Leading fertilizer know-how - · PDF filethyssenkrupp Industrial Solutions licenses Stamicarbon’s CO 2 stripping process variants, which are unrivalled in their efficiency

Industrial Solutions

UreaLeading fertilizer know-how

Cem

ent Mining Steel

Aut

omot

ive

A

eros

pac

e

Mar

ine/

Shipbuilding

Fertilizer Chemical

Thepoweroftrueefficiency

The Business Area Industrial Solutions of thyssenkrupp is a world leaderforplanning,constructionandserviceinthefieldofindustrialplants and systems. Together with our customers we develop solutionsatthehighestlevelanddeliverefficiency,reliabilityandsustainabilitythroughouttheentirelifecycle.Ourglobalnetwork,witharound19,000employeesat70locations,enablesustoprovi-deturnkeysolutionsworldwidewhichsetnewbenchmarkswiththeirhigh productivity and particularly resource conserving technologies.

We are at home in many different industries. Along with chemical, fertilizer,coking,refinery,cementandotherindustrialplants,ourportfolio also includes equipment for open-cast mining, ore proces-sing and transshipment, as well as associated services. In the naval sector,wearealeadingglobalsystemsupplierforsubmarinesandsurface vessels. As an important system partner to our customers intheautomotive,aerospaceandbatteryindustries,weoptimizethevalue chain and improve performance.

Contents04 Introduction

06 The urea process

06 - Fundamentals

08 - Synthesis

12 - Recirculation and evaporation

13 - Desorption and hydrolysis

14 - FeaturesoftheStamicarbon Urea 2000plusTMCO

2 stripping process

16 - UFTfluidbedgranulation

17 - FeaturesoftheUFTfluidbedgranulationprocess

19 Consumption figures and product characteristics

22 Services for our customers

23 Recent references

Introduction

thyssenkrupp Industrial Solutions has inherited a wealth of know-how and experience from Uhde, a renowned partner in the engineering and construction of urea plants for more than four decades and now a constitu-entpartofthecompany.Plantsbuiltbythecompanyare located all over the world, some in regions with ex- treme climatic conditions.

In the last ten years thyssenkrupp Industrial Solutionshasboastedafurtherlandmarkinitsfertilizerplantbu- siness. Fourteen new fertilizer plants with a total annual ureacapacityofalmosttwelvemilliontonneshavebeenconstructed and commissioned.

Three years ago thyssenkrupp Industrial Solutions achieved successfully to conquer the North American market with the award of the contracts for two large CFI Industries fertilizer complexes, in Donaldsonville, LouisianaandPortNeal,Iowa,respectivelyandafirst-of-its-kind 2,200 t/day Urea Pool Reactor plant with an MPinsteadofHPScrubberforAIROrascom,Wever,Iowa. The Donaldsonville complex and the Wever plant areexpectedtobecommissionedin2015andthe Port Neal complex in 2016.

OnehighlightofthepreviousyearswastheengineeringandcommissioningofthebiggestureasolutionplantinEurope,YARASluiskilB.V.,whichwasbuiltonabrown-fieldsitenearavillage.Theplantwasdesignedtopro- duce two different qualities of urea solution: for production of AdBlue/DEF and feed for granulation and prilling.

To meet stringent emission requirements special fea-tures were provided, such as acid washing of process off-gases and an automatic catch pot system including ablow-offabsorberfortheeventofatuberuptureinthe HP synthesis equipment. Another special feature of the plant is that it includes 28 air coolers with a total heat duty of 187 megawatts and a total area of 3,900 m2

forplantcoolingandturbinesteamcondensing.

For the production of urea thyssenkrupp Industrial Solutions offers a portfolio containing the top state- of-the-art technologies from leading licensors:

• UreatechnologyfromStamicarbon,Netherlands, including Urea 2000plusTM and AvancoreTM, Stamicarbon’slatestdevelopmentsfortheirCO

2

stripping process.

• FluidbedgranulationfromUhdeFertilizerTechnology andStamicarbon,bothofNetherlands

• PrillingtechnologyfromStamicarbon.

With the acquisition of the exclusive licence rights for thefluidbedureagranulationtechnologyfromYara Fertilizer Technology, Uhde Fertilizer Technology (UFT) has taken over the full rights to this outstanding gran-ulation technology, which is used in more than 50 urea plantsandisthustheworld’smostsuccessful.

thyssenkruppIndustrialSolutions’references,whichinclude a wide range of services from revamps to turn- keyprojects,havecontributedtoourreputationforplantswithhighprocessefficiencyandreliability,lowemissions and excellent product quality.

In addition, thyssenkrupp Industrial Solutions meets customer requirements in offering tailored emissions management(e.g.acidicscrubbing,flaringofemis-sions,absorbingtechnology,etc.),aswellassafetyanalyses and assistance in permitting management (includingHAZOP,SIL,LOPA,QRA,safetyreports, dispersion calculations).

