green granulation technology - ken monstrey.pdf

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Drastic Reduction in

CAPEX and OPEX

in Urea Granulation Plants

Ken Monstrey

www.greengranulation.com 2

Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants

IN OTHER WORDS:

GGT has drastically reduced the

costs for building and operating a

Urea Granulation Plant, without

compromising on quality 20 40 % reduction How: CRG Process

1. Introduction



CRG Process

Screener

Crusher

Seed belt F1

F2

F3

Elevator

Granulator

Cooler

Final

Product

Traditional

Granulation Process

Elevator

Screener

F1

F2

F3

F4

Final

Product

Cooler

Final Product

Cooler

Crusher

Granulator

Screener

Comparison with traditional processes



Comparison with traditional processes

Lower building costs

Lower total investment costs

Facilitated operations

Lower power consumption

Traditional

Granulation Process CRG Process



1.1. GGT company profile

GGT Asia & GGT Europe

Privately owned company

Licensing granulation technology for nitrogen based fertilizers

Urea business upon today:

9.720MTPD capacity commissioned

15.380MTPD capacity under construction



1.2. The CRG process features

Cold Recycle Granulation Process: Single step cooling

Granulator and cooler in-line

Smaller bucket elevator

-50% on crusher capacity

Smaller atomization air blower

H: 28-32m



1.2. The CRG process features

Fig. GGT CRG PFD



2. Innovations typical for CRG Reducing the total height of the building

Lowering building costs

Facilitating operation and maintenance

Limiting the need for a strong weight bearing and vibration resisting building

Lowering construction costs

No need for high Urea feed concentration

Low investment costs for the Urea Synthesis section

Optimized Internal Dynamics in the fluidized bed and other power saving

innovations

Reducing the power consumption



2.1. Reducing construction related investment

2.1.1. Height of the Building

2.1.2. Strength of the Building

Fig. GGT Sprayer layout China Coal 2x2860MTPD



Reducing construction related investments

2.1.1. Height of the urea granulation building

One single product Cooler, in-line with the Granulator

Only lifting the recycle stream

Combining screen feeder and safety screen

in one device

Less equipment (coolers, fans, crushers)

Redesigning diverters

Fig. GGT Granulator & Cooler Xinlianxin 1000MTPD

Fig. Screen feeder with safety screen




2.1.2. Strength of the urea granulation building

Vibrating screens and crushers located below the granulator

(cfr. synchronized vibrations of all screens that need to be taken into account

for strength calculation)

Highest load-bearing flow is the level of the granulator undercasing

Scrubbers located on ground level with integrated scrubber circulation tank





Fig. GGT 3D Deep Vacuum CRG Process



2.2. Reducing up-stream related investment

Fig. GGT Urea melt feed headers China Coal 2x2860MTPD



Reducing up-stream related investments

Using low urea feed concentration

No influence on the product quality

One single evaporation step

Crystallization heat in the granulator is removed by evaporation of water

reducing the need for air through the system

CRG process can be linked to a wide range of urea feed concentrations

and to all currently existing synthesis processes

Single step cooling in relatively thick bed layer enables proper evaporation of

moisture



2.3. Reducing the power consumption

2.3.1. Optimized internal dynamics in the fluid bed

2.3.2. Deep vacuum in the granulator

2.3.3. Patented double temperature scrubbing system

2.3.4. Optimized ducting

2.3.5. High performance hydraulic urea melt sprayers

2.3.6. Flexibility by optional components

Fig. Plant view


2.3.1. GGT Optimized internal dynamics in the fluid bed

Patented

Open spaces between the banks

Smoother circulation of granules

Bank arrangement eliminates need for thick layer bubbling bed bed level down to 600mm (total P over bed + perforated plate)

Lower pressure of the fluidization air


Reducing power consumption

Fig. GGT Optimized internal dynamics




2.3.2. Deep vacuum in the granulator

One step further (under construction)

All fluidization air pulled through the system by the exhaust fan(s)

No need for a fluidization air fan

One single exhaust fan is possible (pressure drop)

Vacuum enables better evaporation of water in the spray area

When a fluidization air fan is needed for e.g. chiller on the cooler, GGT uses

a fan with low pressure drop

Eliminating the heating of the fluidization air by the fan compression

Patent pending




2.3.3. Patented Double temperature scrubbing

Low pressure drop horizontal scrubbers P 70mmWC

High concentration scrubber solution (55%)

Separate granulator scrubber and cooler scrubber

Use of Blue Fil high efficiency mist eliminators combining minimal pressure

drop with low emission values

PM2.5 : +99,9% > 5 ; +92% > 2,5

Fig. Blue Fil by Mistrix-Benvitec Fig. GGT Double temperature scrubbing




2.3.4. Optimized ducting

Estimated saving in pressure drop due to optimized and minimized ducting:

ca 100mmWC

Fig. GGT Granulator in- and outlet

Fig. Xinlianxin 1000MTPD




2.3.5. High performance hydraulic urea melt sprayers

In-house development

Hydraulic sprayer

Fine atomization, efficient evaporation of water

Low atomization air (0,3Barg)

Seed creation by the urea liquid sprayers

only 50% of the crusher capacity

Fig. GGT Hydraulic urea liquid sprayer

Fig. Tianze 2x1500MTPD atomization air inlets





Alternative cooling means to boost the cooling capacity

Cooling plates making use of cooling water

AirSieve technology extracting fines from the cooler before total cooling

Optional chiller

Depending on ambient design conditions

Flexible components can be shut-off e.g. in winter time


Granules

Gra

nu

les

Air in Air in

Air out

Air out

Water in

Water out

Water in

Water out

GGT Cooling Technology Combining Air and Water Cooling


Fig. GGT Cooling plate technology





Reference list

Commissioned Units

Henan Xinlianxin Fertilizer Company Capacity: 1,000 MTPD - Started-up: 2014 CRG process

Shanxi Tianze Coal Chemical Group Capacity: 2 x 1,500 MTPD - Started-up: 2013 CRG process

Erdos China National Coal Group Capacity: 2 x 2,860 MTPD - Started-up: 2013

Units under Design / Construction

Luoyang Junma Capacity: 600 MTPD - Contract: 2014

Jiangsu Linggu Capacity: 2,700 MTPD - Contract: 2014

Henan Junhua Capacity: 1,500 MTPD - Contract: 2014

Shandong Runyin Biochemical Co. Capacity: 2,000 MTPD - Contract: 2014

Inner Mongolia Manshi Capacity: 2 x 2,860 MTPD - Contract: 2014

Inner Mongolia Huajin Chemical Co. Capacity: 2,860 MTPD - Contract: 2013

www.greengranulation.com 24 24


Up-stream related investments



Fig. GGT 3D Deep Vacuum CRG Process

CRG Process

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26

Thank you!

Green Granulation Technology

In het Midden 35

1422 PA Uithoorn

The Netherlands

Mob: +32 486346037

E-mail: [email protected]

In case of questions please feel free to contact us:

green granulation technology - ken monstrey.pdf

Documents

drastic reduction

urea synthesis section

fertilizers urea business

crg process features

building lowering construction

ggt crg pfd

single product cooler

total investment costs