18th AFA Int’l Annual Fertilizer Forum & Exhibition Feb., 7-9-2012, Sharm El-Sheikh , Egypt Maritim Jolie Ville Hotel
Uhde Ammonia/Urea Plants and their Environment…
Mr. Stepha Aschemann Commissioning Manager Mopco I+II ,Thyssenkrupp Uhde Germany
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Uhde Ammonia/Urea Plants and their Environment 18th AFA Annual Forum & Exhibition Dr. Ulrich Heucke, Sharm El-Sheik, Feb. 7-9, 2012
Urea Overview
Final product of the ammonia / urea plants: granulated urea fertiliser o Urea is a naturally occurring product NH2 o Properties: C=O NH2 – not toxic – not radioactive – not harmful to the environment 2 mm o Uses: 2 - 4 mm – Fertiliser for growing crops (main use) – Animal food – Cosmetics o Industrially, urea is produced from ammonia and carbon dioxide 8 mm
Ammonia/Urea Plants and their Environments Feb. 7-9, 2012 Sharm El-Sheikh, Heucke 2
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SLA-001 9/99
Uhde fertiliser Plants Worldwide
1928 - 1950 1951 - 1970 since 1971
Uhde has designed and built 100+ fertiliser plants worldwide, this is about 20% of the global market
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Uhde Ammonia / Urea Plants in Egypt MOPCO 1 & 2, Damietta (2 new plants under construction/commissioning) • MOPCO III (2008), Damietta • HFC (2007), Helwan • AFC (2006), Alexandria • EFC II (2006), Ain Sukhna • EFC I (2001), Ain Sukhna • Abu Qir III (1998), Alexandria • Abu Qir II (1991), Alexandria • Abu Qir I (1979), Alexandria 8 similar plants currently operating in Egypt
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Uhde Fertiliser Plants - Belgium
Customer: Location: Capacity: Process: Commissioning: Speciality:
BASF Antwerp, Belgium 1,800 t/day of ammonia Uhde 1991 Turnkey
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Uhde Fertiliser Plants - Belgium City of Antwerp, Belgium (pop.: 472,000)
BASF Antwerp Ammonia Plant Distance to residential area about 2 km
Harbour
Village
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Uhde Fertiliser Plants - Austria Danube City of Linz, Austria (pop.: 190,000)
Agrolinz Melamine several ammonia and urea plants (ammonia by Uhde, 1972) Distance to residential area about 1 km Ammonia/Urea Plants and their Environments Feb. 7-9, 2012 Sharm El-Sheikh, Heucke 7
Uhde Fertiliser Plants - Netherlands
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Uhde Fertiliser Plants - Netherlands
Sluiskil village (Residential area) Yara Sluiskil Ammonia and Urea Plants
Yara Sluiskil Urea 5 Plant (by Uhde, 2011) River Distance to population area about 550 m
Harbour
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Uhde Fertiliser Plants - Egypt
Customer: Alexandria fertiliser Co. (Alex Fert) Location: Alexandria, Egypt Capacity: 1,200 t/day of ammonia; 1,925 t/day of urea 1,925 t/day of granulation Commiss.: 2006 Speciality: Turnkey
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Uhde Fertiliser Plants - Egypt
Customer: Abu Qir fertiliser Co. Location: Alexandria, Egypt Capacity: 3,300 t/day of ammonia; 3,250 t/day of urea 3,600 t/day of granulation Commiss.: 1979, 1991, 2006 Speciality: Turnkey
College of Air Defense
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Uhde Fertiliser Plants - Egypt Customer: Location: Capacity:
Egyptian fertiliser Co. (EFC II) Ain Sukhna/Suez, Egypt 1,925 t/day of urea 2,000 t/day of granulation 1,200 t/day of ammonia Process: Uhde (ammonia), Stamicarbon (urea, granulation) Commissioning: 2006 Speciality: Turnkey
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Uhde fertiliser Plants – MOPCO III
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Uhde fertiliser Plants – MOPCO I & II
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Uhde Fertiliser Plants - MOPCO
Customer: Misr fertiliser Production Co. (MOPCO) Location: Damietta, Egypt Capacity: 1,200 t/day of ammonia; 1,925 t/day of urea 1,925 t/day of granulation Commiss.: 2008 Speciality: Turnkey Ammonia/Urea Plants and their Environments Feb. 7-9, 2012 Sharm El-Sheikh, Heucke 15
Environmental Impact of Ammonia / Urea Plants Emissions to Atmosphere Emissions from ammonia / urea complex to atmosphere: flue gas from reformer and boiler: energy efficient plant with low emissions use of low NOx burners to minimise environmental impact (only approx. 150 mg/Nm3 NOx in vent gas) For comparison: EFMA* guideline for new plants: 150 mg/Nm3 World Bank guideline: 300 mg/Nm3 more environmental friendly than many other industries, including power stations vents
from urea granulation: emission of ammonia and urea dust as per international practice: dust: 50 mg/Nm3 in vent gas ammonia: 190 mg/Nm3 in vent gas meets Egyptian law and other international emission limits. *) European Fertiliser Manufacturers Association
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Environmental Impact of Ammonia / Urea Plants Liquid Discharge / Waste Water System Waste water system at MOPCO plants: o All liquid streams collected to a single system o Treatment before final discharge: Multiple Oil/Water separators pH neutralisation Settling pond for removal of suspended solids Effluent pond / retention soil filter for: Removal of carbon and nitrogen compounds: by plants (local reed plants) by microorganisms Fine filtration via underground sand bed and piping system photographs: Dec. 2011 Ammonia/Urea Plants and their Environments Feb. 7-9, 2012 Sharm El-Sheikh, Heucke 17
Environmental Impact of Utility Systems Liquid Discharge / Waste Water System Waste water system at MOPCO plant: Water quality meets applicable Egyptian Law: pH: 6-9 Nitrogen (as ammonia NH3): max. 5 ppm Colour: clear Odour: free Very strict regulation in Egypt! Temperature ambient For comparison (same plant size): • Egyptian law • EFMA *) guideline: World Bank guideline:
5 ppm 10 ppm 15 ppm
Effluent water from Ammonia/Urea plants is not harmful to humans, animals and environment *) European Fertiliser Manufacturers Association Ammonia/Urea Plants and their Environments Feb. 7-9, 2012 Sharm El-Sheikh, Heucke 18
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Summary Ammonia and urea complex: state-of-the art technology same technology as used in other places of the World 100+ fertiliser have been built by Uhde worldwide, including in Mediterranean basin, Middle East and Europe; this represents 20% of the global market Emissions from ammonia / urea complex: not toxic not radioactive compliant with international practice compliant with Egyptian laws (partly very strict law)
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