QAFCO4ammonia/ureacomplexinMesaieed,Qatar,successfully

commissionedbythyssenkruppIndustrialSolutionsin2004.

Capacities: 2,000 t/day of ammonia

3,200 t/day of urea

3,500 t/day granulation unit

4

SAFCOIVfertilizercomplex

inAlJubail,SaudiArabia.


3,250 t/day of urea


5

The urea process Fundamentals

Ureaisformedbyreactingammoniawithcarbondiox-ide.Thisfirstformstheintermediate,carbamate,whichthenbreaksdownintoureaandwater.Thereactionisrelatively slow and incomplete so unreacted feedstocks needtoberemovedfromthereactionproductafterthereaction.Thiscanbedonebyusingfreshfeedstock,eitherCO

2 or ammonia, as the stripping agent. When

CO2 isused,itisknownasaCO

2 stripping process.

thyssenkruppIndustrialSolutionslicensesStamicarbon’s CO

2 stripping process variants, which are unrivalled in

theirefficiency.

Asshownintheblockdiagram,theprocessissimplic-ity itself, allowing excess unconverted ammonia from thesynthesissectiontoberecycledascarbamateinjust one single stage. In this recirculation section the unconverted NH

3andCO

2 are removed from the main

productstream,condensedbackintocarbamateandrecycled to the synthesis section using a high-pressure carbamatepump.

Thefeedstockconsumptionfiguresarealmostequal tothestoichiometricvaluesforammoniaandcarbondioxide, leaving no room for further reduction.

Theeffluentandemissionvaluesareextremelylowandmeet the environmental requirements of most countries.

Process simplicity, with less equipment and fewer pro-cess steps than any other process, guarantees high on-streamreliability,easeofoperationandlowmainte-nancecosts.Furthermore,highcapacitiesarefeasiblein single-line plants.

Reaction sequences in the urea process

Block diagram of the CO2 stripping process

6

Yara Sluiskil, Netherlands

Commissionedby

thyssenkrupp Industrial Solutions in 2011

Capacity: 3,500 t/day of urea solution

7

The urea processSynthesis

These include: (see following pages for diagrams)

• Urea 2000plusTM with standard pool condenser.

• Urea 2000plusTM with pool reactor.

• Urea AvancoreTM with pool condenser.

• Urea 2000plusTM with pool reactor and MPsrubber.

ThepoolcondenserisbasicallyahorizontalreactorvesselwithasubmergedU-tubebun- dle.Itcombinesthefunctionofthefalling-film-typecarbamatecondenserinthecon- ventionalCO

2 stripping process with part of

the reactor function. A 30-40% reduction inthereactorvolumeisachievedbyshiftingthis reaction volume to the pool condenser.

This is of particular advantage for high- capacity single-train plants since the reactor is one of the heaviest items of equipment.

The pool condenser represents the state- of-the-art concept in modern urea plants.

thyssenkrupp Industrial Solutions engineer- edandconstructeditsfirstUrea2000plusTM urea plant with pool condenser for the QAFCO4fertilizercomplex.TheSAFCOIVammonia/urea fertilizer complex provides thyssenkrupp Industrial Solutions with a further reference for this technology.

TheadvantagesofStamicarbon’sprovenUrea 2000plusTM technology with pool condenser are:

• Investment cost savings due to the reduction in size of high-pressure items.

• Operationaladvantagesdrawnfrom recent experience with a pool condenser within a synthesis loop, which include -morestablelevel/pressurecontrol - less sensitivity to changes in the load or the N/C ratio.

• A reduced construction height, resulting in reduced construction costs.

A further step towards full integration of equipment items, such as the high-pressure scrubber,thepoolcondenserandtheureareactor, is the horizontal pool reactor, as usedinStamicarbon’sUrea2000plusTM with pool reactor technology.

thyssenkrupp Industrial Solutions was Stamicarbon’spartnerofchoiceinlaunchingthissynthesistechnologyonthemarketbyintegratingtheworld’sfirstpoolreactorintoDSM’snewureaplantatGeleen,Neth-erlands,andcommissioningtheworld’ssecond pool reactor in 2004. Meanwhile, the world`sbiggestpoolreactorhasbeenengi-neeredbythyssenkruppIndustrialSolutionsand is expected to come on stream in 2016.

InthesynthesissectionammoniaandCO2

are exothermically condensed to ammonium carbamateandtheresultingcarbamateis endothermically dehydrated to urea and water.

The main quantity of ammonia is fed to the synthesis process via a high-pressure pump. Therequiredcarbondioxideismixedwitha small quantity of air to prevent corrosion and compressed to synthesis pressure in a multi-stage compressor. It is then fed via the stripper into the synthesis section under maintenance of the optimum process condi-tionsofapprox.140barand180°C.

Itisourpolicytoofferourcustomersthemostreliablesynthesisprocessesbasedonstate-of-the-arttechnology.

