A REMARKABLE AND PROVEN WAY - GPCA...

A REMARKABLE AND PROVEN WAY TO SURPRISINGLY ENHANCE UREA PLANT CAPACITY

Federico Maffietti

Process Engineer

CASALE SA

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• The biggest Split-Flow Loop

• The biggest Fattening Unit


• One single source for all what you need


• Chinese area

• ‘80 CO2 Stripping Urea Plant

• Nameplate Capacity 1500 MTPD, operated at 1740 MTPD

• CASALE Technical Study in 2009-2010 (Ammonia and Urea Plants)

PATENTED INTERNALS FOR AMMONIA PLANT EQUIPMENT

REVAMPING THE ENTIRE UREA PLANT + NEW FATTENING UNIT


• Enhance capacity from 1500 to 2610 MTPD (+74%)

• Minimize energy consumption

• Increase product quality

• Minimize new HP equipment


• Reactor / HP Condenser Split Flow LoopTM & Full CondenserTM + High efficiency traysTM

• HP Stripper MP Split Flow SectionTM

• Prilling Tower Vortex GranulatorTM


STANDARD CO2 STRIPPING SPLIT-FLOW ONLY 30% INERTS TO REACTOR


FILM CONDENSER FULL CONDENSER


+50% HEAT TRANSFER COEFFICIENT

and ADDITIONAL REACTION

VOLUME

• Minimum investment

• Short installation


• Equipment modification / enhancement

• Items relocation

• Additional pumping capacity

• Surfaces increasing

• Bottlenecks overcome

• Emission reduction

• Performance increasing


• New MP pre-condenser

(MP vapours Urea Solution heat recovery)

• New Additional 1st Evaporator

(HP scrubber TCW Urea Solution heat recovery)

3.5 bar g steam saving: 25 t/h

CW saving: 1250 m3/h


• Prilling / Evaporation load unchanged (1700 MTPD)

• New evaporation for Fattening Unit (910 MTPD)

• Series installation

• High product quality

• No off-spec. product

• Easily excluded, maximum flexibility


• Capacity: 2610 MTPD high quality solid urea

• Product Quality


UoM Before After

Biuret [% wt.] 0.90 0.85

Moisture [% wt.] 0.32 0.30

Formaldehyde [% wt.] 0.30 0.30

Average diameter [mm] 1.7 2.0

Crushing Strength [N] 7.0 10.0

• Gaseous and Liquid Emissions

Vents from Urea Solution Plant

NH3 < 0.2 kg/MT of urea (prilling excluded)

Air from Fattening Unit

NH3 < 35 mg/Nm3

Urea < 30 mg/Nm3

Treated process condensate (from WWT)

NH3 1 ppm

Urea 1 ppm


• Raw Material Consumption

NH3 568 kg/MT

CO2 734 kg/MT

• Process Utilities Consumption

Steam (21.0 barg @ 290 ⁰C) 900 kg/MT

Cooling Water (ΔT = 10 ⁰C) 80 m3/MT

Electricity 38 kWh/MT


• Turn-Down and Operation

Minimum load 1300 MTPD (50%)

Fattening from 140 to 910 MTPD

MP Section & Vortex lined up very easily and quickly


A REMARKABLE AND PROVEN WAY - GPCA...

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