Casale High Efficiency Design for Ammonia-Urea

Fertilizer Complex
By
Federico Zardi, Ermanno Filippi, Andrea Scotto, Fabio Laurenzi
CASALE GROUP
Ammonia plant of the 20s
Ammonia plant of the 21
st
Century
Drops of history
CASALE GROUP CASALE GROUP
AMMONIA PLANTS
UREA PLANTS
UREA PLANT
Presentation outline
CONCLUSION
RECENT PROJECTS
TECHNOLOGIES FOR GRASS ROOT
PLANTS
AMMONIA PLANT
CASALE Ammonia-Urea Process
The CASALE Ammonia-Urea Process is
born 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 Process Ammonia Plant Process
Advanced Ammonia Process
IMPROVED STEAM REFORMING PROCESS
Advanced Ammonia process Advanced Ammonia process
Axial-Radial Shift
3 bed 2 interchanger converter
NH3 WASH
High Efficiency Burner
Waste Heat Boiler
High Efficiency Secondary Reformer Burner
Advanced Ammonia process Advanced 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 high
temperatures
Axial-Radial Shift Converters
Advanced Ammonia process Advanced Ammonia process
Longer catalyst life
stable pressure drop
high resistance to
poison and water carry
over
Low CO slip
Ejector ammonia wash system
Advanced Ammonia process Advanced Ammonia process
Minimize energy consumption of:
Syngas compressor
Refrigeration compressor
Syngas is dried
Pressure recover on
the syngas
Advanced Ammonia process Advanced Ammonia process
Axial-Radial Synthesis Converters
3 Bed 2 Interchanger configuration:
high thermodynamic efficiency and
catalyst volume utilization
minimizing energy consumption
minimizing equipment size
Waste Heat Boiler design
Advanced Ammonia process Advanced Ammonia process
All ferritic parts kept at lower temperature:
No risk of nitrading
High reliability
Performances
Advanced Ammonia process Advanced 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 CO
2
stripping process with
split flow of inerts in the
synthesis loop
Urea Plant Process Urea Plant Process Split Flow Loop urea process
High Efficiency
Hydrolyser
Full
Condenser
High Efficiency
Reactor
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
Maximum
efficiency 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 for
high efficiency at lower cost
High Efficiency Hydrolyser
Complete cleaning of process
condensate
Divided into 2 parts for highest
hydrolysis efficiency
Split Flow Loop urea process
Maximum efficiency
in WWT section
Minimize equipment size
high CO2 conversion (63.5 %)
high stripping efficiency
low amount of unreacted to the
downstream 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 Field Vast Experience in the Field
In the last 30 years:
250 projects in Ammonia
110 projects in Urea
Advanced Ammonia Process Advanced Ammonia Process -- References References
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
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
Conclusions Conclusions
Through continuous technological evolution
Casale developed innovative processes for
ammonia and urea grass-root plants
Casale can design world scale fertilizer plants
responding also to future demands in terms of
capacity, with low energy consumption:
4.6 Gcal/MT urea, without any energy export