On-Site AdBlue® Production: AUS32 & DEF Manufacturing Process
Client Case Study: Sustainable AdBlue® Production for the Energy Sector
At Atmosfer Makina, we specialize in providing innovative solutions for critical industrial needs. Today, we’re highlighting a powerful client case study on how our AdBlue® manufacturing process transformed supply for a leading energy sector player. This demonstrates the significant advantages of on-site AdBlue® production, emphasizing our commitment to both environmental responsibility and operational efficiency.
The energy sector, heavily reliant on diesel engines for generators and machinery, faces stringent NOx emission regulations. Selective Catalytic Reduction (SCR) systems are the standard solution, using AdBlue® (AUS32, DEF). Traditionally, securing a consistent and cost-effective AdBlue® supply, especially in remote energy operations, has presented logistical and financial hurdles, including high transport costs and supply chain vulnerabilities.
Our client, a major energy producer, sought to overcome these challenges. They needed full control over their AdBlue® supply, guaranteed ISO 22241 quality, and a reduced environmental footprint. Atmosfer Makina delivered a customized, autonomous AdBlue® manufacturing facility for on-site production, proving the immense value of our turnkey solutions in the AdBlue® manufacturing process.
Why On-Site AdBlue® Production is Environmentally and Economically Preferable
On-site AdBlue® production through Atmosfer Makina’s solutions offers compelling environmental and economic advantages over conventional supply methods.
Economically, the primary benefit is substantial cost savings. By producing AdBlue® at your facility using urea for DEF, you cut out expenses like freight, storage at third-party distribution centers, and reseller margins. Urea for DEF is a dry granular product, making it significantly cheaper and easier to transport and store in bulk than liquid AdBlue®. This, combined with bulk urea purchasing, delivers a rapid return on investment and sustained savings. Our automated processes also minimize labor costs, giving you greater budgetary control and insulating you from market volatility.
Environmentally, on-site AdBlue® production greatly reduces your carbon footprint. Traditional supply chains involve extensive transportation of liquid AdBlue®, generating significant greenhouse gas emissions. By manufacturing on-site, you drastically reduce this transport, leading to lower carbon emissions and a greener operational profile. It also means less road congestion and reduced risk of transportation-related spills, enhancing overall environmental safety.
Furthermore, on-site production ensures unparalleled supply security and independence. For critical energy operations, uninterrupted AdBlue® supply is vital. Our AdBlue® manufacturing facility mitigates disruption risks, allowing you to produce AdBlue® on demand, guaranteeing continuous supply regardless of external market or logistical challenges.
Lastly, on-site AdBlue® production provides superior quality control. AdBlue® quality directly impacts SCR system performance. Our integrated quality assurance systems continuously monitor the AdBlue® manufacturing process to ensure strict adherence to the ISO 22241 standard. This guarantees consistently pure and correctly concentrated AUS32, protecting your assets and optimizing emission reduction.
Key Components of the AdBlue® Manufacturing Facility
An Atmosfer Makina AdBlue® manufacturing facility is a meticulously engineered, self-contained system comprised of essential key components designed for efficient, high-quality AdBlue® (AUS32, DEF) production from urea for DEF.
Central to the facility is the Urea Storage and Feeding System, which safely stores and precisely delivers granular urea for DEF into the process. The Demineralized Water Production Unit employs advanced water treatment (like reverse osmosis) to create the high-purity water crucial for AdBlue®. An energy-efficient water heating option can optimize urea dissolution, especially in colder climates.
The heart of the AdBlue® manufacturing process is the Mixing and Dissolution Reactor, where urea for DEF is thoroughly dissolved in demineralized water to achieve the precise 32.5% concentration. This process is fully automated with sensors monitoring parameters.
Following dissolution, the Filtration System ensures final purity by removing impurities. We offer an enhanced urea filtration option for the highest purity demands.
Finally, the Quality Control and Monitoring System continuously measures concentration, conductivity, and other parameters, governed by a PLC. This intelligent system ensures consistent ISO 22241 compliant quality, minimal errors, and comprehensive data logging for every batch of AUS32.
Urea Dissolution: Process Flow and Automation
The urea dissolution stage is fundamental in the AdBlue® manufacturing process. It converts solid urea for DEF into liquid AUS32. Our process flow prioritizes precision and advanced automation.
The process begins with automated transfer of urea for DEF from storage into a mixing tank. Simultaneously, demineralized water (potentially heated via the energy-efficient water heating option to 25-40°C) is precisely dosed. This temperature range is crucial for rapid and complete urea dissolution, preventing crystallization.
Specialized agitators ensure homogeneous mixing, while real-time temperature and conductivity sensors monitor the solution. Conductivity accurately indicates urea concentration as it dissolves.
Our sophisticated automation system, driven by a central PLC, orchestrates this entire process. It receives sensor data to dynamically adjust dosing rates of urea for DEF and water, maintaining the exact 32.5% concentration for AdBlue®. This high level of automation eliminates manual variability, reduces errors, and guarantees consistent quality. Detailed logging of all parameters ensures traceability and quality assurance for every AUS32 batch.
