FERTILIZER INDUSTRY AS ONE OF STATE-

OWNED ENTERPRISES
Pupuk Indonesia and
seven subsidiaries
operate 14 urea plants
and 13 ammonia plant.
All of them produce urea
but the most complete
plant is petrokimia
gresik.
And now it can produce
12,47 million tons
fertilizer per year and
produce 5,93 million
tons basic chemical
products per year.

THE HISTORY
The first fertilizer plant (urea) in indonesia is
PUSRI (Pupuk Sriwijaya).
Government found Pupuk Indonesia holding
company in 1997
now we better know it as Pupuk Indonesia
Holding Company (PIHC)
most of the amonia plant in indonesia using
kellog process from Kellog Brown & Root
(KBR)
This process provide good energy efficiency

UNIT AMMONIA
Pemurnian Gas
alam
Pembuatan gas
sintesis
Pemurnian gas
sintesis
Sintesis amonia
Purifikasi dan
refrigerasi
amonia
Amonia Recovery
Hydrogen recovery
dan Purge gas
recovery
Natural Gas :
Solid Particle
Water
Liquid HC
Natural Gas :
Methane
CO2
Mercury
Sulfur

+ Activated Carbon
The activated carbon
will absorb mercury.
Hg+S HgS

DESULFURISATION
Catalyst Cobalt
Molybdenum(CoMo)
ds
Hydrotreater
Catalyst ZnO


The sulfur will be decrease
from 30 ppm to 0,1 ppm
Can prevent catalyst poisoning
Desulfurizer
PEMBUATAN GAS SINTESIS
Natural Gas from desulfurizer mixed with steam and enter primery reformer.
The mole ratio S:N =3,2:1 must be precise to prevent side reaction.


Outlet gas from primery
reforming contain :
66% Hydrogen and
13,4% methane
SECONDERY REFORMING
Secondary reformer melanjutkan reaksi
primery reformer
Reaction Zone
Combustion Zone atau mixing zone
Kadar Methane gas keluaran secondery reformer
berkurang menjadi 0,42% volume
PURIFYING SYN GAS
CO2 absorber and stripper
CO2 gas needed as a raw material for urea that CO2 is separated by
using aMDEA (activated Methyldeetanolamine), then fluids flowed to
the CO2 stripper to get ready for the CO2 gas is fed to the urea
synthesis reactor
We can obtained 99% volume Purity of CO2
Reaction of CO2 absorbtion:


Reaction of CO2 stripper

METHANATOR
Keberadaan CO dan CO2 di amonia converter dapat
merusak katalis oleh sebab itu CO dan CO2 harus
diubah menjadi CH4 sebagai inert agar tidak merusak
katalis. Proses ini disebut methanasi yang terjadi di
methanator



Methanator use nickel as catalyst
Methane will be recycle


AMMONIA SYNTHESIS
Methanator outlet has pressure and
temperature below the operation
condition of ammonia converter. Gas
Pressure and Temperature must be
raised using compressor and heater.
The reaction :


AMMONIA CONVERTER
Operation
Condition:
350-500 C
141 Kg/cm2

REFRIGERATION OF AMMONIA
effuluent of ammonia converter is cooled to 38 C using inlet
of ammonia converter. The refrigeration process of ammonia
occur in ammonia unitized chiller. This process involve 4
step.
38 C - 16,6 C.
16,6 C - -2,2 C
-2,2 C - -17,8 C
-17,8 C - -33 C
Ammonia stored in a tank as liquid
PROSES
UNIT UREA
Urea
Katalis
CO2
Amonia
Cair
UREA PROCESSING
This unit produce urea synthesis by reacting ammonia liquid with
CO2 into Ammonium carbamate. Ammonium carbamate is
converted into urea. this occur in the urea reactor at 155 kg/cm2
pressure and 182 Celsius.
The hidrogen concentration in CO2 inlet allowed maks 0,8%. So
we should remove the hydrogen in dehidrogen coloumn with
platinum catalyst before entering urea reactor.
PURIFICATION
Urea synthesis (liquid) contain urea, amonium
karbamat and excess ammonia. So urea will
separate from other components by feed it to
stripper. The consentration of urea synthesis is
67%. The further ureas purification in LP
decomposer and produce 98,8% volume urea
synthesis, 0,8 % NH3 and 0,4 % CO2.

CONCENTRATOR

Liquid urea is heated to a temperature of 132 Celsius in a
vacuum pressure, it will produce a liquid urea concentration of
98% by weight. then the solution was concentrated in a
concentrator to a final weight of 99.8% with molten pump and
pumped to the top of the prilling tower

PRILLING
prilling tower has 50 meters high
and diameter of 14.5 meters.
99.8% urea concentrated
sprayed and cooled to become
solid. urea droplet will contact
with cold air from the bottom of
the tower and form urea prill