Turkmendokunhimiya’sUreasynthesis

plant with Urea 2000plusTM pool reactor

at Tecen, Turkmenistan

Capacity: 1,050 t/day of urea

8

In the proven 2000plusTM process hydrogen isremovedfromthefreshcarbondioxidefeed stream in the H

2 removal reactor lo-

catedbetweenthecompressionstages.The synthesis reaction results in a chemical equilibrium;partoftheammoniaandcar-bondioxideisnotconvertedtoureaandwaterandneedstoberemovedfromthereactionmixturebymeansofastrippingprocess,usingcarbondioxidetostripoffthe unreacted ammonia (see page 6). This designfeatureishighlyeffectivebecauseofits low energy requirement and retention of the unconverted reactants in the synthesis section.

After stripping, the stripper offgas is then introduced into the high-pressure pool condenser together with fresh ammonia and the carbamatesolutionfromthehigh-pressurescrubber.Theheatreleasedbytheformation ofcarbamateinthehigh-pressurepoolcon- denser is recovered to generate low-pressure steam.

Subsequently,thegasandliquidmixtureflowsintotheureareactor,inwhichthemain urea formation takes place. The liquid reac-tion mixture, which leaves the reactor via an overflow,issenttothetopofthestripper.

The exhaust gases (inert gases, NH3,CO

2

and H2O)whichareseparatedfromthe

liquidatthereactortoparescrubbedinthehigh-pressurescrubberwithcarbamatesolution from the low-pressure recirculation section. Thus, most of the gases are recov-ered and returned to the pool condenser via the high-pressure ejector. The non-con-densableswithdrawnfromthehigh-pressurescrubberarescrubbedinalow-pressureabsorber,therebyminimisingammoniaemissions.

Thehigh-pressuresectionsofrecentlybuilturea plants are made of Safurex®, a duplex steelspeciallydevelopedfortheStamicarbonureaprocessbySandvikofSweden.Thissteel offers excellent corrosion resistance

andhightenacity,aswellasthepossibility of reducing or omitting the addition of passi-vation air.

Safurex® is also used systematically in the new AvancoreTM process. As passivation air is no longer required, there are the following advantages:

• Lower investment costs

• Reactorcanbeplacedatgroundlevel, resulting in savings due to reduced construction height

• H2removalreactorandairblowerareno

longerneeded;

• HPscrubbercanbereplacedbyamuch simplerMPscrubber

• Higher safety standard. The formation of explosive gas mixtures at the plant is ruled out as oxygen is no longer added.

3D model of Urea 2000plusTM

withpoolcondenserforSAFCOIV,

AlJubail,SaudiArabia

3D model of Urea 2000plusTM with

pool reactor for Turkmendokunhimiya,

Tecen, Turkmenistan

9

1

AcidAS/AN

AcidAS/AN

Stamicarbon Urea

24

3

7

9

10

11

12

14

13

1815

16

20

2117

22

23

24

2627

25

29

30

31

32

OR

*

33

34

3

7a

24

4

1

5b

28

19

5a

8

13

13a

8

6

1. CO2 compressor2. H2 removal reactor3. HP ammonia pump4. HP heat e xchanger (stripper)5. HP carbamate condenser (HPCC)

5.a Pool condenser 5.b Pool reactor

6. Reactor7. HP scrubber

7.a HP scrubber sphere 7.b MP scrubber

8. LP absorber9. Dissociation heater and separator

10. LP carbamate condenser 11. Level tank for LPCC 12. HP carbamate pump 13. Atmospheric absorber 13.a Acid scrubber 14. Flash tank 15. Pre-evaporator 16. Urea solution tank

17. Urea solution18. Evaporator19. Condenser20. Flash tank condenser21. NH3 water tank22. Reflux condenser23. Level tank f. r eflux cond.24. First and second desorber25. Hydrolyser

26. Urea melt pump27. Granulator28. First cooler29. Bucket elevator30. Vibrating scr eens31. Final cooler

32.a Granulator scrubber with acid stage32. Granulator scrubber

33. Cooler scrubber34. Roll crusher

NH3

CO2

Air

1

5b

2

12

3

7b

NH3

CO2

Air

2000plus™synthesis with pool condenser Recirculation Evaporation Desorption & hydrolysis Fluid bed granulation

Stamicarbon Urea 2000plus™synthesis with pool reactor

Stamicarbon Urea 2000plus™synthesis with pool reactor and MP scrubber

Special features for reduction of plant emissionsAcid scrubbing for process vents

Gases

Liquids

Urea

Steam

Acid / Salt Solution of acid

/ cooling water

CO2

Air

AirAirAir

Ureagranules

Synthesis section Granulation section

Purified

UF

processwater

NH3

32a 33

Nitric acid + NH3 Ammonium nitrate (AN) solution Sulphuric acid + NH

3 Ammonium sulphate (AS) solution

Liquid fertilizer Liquid fertilizer AS crystals or pellets Incorporation in granulesUAN solution

