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Prilled Urea- A Cost Prilled Urea- A Cost Effective Way to Feed the Effective Way to Feed the WorldWorld
Sule AlabiJonathan AranaElizabeth MoscosoOleg Yazvin
Mentor: Dan Rusinak – Middough
Team EchoTeam Echo
104/20/23
Table of Contents•Purpose
•BFD Overview of Urea Plant
•Process Description
•Sinks & Loads
•Sizing and Costing
•Conclusion
•Q & A 2
Purpose:◦ Convert shale gas
into a nitrogen-based fertilizer
Plant Location: ◦ Williston Basin
Reason for Location: ◦ Bakken Shale Gas
Formation
3
Urea- Solution & Prill Urea has a high nitrogen content (47%)
Liquid Urea (72.0wt%) - Urea Ammonium Nitrate (UAN 32)
Prilled Urea (99.8wt%)- Controlled release fertilizer
Overall Reaction:
◦ Overall Exothermic: -120 BTU/mol
CO2 2NH 3 NH2COONH 4
NH2COONH 4 Urea H2O
4
Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
5
Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
6
Urea Production PlantConverts reactants into urea
◦ NH3 and CO2 from Nitrate Plant ◦ Produces 72 wt% Urea solution
Main Components of Plant◦ Reactor◦ Stripper◦ Decomposer◦ Scrubber◦ Absorber
Overall Reaction:
CO2 2NH 3 NH2COONH 4
NH2COONH 4 Urea H2O
7
R-111
163
161
111
173
177
C-141
131
151
187
101
183
185
R-121
193
194 196
195
121
165
V-171
167171
V-161
141
V-181
181
198
197
P-151
175
C-131
191
192
P-191
120
V-185
188
R-101
Urea PFDUrea PFD
8
Urea Production Plant – Sinks & Urea Production Plant – Sinks & LoadsLoads
R-101
R-111
163
161
111
173
177
C-141
131
151
187
101
183
185
R-121
193
194 196
195
121
165
V-171
167171
V-161
141
V-181
181
198
197
P-151
175
C-131
191
192
P-191
120
V-185
188
Unit Type Energy Utility Amount
Reactor Sink1,376
MMBtu/dayCooling Water
1.042 MMGal/day
Stripper Load1,199
MMBtu/day Steam 792 Tons/day
Decomposer Sink1,098
MMBtu/dayCooling Water
0.975 MMGal/day
Scrubber Sink984
MMBtu/dayCooling Water
0.829 MMGal/day
Compressor Load 200 HP Electricity3,576
KWH/day
Energy Saver
Sink
Load
9
Urea Production Plant- AspenMass Balance
◦ No Convergence Recycle streams
◦ Attempted Solution Increased number of iterations- no change Cut recycle streams- Mass Balance Converged
Energy Balance ◦ No Values Given
No Ammonium Carbamate properties within Aspen data libraries
◦ Attempted Solutions Free energy of formation Heat of formation Heat of dissolution in water
◦ Pending Solutions Heat Capacity Component with similar properties
10
Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
11
Evaporation SectionEvaporation SectionMultiple-Effect Evaporation under
VacuumIncoming Urea Solution:
◦ 72% Urea, 28% WaterTwo evaporators required
◦ 1st Evaporator: 72% to 94.6% Urea
◦ 2nd Evaporator: 94.6% to 99.8% Urea
12
Evaporator PFDEvaporator PFD
P-200
E-205
E-210
E-215
202
205
250210
220
213
230
225
227
200
215
P-220
207209
240 245
T-250
151
P-217
13
Evaporator ProcessEvaporator ProcessTemp and Pressure are the main
operating parameters
14
Importance of Vacuum Importance of Vacuum PressurePressureMinimization of Biuret (Poison)Lowering of Boiling Point for next
evaporation stageConsequently, reduces steam
load
15
Evaporator- Sinks & LoadsEvaporator- Sinks & Loads
P-200
E-205
E-210
E-215
202
205
250210
220
213
230
225
227
200
215
P-220
207209
240 245
T-250
151
P-217
Unit Type Energy(MMBtu/day) Utility Amount
Evaporators Load 1,376 Steam 792 Tons/day
Condenser Sink 1,299 Cooling Water1.042
MMGal/dayEnergy Saver
Sink
Load
16
Evaporator Aspen Evaporator Aspen SimulationSimulation
17
Evaporator Equipment Costs & Evaporator Equipment Costs & SizingSizing
Particulars Evap1 Evap 2 Condenser
Heat Duty (BTU/hr) 1.7X 10^7 8.7 X 10^6 ---
Area (sq. ft.) 718 563 30
Fluid Urea Solution Urea Solution Cooling Water
Pressure 510 mmHG Vacuum 735 mmHG Vacuum ---
Flow Rate (TPD) 2,568 2,568 25,265
Temp In (F) 221 202 93
Temp Out (F) 202 211 107
Total Direct Cost ($) 102,000 80,000 27,999
Equipment Cost ($) 173,000 136,000 8,000
