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Carseland Nitrogen Operations produces 535,000 tonnes of ammonia and 680,000 of urea annually. All but 110,000 tonnes of the ammonia is used to manufacture urea. Included in 680,000 tonnes of urea production is 190,000 tonnes of controlled release urea - ESN® and Duration®. These products are sold mainly in Western Canada and the United States.
Natural gas, air, and water are the raw materials used to manufacture anhydrous ammonia. The word “anhydrous” means that there is no water in the ammonia. Water comes from the nearby Bow River and natural gas is bought from local producers. Farmers inject gaseous ammonia into the soil as a fertilizer. Ammonia is a nutrient supplement for most crops and is used for industrial purposes including promoting bacterial growth in waste treatment plants and as an efficient refrigerant.
Ammonia is one of the two raw materials used to produce urea. By reacting ammonia and carbon dioxide at high pressure and temperature, urea is formed. Urea is primarily used as a fertilizer. It is also used as a raw material in the production of some glues and resins, as a protein supplement in animal food, and to melt ice on airport runways.
Agrium also produces 190,000 tonnes/year of controlled release urea products at the Carseland Site, including 40,000 tonnes/year of Duration® and 150,000 tonnes/year of ESN®. These two products have a flexible micro-thin polymer coating surrounding the nitrogen granule. This technology provides for a better matching of nutrient availability in the soil with plant nutrient requirements.
Innovation and modern technology have gone into the development of the Carseland plant. The process is computer controlled to maximize production, minimize energy use, and to improve operating reliability. Carseland was the first fertilizer production facility to have zero water discharge and its urea plant was the first in the world to use all centrifugal pumps and compressors in the high pressure section of the plant.
The plant has a dry storage building which houses both urea and ESN®, with a combined capacity of 74,000 tonnes. The 400 meter long facility uses a high capacity reclaim system to recover urea and/or ESN® from anywhere in the building. Agrium rescreens the products before loading into trucks or rail cars.
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