* Recycle to evaporation

Recycling from

granulation

10

1

AcidAS/AN

AcidAS/AN

Stamicarbon Urea

24

3

7

9

10

11

12

14

13

1815

16

20

2117

22

23

24

2627

25

29

30

31

32

OR

*

33

34

3

7a

24

4

1

5b

28

19

5a

8

13

13a

8

6

1. CO2 compressor2. H2 removal reactor3. HP ammonia pump4. HP heat e xchanger (stripper)5. HP carbamate condenser (HPCC)

5.a Pool condenser 5.b Pool reactor

6. Reactor7. HP scrubber

7.a HP scrubber sphere 7.b MP scrubber

8. LP absorber9. Dissociation heater and separator

10. LP carbamate condenser 11. Level tank for LPCC 12. HP carbamate pump 13. Atmospheric absorber 13.a Acid scrubber 14. Flash tank 15. Pre-evaporator 16. Urea solution tank

17. Urea solution18. Evaporator19. Condenser20. Flash tank condenser21. NH3 water tank22. Reflux condenser23. Level tank f. r eflux cond.24. First and second desorber25. Hydrolyser

26. Urea melt pump27. Granulator28. First cooler29. Bucket elevator30. Vibrating scr eens31. Final cooler

32.a Granulator scrubber with acid stage32. Granulator scrubber

33. Cooler scrubber34. Roll crusher

NH3

CO2

Air

1

5b

2

12

3

7b

NH3

CO2

Air

2000plus™synthesis with pool condenser Recirculation Evaporation Desorption & hydrolysis Fluid bed granulation

Stamicarbon Urea 2000plus™synthesis with pool reactor

Stamicarbon Urea 2000plus™synthesis with pool reactor and MP scrubber

Special features for reduction of plant emissionsAcid scrubbing for process vents

Gases

Liquids

Urea

Steam

Acid / Salt Solution of acid

/ cooling water

CO2

Air

AirAirAir

Ureagranules

Synthesis section Granulation section

Purified

UF

processwater

NH3

32a 33

Nitric acid + NH3 Ammonium nitrate (AN) solution Sulphuric acid + NH

3 Ammonium sulphate (AS) solution

Liquid fertilizer Liquid fertilizer AS crystals or pellets Incorporation in granulesUAN solution

* Recycle to evaporation

Recycling from

granulation

11

The urea process Recirculation and evaporation

Onlyonerecirculationstageisrequiredduetothelowammoniaandcarbondioxidecon-centrations in the stripped urea solution.

Theammoniaandcarbondioxidestillcon-tainedintheureasolutiondischargedbythestripper are recovered in this low-pressure stage. The ideal ratio of ammonia and car-bondioxideintherecoveredgasesmeansthatdilutionbytheresultingammoniumcar-bamatesolutionisminimiseddespitethelowpressureofaround4bar.Asaresult,thecarbamatepumprequiresamuchlowerca-pacity and less unwanted water is recycled to the synthesis section.

The urea solution leaving the recirculation section is further concentrated in the evap-oration section to meet the requirements of the granulation process. Vacuum evapora-tionischosentominimisebiuretformation.A urea solution tank is provided to collect the solution during periodic cleaning of the granulator.

The entire process condensate is collected in a process condensate tank, from where it is sent to the desorption section.

OrascomConstructionIndustriesfor

SonatrachOrascomFertilizerCompany(Sorfert)

Arzew, Algeria

3D model of urea solution and

granulation plant with 3,450 t/day capacity

12

The urea process Desorption and hydrolysis

Inthefirstdesorber,ammoniaandcarbondioxide are expelled from the process condensate. The condensate is then pumped to the hydrolysis column, where any urea that is still present is dissociated. The ammonia andcarbondioxidethusliberatedarede-sorbedintheseconddesorberwiththeaidof steam.

Thegasleavingthefirstdesorberatthetopisfedtotherefluxcondenser,wherethe

NH3,CO

2 and H

2Ovapoursarecondensed,

and the majority is then pumped to the LP carbamatecondenser.Therestisreturnedtothefirstdesorber.

The process water leaving the second de-sorbermeetseventhemoststringentsta-tutory environmental requirements, allowing thiswastewatertobeusedasmake-upforthecoolingwatersystemorevenasboilerfeedwater. Consequently, there is no waste- watereffluentstreamfromthisureaprocess.

13

The urea process FeaturesoftheStamicarbon Urea 2000plusTMCO

2 stripping process

TheStamicarbonUrea2000plusTM CO

2 stripping process offers a

varietyofbenefits,includinglower capital investment and

operatingcosts;areductioninenergy consumption, main-

tenancecostsandemissions;increasedefficiencyandon-stream

time;andimprovedsafetyandreliability.Thesebenefitsaredescribedingreaterdetailon

the right:

EASY MAINTENANCE

Thelimitedamountofequipmentandtheplant’scompactarrangementgreatlyfacili-tate plant maintenance.

