Companies Social Responsibility towards Development Companies’ social role maximizes over time taking in mind the governments reduction of services and roles in economic development field, as a result of the borne financial difficulties. Therefore, requirements arise calling for companies to carry out a significant and effective role in the provision of services, alleviation of people sufferings, combating poverty, establishment of specialized training centers and raising the human capacities, whether employees or community people, in order to be qualified for better future job opportunities. The concept of companies’ social responsibility is a new one with many definitions, all of which revolve around companies’ bearing of responsibility towards four main brackets: - Capital holders, i.e. owners - Staff and employees - Clients and related bodies Dr. Shafik Ashkar - Community and environment AFA Secretary General Hence, the stated above exceeds the traditional commercial-based role of companies, aiming at achieving the best results and profits benefiting the owners and shareholders of companies and national economy, represented in direct revenues of taxes and related issues. To elaborate, the companies’ role surmounted the previously mentioned by intertwining with society different brackets, widely abiding by occupational health and safety issues together with respecting employees’ rights via being committed to ethical competition rules and doing away with monopoly and dumping practices. Practical experiences have indicated that the more the companies’ contribute in local community services, the more political, economic and social security stability are achieved, thus effectively impacting sustainable economic development and entrenching people satisfaction with companies’ performance. It is noteworthy that there is no clear definition for or limits to companies social responsibility. Also, there are no rules and systems governing such a responsibility. However, realistically speaking such a responsibility remains literary moral and an ethical feeling towards the community people based upon the meaningful volunteered initiative of being a common responsibility. Social responsibility concept gradually evolved as a result of the following developments: - The concept of globalization and the adoption of many local and multinational companies to the slogan of social responsibility, human rights and environment protection in an amazing way touching people’s feelings and needs. - The increase in people and government requirements demanding the protection of consumer, human and environment in order to avoid pressures imposed by people and reconcile with the society in general and the areas of companies’ economic activities in particular.
In the light of the aforementioned, still there are many companies not acquainted with the importance of and contributing in the social responsibility issue. Thus, there is a dire need for companies to set clear policies and purposeful social projects in agreement with the society, which will be positively reflected on both parties relationship and will deepen the society acceptance to such companies’ activities in line with adhering to rules and provisions governing companies’ activity. Regards
Issue Number (61) Sept.- Des. 2011
Editor-in- Chief
Dr. Shafik Ashkar Secretary General
Deputy Editor-in- Chief Mrs. Mushira Moharam Members of Editorial Board (General Secretariat) Eng. Mohamed M.Ali Mr.Yasser Khairy Member of Editorial Board (Chairmen of AFA Committees) Dr. Mohamed Benzekri
AFA Economic Committee Chairman
Mr. Hussein Abdel Karim
AFA Technical Committee Chairman
Mr. Mohamed Yousry
AFA HSE Committee Chairman
Agricultural Consultant Dr. Mohamed M. El Fouly
All correspondences to be addressed to: Arab Fertilizers Association P.O. Box 8109 Nasr City 11371 9 Ramo bdg. Omar ben Khattab St. Nasr Road - Nasr City Cairo, Egypt Tel: +20 2 24172347 Fax:+20 2 24173721 +20 2 24172350 E-mail: info@afa.com.eg www.afa.com.eg Colour separation & printed by Tel : 37617863
”Arab Fertilizers” Journal is published by the General Secretariate of Arab Fertilizers Association (AFA).
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24th AFA Int’l. Technical Fertilizers Conference Press Release
NEW CONTRACT AWARDED FOR FERTILIZER PROJECT IN EGYPT 22 OCP and Yara initiate global partnership 23 Haldor Topsøe A/S appoints new Chief Executive Officer 23 Topsøe receives order for two SNOXTM plants from Petrobras, Brazil 23
AFA is a non-profit, non-gov. Arab Int’l. Organization established on 1975. AFA is operating under the umbrella of Council of Arab Economic Unity/ Arab League. AFA comprises all companies are producing fertilizer in Arab world in 14 Arab countries. All rights reserved. Single and multiple photocopies of extracts may be made or republished provided that a full acknowledgment is made of the source. The Journal is providing the chance for publishing adverts for the companies involved in manufacturing and trade of fertilizer and
AFA Board of Directors Chairman
Mr. Mohamed R. Al-Rashid Board Members
With Member Companies
24 QAFCO-5 Inauguration SABIC announces interim consolidated financial results for the period ended 27 December 31, 2011 Studies & Researches
DAP & PHOSPHORIC ACID PLANT
IMPROVEMENTS 28
Mr. Fahad Saad Al-Sheaibi Saudi Arabia Mr. Hedhili Kefi Tunisia
Mr. Mohamed A. El-Mouzi Egypt
Mr. Khalifa Al-Sowaidi Qatar
Mr. Mohammed S. Badrkhan Jordan
Mr. Mohamed Abdallah Mohamed IRAQ
Mr. Abdel Rahman Jawahery
High-Efficient Methods of
Heat- Exchangers Cleaning 37 Phosphate Plant Yield
Comparisons 40
Topsøe solutions for sulphuric acid and
ammonia plants 46
Bahrain
Mr. Jihad N. Hajji Kuwait
Mr. Khalifa Yahmood Libya
Mr. Saleh Yunis Syria
Mr. Mazouz Bendjeddou Algeria Mr. Jamal Eddine Bensari Morocco Eng. Ahmed AL Awfi Oman
other agricultural inputs. The arrangements for that should be discussed with the journal’s management. The articles and all material contained herein do not necessarily represent the view of AFA unless the opposite clearly mentioned. The contributions of researchers, students, and experts in the field of fertilizer industry and trade are highly welcomed for free publication provided that they have not been published before. The General Secretariat is not obliged to return the articles which are not published.
Congratulations
New Appointments in AFA Board Council AFA welcomes its new Board Chairman & Vice Chairman During the 91AFA Board of Directors Council Meeting held in Amman on November 23, 2011, Mr. Mohamed Rashed Al-Rashid General Manager of FERTIL (UAE) was nominated as AFA’s Chairman for the year 2012. Mr. Fahad Al Sheaibi, Executive Vice President, Fertilizer SBU - SABIC (Saudi Arabia) was nominated as AFA Vice Chairman for the same period.
Mr. Fahad Al Sheaibi
Mr. Mohamed R. Al-Rashid
Thanks & Appreciation AFA Chairman, Board members, Secretary General & Secretariat team extend deep appreciation and gratitude to Eng. Mohamed Adel Al-Mouzi for his fruitful and valuable efforts boosting AFA march and proceedings, during his chairmanship of AFA Board of Directors; wishing him all success. Eng. Mohamed A.Al-Mouzi
Nomination of AFA Committees Chairmen for the years 2012 / 2013 * HSE Committee: Mr. Mohamed yousry (Egypt) HSE Manager - ALEXFERT * Technical Committee: Mr. Hussein Abdel Karim (Saudi Arabia) Operation Manager - SAFCO / SABIC. * Economic Committee: Dr. Mohamed Benzekri (Morocco) Manager, Marketing Researches - OCP
Also, we express our great appreciation and thanks to Mr. Yehya Mashaly, Mr. Saed Bokisha and Mr. AbdulRahman Zuraig for their distinguished performance during their chairmanship of AFA Specialized Committes; Wishing them the best of luck and success.
AFA organized its 24th AFA International Technical Fertilizers Conference, highliting the theme: Best Available Technology for Fertilizer Industry: Energy and Water Optomization, HSE, Operations and Equipment and R&D - in cooperation with AFA Jordanian member companies: Jordan Phosphate Mines Company, Arab Potash Company, Nippon Jordan Fertilizer Company, Indo-Jordan Chemicals Company, Arab Fertilizers and Chemical Industries (KEMAPCO) and Jordan National Shipping Lines, during the period Nov. 22 – 24, 2011, in Amman, Jordan. The Conference was held for the 5th time in Jordan; being convened in 1990, 1994, 1997 and 2004, hence reflecting the international attention paid to Jordanian fertilizer industry from one side and the support given by the Jordanian companies to AFA activities from another side. The Conference highlights a number of issues: - New fertilizer industry technology - Energy and water optimization - Health, Safety and Environment - Maintenance and Operation role. - Research and development in fertilizer industry - Case studies provided by Arab companies reflecting 6
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24th AFA Int’l. Technical Fertilizers Conference Best Available Technology for Fertilizer Industry:
Energy and Water Optomization, HSE, Operations and Equipment and R&D Nov. 22 – 24, 2011Amman- Jordan
From L. to R. Dr. Ashkar, Mr. Baderkhan and Mr. Al-Mouzi
the distinguished status occupied by such companies in fertilizer industry field. Such a Conference is considered one of the largest and most important regional and international gatherings with reference to fertilizer industry. More than 350 experts from
all over the world took part in the Conference. Besides, the Conference, convened annually in one of AFA Arab member countries, attracts the biggest international companies of fertilizer industry technology, equipment and chemicals production so as to present the
Mr. Al Mouzi:
We should work on enhancing Arab economic integration
state-of-the art production in the former fields. Conference participants represent 97 companies from 28 countries, namely: 14 Arab countries: Tunisia, Kingdom of Saudi Arabia, Algeria, Bahrain, Egypt, United Arab of Emirates, Morocco,
Jordan, Kuwait, Sultanate of Oman, Qatar, Iraq, Syria and Libya. 14 Non- Arab countries: Canada, Germany, Belgium, Denmark, France, India, Holland, Italy, Russia, Britain, United States of America, Switzerland, Singapore and Pakistan.
H.E. Mr. Mohamed Adel AlMouzi AFA Board Chairman inaugurated the Opening Session with the following speech: • It is my great pleasure to welcome you all in the opening ceremony of the 24th AFA International Technical Conference, held in Hashemite Kingdom of Jordan as severally convened before. I also seize the opportunity to extend, in my name and on behalf of AFA board members, all thanks to the Jordanian government and AFA companies for the support provided to such Conference proceedings. • Our Conference today has became an event sought by international companies specialized in fertilizer industry technology, equipment and chemical production, in order to present their latest developments in this concern. In the same vein, the Conference is considered an opportunity for Arab fertilizer industry specialists and experts to meet with their peers in international companies and raise the state-of-the-art developments via regional working papers presenting companies expertise in different technical fields. • Since its establishment AFA works and sets its mechanisms and programs according to the latest developments witnessed and challenges faced by fertilizer industry. This method is clarified in AFA annual plans, which take in consideration all Arab fertilizer industry needs and coping with international developments. AFA purpose from the previous effort has been to raise the level of efficiency, improve the standard of performance and promote such an industry on scientific basis. Therefore, this year Conference is convened under the title “The Available Best Technologies in Fields of Energy, Environment Protection, Water Rationalization and Production Methods Maintenance and Development” Issue 61
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• Arab fertilizer industry occupies an effective and vital status internationally, bearing in mind the Arab region abundance of resources; namely phosphate material, natural gas, potash and sulfur. Furthermore, Arab fertilizer industry possesses a foundation of trained human capacity, hence being an attracting factor for the establishment of common projects and the encouragement of foreign investments with the state-of-the-art production technologies. • In such a field Arab fertilizer industry occupies a high percentage of the international production and Arab exports of fertilizer products, including inter alia • Today’s world is a world of economic and industrial blocs; the world main power. Thus, we should work on enhancing Arab economic integration by promoting opportunities for economy development via coordinating efforts to set comprehensive Arab strategies. Taking in consideration, the Arab region being rich with technical, human and financial potentials assisting the effective Arab situation. • I would like also to take this opportunity to warmly thank the Jordanian companies, which supported and contributed in the convening of such a Conference: - Jordan Phosphate Mines Company - Arab Potash Company - Nippon Jordan Fertilizer Company - Indo-Jordan Chemicals Company - Arab Fertilizers and Chemical Industries (Kemapco) - Jordan National Shipping Lines • With reference to the program of the 24th AFA International Technical Conference, it includes 23 working papers submitted by 14 Arab and non-Arab 8
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countries highlighting three major sectors, that is to say: - Nitrogenous Industries - Phosphate Industries - General Topics (Health, Safety and Environment ….) • All of the stated above papers present distinct regional and in-
ternational expertise, aiming at identifying the latest developments in related industry technologies and enhancing such an industry competitiveness, environmental and human friendliness and societal and developmental responsibility bearing.
