02 f zardi - casale high efficiency design for ammonia-urea fertilizer complex
Post on 03-Jun-2018
238 Views
Preview:
TRANSCRIPT
8/11/2019 02 F Zardi - Casale High Efficiency Design for Ammonia-Urea Fertilizer Complex
http://slidepdf.com/reader/full/02-f-zardi-casale-high-efficiency-design-for-ammonia-urea-fertilizer-complex 1/7
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
http://slidepdf.com/reader/full/02-f-zardi-casale-high-efficiency-design-for-ammonia-urea-fertilizer-complex 2/7
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
8/11/2019 02 F Zardi - Casale High Efficiency Design for Ammonia-Urea Fertilizer Complex
http://slidepdf.com/reader/full/02-f-zardi-casale-high-efficiency-design-for-ammonia-urea-fertilizer-complex 3/7
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
8/11/2019 02 F Zardi - Casale High Efficiency Design for Ammonia-Urea Fertilizer Complex
http://slidepdf.com/reader/full/02-f-zardi-casale-high-efficiency-design-for-ammonia-urea-fertilizer-complex 4/7
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
8/11/2019 02 F Zardi - Casale High Efficiency Design for Ammonia-Urea Fertilizer Complex
http://slidepdf.com/reader/full/02-f-zardi-casale-high-efficiency-design-for-ammonia-urea-fertilizer-complex 5/7
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
8/11/2019 02 F Zardi - Casale High Efficiency Design for Ammonia-Urea Fertilizer Complex
http://slidepdf.com/reader/full/02-f-zardi-casale-high-efficiency-design-for-ammonia-urea-fertilizer-complex 6/7
• 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
8/11/2019 02 F Zardi - Casale High Efficiency Design for Ammonia-Urea Fertilizer Complex
http://slidepdf.com/reader/full/02-f-zardi-casale-high-efficiency-design-for-ammonia-urea-fertilizer-complex 7/7
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
top related