Furthermore, our layout guarantees easy access for servicing and maintenance with all rotating equipment located at ground level.

LARGE SINGLE-STREAM PLANTS

thyssenkrupp Industrial Solutions is a world leader in the construction of urea plants and our commitment to providing advanced technology for the future constitutes the drivingforcebehindourin-houseresearchanddevelopment:

Overthepastfouryearsadailyproductioncapacityof3,500t/dayofureasolutionhasbecomethenormalcapacityforsingle-trainureasolutionplantsengineered,builtandcommissionedbythyssenkruppIndustrialSolutions.

Engineeringstudiesforevenlargerplantshavealreadybeencompleted.Single-traincapacitiesof4,000t/dayandmorearetechnicallypossible,whichmeansStamicarbontechnologyandthyssenkruppIndustrialSolutions‘know-howareavailabletobuildthelargest urea plants in the world.

TheAbuQirIIIplantinEgyptprovidesaforetasteofthefuture,sinceitsdesorptionandhydrolysissectionpurifiestheprocesscondensatefromtwoplantsandisequiva-lent in size to a condensate treatment section of a 3,700 t/day urea plant.

HIGH SAFETY STANDARDS

Theprocessfeed,inparticularCO2,containscombustiblessuchashydrogen.Ifpre-

cautionsarenottaken,thesecombustiblescancombinewiththeoxygeninthepas-sivationairtocreateahighlyflammableatmosphere.Althoughthisphenomenonex-istsinallcompetitiveprocesses,noneuseStamicarbon’ssafetyprecautions,primarilya hydrogen removal reactor and continuous monitoring. Equipment designed to cope with the failure of these eliminates the danger to personnel and equipment.

LOWERINVESTMENTANDHIGHERRELIABILITY

SAFUREX®,anewmaterialspeciallydevelopedfortheStamicarbonprocessbythecompanySandvik,nowenablesthyssenkruppIndustrialSolutionstoofferitscustom-ersanevengreaterdegreeofplantreliability.

Itsimprovedcorrosionresistanceincarbamatesolutionsandgreaterresistancetostress corrosion cracking make the new material a perfect choice. In addition, its superiormechanicalpropertiesallowwallthicknessestobereducedwithoutcom-promising strength. As a synthesis unit made completely of SAFUREX® does not requiretheadditionofpassivationoxygen,itsefficiencyisenhancedandtheriskofexplosion is eliminated.

SAFUREX®paysoff,bothininvestmentandintheservicelifeofyourplant.SAFCOIVistheworld’sfirstplantinwhichtheentiresynthesisunitismanufacturedfrom SAFUREX®.

ON-STREAMTIME

Intoday’scompetitivemarketunscheduleddowntimeismorecostlythaneverbefore.Operationalsimplicitycombinedwithgravityflow,fewerprocesssteps,lesssynthesisequipment and extremely moderate synthesis conditions facilitate operation and guar-antee high on-stream times.Theoperatingtimebetweenplannedshutdownshas,inthemeantime,beenincreasedtoaremarkablefouryearsofoperation.

14

PROCESSEFFICIENCY

TheprocessconditionsintheCO2 stripping process result in an optimum conversion

ofbothreactants,eliminatingtheneedforanMPrecirculationsectionandapureammonia recycle.

StrippingwithCO2,whichismuchlesssolubleinureathanNH

3,contributessubstan-

tially to the extremely low recycle rates.

CO2 and NH

3consumptionhavebeenreducedtoalmoststoichiometricvaluesthrough

continuous process improvement with respect to emissions.

LOWCORROSION

Theaggresivenatureoftheprocessfluidsmeansthattheprocesswiththelowesttemperature will ultimately create the least corrosive conditions.

Uniquepreventiveprocessconditionsandapplicationofthebestavailableconstruc-tion materials minimise corrosion and achieve outstanding on-stream factors. There is no need for costly zirconium or titanium materials.

LOWUTILITIESCONSUMPTION

Thefavourableprocessconditionsallowexcellentheatrecoverywithintheureaunit,forinstancetherecoveryofheatreleasedduringcarbamatecondensation.

A steam system integrated into the ammonia complex improves overall utility con-sumption.Lowsynthesispressure,lowcarbamaterecycleandthefactthatwedonothave a separate ammonia recycle, are all factors which minimise energy consumption.

LOWEMISSIONS

The low NH3/CO

2ratioreducesthecontentoffreeammoniaintheureasolution,thereby

minimisingammoniaemissionsinthefinishingsection.

Applicationofstate-of-the-arttechnologyfortreatinggaseousandliquideffluentsen-suresminimalenvironmentalimpact.Theresult:apurifiedprocesscondensatethatcanbereintroducedasmake-upwaterforcoolingwaterorasboilerfeedwater.