Mr. Baderkhan: Jordan continuously worked
on entrenching the Arab, regional and international cooperation foundation H.E. Mr. Mohamed Baderkhan, Representative of Jordanian Fertilizer Industry in AFA Board Council, started his speech by welcoming the distinguished participants attending the conferenceand also extend his gratitude for the technical participation of experts from companies, institutions together with Arab and foreign centers specialized in fertilizer technologies. He further added, it is worth mentioning that such experts’ participation will assist in highlighting the new production technologies, underscoring the latest practices in the field of safety, vocational health and environmental preservation, raising the efficiency and rationalizing the usage of energy and water in addition to supporting fertilizer industry researches. These previously stated issues
became of necessity to face the future challenges and shoulder the responsibilities of such an industry; namely the provision of food, clothes and energy for the increasing world population currently facing a tangible reduction in the world food stock, decrease in agricultural land per capita and the expected negative impact of climate change on future agricultural seasons.
• Recognizing the importance of fertilizer industry, aiming at developing such an industry, maximizing its revenues and added value and employing such in order to serve economic and social development, the Hashemite Kingdom of Jordan continuously worked on entrenching the Arab, regional and international cooperation foundation and exchanging technical and commercial expertise with other producers. Therefore, holding today’s Conference comes as a practical manifestation for the former orientation.
vocational safety, environment preservation and local communities’ development. • I would like to seize this occasion to state some figures related to fertilizer production in the Hashemite Kingdom of Jordan. To elaborate, the annual production currently reaches 7.5 million tons of phosphate rocks, 560 thousand tons of phosphoric acid, one million ton of di-phosphate ammonium, 300 thousand tons of DAP, 2.5 million tons of potash, 150 thousand tons of potash nitrate fertilizer, 80 thousand tons of potassium sulfate and 15 thousand tons of di-phosphate calcium. • Jordan has occupied an important status in Arab fertilizer industry, through adopting a strategic policy coping with international market requirements and depending on directly expanding end and by-products of fertilizers or participating with strategic partners. In this regard, allow me to refer to the following projects:
• Hashemite Kingdom of Jordan gives due concern to the human capacity, being the pillar stone of the sustainable development. In this context, fertilizer sector in the Kingdom strives to implement ambitious programs so as to increasingly improve work conditions and enhance
- Implementing the new expansion project in Arab Potash Company, this increased the company productivity from 2 to 2.5 million annually. - Implementing JIFCO project, which is a common project with IFFCO to produce annually 475 thousand tons of phosphoric
• Convening the AFA International Technical Conference, for the fifth time in Jordan since the establishment of AFA in 1975, and in cooperation with the Jordanian fertilizer companies reemphasize the special interest paid by Jordan to such a sector, the lands of which are rich with mineral resources and the Dead Sea being abundant with high economic value salts.
acid in Eishidya. - Implementing PJA project, which is a common project between Phosphate Company and Petrokimia Gresik Indonesian Company to produce annually 200 thousand tons of phosphoric acid in Indonesia. - Implementing JAFCO project, which is a common project with partners from Bahrain, ARMICO and other investors to produce potassium sulfate, calcium chloride, TSP and di-phosphate calcium. - It is noteworthy that there are 23 medium and small sized fertilizer companies, which produce compound and liquid fertilizers, for local market and exports. • Gathering today in such a Conference reflects our common desire to continue the development of this strategic industry providing the opportunity for the best utilization of nation’s resources, representing an indispensible introduction to sustainable agriculture, narrowing the food gap and reducing the world hunger rate. • At the end, I re-extend my thanks to AFA board members and secretariat for the strenuous efforts made to promote Arab fertilizer industry. Wishing the Conference and participants all success and a pleasant stay in Jordan that is always proud of the attendance of such a galaxy of people.
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Dr. Ashkar:
An increasing demand on fertilizers, highly contributing in agricultural productivity quantity and quality increase Dr. Shafik Ashkar, AFA Secretary General delivered the following speech at the Opening Session: “Filled with happiness, I stand before you in the opening ceremony of the 24th AFA International Technical Conference, held in the dear land of Amman; the land of intimacy, Arab gathering and faithfulness. So, I start by welcoming you all. Arab fertilizer industry represents a major hub for world market fertilizer provision and that in the shed of the growing demand on different kinds of food and biofuel industry, which also became part and parcel of many countries official policies, at the top of which Brazil, USA and European Common Market. Therefore, the aforementioned leads to an increasing demand on fertilizers, highly contributing in agricultural productivity quantity and quality increase in addition to improving agricultural product amount to range between 30% and 85%, especially in the light of the decrease in rainfall percentage, the limited arable lands, the rise of desertification, disputes and wars. Consequently, without fertilizer usage many countries will lose its relative advantage in achieving self-sufficiency in line with the 80 million people increase witnessed annually by the world population, reaching about 7 billion people by the end of 2011. Such a figure is expected to reach 8 billion by 2030 and 9 billion by 2050. Ladies and Gentlemen: When talking about Arab fertilizer industry, we emphasize that it represents the backbone of compound fertilizer industry, as our Arab world is abundant with 10
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major resources, namely: • 70% of phosphate rock international stock • 30% of natural gas international stock • 6% of potash salts international stock
Moreover, Arab fertilizer industries occupies major shares in international production and exports in a way maximizing annually as shown generally in the table presenting the different products. Hence, Arab fertilizer industry has recorded, during its more than 100 years march, a huge and tangible development and an increasing share of world production and international exports. Such took place as a result of the region oil and natural gas sector development together with the boom witnessed by the Arab Gulf countries in producing nitrogenous
fertilizers parallel to the continuous rise in phosphate rocks and fertilizers productivity, during the last three decades. Therefore, the Arab region, extending east and west Suez Canal, was effectively positioned on the map of fertilizer production and exporting to international markets. It is also worth mentioning that this rate of production and exporting will heighten greatly by 2016 after the completion of the future projects of ammonia, nitrogenous, phosphate rocks, potash and phosphate fertilizers production.
When talking about Arab fertilizer industry, by any means, we cannot ignore highlighting the water issue, on which fertilizer industry is based. Also, in the light of all related indicators, they prove that the region will face a serious crisis as a result of the continuous decrease in the amount of the region rivers water, the drop in water reservoir and water overconsumption in some Arab countries. Bearing in mind the fact that the Arab region population will reach 600 million people during the coming 40 years, a serious
competition emerges between the different needs for water usage; drinking, agriculture and industry. A bell rings, here, reminding us of the 83 million people in the Arab region suffering from a shortage in pure potable water. So, from this podium, I call upon you all to achieve more integration and coordination through: 1) Enhancing Arab fertilizer industry sector, providing required raw materials with acceptable prices and conditions, setting legislations supporting the establishment of such indus-
try and taking in consideration the close and direct relationship between fertilizer industry and agricultural system and producing strategic food crops via including: - The untapped agricultural resources (lands – water) in Sudan, Egypt, Syria and Morocco aiming at bridging the food gap and supporting food security, as Arab food import volume amount to more than USD 40 billion annually. 2) Investing in required infrastructure to develop the interArab countries exchange, where fertilizer industry raw materials are provided and where huge agricultural projects establishment are planned. In other words, there is an opportunity to invest in the logistics system, marine lines and different transportation means in order to increase inter-Arab integration opportunities. 3) Intensifying processes of searching and excavating for raw materials in the Arab region to make use of the available of which: sulfur, phosphate, iron, glass sand, copper, rare elements and uranium, in an attempt to discover new sources after the scientific development witnessed in the field of searching, excavating and remote sensing. 4) Establishing Arab engineering companies, encouraging the sci-
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entific research and focusing on conducting common researches for the service of fertilizer industry and its applications. 5) Making use of and directing part of the locally available and emigrating Arab money surplus for investing in and financing agricultural integrating projects and producing different kinds of fertilizers in addition to agricultural seeds. • With reference to the current International Conference, we, in supporting the technological aspect of the Arab fertilizer industry, have worked on inviting many international experts and others from the Arab region to present the latest and best scientific experiences in this regard and to exchange expertise and accumulative knowledge among AFA members. • Thus, the Conference is convened amidst such circumstances and developments and in harmony with AFA goals, seriously seeking the enhancement of Arab fertilizer industry status and competitiveness and strengthening the coordination and cooperation method among Arab companies and related international institutions; so as to achieve a number of objectives: - Continuing the flow of fertilizers to international markets without delay or stopping in addition to diversifying fertilizers according to the regional and international demand requirements. - Following up all developments accomplished in fertilizer industry engineering and technological fields and using the best available technologies. - Encouraging scientific research targeting fertilizer industry service. - Supporting and building the 12
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specialized administrative and technical capacities for such an industry via conducting specialized workshops. - Following up the rapid changes affecting the world climate and the global warming and its impact on both Man and environment. Emphasizing on the concept of environment, health and safety as a culture, method and practice to preserve both Man and environment. Applying the best methods related to health, safety and preserving both Man and environment. Increasing the investments in such a field for the protection of the society. So, AFA has launched an annual prize in such a field to raise the competition between the Arab factories in this concern; 9 factories are currently competing on 2011 prize, the winner of which will be announced during the Conference.
- Encouraging member companies to use the renewable energy means and emphasizing on the necessity of using the available of which and lessening the dependence on the fossil fuel. - Urging on rationalizing water usage and supporting related researches. Searching for the best methods to reduce water usage in industry, as water represents the pillar stone of economic and social development. Taking in consideration the existing and escalating competition between using water for potable, agricultural and industrial purposes in an Arab region considered one of the driest regions and the most decreasing in rainfall rates and water reservoir. • I would like to highlight the efforts exerted by AFA members, namely abiding by local and international legislations and standards so as to raise the
production units’ efficiency and reduce energy consumption in all production phases, aiming at promoting Arab companies competitiveness together with preserving the environment. Such efforts have borne fruit as underscored by the 2010 benchmarking study conducted by an independent international organization for more than 37 Arab fertilizer industry production units. The study proved the said units’ application to the best regional and international practices and commitment to the best stipulated standards. • Therefore, the objectives and directions aforesaid were taken in consideration when choosing the Conference topics; selecting working papers in line with such objectives together with
specialized international speakers and experts and successful applied cases and industrial treatments followed by Arab companies in both production and environment and vocational safety fields. This effort reflects the decision-takers knowledge of Arab fertilizer industry value and being prepared to go on forward in its leading role as a developmental and social momentum on the Arab countries’ level and even developing such a role as a major supplier of fertilizers internationally and providing the highest levels of quality and commitment. • At the end, I welcome on your behalf the speakers, experts and international companies participating in the accompanying exhibition. Wishing such a 3-day
scientific gathering, serious discussions, recommendations and directions highlighting the strategic and future role of fertilizer industry in creating job opportunities, supporting efforts to narrow hunger gap and achieve the required food security. • I further seize such a sublime scientific scene to extend my thanks again to the sponsoring companies. • I also would like to express my gratitude to AFA specialized committees and secretariat for their contribution together with the assisting teams from both Potash and Phosphate Jordanian Companies in accomplishing such an international specialized conference.