Total Utility Cost ($) 66,000 52,000 6.46 MM
Total Maintenance Cost ($)
5000 3800 3,000
Total ($) Operating Cost 1.1 MM 860,000 1.2 MM
18
Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
19
Prill SectionPrill SectionConverts Urea Melt into PrillMain Components
◦ Prill Tower ◦ Screen◦ Cyclone◦ Bag House◦ Heater◦ Dehumidifier
20
Prill PFDPrill PFDD-320
P-310
M-370
E-375
310
P-305
315
S-350
F-330
350
B-360
320
330
360398
345
325
P-316
370
355
390
210
397
395
301
375
380
F-360
342344
21
Prill Sinks & LoadsPrill Sinks & LoadsD-320
P-310
M-370
E-375
310
P-305
315
S-350
F-330
350
B-360
320
330
360398
345
325
P-316
370
355
390
210
397
395
301
375
380
F-360
342344
Unit Type Energy(MMBtu/day) Utility Amount
Heater Load 1,298 Steam ~1 Tons/dayEnergy Saver
Sink
Load
22
Prill Section Cost and Prill Section Cost and SizingSizingResearch yielded a previously done
mathematical simulation of prilling tower◦From simulation data, airflow and size for
our prilling tower were obtained◦Cost for prilling tower will be
approximated by a similar capacity storage tank
Cyclone and bag house sizing in progress due to potential redesign of prilling tower
23
Potential Redesign of Prilling Tower
Standard Oil Patent Filed in 1978
Uses co-current airstream and fluidized bed
Benefits:◦Less dust
emissions◦Smaller tower
required 24
Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water Treatment
Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
25
Waste Water Treatment Waste Water Treatment PlantPlant For every ton of urea produced 0.3 tons of waste water is produced
Co-Current thermal hydrolysis of urea with steam Main Components:
◦ 1stDesorber ◦ Hydrolyzer ◦ 2ndDesorber◦ 2 HX
Overall Reaction: Reverse of Urea Plant
Overall Endothermic: +58 BTU/mol
Urea H2O NH2COONH
NH2COONH NH 3 CO2
26
Waste Water Treatment Waste Water Treatment PlantPlant
Waste Water Content:◦2- 9 wt% Ammonia◦0.8- 6 wt% CO2
◦0.3-1.5 wt% UreaSimple discharge is a waste of
resources and environmentally harmful
Ammonia is hazardous, toxic, and volatile
Urea promotes algae growth and hydrolyses slowly
EPA Emission Requirements: 10 ppm27
WWTP ProcessWWTP Process
E-401
D-421
400
E-411
410
415
450
E-421
S-445
490
494
P-401
496
492
498
455
E-441
P-411
483
430
D-431
445
420
475
480
440
499
485
405
470
465
185
210
28
WWTP Sinks & LoadsWWTP Sinks & Loads
Unit Type Energy(BTU/HR) Utility Amount
Condenser Sink 34,538Cooling Water 5400Gal/day
Heat Exchanger Sink 280,000
Cooling Water 8100Gal/day
Hydrolyzer Load -1.03*10^7 Steam 354TPD
E-401
D-421
400
E-411410
415
450
E-421
S-445
490
494
P-401
496
492
498
455
E-441
P-411
483
430
D-431
445
420
475
480
192
499
485
405
470
465
Energy Saver
Sink
LoadLoadLoad
Sink
Load
29
WWTP Aspen SimulationWWTP Aspen Simulation
30
WWTP Equipment SizingWWTP Equipment Sizing
UnitTotal Direct
Cost ($)Equipment
Cost ($) Area (sq. Ft.)Heat Duty
(BTU/hr)
Condenser 43,300 8000 7 34,538
Heat Exchanger 1 55,900 9400 47 280,000
Heat Exchanger 2 54,200 9400 43 183,000
Hydrolyzer 260,100 81200 --- -1.03 X 10 ^7
Desorber 1 122800 35100 --- .0012
Desorber 2 98200 15300 --- 0
31
WWTP Equipment Costs WWTP Equipment Costs Total Project Capital Cost 2.25
MillionTotal Operating Cost 1.2 MillionTotal Utilities Cost $42,000/yr
32
Daily EconomicsDaily Economics
33
Materials Cost (Money We Spend) Amount Overall Cost
NH3 $521.00 Per Ton 891.07 Tons Per Day $464,000 Per Day
CO2 $15.00 Per Ton 1153 Tons Per Day $17,300 Per Day
Product Price (Money We Get) Overall Price
Urea to UAN $230.00 Per Ton 836 Tons Per Day $159,700 Per Day
Prilled $570.50 Per Ton 793 Tons Per Day $422,000 Per Day
Profit: $100,000 Per Day
Profit: $37 Million Per Year
ConclusionConclusion
34
• Total Plant Cost: $400 Million• Produce 793 TPD of Prilled Product• Produce 836 TPD of Urea melt for
UAN Plant • Numerous Instances of Efficient
Energy Usages.• Aspen Simulation: Great Start
Thank youQuestions?
35