SIMPLEOPERATION

The process involves far less equipment and fewer process steps than competitive processes and, with its unique measurement of the NH

3/CO

2 ratio using an advanced

density meter, operational comfort is always ensured.

We take full advantage of the advances in computer control technology and supply advanced process control systems to suit the needs of your operators.

To facilitate process handling even further, we also provide operator training on pro-cess simulators.

Blocking-in of the synthesis loop during plant shutdown (up to 72 hours) greatly facili-tatesrestartandenablesarapidreturntoproduction.

Thehighpressurecentrifugalpumpsinammoniaandcarbamateservice,whichwereintroducedbythyssenkruppIndustrialSolutionsanddevelopedtogetherwithFlow-serve (Irving, USA), have more than lived up to expectations: In operation at the QAFCO4plantssincelateDecember2004,theyhaveprovedthemselvestobehighlyreliableandtorequireminimalmaintenance.

+ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + +

15

The urea process UFTfluidbedgranulation

TheUFTfluidbedgranulationprocessistheleadinggranulationtechnologybecauseofitshighefficiencyandagranulatorthaten- sures excellent product quality with extremely low solids recycle rates. The process offers maximumoperatingflexibilityandreliabilityas well as minimum maintenance require-ments and the need for fewer operating staff. Moreover, the fact that it produces no wastewater and only minimal dust emissions also means it conforms to the most stringent environmental laws, while producing extremely hard, round granules that are resistant to crushingandabrasion.Thesegranulescanbeproducedinawiderangeofpre-definedsizes (see page 17 for more details of the advantages.)

Thisadvancedprocesshasenabledtheconstructionoftheworld’slargestsingle-train granulation plants with a capacity of 3,850 t/day.

The UFT process comprises the following steps. Formaldehyde is added to the urea meltasagranulationaidbeforeitisinjectedinto the granulator. The granulation mode causes accretion, which means that granules areformedthroughsolidificationoftheureamelt deposited on the seed material.

Fluidisationair,whichisnotdehumidifiedeven in very hot, damp climates, is supplied to the product layer through a perforated plate. The granulated product extracted from thegranulatoriscooleddowninthefirstfluidbedcoolerandliftedbybucketelevatorstothe screening section.

Any oversize material is crushed and returned to the granulator as seeding particles together with any undersize grains.

Thespecification-gradeproductissenttostorageafterfinalcooling.

Urea dust entrained in the air from the granulator,thefluidbedcoolersandvariousde- dustingpoints,isrecoveredinascrubbingsystem.

Process condensate from the desorption section is used as make-up water for the scrubbingliquid,whichisrecycledtotheevaporation section as 45% solution.

Stamicarbon’s granulation technologyIn1995Stamicarbonintroduceditspatentedgranulation technology, which was devel- oped in the 1970s and 1980s. This technology,firstappliedbythyssenkruppIndustrial Solutions for three grassroots plantsinEgypt,canbeofferedasanalternative.

Viewofafluidbedgranulator

16

The urea process FeaturesoftheUFTfluidbedgranulationprocess

FlexibilityItsoutstandingflexibilityallowstheproduc-tion of virtually all requested product size distributions,fromanaveragediameterof 2 to 8 mm, in the same plant without inter- ruptingoperationforsizechange.Adjustableturndown ratios with less than 50% of the nominalcapacityarefeasible.Furterhmore,the granulation unit has simple start-up and shutdown procedures.

On-stream timeTheinherentreliabilityoftheprocessislargely due to the fact that the granulators havenomovingparts,theblowersandfansareonlyusedforthetreatmentofambientorscrubbedairandnobeltconveyorsarerequired to transport solids within the granulation unit.

EmissionsA new exclusive cooperation with KIMRE means that an even more cost-effective scrubbingtechnologyisnowusedtorecoverthevaluableproduct.Thehorizontal-typescrubbersallowcustomisedconfigurationswithspeciallydesignedscrubbingpadsforveryhighseparationefficiencyandlowpres- sure drop to meet the most stringent environmental requirements.

Large single-train capacitiesWith its compact granulation unit the process is the ideal choice for large single-train urea production plants. The granulation units forSAFCOIVinSaudiArabiaandQAFCO4inQatarareexcellentexampleswiththeircapacities of 3,600 t/day and 3,500 t/day of urea granules, respectively.

Theworld`sbiggestgranulationplantalready has a capacity of 3,850 t/day.

Product qualityThe granules produced are of a high quality with a well-rounded shape, and they are very hard and particularly resistant to crushingandabrasion,makingthemdustfree,non-cakingandcompletelyfree-flowing.

High efficiencyWith its sophisticated product size select- ivity,thegranulatorminimisesboththeurearecycle and the load for the evaporation section.