Thanks & Appreciation In recognition of their cooperation and support for the conference and the activities of the Arab Fertilizers Association, H.E. Mohamed Adel El-Mouzi, AFA Chairman presented AFA Shield to H.E. Nabih Salama Chairman of Arab Potash Company and to H.E. Mohamed Baderkhan Deputy CEO of Jordan Phosphate Mines Co.
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Session I 1. DAP & Phosphoric Acid Plant Improvement Mr. John Wing - Phosphate Consultant John Wing, P.E. USA 2. Phosphate Plant Yield Comparisons Mr. Richard D. Harrison – Process Supervisor / Fertilizer Consultant PegasusTSI Inc. USA 3. Novel Large Scale Energy Efficient Technology for Urea Production Mr. Rinat Anderzhanov - Deputy Technical Director of Inoviations R&D Institute of Urea Russia 4. Guaranteed (Risk Free) Energy Savings in Water and Steam Systems through Avanceon’s Proprietary «iwater» & “iboiler” Mr. Armaghan Yusuf – Business Manager Avanceon Pakistan
Session II
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5. Utilization of Satellite Image To Improve Solar Ponds Production Mr. Zaid Halasah - Senior Chemist APC Jordan 5
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1. The major research activities of the Research Institutes for Fertilizers (JSC “NIUIF”) Mr. Yuri Chernenko - General Director JSC “NIUIF” Russia 2. FSA Neutralization with Calcium Compounds Mr. Salah Albustami - Process Engineer JACOBS USA 3. Catalysts for Sulphuric Acid and Ammonia Plants Mrs. Ayten Y. Wagner – Arae Manager – Catylest Devision Mr. Henrik Larsen - General Manager , Marketing & Sales Synthesis Haldor Topsoe Denmark 4. IJC Experience on Revamping of Sulfuric Acid and Phosphoric Acid Plants Mr. Awinash Peshwe - Plant Head IJC Jordan 5. Replacement of High Pressure Scrubber in SAFCO-II Urea Plant Mr. Bellary Muhammad Usman – Maintenance Superintendent SAFCO S. Arabia
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Session IV
Session III 1. Meeting environmental issues facing new and existing urea Fluid –bed Granulation with Plants Mr. Harald Franzrahe – Process Manager Uhde Fertilizer Technology B. V. Netherlands 2. Revamping of a Conventional Total Recycle Urea Plant Mr. Narayansamy Selvaraj – Head of Urea -1 Plant Mr. Mohamed Al Naemi – Urea -1 Plant engineer QAFCO Qatar 3. Best-practice on RBI driven Integrity Assurance from Concept to Implementation Mr. Salah Abdulaziz Zainaldin - Senior Inspection Engineer (Designated). GPIC Bahrain 4. Health, Safety and Environment in Fertilizer Industry Story behind APC Success in achieving 4000000 MHW Free of LTI-s Mr. Sami Amarneh QES Manager APC Jordan
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1. 10 Years of Safurex Experiences in Stamicarbon Urea Plants Mr. Joost Roes – Acqisition Manager Stamicarbon Netherlands
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2. Capacity Increase of Urea Plants Mr. Thomas Krawczyk – Senior Process Engineer Uhde GmbH Germany
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3. M.P. Boiler Super Heater Coil Failure and Replacement Mr. Adel Al Wahedi - Mechanical Engineer FERTIL UAE
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4. Carbon Dioxide Recovery Plant at GPIC – A Sustainable Option Mr. Jamal Ali Al Shawoosh - Methanol Plant Superintendent GPIC Bahrain
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5. The challenge of Adding Cooling capacity to an Existing Fertilizer Plant Ms. Marietta Mansvelt - Technical Service Manager Solex Thermal Science Inc. Canada
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n o i t bi 24th AFA Int’l. Technical Fertilizers Conference
Session V
1. Brief Capability Introduction on Jordan National Shipping Line Co. Capt. Issa Awad Hasan, - Business Development Manager JNSL Jordan 2. Analysis of Safety Performance of Indian Fertilizers Plants Mr. Manish Goswami - Dy. Chief (Technical) FAI India 3. Commissioning and Revamping Fertilizer Plants Through an Objective Oriented Approach Mr. Gian Pietro Testa – Consultant for Saipem (Italy) - Business Development Manager O.V.S K&T Monaco 4. Environmental friendly way of spent catalyst recycling Mr. Clemens Kuhnert - Area Manager ME & Africa Nickelhütte Aue GmbH Germany 5. A new approach for Urea Plant Optimization using Advanced Process Control Mr. Christiaan Moons – Sales Director- IPCOS Mr. Luc Dieltjens - Process Engineer Stamicarbon Belgium
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Jordan Phosphate Mines ( JPMC)
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The Conference was accompanied by an industrial exhibition, in which a number of important international companies participated from Jordan, Egypt, Belgium, Britain, Denmark, Canada, Holland, Germany and Singapore. Jordan Phosphate Mines ( JPMC) was established as a private shareholding company in 1949 and later registered as a public shareholding company in 1953. The Company’s objectives include phosphate exploration, mining and marketing, the manufac-
ture of fertilizers, and the establishment of initiatives in related fields. JPMC is headquartered in Amman, with its main mining operations located in Al-Hassa, Al-Abiad and Eshidiya (south of Jordan), with the addition of a smaller operation located in Russeifa. JPMC also owns and operates an industrial complex in Aqaba for the production of chemical fertilizers. JPMC has a special standing among international companies producing and manufacturing phosphate ore, which is essential to the fertilizer Industry, and considered a major element in food production worldwide. 2006 was a turning point in the history of JPMC. The Company was privatized in line with the government’s strategy aimed at privatizing public shareholding companies, which reflects positively on both the performance of companies and the national economy. In its quest to meet the challenge of global competition, JPMC underwent a fresh start that witnessed changes in recent years in the financial, production marketing and administrative areas. Investments were increased in the transformative industries’ projects that shape the future of the phosphate industry.
The Arab Potash Company
The Arab Potash company (APC) is a pan Arab joint venture established in 1956 to produce Potash and minerals from the Dead Sea. The Company currently has annual consolidated sales of around 560 million JDs, and a workforce of over 2,000 employees. APC’s annual production capacity stands at 2.45 MTwith the recent opening of the new Cold Crystallization plant (NCCP). The new plant is equipped with top of the line technology that minimizes potash-dust and gaseous emissions to record-breaking standards worldwide. APC now represents about 4% of Potash production worldwide.»
kemapco
Arab Fertilizers & Chemicals Industries Ltd. (KEMAPCO) has a plant production capacity of 150,000 tons/year of potassium nitrate (NOP) and 75,000 tons/year of Docalcium phosphate (DCP). Since Feb. 1st 2007 the company has been 100% owned by Arab Potash Company. The company was originally established under the name Kemira Arab Potash Company Ltd. (KEMAPCO) as a 50:50 joint venture set up in Jor-
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dan in 1999 between Kemira GrowHow (Finland) and Arab Potash Company (Jordan).
Telephone: +32 (0)2 643 15 11 Fax: +32 (0)2 647 74 35
Jordan National Shipping Lines (JNSL)
Solex Thermal Science Inc.
Established and operated since 1976, JNSL positioned itself as a grade “A” provider of shipping services in the local and international markets. Over the years has made it its mission to provide distinguished, diverse, and personalized shipping services to clients and maintain customer satisfaction irrespective of group expansion to the regional and global markets. Our services : - Ship Owner - Ship Operators - Commercial Ship Management - Technical Ship Management - Ship Brokers - Ship Agents - Maritime Education - Freight Forwarding & Specialized Projects Tel: +962 6 5511500 Fax: +962 6 5511501 e-mail: info@jnslgroup.com www.jnslgroup.com
SNC-LAVALIN (Belgium)
SNC-LAVALIN is one of the leading groups of engineering and construction companies in the world, and a key player in the ownership and management of infrastructure. In business since 1911, SNC-LAVALIN companies are active across 35 other countries worldwide (over 24.000 employees). They are currently working on projects in approximately 100 countries. SNC-LAVALIN provides engineering, procurement, construction, project management and project financing services to a variety of industry sectors, including FERTILIZERS, power, mining & metallurgy, infrastructure, chemicals & petroleum, pharmaceuticals, environment, agrifood, agriculture, mass transit, defence and telecommunications. SNC-LAVALIN has a unique reputation in the Fertilizer Industry, with more than 35 years of global experience, a commitment to offer “one single source solution for the fertilizer industry”. sa SNC-LAVALIN nv Head Office Avenue Louise 251 – Box 16 B-1050 Brussels Belgium
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Calgary, AB, Canada Solex Thermal Science specializes in the science of heating, cooling and drying bulk solids with a track record of over 20 years and more than 120 successful installations in the fertilizer industry. Solex coolers serve all kinds of fertilizer such as Urea, NPK, MAP, DAP and of course AN, CAN and LDAN. The Solex proprietary software ThermaPro allows exact modeling of the heat transfer of the product during cooling. Go to www.solexthermal.com to learn more. Services: With a wide network of agents and service centers in North America, Europe and China, Solex offers commissioning service, after sales support, and process optimization during the lifetime of the equipment installed. p. (403) 254-3518 f. (403) 254-3501 www.solexthermal.com
Haldor Topsøe A/S (Denmark)
For more than 70 years, Topsøe has been a main supplier of catalysts and technology for the ammonia and methanol industries. Due to focus on constant innovation and development, Topsøe has supplied catalysts and technology for approx. 50% of the new ammonia plants constructed within the last decade. This R&D effort, combined with extensive knowledge and insight about actual ammonia plant operation, is utilised when offering new catalysts, improved process layout and design for the fertiliser industry. For the production of sulphuric acid Topsøe>s innovative catalysts and processes provide energy-efficient operation, lower SO2 emissions and higher production rates.