Advanced Monitoring and Filtration Technologies
Atmosfer Makina’s commitment to top-tier AdBlue® (AUS32, DEF) relies on our advanced monitoring and filtration technologies. These are vital for ensuring every liter produced meets the stringent ISO 22241 quality standard.
Advanced Monitoring: High-precision sensors continuously track urea concentration, temperature, pH, and electrical conductivity (a key indicator of purity and concentration). A sophisticated PLC uses this real-time data to make instant adjustments, ensuring consistent quality. Proactive diagnostics, alarms, and detailed data logging provide comprehensive oversight and traceability for continuous AdBlue® production.
Advanced Filtration Technologies: Purity is critical to protect SCR systems. Our AdBlue® manufacturing facilities incorporate multi-stage filtration technologies to remove impurities from urea for DEF and water. This includes pre-filtration and fine filtration. We offer an enhanced urea filtration option for the absolute highest purity requirements, safeguarding sensitive SCR catalysts. These systems are designed for minimal maintenance and maximum efficiency.
Storage, Loading, and Supervision of Finished AdBlue®
Once AdBlue® manufacturing process is complete and quality-approved, efficient storage, loading, and supervision of finished AdBlue® are crucial. Atmosfer Makina provides integrated solutions for these post-production steps, ensuring product integrity and availability.
Our storage tank options are specifically designed for AdBlue®, made from compatible materials (stainless steel, specialized plastics) to prevent contamination. Tanks come in various sizes, often with insulation for temperature control (-11°C to 30°C) and integrated level monitoring for inventory management.
For efficient distribution, we offer diverse packaging and loading solutions. This includes bulk loading stations for tankers, automated filling stations for IBC Tanks (Intermediate Bulk Containers) or drums, catering to various dispensing needs. All solutions prioritize safety and accuracy.
Supervision of Finished AdBlue® extends throughout the on-site supply chain. A central PLC monitors storage levels and dispensing rates, even for IBC tanks. All data is logged for traceability, compliance, and performance analysis. Remote monitoring capabilities provide complete oversight of your AdBlue® manufacturing process, from production to distribution.
Frequently Asked Questions (FAQ)
Q: What is AdBlue® (AUS32, DEF) and why is its quality so important?
A: AdBlue®, also known as AUS32 or Diesel Exhaust Fluid (DEF), is a 32.5% urea solution for SCR systems to reduce NOx. Its quality is critical because impurities can damage SCR catalysts, leading to costly repairs and reduced performance. Our AdBlue® manufacturing process guarantees ISO 22241 compliant purity.
Q: How does on-site AdBlue® production save money?
A: On-site AdBlue® production offers significant economic savings by eliminating transportation, delivery, and supplier markups. Buying bulk urea for DEF is cheaper and easier to manage, reducing logistics costs. Our automated systems also lower labor expenses, providing a fast return on investment.
Q: What raw material is needed for your AdBlue® production systems?
A: Our systems primarily use urea for DEF, specifically high-purity automotive grade urea in granular form. This is efficiently dissolved in demineralized water to create AdBlue® (AUS32).
Q: How does your AdBlue® manufacturing process contribute to environmental sustainability?
A: By producing AdBlue® on-site, we significantly reduce the need for long-distance transport of liquid DEF, thereby lowering the carbon footprint associated with logistics. This directly contributes to a greener supply chain and supports your environmental responsibility goals.
Q: Can I store the urea for DEF and the finished AdBlue® using Atmosfer Makina’s solutions?
A: Yes. We offer integrated solutions for both: bulk storage options for urea for DEF and various storage tank options specifically designed for the compliant storage of finished AdBlue®, ensuring product integrity.
Q: Do you offer ways to package the produced AdBlue® for distribution?
A: Yes, we offer various packaging and loading solutions, including automated filling stations for IBC Tanks or drums, and bulk loading arms for tank trucks. These can be integrated with your AdBlue® manufacturing facility for efficient and safe distribution.
Q: What kind of after-sales support does Atmosfer Makina provide for its AdBlue® production systems?
A: Atmosfer Makina offers comprehensive after-sales support, including expert technical assistance, remote monitoring for your AdBlue® manufacturing facility, maintenance guidance, and prompt troubleshooting to ensure continuous and reliable AdBlue® production.
Contact Atmosfer Makina
Ready to transform your chemical production with intelligent automation?
The path to faster, more precise, and more profitable chemical manufacturing begins with the right filling and packaging machinery. Contact us today to discuss a tailored solution for your specific needs.
| Category | Details |
| Location | Kızılcaşar MAh. 4200 cad. no:39 Atabilge incek Sitesi c blok d:140 Gölbaşı /Ankara |
| Office Phone | +90 312 504 64 60 |
| Mobile / WhatsApp | +90 541 947 04 14 |
| +90 539 549 05 12 | |
| General Email | [email protected] |
| Sales Email | [email protected] |
| Technical Support Email | [email protected] |