TheUFTfluidbedtechnologyisrenownedasthemostsuccessfulgranulationprocess. thyssenkrupp Industrial Solutions now has unlimited access to this technology, which features the following highlights:

Urea granules are produced in all

requestedproductsizedistributions.

17

18

Feedstock

NH3 (100%) ..................................................... kg .............. 564

CO2 (100%) ..................................................... kg .............. 730

Utilities, power and auxiliary materials(1)

Steam(108barabs./505°C) .............................. kg .............. 860Coolingwater(T=10°C) ..................................... m3 ................88Electric power .................................................. kWh................58Formaldehyde ................................................... kg ..................4.5

Product quality

N content ....................................................... wt.% ..............46.2Biuret content ................................................. wt.% ................0.8Moisture content ............................................. wt.% ................0.2Formaldehyde content ..................................... wt.% ................0.45Crushing strength .............................................. kg ..................3.0 (3.0 mm Ø)Particle size (typical) .......................................... % ................90 (2.0 - 4.0 mm Ø)

Wastewater quality

Urea concentration ...................................... ppmbywt. ............1Ammonia concentration ............................... ppmbywt. ............1

Effl uents from granulation

Urea dust ..................................................... mg / Nm3 ........... 30NH

3(2) ........................................................... mg / Nm3 ............ 30 / 140

(1) IncludingCO2 compression

(2) With/withoutacidicscrubbing,whichgeneratesasmallquantityofammoniumsulphateorammoniumnitratesolution.

Allconsumptionfiguresarepermetrictonoffinalproductandserveasgeneralinformationonly.Localconditionsmayhaveaconsiderableinfluenceontheperformancefigures.

Consumptionfigures and product characteristics

Theworld’slargestureastoreattheQAFCO4

fertilizercomplexinMesaieed,Qatar.

Withasizeofaboutsixfootballpitchesand

a capacity of 160,000 tonnes it is truly gigantic.

19

20

Fertilizercomplexno.4(SAFCOIV)forSaudi

ArabianFertilizerCompanyinAlJubail,SaudiArabia


3,250 t/day of urea


21

Services for our customers

thyssenkrupp Industrial Solutions is dedicated to provi-ding its customers with a wide range of services and to supporting them in their efforts to succeed in their line ofbusiness.

With our worldwide network of local organisations and experienced local representatives, as well as first-class backingfromourheadoffice,wehavetheidealqualifi-cations to achieve this goal.

We at thyssenkrupp Industrial Solutions place particu-lar importance on interacting with our customers at an earlystagetocombinetheirambitionandexpertisewith our experience.

Whenever we can, we give potential customers the op-portunity to visit operating plants and to personally eva-luatesuchmattersasprocessoperability,maintenanceandon-streamtime.Weaimtobuildourfuturebusi-ness on the confidence our customers place in us.

We provide the entire spectrum of services associated withanEPCcontractor,fromtheinitialfeasibilitystudy,through financing concepts and project management right up to the commissioning of units and grassroots plants.

Ourimpressiveportfolioofservicesincludes:

• Feasibilitystudies/technologyselection.

• Project management.

• Arrangement of financing schemes.

• Financialguidancebasedonanintimate knowledge of local laws, regulations and tax procedures.

• Environmental studies.

• Licensingincl.basic/detailengineering.

• Utilities / offsites / infrastructure.

• Procurement / inspection / transportation services.

• Civil works and erection.

• Commissioning.

• Training of operating personnel using operator training simulator.

• Plant operation support / plant maintenance.

• Remote Performance Management (Teleservice).

Weliketocultivateourbusinessrelationshipsandlearnmoreaboutthefuturegoalsofourcustomers.Ourafter- sales services include regular consultancy visits which keeptheownerinformedaboutthelatestdevelopmentsor revamping options.

Ourpolicyistoensureutmostqualityintheimplemen-tation of our projects. We work worldwide to the same quality standard, certified according to:

DIN/ISO9001/EN29001.

We remain in contact with our customers even after projectcompletion.Partneringisourbyword.

By organising and supporting technical symposia, we promoteactivecommunicationbetweencustomers,licensors, partners, operators and our specialists. This enablesourcustomerstobenefitfromthedevelopmentof new technologies and the exchange of experience aswellastroubleshootinginformation.

thyssenkrupp Industrial Solutions stands for tailor-made concepts and international competence. For more information contact one of the thyssenkrupp IndustrialSolutionsofficesnearyouorvisitourwebsite:

www.thyssenkrupp-industrial-solutions.com

22

Completion Customer Plant Site Plant Capacity Licensor or Contract Process Know-how Project Notes

2016 AIROrascom Wever, Ureaplant Ureasolution 2,200t/d Stamicarbon E,P,Poolreactor, Iowa,USA Granulation Ureagranules 1,200t/d UFT Bulkflowcooler

