a remarkable and proven way - gpca...
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![Page 1: A REMARKABLE AND PROVEN WAY - GPCA …gpcafertilizers.com/2015/wp-content/uploads/2015/10/Casale-SA... · A REMARKABLE AND PROVEN WAY ... • CASALE Technical Study in 2009-2010 (Ammonia](https://reader037.vdocuments.us/reader037/viewer/2022102919/5a7234ca7f8b9a98538d69cb/html5/thumbnails/1.jpg)
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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
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• One single source for all what you need
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• 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
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• Enhance capacity from 1500 to 2610 MTPD (+74%)
• Minimize energy consumption
• Increase product quality
• Minimize new HP equipment
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• Reactor / HP Condenser Split Flow LoopTM & Full CondenserTM + High efficiency traysTM
• HP Stripper MP Split Flow SectionTM
• Prilling Tower Vortex GranulatorTM
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STANDARD CO2 STRIPPING SPLIT-FLOW ONLY 30% INERTS TO REACTOR
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FILM CONDENSER FULL CONDENSER
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+50% HEAT TRANSFER COEFFICIENT
and ADDITIONAL REACTION
VOLUME
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• Minimum investment
• Short installation
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• Equipment modification / enhancement
• Items relocation
• Additional pumping capacity
• Surfaces increasing
• Bottlenecks overcome
• Emission reduction
• Performance increasing
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• 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
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• 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
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• Capacity: 2610 MTPD high quality solid urea
• Product Quality
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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
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• 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
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• 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
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• Turn-Down and Operation
Minimum load 1300 MTPD (50%)
Fattening from 140 to 910 MTPD
MP Section & Vortex lined up very easily and quickly
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