Middle East Star (Egypt)
Middle East Star MES was established in 1981 as privately owned commercial agents and technical consultants company. Over the past period we managed to realize specific growth targets, partnering with international suppliers to offer our regional customers innovative integrated solutions and services. Middle East Star MES comprises two main lines of
activities serving the process sector as well as special projects for the industrial sector in Egypt. Due to consistent expansions since 1981, MES manages to contribute the spinoff of number of representations, projects & organizations. Our policy is built on maintain maximum control over our operation through the efficient utilization of our resources and effective contribution of more spin off(s) whenever feasible. Middle East Star MES integrated delivery program ranges for: 1. Water Treatment: Water and waste water treatment units, Desalination packages, RO units, Ultra Filtration. 2. Reciprocating & Screw (process) compressors . 3. Tubes: Casting Tubes, Ammonia Reformers, Ethylene Cracker Furnace colis. 4. Inspection on reformer tubes by Eddy Current technique- Services. 5. Heat Transfer Equipment: Plate & Shell & Tube Heat Exchangers, Pressure vessels, Columns & Reactors, Condensers, Evaporators, Absorbers, Indirect fired heaters, Boilers, Chillers & Refrigeration packages 6. Various packages Fuel gas units, 2&3 Phase sepa-
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rators, Chemical Injection units & Flare Packages + valves & actuators. 7. Process Filters: Coalescers, Liquid/Liquid, Solid/ Liquid, Solid &Liquid Gas separation & Filtration. Contact person: Soha Rashed - Project Manager Mobile: +20 10 0143 9015 Tel: +20 2 262 33 110 Fax: +20 2 262 33 272 E-mail:mailto:soha.rashed@mes1981.com soha. rashed@mes1981.com Contact person: Soha Rashed – Project Manager Mobile: +20 10 0143 9015 Tel: +20 2 262 33 110 Fax: +20 2 262 33 272 E-mail: mes support@mideastar.com.eg
AUMUND Fördertechnik GmH
An AUMUND Group Company (Germany) AUMUND Fördertechnik is a specialist of most reliable and efficient solutions in bulk handling. The company, located in Rheinberg, Germany, is particularly well-known for its abrasive or hot materials handling equipment as well as for top quality customised solutions. Many projects in the potash, phosphate and fertilizer industry justify the good AUMUND reputation. A comprehensive range of products is available including all kinds of pan, apron or chain conveyors, as well as bucket elevators and silo or storage discharge machines. Capacities can vary from a few tons per hour to very high tonnages ( > 1,000 t/h), proven by thousands of references in all kinds of industries worldwide. References are installed at e.g. Kali+Salz, Villares Mineração, Vale, BASF, Bayer AG. AUMUND Group equipment can be found in many applications: - crusher feeding and hopper discharge in quarries - chain conveyors in different stages of industrial processes - belt and chain bucket elevators for vertical material lift - pan and apron conveyors - storage, silo and hopper discharge - storage and blending bed equipment (SCHADE Lagertechnik) - automatic wagon unloading systems (SCHADE Lagertechnik) - ship unloading and loading equipment (B&W Mechanical Handling)
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- mobile stacking and loading (B&W Mechanical Handling) Contact: Mr. Christoph Scholz Sales Manager AUMUND Fördertechnik GmbH Saalhoffer Strasse 17 47495 Rheinberg Germany T +49 2843 720 F +49 2843 60270 E scholz@aumund.de
KOEPPERN (Germany)
Since 1898 Maschinenfabrik Köppern GmbH & Co. KG has developed into a well-experienced medium-sized enterprise offering specialized equipment all over the world. Among its range of products and activities the development and fabrication of roller presses are to be found as well as engineering services for complete roller press-containing plants. Köppern roller presses are intended for briquetting and compacting of fine-grained bulk material and also for crushing brittle basic material. Telefon /Phone: ++ 49 2324 207- 259 Telefax /Fax: ++ 49 2324 207- 207 E-Mail: c.lonken@koeppern.de Internet: http://www.koeppern.com CFI holding Pte. Ltd. (“CFIh”) - Singapore specializes in chemicals, fertilizers, explosives and crystallization/evaporation processes. CFIh is the worldwide leader in ammonium nitrate and LDAN with an international presence (France, India, Tunisia, Brazil, Singapore). Wide range of services from feasibility study to full engineering for revamping projects or grass-root plants.
CFIh also offers services related to procurement, on-site activities and product/process development. FMB - UK FMB is a leader in the provision of timely and accurate intelligence on the world fertilizer market and has recently launched the industry’s first fertilizer dashboard. FMB’s reports monitor global trade and pricing for nitrogen, phosphate, sulphur, potash and ammonia. Founded in 1982, FMB publishes 100 price references, which are widely used for benchmark pricing and settlement of derivatives. Its five global conferences FMB West and East Europe, FMB Africa, Fertilizer Latino Americano and FMB Asia are key industry trading events. In 2011, FMB was acquired by Argus Media, a leading global energy price reporting agency that covers the oil, electricity, natural gas, coal, bioenergy, emissions and transportation markets. For further information and a free trial subscription, visit www.fmb-group.co.uk. FMB Consultants Ltd. (An Argus Media Company) FMB House 6 Windmill Road Hampton Hill TW12 1RH ENGLAND Phone: +44 20 8979 7866 Fax: +44 20 8979 4573 Modern Scientific supplies MSS is one of the Jordanian leading distributors for Scientific and Laboratory Instruments. We are sole agent for many European and American Companies specialized in testing instruments for feed , food, fertilizers , pharmaceuticals …etc , We
have more than ten years of experience in Selling, Commissioning and Servicing these instruments with Factory Trained Engineers having good reputation in the Jordan/Middle East Market. Many of the Fertilizers companies bought our equipments for Nitrogen (N) testing as well as Phosphorus (P), and Potassium (K) . We are present in all the middle east markets with our partners to help our customers.
UNIDENSETM Technology GmbH
UNIDENSETM Technology GmbH is your reliable Reformer specialist. We are not only a service company we are also a technology company. Our automated loading system, the UNILOADERTM and other new technologies, which will be introduced at the Nitrogen & Syngas 2012. The UNILOADERTM is a machine which enables reformer tubes loading with catalyst by the UNIDENSETM principle automatically. Our OUTTUBETM & INTUBETM Cleaner are revolutionizing the cleaning technique for reformer tubes and has been trial run for other application as well.
Stamicarbon
Stamicarbon, the innovative, experienced and reliable licensor Stamicarbon is the global market leader in the development and licensing of patented urea technology. This leading position is maintained by its continuous innovations, like AVANCORE®, Mega Plant, Urea 2000plus™, Granulation Technology and Safurex® material. Stamicarbon has over 60 years> experience in licensing its urea technology, delivering optimum environmental performance, safety, reliability and productivity at the lowest investment level.
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Press Release Maire Tecnimont S.p.A. announces that its main operating company Tecnimont S.p.A. has been awarded an EngineeringProcurement-Construction-Commissioning (EPCC) Contract on lumpsum turnkey basis for the realization of a new Fertilizers Complex within the existing industrial area in the Aswan Governorship (Upper Egypt). The client is Egyptian Chemical & Fertilizers Industries – KIMA, an Egyptbased company that operates in the chemical sector. The overall project value is approximately USD540 million and the completion is expected by the end of July 2014. This award highlights the efficacy of the synergies in the fertilizers sector between the Group’s sister companies (fully controlled by Maire Tecnimont): Tecnimont, the leading EPC company of the Group, and Stamicarbon BV, the Group’s Licensing and Intellectual Property center who is the world market leader in urea licensing.
NEW CONTRACT AWARDED FOR FERTILIZER PROJECT IN EGYPT
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The new Fertilizers Complex will be composed by: one Ammonia production unit of 1,200 ton/day capacity, implementing the KBR “Purifier” technology; one Urea melt production unit of 1,575 ton/day capacity, implementing the “Pool Reactor” technology of Stamicarbon; one Urea granulation unit of 1,575 ton/day capacity, im-
plementing the urea granulation technology of Stamicarbon; all the necessary Utilities & Off-site facilities to support the process units. This contract reinforces the presence of Maire Tecnimont Group in Egypt with the first EPC project and consolidates its track record in the fertilizer sector. Maire Tecnimont SpA Maire Tecnimont S.p.A. is the parent company of an Engineering, Main Contracting & Licensing group which operates in three sectors: Oil, Gas & Petrochemicals, Power, Infrastructure & Civil Engineering. The Group, quoted on the Milan Bourse, is present in over 30 Countries, controls over 50 operating companies and can rely on a workforce of about 5,300 employees, of which more than half are located internationally. At 31 December 2010, the Group reported Revenues of €2,536 million and Net income, after minorities, of €62 million.
OCP Announcement OCP and Yara initiate global partnership Casablanca (2011-12-13): OCP S.A. and Yara International ASA have agreed on the key terms of what will be a first major step towards a global partnership. OCP will be acquiring a 50% stake in Yara’s industrial complex in Rio Grande (Brazil) which includes fertilizer production facilities, the largest fertilizer port terminal in the region and warehousing capabilities. OCP will supply the phosphate rock to the facility for the production of phosphate fertilizers and will use the terminal and warehouse to increase the availability of phosphate fertilizers in the region. OCP will also be entering into a long-term supply agreement with Yara for the supply of phosphate
rock. This supply agreement will ensure stable returns for OCP while supporting Yara’s production operations in Europe. “OCP is committed to meet the growing global demand of fertilizers. We are pleased to build this partnership with Yara which further consolidates our existing long term relationship with Yara” said Mostafa Terrab, Chairman & CEO of OCP. “The access to port facilities and fertilizer production capacity in Rio Grande is key to OCP’s strategy in the region, and positions OCP to better serve our customers.” added Mhamed Ibnabdeljalil, Executive Vice President, sales, marketing & raw material procurement.
Our CEO since September 2007, Niels Kegel Sørensen has handed in his resignation from his position. The Board has at its meeting today accepted his resignation. The Board expressed their sincere recognition of the 35 years of employment of Niels Kegel Sørensen in the company and in particular his great efforts, first as CEO of the subsidiary Haldor Topsoe, Inc. and later as CEO of Haldor Topsøe A/S. During his term, the company has achieved excellent results despite difficult times in the global market. Dr. Bjerne S. Clausen has as from today been appointed new CEO. Bjerne Clausen has been employed in the company since 1979, first as researcher in R&D with the responsibility of many of the company’s international cooperations and later as Direc-
tor of R&D. In 2008, Bjerne Clausen was asked to take over the management of the Technology Division, and as Executive Vice President, he initiated many changes and more efficient procedures, and today this division contributes significantly to the growth, strategy and revenue of the company. The chairman of the Board, Dr. Haldor Topsøe states: ”Haldor Topsøe A/S supplies some of the world’s most efficient solutions to the world’s energy, environmental and climate challenges. The company is thus facing some very exciting and interesting development opportunities and the Board is very pleased that Bjerne Clausen with his unique experience and background has accepted to manage the company on the way forward.”
