FERTILIZER INDUSTRY AS ONE OF STATE-OWNED ENTERPRISES

• Pupuk Indonesia and seven subsidiaries operate 14 urea plants and 13 ammonia plant. All of them produce urea but the most complete plant is petrokimia gresik.

• And now it can produce 12,47 million tons fertilizer per year and produce 5,93 million tons basic chemical products per year.

THE HISTORYThe first fertilizer plant (urea) in indonesia is

PUSRI (Pupuk Sriwijaya).Government found Pupuk Indonesia holding

company in 1997 now we better know it as Pupuk Indonesia

Holding Company (PIHC) most of the amonia plant in indonesia using

kellog process from Kellog Brown & Root (KBR)This process provide good energy efficiency

UNIT AMMONIA

Pemurnian Gas alam

Pembuatan gas sintesis

Pemurnian gas sintesis

Sintesis amoniaPurifikasi dan refrigerasi

amoniaAmonia

Recovery

Hydrogen recovery dan

Purge gas recovery

Natural Gas :• Solid Particle• Water• Liquid HC

Knockout Drum

Mercury Removal(Mercury Guard Chamber)

Natural Gas :• Methane• CO2• Mercury• Sulfur

+ Activated CarbonThe activated carbon will absorb mercury.Hg+S HgS

DESULFURISATION• Catalyst Cobalt

Molybdenum(CoMo)• dsHydrotrea

ter

• Catalyst ZnO

• The sulfur will be decrease from 30 ppm to 0,1 ppm

• Can prevent catalyst poisoning

Desulfurizer

PEMBUATAN GAS SINTESISNatural Gas from desulfurizer mixed with steam and enter primery reformer.The mole ratio S:N =3,2:1 must be precise to prevent side reaction.

Outlet gas from primery reforming contain :66% Hydrogen and 13,4% methane

SECONDERY REFORMING

Secondary reformer melanjutkan reaksi primery reformer

Reaction Zone

Combustion Zone atau mixing zone

Kadar Methane gas keluaran secondery reformer berkurang menjadi 0,42% volume

PURIFYING SYN GASCO2 absorber and stripper

CO2 gas needed as a raw material for urea that CO2 is separated by using aMDEA (activated Methyldeetanolamine), then fluids flowed to the CO2 stripper to get ready for the CO2 gas is fed to the urea synthesis reactor

• We can obtained 99% volume Purity of CO2• Reaction of CO2 absorbtion:

• Reaction of CO2 stripper

METHANATOR • Keberadaan CO dan CO2 di amonia converter dapat

merusak katalis oleh sebab itu CO dan CO2 harus diubah menjadi CH4 sebagai inert agar tidak merusak katalis. Proses ini disebut methanasi yang terjadi di methanator

• Methanator use nickel as catalyst• Methane will be recycle

AMMONIA SYNTHESIS• Methanator outlet has pressure and

temperature below the operation condition of ammonia converter. Gas Pressure and Temperature must be raised using compressor and heater.

• The reaction :

AMMONIA CONVERTER

Operation Condition:• 350-500 C• 141 Kg/cm2

REFRIGERATION OF AMMONIAeffuluent of ammonia converter is cooled to 38 C using inlet of ammonia converter. The refrigeration process of ammonia occur in ammonia unitized chiller. This process involve 4 step.

• 38 C - 16,6 C.• 16,6 C - -2,2 C• -2,2 C - -17,8 C• -17,8 C - -33 C

Ammonia stored in a tank as liquid

PROSESSynthesis

Loop

Purification

Concentration

Prilling

Recovery

UNIT UREA

Urea

Katalis

CO2

Amonia

Cair

UREA PROCESSINGThis unit produce urea synthesis by reacting ammonia liquid with CO2 into Ammonium carbamate. Ammonium carbamate is converted into urea. this occur in the urea reactor at 155 kg/cm2 pressure and 182 Celsius.

The hidrogen concentration in CO2 inlet allowed maks 0,8%. So we should remove the hydrogen in dehidrogen coloumn with platinum catalyst before entering urea reactor.

PURIFICATIONUrea synthesis (liquid) contain urea, amonium karbamat and excess ammonia. So urea will separate from other components by feed it to stripper. The consentration of urea synthesis is 67%. The further urea’s purification in LP decomposer and produce 98,8% volume urea synthesis, 0,8 % NH3 and 0,4 % CO2.

CONCENTRATOR

Liquid urea is heated to a temperature of 132 Celsius in a vacuum pressure, it will produce a liquid urea concentration of 98% by weight. then the solution was concentrated in a concentrator to a final weight of 99.8% with molten pump and pumped to the top of the prilling tower

PRILLINGprilling tower has 50 meters high

and diameter of 14.5 meters. 99.8% urea concentrated sprayed and cooled to become solid. urea droplet will contact with cold air from the bottom of the tower and form urea prill