based on the three essential nutrients nitrogen, phosphorus and potassium.

Fertilisers are mainly classified into two main types, organic and inorganic fertilisers. With Organic or Natural fertilizers derived from agricultural waste or animal manure have limitations in production, Inorganic or chemical fertilizer generated by chemical techniques play a vital role in present scenario.

Fertilizer is basically dependent on Soil characteristics and climatic conditions of that region and types of fertilizers can be broadly classified as

Nitrate-based fertilizers uses ammonia to produce nitrate fertilizers such as ammonium nitrate (AN). Ammonia may also be mixed with liquid carbon dioxide to create urea. Both these products can be further mixed with water to form UAN (urea ammonium nitrate) solution.

Phosphate based fertilizers such as single superphosphate (SSP), triple superphosphate (TSP), monoammonium phosphate (MAP), di-ammonium phosphate (DSP) are produced from mined ores. Phosphate rock is primarily treated with sulphuric acid to produce phosphoric acid, which is either concentrated or mixed with ammonia to make a range of phosphate fertilizers.

Potassium, Calcium, magnesium and sulphur based fertilizers are basically produced from mined ores. Several chemical processes can be used to convert the potash rock into potassium chloride, sulphate and nitrate.

For Nitrate based fertilizers Thermal Systems provides boilers for Weak Nitric Acid | Ammonium Nitrate | Methanol plants.

For Phosphate & Sulphur based fertilizer, Thermal Systems provides boilers for Sulphuric acid plant | Heat exchangers & pre heaters.


  • Sulphuric Acid Plant
  • Weak Nitric Acid (WNA) Plant
  • Methanol
  • Ammonia


  • Waste Heat Recovery Boiler
  • Gas to Gas Heat Exchanger
  • Steam Air Preheater
  • Process Gas Cooler
  • HRSG


  • FEED Engineering
  • System Engineering
  • Process Feasibility
  • Design & Manufacturing
  • Supply and E&C




PRESSURE (kg/cm2)






Sulphuric acid making process results in generation of high temperature gases. To maximize energy recovery and acid yield, the gases are cooled in boilers, heat exchange equipment’s thereby generating high pressure steam which is further used to generate power.

Sulphuric Acid is mainly obtained by burning molten sulphur, from metallurgical off-gases or by decomposing spent sulfuric acid.

Thermal systems provides WHB system | Heat Exchangers | Pre heating Units for various industrial segments manufacturing Sulphuric Acid.


Nitric Acid process mainly involves oxidation, condensation & absorption to produce WNA. Oxidation process takes place in an exothermic reaction wherein high temperature gases are generated. Converter boilers, Economisers with Start up heaters are process equipments which ensure maintenance of temperature profile as required in process.

TSPL is into design & supply of converter boilers | WHBs |ECOS with Startup heaters etc.


Methanol is predominantly produced from natural gas by reforming the gas with steam and then converting and distilling the resulting synthesized gas mixture to create pure methanol. A process Gas waste heat boiler is an important equipment used to cool hot synthesis gas. The heat from process gas is used to generate steam ( HP / LP)

TSPL provides single or twin boiler design combined with a common steam drum & Superheater if required as per plant / process needs.


For any process industry to thrive, the quality, reliability and cost of electricity are important factors. Process industry thus sets up its own power generation plant for self-use thereby reducing dependability on the grid.

TSPL provides concept to commissioning solutions for Power generation by utilising fossil fuels available to combust it in a AFBC / TG boiler or utilize Waste Gases in a WH Boiler to produce steam thereby generating power by a Steam Turbo Generator.

Heat Recovery Solutions for Fertilizer Industry