Haldor Topsøe A/S appoints new Chief Executive Officer
Topsøe receives order for two SNOXTM plants from Petrobras, Brazil
The order includes supply of proprietary equipment for two SNOXTM flue gas cleaning plants. Topsoe has signed an agreement with the Brazilian oil company Petrobras for the supply of critical equipment and materials for two SNOXTM plants. The plants will be installed at the new RNEST grass root refinery in Pernambuco, Brazil. The supply covers internals for 80 WSA condensers for condensation of sulphuric acid, 8 units for acid mist control and a complete acid system. Cleaning flue gases The SNOXTM plants will clean the off gases from three boilers in the refinery that supplies electricity and steam for internal use. The boilers are fired with heavy fuel oil and petcoke. Based on catalytic processes the SNOXTM technology converts sulphur dioxide to industrial grade sulphuric acid and NOx to harmless nitrogen. Sulphuric acid production In addition to treating the boiler flue gases, the Claus plant tail gases, the amine gases containing hydrogen sulphide and the SWS gases containing ammonia will also be treated in the SNOXTM plants. The SNOXTM plants are designed for possible elimination of the Claus plants, which then means that all sulphur compounds in the refinery are converted into sulphuric acid. The two SNOXTM plants will be installed in parallel and will each treat up to 650,000 Nm3/h of flue gas while producing up to 750 MTPD of sulphuric acid. In addition to the production of sulphuric acid up to 100 ton/hour of high pressure steam will also be exported from the SNOXTM plants to the refinery steam grid. The contract for basic engineering was signed with Petrobras earlier and has already been executed. The supply of equipment will take place during the coming 16 months, and start-up of the SNOXTM plants is planned for 2013. Issue 61
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QAFCO-5 With Member Companies
Inauguration
20th of Dec. 2011 Mesaieed Industrial City, Qatar
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Four Decades of Achievements: Throughout its four decades and since its inception in 1969, QAFCO has cruised its way confidently and established a brand image in both the regional and world fertilizer arenas. From one line of production of ammonia and urea, QAFCO has progress, achieving six ammonia plants and five urea plants, and has diversified its range of products to include urea formaldehyde, aqueous ammonia, urea solution and melamine. QAFCO Feeds the World: Feeding the rapidly increasing world population topped QAFCO’s agenda with the company placing special emphasis on environmental concerns and secured sources of safe and healthy food supply channels. Hence, QAFCO adopted “Feeding the World” as a slogan and continued exploring strategies to further strengthen this stand. After its excellent industrial exposure and breadth of rich experience gained from previous initiatives, the company released the QAFCO-5 expansion project as a recent endeavor to develop production facilities and meet the growing demand for food worldwide. Exploring Possible Choices: To keep up to its promises and live to the expectations of clients, QAFCO explored all possible scenarios to expand the production facilities, establish new ones and introduce the latest technolo-
gies in order to reach the milestones in production and product quality. Hence, immediately after QAFCO-4 came on line in 2004, a detailed feasibility study was carried out considering to increase the company’s production volume of both ammonia and urea. During the initial stages of the project, several options to expand were evaluated. The most favorable economic alternative was demonstrated to be the investment in a double-train ammonia facility, upgrading half of the ammonia to urea granules, with the intention to expand the urea capacity at al later point in time. QACO-5 EPC Contract: The letter of intent for the construction QAFCO-5 project was signed on the 2nd of February 2005, in Oslo Norway between Qatar Petroleum (QP), Yara International and Qatar Fertiliser Company (S.A.Q.). The EPC contractor for QAFCO-5 is a consortium of Saipem S.p.a. (Italy), Hyundai Engineering and Construction (South Korea). Saipem has significant experience in implementation of fertilizer projects, owns the Snamprogetti urea technology and has access to ammonia license from Haldor Topsoe. In QAFCO5 project, Saipem is the EPC lead contractor and fully responsible for all engineering, procurement and commissioning and startup activities with Hyundai Engineering and Construction responsible for construction and construction management, as well as being fully responsible for the expansion of the jetty. The majority of the equipment and bulk materials for the project have been sourced from foreign companies all over the world, while construction resources have been sourced by HDEC through subcontractors originating primarily from the Far East. Main Units of QAFCO-5:
QAFCO-5 expansion project comprises of three main units a follows: 1. Ammonia Plants: Two identical ammonia plants based on natural gas as feedstock, with a design capacity of 2200 mtpd. The annual production capacity is 750,000 metric tons per ammonia plant. The licensor for the plant is Haldor Topsoe, a Danish company specializing in designing process plants with a focus on fertilizer, chemical and petrochemical industries. 2. Urea Plant: The urea plant has a desing capacity of 3800mtpd of urea, including a granulator unit with a design capacity of 3850 mtpd. The annual production capacity of this plant is 1,350,000 metric tons of urea. The licensor for the urea plant is Snamprogetti, a main contractor for the design and implementation of large-sized projects in petrochemical and fertilizer. The granulation plant of QAFCO-5 is licensed by Uhde Fertilizer Technology. 3. Urea Formaldehyde Plant: This is a complete process plant for the production of 85 mtpd of Urea Formaldehyde condensate (UFC-85) based on methanol and urea as feedstock. The annual production capacity of this plant is 30,000 metric tons and the licensor for the plant is Perstorp. Auxiliary Units of QAFCO-5: In addition to the main plant, QAFCO-15 consists of the following supporting units: • A complete urea granules storage facility with a capacity of 100,000 mt with a reclaimer. • A complete material handling system with pipe conveyer which is over 4 km length and with a capacity of 1000 mtph for export of urea granules to the new export system on Jetty 1. • A berth extension of Jetty No.1 that facilitates loading of ships between 5000DWT up to
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With Member Companies
QAFCO-5
Inauguration
70,000DWT size of urea bulk carriers. • A complete steam and power generation plant including 2 cogenerating units, a steam turbine generator and two auxiliary boilers for supply of power and steam to plants at QAFCO5 site. • One single Main Central Control Room Buiding, CCR-2. • Two 50,000 metric tons Ammonia Storage Tanks and 1000 metric tons per hour Ammonia Loading Systems, all installed at the existing QAFCO site. • A new seawater multi-cell cooling unit capable of supplying the full cooling duty for all the facilities on QAFCO-5 site, with fresh seawater makeup from the outfall of either QAFCO-3 and /or QAFCO-4 at the existing QAFCO site. • A new 132 kV distribution station at QAFCO-5 site, connecting both sites with the external grid. • A new Multi-Effect Distillation Thermo-Compression (MED) Desalination Plant capable of supplying a minimum of 225 m3/hr of desalinated water. • Electro-chlorination units and chemical dosing systems capa-
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ble of supplying the toal chemical treatment requirements of the closed seawater cooling system at QAFCO-5 site. QAFCO-5 Contribution to Overall Production: QAFCO-5 project is expected to significantly increase QAFCO’s overall production capacity. The below graphs show the projected increase in capacity for both ammonia and urea finished product from QAFCO, after implementation of QAFCO-5 and beyond 2012, including Unrea-6. Forecasted Ammonia Production – kt / year FIGURE Forecasted Urea Production – kt / year (granules and prills) FIGURE By implementing QAFCO-5 project, the company will increase its production of ammonia by 73%, and have an excess of ammonia of approximately 700 kt from QAFCO-5 up to the time of implementing QAFCO-6 project, after which Urea-6 plant will upgrade all the excess ammonia from Ammonia-6 plant. The Urea production capacity will increase by 43% adding 1.35 million metric tonnes to the existing capacity, increasing yearly production capacity to 4.3 million metric tonnes. Zero Environmental Impact:
In terms of impact on the environment, the implementation of a cogeneration unit at the QAFCO site, as a replacement of open cycle gas turbines and fired boilers, high values of NOx reduction will be obtained, by virtue of the effective use of waste heat from the gas turbines. QAFCO-5 plants are designed for minimal impact on the external environment. Process flares are installed in all ammonia and urea plants to avoid emission of chemicals due to process upsets. Safety is Top Priority: As in any project of this scale, the safe implementation of the project and care for the safety and health of the entire work-force is a key responsibility and challenge for the project management from Contractor to Client. Challenging situations are dealt with by the Project Management and discussed in weekly joint meetings, held with the intention to avoid repetition of incidents and accidents. Key challenges with respect to project schedule were discussed at all levels of the organization, from weekly construction and commissioning meetings, following key milestones, up to Steering Committee meetings. As soon as delays did arise, recovery plans were issued and resources added to stop recurrence of any further delays.
SABIC
announces interim consolidated financial results for the period ended December 31, 2011 Saud Basic Industries Corporation (SABIC) has announced the interim consolidated financial results for the fourth quarter and twelve months period ended December 31, 2011: 1 The net income for the quarter ended December 31, 2011 was SR 5.24 billion compared to the net income of SR 5.81 billion for the same quarter in 2010 representing a decrease of 10%, and compared to the net income for the third quarter of 2011 of SR 8.19 billion representing a decrease of 36% 2. The gross profit for the quarter ended December 31, 2011 amounted to SR 13.38 billion compared to the same quarter in 2010 of SR 12.99 billion representing an increase of 3 % 3. The income from operations for the quarter ended December 31, 2011 amounted to SR 9.51 billion compared to SR 10.01 billion for the same quarter in 2010. This represents a decrease of 5% 4. The net income for the twelve months ended December 31, 2011 amounts to SR 29.21 billion compared to the net income of SR 21.53 billion for the same period in the preceding year, an
increase of 36% 5. The earnings per share for the twelve months ended December 31, 2011 amounted to SR 9.74 compared to SR 7.18 for the same period in 2010 6. The gross profit for the twelve months ended December 31, 2011 was SR 62.11 billion, compared to SR 48.55 billion for the same period in 2010, an increase of 28% 7. The income from operations for the twelve months ended December 31, 2011 was SR 48.80 billion, compared to SR 37.89 billion for the same period in 2010, an increase of 29% 8. The increase in net income for the twelve months period ended December 31, 2011 compared to the same period in 2010 is attributable to the increase in production and sales volumes and higher product prices. The decrease in net income for the quarter ended December 31, 2011 compared to the same period in the preceding year and third quarter of 2011 is mainly driven by lower pricing environment in global markets for most of the products, despite increase in sales volumes.
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Studies & Researches
DAP & PHOSPHORIC ACID PLANT IMPROVEMENTS Proven Winners for Capacity, Profitability, Quality, By-Products, and Clean Operation by John Wing, P.E.
ABSTRACT
DAP PLANT MODIFICATIONS
A selection of attractive modifications are described, based on successful projects. DAP innovations include: Dual Mole Reactor-Granulator Acid Scrubbing BFL Vaporizer/Scrubber - Vaporizes all ammonia with free heat from air leaving the reactor-granulator acid scrubber. This unit provides a 3rd stage of scrubbing – potentially eliminating need for any tail-gas scrubber. Product Screen Diverter Systems – easy capacity increase Automated Recycle Control - continuously monitors recycle particle size and adjusts process to keep size in mid-range. Dual diameter reactor (pre-neutralizer) Pipe Reactor Cooler Air Chiller Tran-Tech Product Cooler
Several features should be included in most new granular diammonium phosphate (DAP) plants. They often provide attractive payout as modifications to existing plants. These innovations reduce capital and operating cost, cut ammonia loss and steam use to near zero, facilitate operability and product quality, and reduce air emissions at minimum cost. • Dual Mole Reactor-Granulator Scrubbing : Fumes from granulator and reactor (pre-neutralizer) are scrubbed with acid in two stages of countercurrent scrubbing - providing near zero ammonia loss. • BFL vaporizer-scrubber: All ammonia feed can be vaporized with free heat - eliminating the cost of steam heat. This ammonia vaporizer doubles as an efficient tail-gas scrubber, cleaning and cooling the exit air. • Screen Diverter System: Screening equipment is minimized with a system that routes only enough material as is required to the product screens. • Automated Recycle Control System: This system continuously monitors particle size of the recycling stream and adjusts the process to keep size in the middle range. • Dual-Diameter Reactor: This reactor is large at the top to minimize entrainment, and small at the bottom to minimize formation of an insoluble phosphate compound. • Pipe Reactor: Ammonia mixes with phosphoric acid, and the reacting mixture spews into the granulator. Benefits are reduction of insoluble phosphate and energy savings. • Cooler Air Chiller: Part of the ammonia feed becomes the refrigerant to chill cooler inlet air. Cooler and associated air handling equipment can be much smaller. Existing plants can boost capacity and/or reduce product temperature. • Tran-Tech Cooler: A simple device supplements cooling of the product as it enters the storage pile.
Phosphoric Acid plant projects to consider include: Conversion from Dihydrate to Hemi: Makes acid at 42% concentration vs. ~27% No need for most evaporation. Usually no rock grinding is needed. Conversion to Hemi-Di – similar benefits plus 98.5% recovery & clean gypsum Utilize gypsum – many ways to make gypsum an asset rather than liability Recover uranium – major investment with high profit potential Recover fluosilicic acid – high-purity grade for AlF3 feed A variety of profitable uses for phosphogypsum Advances in dry gypsum stacking Purify phosphoric acid to technical or food grade Project management and start-up issues are discussed.
