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Boosting profitability for urea producers
6th GPCA Fertilizer Convention, Dubai, 14-16 September 2015
Integration of urea-formaldehyde production
2 Mission statement for GPCA Fertilizer convention
Innovating for growth: Ensuring an efficient and sustainable
future.
3
INNOVATION
IS CREATING RESULTS BY DOING NEW THINGS
4
Formaldehyde-based resins
Without formaldehyde-based resins
Utilized Wasted
63%
With formaldehyde-based resins
Utilized Wasted
95%
Source: American Chemistry Council 2015
Improving wood resources
5
Urea-Formaldehyde Concentrate Advantages in urea production
• Production • Improved anti-caking properties
• Increased crush strength
• Less powder formation
• More uniform size of particles
• No urea product discoloration
• End-user • Less urea lost due to wind
• Slower release of fertilizer
• Better utilisation of nitrogen
• Higher crop yields
• Better utilzation of natural gas
6
Co-production of UFC-85 fits in easily with Urea production Process steps
Feed purification
Primary reforming
Autothermal reforming
Natural gas
MeOH Formaldehyde
synthesis UFC-85 / AF
product
Air
Shift CO2 removal Methanation NH3 synthesis NH3 product
Urea synthesis
NH3
Urea product
Absorption
Form-aldehyde
UFC-85
7
Integration of formaldehyde units in urea plants Topsoe has 25 years of experience
• Integration makes sense financially
• It allows for constant supply
• T/A’s can be easily coordinated
• Operation of the plants is easy and can use exiting man-power
• Fast installation and commissioning
• High degree of quality assurance
• Compact design
• Fully automatic operation
• Short payback time
8
The Topsoe UFC-85 Process Optimal performance
urea solution
Catalytic incinerator
Purified tail gas
Air
Blower
Pump
Methanol
After cooler
Evaporator/ Preheater
Recycle gas
Absorber
UFC Product
9
FK-100 The latest generation formaldehyde synthesis catalyst
• Higher selectivity
• Higher yields
• Lower by-product formation
• Operational flexibility
• Extended catalyst lifetime
• Chromium-free for safe handling
10
Integrated production of UFC-85 What to consider?
• New or existing urea plant?
• Prilling or granulation process?
• Daily quantity
• Local availability and price
• Opportunity for sale of surplus production
11
Methanol and Ammonia prices Price fluctuations make co-production an attractive option
0
200
400
600
800
1000
May/01 May/03 May/05 May/07 May/09 May/11 May/13 May/15
MIDDLE EAST METHANOL AND AMMONIA PRICES USD/ton
Source: Topsoe market research
• Highest profitability for co-production when MeOH > NH3
• UFC-85 manufacturing price is strongly correlated to the MeOH price
• Producers with fixed contract prices are generating larger profits
12
UFC-85 plant An investment in added value
Internal Rate of Return: 33%
Cost Gain
Price for plant and storage $18,000,000 -
0-12 months 0 $6,300,000
12-24 months 0 $6,300,000
24-36 months 0 $6,300,000
36-48 months 0 $6,300,000
48-60 months 0 $6,300,000
60-120 months 0 5 x $6,300,000
Net Present Value : $20,700,000
13
Optimisation of UFC85 quality for improved production
Topsoe technical service improves product performance
• Challenge • Improving UFC85 to improve product at a
neighbouring consumer
• Too much Dimethyluron gave poor ‘glue’ performance
• Solution • Contacted Topsoe technical services for
analysis, sampling and recommendations.
• Absorber operation modified with respect to, i.e. recycle flows, pH and temperatures
• Outcome • Improved product quality; Dramatic reduction
in dimethyluron content
• Improved satisfaction from customer
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Before After
Dimethyloluron
Methylenediurea
N,N'-dimethylolurea
Oxymethylenediurea
Trimethylolurea
14
Efficient removal of VOC’s from Formaldehyde plant
Reliable option to improve environmental performance
• Challenge • Reduce VOC emissions to comply with
environmental regulations
• Purge gas contains up to 2.2 vol% VOC’s
• Solution • Installed Topsoe CK-304 and CK-322 catalysts
• CK-322 has high performance in the hot-zone of the incinerator without using precious metals
• Outcome • VOC conversion > 99%
• Formaldehyde < 10 mg/Nm3
• Autothermal operation at both minimum and maximum operation
15
Chemanol An innovative company since 1991
• 18 expansion projects over 24 years
• Product portfolio
• Methanol
• Formaldehyde
• Derivatives
• Revenue • 2004: 60 mil USD
• 2013: 240 mil USD
16
Chemanol and Topsoe Expansion projects over 23 years
67 MTPD
formaldehyde
1991
67 MTPD
formaldehyde
1993
120 MTPD
formaldehyde
1996
400 MTPD
formaldehyde
2008
Revamp
(117) MTPD
2002
Revamp
(117) MTPD
2004
Revamp
(220) MTPD
1998
700 MTPD
Methanol
2009
17
Topsoe co-production references 16 units in operation
Source: Topsoe co-production reference list 2015
4
18
Thank You To find out more or get in contact
www.topsoe.com
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