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Casale High Efficiency Design for Ammonia-Urea

Fertilizer Complex

ByFederico Zardi, Ermanno Filippi, Andrea Scotto, Fabio Laurenzi

CASALE GROUP

Ammonia plant of the 20’s

Ammonia plant of the 21st Century

Drops of history

CASALE GROUPCASALE GROUP

AMMONIA PLANTS

UREA PLANTS

• UREA PLANT

Presentation outline

CONCLUSION

RECENT PROJECTS

TECHNOLOGIES FOR GRASS ROOTPLANTS

• AMMONIA PLANT

8/11/2019 02 F Zardi - Casale High Efficiency Design for Ammonia-Urea Fertilizer Complex

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CASALE Ammonia-Urea ProcessThe CASALE Ammonia-Urea Process isborn integrated

The energy consumption is:

4.6 Gcal per ton of Urea

All included

No steam or electricity export

Integrated power generation

CO2 balanced

Integrated steam balance

CASALE Ammonia-Urea Process

Ammonia Plant ProcessAmmonia Plant Process

Advanced Ammonia Process

IMPROVED STEAM REFORMING PROCESS

Advanced Ammonia processAdvanced Ammonia process

Axial-Radial Shift

3 bed 2 interchanger converter

NH3 WASH

High Efficiency Burner

Waste Heat Boiler

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High Efficiency Secondary Reformer Burner

Advanced Ammonia processAdvanced Ammonia process

Minimize equipment size and guarantees high reliability:

• Superior mixing in the flame

• Short flame lengths

• Homogeneous conditions at catalyst bed inlet

• Low pressure drop

• Protection of burner and lining against hightemperatures

Axial-Radial Shift Converters

Advanced Ammonia processAdvanced Ammonia process

Longer catalyst life stable pressure drop

high resistance topoison and water carry

over

Low CO slip

Ejector ammonia wash system

Advanced Ammonia processAdvanced Ammonia process

Minimize energy consumption of: Syngas compressor

Refrigeration compressor

Syngas is dried

Pressure recover onthe syngas

Advanced Ammonia processAdvanced Ammonia process

Axial-Radial Synthesis Converters

3 Bed 2 Interchanger configuration:

high thermodynamic efficiency and

catalyst volume utilization

minimizing energy consumption

minimizing equipment size

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Waste Heat Boiler design

Advanced Ammonia processAdvanced Ammonia process

All ferritic parts kept at lower temperature:

No risk of nitrading

High reliability

Performances

Advanced Ammonia processAdvanced Ammonia process

S/C ratio : 2.9

CO slip from LTS : < 0.3% vol.

CO2 slip from absorber : < 300 ppm vol.

Ammonia conversion : 21%

Low investment

Low energy consumption : <6.5 Gcal/MT

SPLIT FLOW LOOP™ process

Improved CO2 stripping process with

split flow of inerts in thesynthesis loop

Urea Plant ProcessUrea Plant Process Split Flow Loop™ urea processHigh Efficiency

HydrolyserFullCondenser

High EfficiencyReactor

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Split Flow Loop™ urea process

Casale High Efficiency Reactor

High Efficiency Trays

High Efficiency Trays

Enhanced heat & mass transfer

High liquid/vapor mixing

Minimize reactor size

Minimize energy consumption

Split Flow Loop™ urea process

Maximumefficiency in reactor

Two-phase flow in tubes

High exch. coefficient

Urea is formed

Submerged condenser

Full Condenser TM design

Minimize equipment size

Split Flow Loop™ urea process

Simple design forhigh efficiency at lower cost

High Efficiency Hydrolyser

Complete cleaning of processcondensate

Divided into 2 parts for highesthydrolysis efficiency

Split Flow Loop™ urea process

Maximum efficiencyin WWT section

Minimize equipment size

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• high CO2 conversion (63.5 %)

• high stripping efficiency

• low amount of unreacted to thedownstream sect.

Performances

Split Flow Loop™ urea process

Performances

• Steam:

tot process cons. (22bar) 770 kg/MT

• NH3 consumption: 568 kg/MT

• CO2 consumption: 735 kg/MT

• Electricity consumption: 22 kWh/MT

Split Flow Loop™ urea process

Vast Experience in the FieldVast Experience in the Field

In the last 30 years:

250 projects in Ammonia

110 projects in Urea

Advanced Ammonia ProcessAdvanced Ammonia Process -- ReferencesReferences

1 plant 2050 MTD in op. in Iran (RPC) since 2008

1 plant 2050 MTD in construction stage

3 plants 2050 MTD under basic design

RPC plant

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One grass-root plant built in

France

SPLIT FLOW LOOP™ process - Implementation

In operation since 2003 in

Ukraine producing 1500 MTD

Operating in 2 more plants

with capacity up to 2300 MTD

ConclusionsConclusions

Through continuous technological evolutionCasale developed innovative processes forammonia and urea grass-root plants

Casale can design world scale fertilizer plantsresponding also to future demands in terms ofcapacity, with low energy consumption:

4.6 Gcal/MT urea, without any energy export