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DUAL-MOLE REACTOR/GRANULATOR SCRUBBING
Most of the ammonia and fluoride fumes in a DAP plant originate at the reactor and granulator. These fumes are cleaned with 2-stage counter-current acid scrubbing, controlled at two different N/P mole ratios. Advantages of Dual Mole Scrubbing are: • Ammonia losses are greatly reduced. • It is much easier for the main acid scrub bing system to operate at optimum mole ratio, because it is protected from excess ammonia. • Atendency to emit sub-micron ammonium fluoride mist is avoided. • When this is followed with a BFLVaporizer-Scrubber, exit air is so clean that no tail-gas scrubber is needed. The first stage of Double Mole Scrubbing is controlled at an N/P mole ratio which is well above 1.0, and the second stage is done at well under 1.0 mole ratio. Mole ratio near 1.0 is always avoided, because that is a minimum solubility point, where severe scaling and fouling occur. This 2-stage counter-current scrubbing system is highly effective in removing the two serious contaminants in this gas stream - ammonia and fluorides. Ammonia loss will be well under 1%, versus typically 2-5% for single-stage scrubbing. Double Mole Scrubbing is more tolerant of high ammonia emissions from the reactor and granulator - a situation which could cause serious fouling problems by driving the mole ratio to 1.0. Double Mole Scrubbing should be standard equipment in all new DAP plants, and it is frequently an attractive modification for existing plants, depending on actual ammonia losses and its value. BFL VAPORIZER-SCRUBBER
This system uses waste heat from the reactor-granulator acid scrubbing system to vaporize all ammonia feed a DAP or MAP plant. The system is located in the gas stream exit reactor-granulator acid scrubbing. Condensate from the hot gas side is separated and recirculated as scrubbing water. An important side-benefit is that so much heat is removed from effluent air that ammonia removal is enhanced. The effluent condensate contains very low concentrations of ammonia, fluoride, and phosphate, so surplus condensate is discharged with minimal loss of valuable material. Typically the surplus condensate would be sent into acidic pond water or other impure water stream.
A recent advancement uses a plate type vaporizer, instead of the original shell-and-tube type. Advantages include improved scrubbing, lower cost, and very low pressure drop for process air.
The combination of 2-stage acid scrubbing, the BFL vaporizer-scrubber, and efficient cyclone and scrubber design eliminates the need for a separate tail-gas scrubber. With efficient cyclones and welldesigned acid scrubbers, the system will meet rigorous air emission standards. Vent gasses from the dryer, cooler, and equipment vents contain lesser amounts of contaminants, and emission standards can be met without tail-gas scrubber. Any new DAP plant design should be seriously consider this opportunity to eliminate the expensive tail-gas scrubbing system. However, it might not be practical to take advantage of this opportunity when retro-fitting an existing plant. “BFL” refers to Belledune Fertilizers Ltd., where an early version was successfully employed in the gas stream directly from the reactor (before acid scrubbing). That early arrangement is suitable only for plants that can handle issues involving water balance and ammonia. The essential rule for vaporizing ammonia is to use free heat. Ammonia is so volatile that many forms of free heat can be employed, rather than valuable steam. The BFL Vaporizer is only one of three methods of vaporizing ammonia with free heat that I have designed for DAP plants. Another source of free heat is warm tail-gas scrubber water. Like the BFL Vaporizer this cools the gas stream, which helps remove ammonia and fluorine from the air leaving the DAP plant. Ambient air works in tropical climates, and I designed ambient air vaporizing for the Philphos plant in the Philippines. Warm water from the sulfuric acid area or other sources could also be considered for vaporizing ammonia. SCREEN DIVERTER SYSTEM
This innovation allows use of fewer screens to achieve separation of fines and on-size material. In conventional granulation plants, product screens receive all recycling material after the coarse screens have removed oversize. The Screen Diverter System utilizes a system of diverters and by-pass chutes to limit the product screen feed to no more feed than is required to provide enough product. This minimizes the number of products screens that are needed, and it improves product size distribution. Issue 61
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Studies & Researches AUTOMATED RECYCLE CONTROL SYSTEM
This system continuously monitors particle size of the recycling stream. The resulting information on particle size distribution enables computerized adjustments of the process to keep size in the middle range. It was developed by HiTech Solutions Inc. and successfully implemented in the USAC Bartow DAP plant at rates exceeding 150 STPH DAP, making DAP of exceptionally high quality at 2-4 mm particle size. DUAL-DIAMETER REACTOR
The reactor (pre-neutralizer) where phosphoric acid slurry is ammoniated should have a large upper diameter to reduce entrainment of slurry to the vent duct. This large diameter would be detrimental if it increased the slurry residence time, because of a side reaction which renders some of the phosphate insoluble. Therefore, the lower part of the reactor is smaller in diameter, to limit slurry residence time and minimize the undesirable reaction. This innovation was pioneered at the W R Grace (now Mosaic) #4 DAP plant at Bartow, Florida, USA. PIPE REACTOR
Ammonia mixes with phosphoric acid in a pipe reactor, and the reacting mixture spews into the granulator. Benefits are reduction of insoluble phosphate and energy savings. Various versions of the pipe reactor principle are offered by Jacobs, PegasusTSI, S A Cros, TVA, Uhde, Grande Paroisse, ERT-Espindesa, and others. Some do part of the ammoniation in a pre-neutralizer reactor, and some route acid and scrubber acid directly to the pipe reactor without a pre-neutralizer. COOLER AIR CHILLER
Part of the ammonia feed is borrowed to become the refrigerant to chill cooler inlet air to about 5 degrees C. This cold air is much more effective for cooling DAP than ambient air. New plants can be designed with a much smaller cooler and associated air handling equipment. Existing plants can boost capacity and/or reduce product temperature by routing the cold air from a cooler chiller to the cooler. TRAN-TECH PRODUCT COOLER
A simple machine is utilized along with special 30
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procedures to supplement cooling of the product in the storage building. It is a mechanical device that cools product with ambient air. Optional enhancements can involve distributing the product over an extended area in the storage pile and ventilating the storage building. This provides a modest increase in product cooling system at less expense than alternatives such as using an ammonia cooler-chiller or increasing the size and air flow thru the conventional cooling system. The Tran-Tech Cooler was invented and patented by Mr. Sa Cao Tran ( stran@agrifos. com ). It proved successful in operation in the Royster DAP plant in Florida, which had no other cooler whatsoever. PHOSPHORIC ACID PLANT MODIFICATIONS COMPARING DIHYDRATE, HEMI, & HEMI-DI ITS ALL IN THE GYPSUM
We call them phosphoric acid plants, but they make much more gypsum than phosphoric acid. Various phosphoric acid processes are named for the type of gypsum that is produced. Gypsum is calcium sulfate with various amounts of water of hydration attached to the calcium sulfate molecules. The key to good operation of a phos acid plant is to make good gypsum. Characteristics of good gypsum are large crystals that filter well and a minimum of phosphate content in the gypsum. Gypsum crystals are in the Di (dihydrate) form at lower concentration and temperatures, and in the Hemi (hemihydrate) form at higher concentration and temperature. The Dihydrate (Di) process makes gypsum in the form of calcium sulfate dihydrate, which has two water molecules per calcium sulfate molecule. The Hemi process makes gypsum in the form of calcium sulfate hemihydrate, which has half a water molecule per calcium sulfate molecule. Either a hemihydrate or dihydrate process can have stable operation if the conditions are clearly in either the hemihydrate or dihydrate zone. Problems occur between the zones, because the crystals dont know which form they are supposed to be, resulting in poor crystals and formation of scale. Think of the transition zone boundary as a line of dragons that needs to be avoided. Special techniques are necessary where conditions must cross this transition zone, such as occurs on a Hemi filter. The Hemi process became successful only after good dragonfighting techniques were developed for filtration and gypsum disposal.
DIHYDRATE PROCESS
This was the conventional process for most of the 20th century. Dihydrate plants have made the phosphoric acid for most of the high analysis phosphate fertilizer that has ever been produced. This process has a long track record or reliable operation, but it lacks the energy efficiency and many of the operating advantages of the Hemi process. Most phosphate rocks must be finely ground before processing. Operating conditions in the Di process stay below the Hemi/Di transition boundary, but it is economically necessary to push as deeply as practical into that boundary zone. The filter product phosphoric acid is typically only 25-29% P205, so substantial further concentration of product acid is required before making phosphate fertilizers. Innovations have been used to expand capacity of some dihydrate plants to more than double their original capacity. Dihydrate process advantages include: • Long track record of experience • Predictable performance • High capacity relative to equipment size •Moderate recovery and sulfuric acid require ment • Proven potential for recovery of uranium by-product • Best for recovery of fluosilicic acid by-product Disadvantages include: Fine grinding of rock is normally required Acid must be further concentrated to make most phosphate fertilizers. Large steam and cooling water requirement HEMI PROCESS
The Hemi (hemihydrate) process produces phosphoric acid directly from filtration at 40-45% P205 concentration. Most Hemi plants use phosphate rock as received without drying or grinding. Two entire plant sections are usually rendered unnecessary: • Evaporation to ~42% P205 • Rock grinding (when using concentrate or other rock smaller than 2 mm) Cooling water, acid storage, clarification, and steam distribution systems are reduced to a fraction of their conventional size. Capital cost for the phosphate complex is roughly 20-25% less than for a dihydrate-based complex, which would require rock grinding, evaporation, larger cooling water and steam distribution systems, and often elaborate acid clarification systems. Modern Hemi phosphoric acid plants tend to be easier to operate and require less cleaning than dihydrate
plants. One reason is that the reaction takes place in a stable range of hemihydrate crystals. In contrast, dihydrate plants must (out of economic necessity) operate near the unstable transition between dihydrate and hemihydrate. Hemi process advantages include: • Minimum capital cost • Energy benefit from needing little or no steam to concentrate acid • Eliminate 27-42% evaporators • Usually eliminate rock grinding • Low cooling water requirement, because of eliminating evaporators • Moderate phosphate recovery • Added recovery benefit where gypsum water is recirculated • Low sulfuric acid requirement • Easy to run and maintain; tolerant of process upset • Higher analysis fertilizer, due to purer acid Hemi has become the preferred process for making phosphoric acid in the 21st century. Early Hemi plants were difficult to operate because of scaling problems that occurred because of having to cross the zone of transition between Hemi and Di gypsum crystals. During the last few decades people have developed ways to enjoy hemis high concentration advantage without suffering its potential chaos. HEMI-DI PROCESS
This advanced process begins with a Hemi reactor and Hemi filtration section, but it adds a transformation reactor and a second filtration. The payoff for the added cost and complication is extremely high recovery and high quality gypsum. Hemi-Di advantages include: • 98-99% P205 recovery • Very low sulfuric acid requirement • Energy benefit from needing little or no steam to concentrate acid • Eliminate 27-42% evaporators • Usually eliminate rock grinding • Low cooling water requirement • Gypsum purity is suitable for making a wider variety of by-products • Potential for enhanced uranium recovery (to be confirmed) • Higher analysis fertilizer Each of the three processes has its strengths and weaknesses. The following table briefly compares the Dihydrate, Hemi, and Hemi-Di phosphoric acid processes. Issue 61
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Studies & Researches DI, HEMI, & HEMI-DI PROCESS COMPARISON TABLE (Ratings with 5 being excellent)
CRITERIA
DI
HEMI
HEMI -DI
Capital Cost, Reactor & Filters Capital Cost, Other Sections Operating Cost & Benefits Energy Efficiency, Total Plant Product Acid Concentration Evaporators & Steam Req=t P2O5 Recovery at Filter P2O5 Losses Other Than Filter
5 2 2 1 1 1 3 3
4 5 4 5 4 4 2 4
2 5 5 4 5 4 5 3
Recovery of Losses from Recirculated Water Sulfuric Acid Consumption Rock Size Requirement
3
5
1
3 1
3 4
5 4
Cooling Water Requirement Product Clarification, Storage
2 1
4 4
4 4
Capacity per Size of Eqip. Reagent Requirements
4 4
3 3
2 3
Familiarity & Experience Complexity of Operation
5 2
4 4
3 2
Uranium Recovery Gypsum Utilization
4 2
0 2
5? 4
CONVERTING FROM DI TO HEMI OR HEMI-DI
When should one consider converting an existing Di plant to Hemi or Hemi-Di? A key issue is that the Hemi process requires very little evaporation of product acid. The huge quantity of steam that had been going to the evaporators becomes available, so the decision is largely based on how much value can be obtained from all of that steam. The surplus steam would normally be used to generate electric 11 power. If there is surplus capacity in an existing power co-generation facility, and if this power can be used effectively or sold at a good price, then there is major justification for converting the plant to the Hemi process. When electric power was cheaper, it was difficult to justify the expense of new power cogeneration facilities. Now electricity is so valuable that this old rule of thumb no longer holds true. If a Di plant needs another evaporator, one should consider converting to Hemi instead of buying the evaporator. Since a Hemi plant avoids the need to 32
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REMARKS
(for typical or average situations, with exceptions) Di has smallest Reac. & Filt. H-D has 2 Rx & Filter stages Hemi & H-D need no rock grinding, less evaporation, id t rock grinding & li & much t evap. H-D: high recovery Di needs Di needs rock grinding, much more steam & cooling water Di 25-29% P2O5, Hemi 40-45%, H-D 40-50% Hemi & Hemi-Di make DAP with little or no evaporation. Di ~96%, Hemi ~95%, Hemi-Di ~98.5% Hemi & H-D avoid handling 27% acid. nd H-D has 2 Rx & Filter Works only where water recirculates from gypsum stack. 2% benefit to Hemi & H-D due to low SO4 in product, etc. Di needs <0.4 mm (35 mesh). Hemi & H-D can use <2 mm (9 mesh) Hemi & H-D need no 42% evap. condenser water Hemi & H-D have no 27% acid; often need no clarification nd
Di has smallest equip. H-D requires 2
reactor & filters
Hemi may need anti-scalant Hemi & Hemi-Di may use clay or silica. Most existing plants are Di, but many are Hemi & H-D. Di needs grinding, much evaporation, etc. nd Hemi-Di has 2 Reactor & Filters Hemi-Di may be best, but needs development. Hemi-Di gypsum is purest.