2016 CFIndustriesInc.(CFI) PortNeal, Ureaplant Ureasolution 3,500t/d Stamicarbon E,P Iowa, USA Granulation Urea granules 3,500 t/d UFT

2015 CFIndustriesInc.(CFI) Donaldsonville,Ureaplant Ureasolution 3,500t/d Stamicarbon E,P Louisiana, USA Granulation Urea granules 3,500 t/d UFT

2015 EgyptianNitrogen Damietta, Ureaplant Ureasolution 2x1,925t/d Stamicarbon Turnkey ProductsCo.SAE Egypt Granulation Ureagranules2x2,000t/d Stamicarbon

2012 SamsungforRuwais Ruwais, Ureaplant Ureasolution 3,500t/d Stamicarbon E,P FertilizerIndustries AbuDhabi,UAE Granulation Ureagranules 3,500t/d UFT

2012 OrascomConstruction Arzew, Ureaplant Ureasolution 3,450t/d Stamicarbon E,P Industries for Sonatrach Algeria Granulation Urea granules 3,450 t/d UFT OrascomFertilizer Company (Sorfert)

2011 YaraSluiskilB.V. Sluiskil, Ureaplant Ureasolution 3,500t/d Stamicarbon Turnkey Netherlands

2008 MisrOilProcessingCo. Damietta, Ureaplant Ureasolution 1,925t/d Stamicarbon Turnkey Egypt Granulation Urea granules 2,000 t/d UFT

2007 Helwan Helwan, Ureaplant Ureasolution 1,925t/d Stamicarbon Turnkey FertilizerCo. Egypt Granulation Ureagranules 2,000t/d Stamicarbon

2006 Egyptian Fertilizer Ain Sukhna/ Urea plant Urea solution1) 1,925t/d Stamicarbon Turnkey Co. (EFC II) Suez, Egypt Granulation Urea granules2) 2,000t/d Stamicarbon2012 1)expansionto 2,250t/d Stamicarbon E,P,MPsection add-on

2)expansion to 2,250 t/d UFT E, P

2006 AlexandriaFertilizerCo. Alexandria, Ureaplant Ureasolution 1,925t/d Stamicarbon Turnkey (AlexFert) Egypt Granulation Ureagranules 2,000t/d Stamicarbon

2006 SaudiArabian AlJubail, Ureaplant Ureasolution 3,250t/d Stamicarbon Turnkey FertilizerCompany SaudiArabia Granulation Ureagranules 3,600t/d UFT Poolcondenser (SAFCOIV)

2004 Turkmendokunhimiya Tecen, Ureaplant Ureasolution 1,050t/d Stamicarbon E,P via Gap Insaat Turkmenistan Granulation Urea granules 1,050 t/d UFT Pool reactor

2004 QatarFertilizer Mesaieed, Ureaplant Ureasolution 3,200t/d Stamicarbon Turnkey Company(QAFCO4) Qatar Granulation Ureagranules 3,500t/d UFT Poolcondenser

2004 ASEANBintuluFertilizer Bintulu, Ureaplant Ureasolution 2,250t/d Stamicarbon E SdnBhd(ABF) Malaysia Expansionby 446t/d 2ndExpansion Granulation Urea granules 2,400 t/d UFT Expansionby 550t/d

2003 QatarFertilizer Mesaieed, Ureaplant Ureasolution 3,000t/d Stamicarbon E Company(Qafco3) Qatar Expansionby 1,000t/d Expansion Granulation Urea granules 3,000 t/d UFT Expansionby 800t/d

2000 Egyptian Fertilizer Ain Sukhna/ Urea plant Urea solution1) 1,925t/d Stamicarbon Turnkey Co. (EFC I) Suez, Egypt Granulation Urea granules2) 2,000 t/d UFT 2012 1)expansionto 2,250t/d Stamicarbon E,P,MPsection add-on

2)expansion to 2,250 t/d UFT E, P

1999 IncitecLtd. GibsonIsland, Ureaplant, Ureasolution 740t/d Stamicarbon Turnkey Australia evaporation Granulation Urea granules 950 t/d UFT

1998 CFIndustriesInc.(CFI) Donaldsonville, Ureaplant Ureasolution 2,000t/d Stamicarbon E,P USA Granulation Urea granules 2,000 t/d UFT

Recent references

E Engineering

P Procurement

C Construction

23

Industrial Solutions Fertilizer and Syngas Technologies

thyssenkrupp Industrial Solutions AG Friedrich-Uhde-Straße 15 44141 Dortmund Germany P: +49 231 547 0 F: +49 231 547 10 www.thyssenkrupp-industrial-solutions.com

PT 0

05/0

/e/3

00/2

0170

1/S

Z/Pr

inte

d in

Ger

man

y

Documents

Leading fertilizer know-how - · PDF filethyssenkrupp Industrial Solutions licenses Stamicarbon’s CO 2 stripping process variants, which are unrivalled in their efficiency