concentrate acid from 27 to 42% P205, conversion to Hemi would eliminate any shortage of evaporation capacity. The capital that is saved by avoiding one new evaporator may cover most of the cost of a Hemi conversion. Furthermore, a Hemi conversion would greatly reduce need for steam, cooling water, and acid storage facilities potentially bringing additional capital cost savings. If a Di plant is having difficulty meeting grade with DAP or TSP, a Hemi conversion would increase P205 content in DAP, TSP, or MAP by 2 percentage points. It should also help N concentration, depending on ability of the product to consume ammonia. Where there are two or more phos acid plants, converting only one of them to Hemi may solve DAP or TSP grade problems for the entire facility. The Belledune Fertilizer plant in New Brunswick Canada is an example of a very profitable Hemi conversion. The plant might have been shut down because of high cost and difficulty in meeting DAP
grade. After converting an old Prayon Mark 2 dihydrate to Hemi in 1986, cost were slashed by totally eliminating the evaporation section and associated fuel cost for generating steam. Recovery averaged 95%, and capacity easily topped the modest increase in design rate limited only by raw material and product requirements. The superintendent called it one sweet plant to run. Belledune continued to operate for a decade, and was considered one of the worlds easiest running phosphoric acid plants. DAP grade became easy to reach, using 40% acid that needed no settling to remove solids. Further conversion to Hemi-Di involves major expense for the second reaction and filtration facilities. Justification for this expense comes from the major reduction in raw material cost that is achieved by Hemi-Dis 98-99% recovery efficiency and often by the improvement in quality of the phosphogypsum by-product. Recent increases in phosphate rock and sulfur prices make Hemi-Di especially attractive. CONVERTING TO HEMI OR HEMI-DI WHILE EXPANDING
Additional economic opportunities arise when simultaneously converting an existing dihydrate plant to Hemi or Hemi-Di while expanding capacity. First, a major expansion can be made without adding evaporators, because Hemi needs so little evaporation. Second, the existing cooling water system will accommodate a major expansion, because of savings in evaporator condenser cooling water requirements. Third, the rock grinding section is likely to be eliminated, so no expansion is required there. The acid storage tank area may not need expansion when a Di plant is converted to Hemi or Hemi-Di of substantially greater capacity. Tanks that had been used for 27% acid storage will become available for other acid storage service. Acid clarification requirements are reduced or eliminated, because the Hemi acid will be purer. Arcadian (now PCS) in Louisiana made good use of those down-stream advantages when they expanded capacity by a third while converting to the Hydro Hemi process. After hearing of Belledunes success, Arcadian converted its Prayon Mark 2 plant with Bird filter to Hemi. Expenses beyond the reactor and filter sections were minimized because: • Rock Grinding was totally abandoned and bypassed, with un-ground BuCraa rock feeding from a rock washing filter directly to the reactor.
• Elimination of the requirement to concentrate acid from 27 to 42% P205 allowed existing evaporators to make more capacity. • One evaporator was dedicated to boosting concentration from 54% to 60-62% P205 for feeding a super-phosphoric acid facility, thus increasing super-acid rate. • Requirements for cooling water were reduced. • No new phos acid storage facilities were required. The Arcadian Hemi plant started very easily achieving design capacity and conditions within two days. The plant easily performed so well that the client accepted it without doing the customary performance test run. It frequently ran at 110% of design capacity, and occasionally achieved up to 130% of design capacity. Recovery consistently exceeded 96%. Arcadian and Belledunes experience demonstrated that Prayon reactors and tilting pan filters are well suited to conversion to the Hemi process. The exceptionally high quality Hemi acid was welcome as feedstock to a food-grade phosphoric acid plant and a super-phosphoric acid facility. Arcadians liquid fertilizer product was considered to be the best in the domestic industry. Expansion while converting a Di or Hemi plant to Hemi-Di can be facilitated by using the existing filters in the dihydrate section of the Hemi-Di process. Dihydrate filtration in a Hemi-Di plant needs only about 60% of the filter area as hemi filtration. The old filters may be big enough to act as dihydrate filters in a new and larger Hemi-Di plant. URANIUM RECOVERY
Much of the world’s phosphate rock has about half a kilogram uranium per ton of P205. Uranium was recovered from most central Florida phosphoric acid a quarter century ago, before a sudden downturn in price forced recovery plants to shut down when their sales contracts expired. A few years ago I was involved in an assessment that predicted that uranium recovery would be profitable at prices over $25/ pound U3O8. Fertilizer International reported $2530/lb operating cost in its May-June 2011 issue. Uranium prices have climbed to nearly $53/pound, so prospects are bright. Furthermore, Urtek of Australia recently piloted its advanced PhosEnergy process in the USA and has another pilot plant nearing start-up. Substantial benefits in cost, recovery, and environment are claimed, compared to previous technologies.
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Studies & Researches The Di process has a proven track record of successful uranium recovery. The Hemi process is not attractive for uranium recovery. Its high product acid concentration makes uranium extraction difficult, and uranium content in the acid is low. Uranium recovery might be even more attractive with a Hemi-Di process. A very high uranium/P205 ratio occurs in a certain weak acid filtrate stream within the Hemi-Di process. It should be far easier to extract uranium from this stream than from the conventional extraction from 27% P205 acid. However, this procedure has yet to be proven and developed. Nuclear power is finding favor as an economically and environmentally attractive source of electric power. Major nuclear power expansions with are proceeding worldwide for modern 4th generation nuclear reactors, which are inherently far safer than the 40-year-old plants at Fukushima, Japan. China targets 43 million kwh of nuclear power by 2015 and 100 by 2020. India plans a 13-fold increase by 2030. Asia is expected to expand from current 4% of all nuclear power to 30% within the foreseeable future. Both political parties in America are supporting major expansion of nuclear power. Potential recovery of uranium from phosphoric acid has been estimated to be 20 million pounds of U3O8 annually. Uranium extraction requires substantial capital investment, but it could prove financially attractive for phos acid plants which consume rock with good uranium content. FLUOSILICIC ACID RECOVERY
Fluosilicic acid (FSA) is often recovered from phosphoric acid plants. When it contains relatively high concentrations of P205 (0.1-0.25%), it is sold at relatively low price for use in fluoridating municipal water. When P205 is limited to a few hundred ppm, it is sold at a higher price for making aluminum fluoride. The Di process excels in opportunity to recover FSA, because FSA can be recovered from the evaporators that concentrate acid from 27-42% acid, as well as from the higher concentration evaporators. Hemi and Hemi-Di processes eliminate the need to evaporate acid from 27 to 42% P205, so this opportunity to recover FSA from 27-42% evaporators does not exist. Some FSA is recovered from Hemi reactor fumes or from flash cooler vapors, as well as from evaporators for higher acid concentrations.
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GYPSUM STACKING & UTILIZATION
Within the phosphate industry we rightfully take pride in the many benefits of phosphate to people throughout the world. The most important benefit is the vital role of phosphate fertilizer in feeding people. It’s easy to ignore the fact that our primary product in terms of tons produced is gypsum. We make about five tons of phosphogypsum for every ton of P2O5. What do we do with our biggest product? Usually nothing – well, actually less than nothing. We usually pile it up (at considerable cost) and hope to leave it there forever. Unfortunately, “forever” comes too soon! Even after a phosphoric acid plant permanently shuts down, complex procedures must be enacted to close the gypsum stack. In the US the acidic water in a wet stack must be neutralized, and then the stack is capped and closed, at costs running into the tens of millions of dollars per stack. The standard practice of throwing phosphogypsum away can be quite expensive. Phosphogypsum can be utilized in many ways. It is superior to limestone as roadbed material. Farmers use it as soil conditioner, and they reap the benefits of its sulfate content plus significant quantities phosphate and minor plant nutrients. Relatively pure gypsum can be utilized in cement or processed to make such valuable product as sulfuric acid, ammonium sulfate, calcium carbonate, wallboard, or even hydrogen and glass. The Hemi-Di, Hemi-Di-Hemi, and Di-Hemi processes provide such high recovery (98-99%) that the gypsum has very low P205 content. The low P205 content is essential for many phosphogypsum uses. The Florida Industrial and Phosphate Research Institute (FIPR) is involved in a comprehensive program to promote and support utilization of phosphogypsum for a variety of uses worldwide. The Stack Free program aims to eliminate the cost and environmental hazards of stacking gypsum by utilizing phosphogypsum in profitable ways. Progress can be followed at the website www.stackfree.com. The Stack Free effort faces a major task, because the great majority of phosphogypsum is stacked. Some is discharged to the sea, and very little is utilized for anything. Petrokimia Gresik was an early leader in phosphogypsum utilization, having built a hemi-di phosphoric acid plant about 30 years ago, with all gypsum being utilized for either ammonium sulfate plus calcium carbonate, or as cement retarder. Mobil Chemicals in Texas provided several months’
production of phosphogypsum for roadbed material near Houston Texas, until the US EPA banned all gypsum utilization, citing environmental concerns. The EPA has since softened objections, but has been very slow to permit phosphogypsum utilization. Most phosphogypsum is pumped as slurry to “wet” stacks. Some is stacked “dry”, and some is piped into the ocean. In a wet stack gypsum and water separate within an area that is confined by gypsum dikes, and the water decants and is returned and re-used. Wet stacking is considerably less expensive to install and maintain than dry stacking. Wet stacking enables major recovery of water-soluble P2O5 losses when returned pond water is employed for washing filter cake. This re-recovery effect boosts overall P2O5 recovery by about 1-3% with a Dihydrate plant. A Hemi plant will re-recover nearly 2% additional P2O5 from returning gypsum stack water, because (unlike dihydrate gypsum) most of the citrate-soluble P2O5 in Hemi gypsum becomes water-soluble in a wet stack. Thus, roughly half of the citrate-soluble losses in Hemi filter cake can be re-recovered when washing filter cake with water that is returned from the gypsum stack. Phosphoric acid plants in desert regions sometimes find it more practical to transfer the gypsum to “dry” stacks using belt conveyors and slingers. Dry stacking prevents water loss, which is a major concern in a desert. Jordan Phosphates Mines Co. (JPMC) has much experience with dry stacking at their Aqaba plant, using a series of belt conveyors on the stack, which is on a hill far above the plant. Indo-Jordan Chemicals Co. has an advanced gypsum stacking system that employs large conveying machines that move on rails on gypsum stacks. HiTech Solutions designed a third generation gypsum stacking system that would use very large movable conveying and stacking equipment that moves on the ground, without getting onto the gypsum. That system has been demonstrated with other materials, but not yet with phosphogypsum. HIGH PURITY PHOSPHORIC ACID
Most phosphoric acid is processed as fertilizer grade material. Higher purity phosphoric acid is required for other uses, and purer acid brings higher prices. Animal feed requires that fluorine be limited to less than 100 P/F ratio. Defluorination processes remove part of the fluorine from fertilizer grade acid to meet this higher grade. The acid is then processed into feed grade phosphates, typically dicalcium phos-
phate (dical). Feed grade dical can be produced while neutralizing acidic pond water with lime. Exceptionally pure phosphoric acid demands greatly higher prices. There are various technical and food grades for phosphoric acid. They are usually produced by removing impurities from wet process phosphoric acid using ion exchange and other procedures. Several licensed technologies are available for purifying phosphoric acid. Thermal processes make high purity phosphoric acid directly from phosphate rock. An interesting thermal process is the Improved Hard Process, which employs break-through technology to produce high purity acid from exceptionally impure phosphate material. Overall cost to produce technical grade phosphoric acid is expected to be very attractive. The process has been demonstrated in lab and pilot plant scale by JDC Phosphate, and a demonstration plant is likely to be operated in Florida soon. PROJECT MANAGEMENT & START-UP COMMENTS I’m a strong believer in a team approach to projects. Everyone should care about everything – especially the parts they know something about yet are not directly responsible for. Be ready to help your colleagues do their jobs better, and don’t be too proud to receive their support in return. Keep the overall goals of the project clearly in mind. That helps you see how much you and your colleagues share the same objectives. Sometimes I wonder why the owner’s people sit on one side of the conference table and the engineering/construction people sit on the other. We all have so much in common when it comes to what we want to happen. There’s no glory in start-ups. In the rare case where everything goes according to plan, and the plant starts up nicely, people just yawn and say, “That’s the way it was supposed to happen.” Reality is that every mistake that anyone ever made in engineering, construction, training, operation, management, maintenance, etc. rears its ugly head, and there are problems. There’s lots of wailing, scurrying, re-figuring, re-planning, re-designing, re-doing, and retrofitting. This is a time for all to work as a team to do whatever is need to get the job done. EFFECTS OF RECENT TRENDS Some recent trends provide opportunities to benefit from modifications and expansions of existing phosphoric acid and granular phosphate plants. Issue 61
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Studies & Researches Increased demand for phosphate fertilizers will spur new granular phosphate plants, and will encourage expansion of existing facilities. Many innovations that minimize ammonia losses and operating costs, improve product quality, save steam and electric power, and keep plants environmentally friendly will be implemented in new and existing plants. Recent sharp increases in cost of sulfur and phosphate rock make it more attractive to invest in the added recovery benefit of the Hemi-Di process. Soaring fuel costs have turned emphasis to the energy-efficient Hemi and Hemi-Di processes. Other incentives for Hemi & Hemi-Di processes are that they need only a fraction as much evaporation and REFERENCES
cooling water as dihydrate, and they usually need no rock grinding. A flurry of interest in new nuclear power plants has escalated the value of uranium, thus enhancing prospects for extracting uranium from phosphoric acid. The Di process and probably the Hemi-Di process produce acid from which uranium can be extracted economically. Upgrading of the quality of phosphoric acid to animal feed grade, food grade, or other high purity forms should be considered to enhance revenue, relative to fertilizer production. Rev. 3 18 Oct 2011 / DAP & Phos Acid Improvements-AFA 2011-JWing-rev3
AIChE Clearwater International Phosphate Conference, List of all papers from 1977 to present. Download papers from 2006 to present. 24 phosphate-related topics. www.aiche-cf.org Pierre Becker, Phosphates & Phosphoric Acid, 2nd Ed., Marcel Dekker Inc., NYC, 89. BuShea, et al., Application of BSF Technologies CTC3 to a Phosphate Complex, AIChE Natl Convention, Orlando, 3/90 and 1990 AIChE Clearwater Conference J. David Crerar & Barry T. Crozier, Practical Retrofitting to the Hemihydrate Process and Plant Performance Data, AIChE Meeting, Lakeland FL, Mar. 87. Joseph W. Guida, Phosphoric Acid and Uranium Recovery - Take 3” Fertilizer International, Jan-Feb., 2008 “Hemi Forever? Anonymous, Fertilizer International, July-Aug. 2006, pages 43-48. J.Hilton, B.Birkey, A E Johnston, “The Constructive Regulation of Phosphates & Phosphogypsum”, Proceedings of IRPA 12, Buenos Aires, Brazil, 2008 Sam Houghtaling & John Wing, Hemi or Hemi-Di - Our Future, AIChE Spring National Meeting, New Orleans LA, April,92. Sam Houghtaling, “DAP Plant Operating Data”, AIChE Conf., New Orleans, Apr.,’86. Joseph Megy, “Improved Hard Process”, Regional Phosphate Conference, Lakeland FL, USA, Oct., 2008. Sa Cao Tran et al, “Apparatus for Cooling a Granular Material Using Ambient Air, the Rotary Vertical Cooler”, AIChE Clearwater Conf., May,’99. Donal Tunks, “DAP Plant Optimization”, AIChE Clearwater Conference, June, 2010. “Uranium Recovery - Higher Values Foster a Fresh Look”, Anonymous, Fertilizer International, May-June 2011, pages 69-70. John Wing, Phosphoric Acid Reactors, Regional Phosphate Conference, Oct. 2010. John Wing, Selecting a Phosphoric Acid Process, AIChE Clearwater Conf., June, 2008. John Wing, The Hemi Era in Phosphoric Acid, AIChE Clearwater Conf., June,06 John Wing, From Phosphate Rock to DAP at Lower Cost, AIChE Clearwater Conf., May,99. John Wing, “The Case for Converting Phos Acid Plants to Hemi”, AIChE Clearwater, May,’95. John Wing, Florida Phosphate Technology - 2000”, AIChE Clearwater Conv., May,89. John Wing, “Hemihydrate Phosphoric Acid Plant Conversion at Belledune, Canada”, AIChE Meeting, Lakeland FL, Oct.,’87. 36
Issue 61
High-Efficient Methods of HeatExchangers Cleaning ОТКРЫТОЕ АКЦИОНЕРНОЕ ОБЩЕСТВО «НАУЧНО-ИССЛЕДОВАТЕЛЬСКИЙ И ПРОЕКТНЫЙ ИНСТИТУТ КАРБАМИДА И ПРОДУКТОВ ОРГАНИЧЕСКОГО СИНТЕЗА» ОТКРЫТОЕ АКЦИОНЕРНОЕ ОБЩЕСТВО (ОАО «НИИК»)
Alexander Chirkov
«НАУЧНО-ИССЛЕДОВАТЕЛЬСКИЙ И ПРОЕКТНЫЙ ИНСТИТУТ КАРБАМИДА И ПРОДУКТОВ ОРГАНИЧЕСКОГО СИНТЕЗА» (ОАО «НИИК»)
JOINT STOCK COMPANY RESEARCH AND DESIGN INSTITUTE OF UREA (JSC NIIK)
JOINT STOCK COMPANY RESEARCH AND DESIGN INSTITUTE OF UREA (JSC NIIK)
Head of corrosion, welding and diagnostics dept. chirkov@niik.ru Co-author: Razgonin Roman
Technical specialists of R&D Institute of Urea started developing solutions for heat-exchange equipment cleaning due to the process conditions breaks at urea plants, corrosion phenomenon and mechanical damages of heat-exchange equipment caused by faulty cleaning of heat-exchange equipment. Currently R&D Institute of Urea succeeds in the following cleaning methods: 1. Thermo-abrasive blasting (TAB); 2. Vortex blasting; 3. Chemical cleaning (by ortophosphoric acid); 2 ذHeat-exchanger tubeThe sheet. The difference 4. Ultrasonic cleaning; Picture 2 –Picture Heat-exchanger tube sheet. difference betweenbethe cleaned Picture 2 – Heat-exchanger tube sheet. The difference between the cleaned and uncleaned areas is the obvious. tween cleaned and uncleaned areas is obvious. 5. Electro-hydro-mechanical cleaning(EHMC); and uncleaned areas is obvious. 6. Hydrocleaning;
ОТКРЫТОЕ АКЦИОНЕРНОЕ ОБЩЕСТВО «НАУЧНО-ИССЛЕДОВАТЕЛЬСКИЙ И ПРОЕКТНЫЙ ИНСТИТУТ КАРБАМИДА И ПРОДУКТОВ ОРГАНИЧЕСКОГО СИНТЕЗА» (ОАО «НИИК»)
JOINT STOCK COMPANY RESEARCH AND DESIGN INSTITUTE OF UREA (JSC NIIK)
The cleaning methods are described in detail below. Thermo-abrasive blasting Technical specialists of R&D Institute(TAB) of Urea started developing solutions for heat-exchange equipment cleaning due to the process conditions breaks at urea The TAB method is successfully applied for removplants, corrosion phenomenon and mechanical damages of heat-exchange equipby faulty cleaning of heat-exchange equipment. alment of caused the scales formed on the tube internal surface of theCurrently heaters at urea and ammonia plants R&D Institute of Urea succeeds in the following cleaning during methods: their operation and also for removal of fouling and а) before the TAB 1. Thermo-abrasive blasting (TAB); а) before the TAB 2. Vortex blasting; asphaltene deposits of the heat-exchange tubes at 3. Chemical cleaning (by ortophosphoric acid); 4. Ultrasonic cleaning; petroleum plants. TAB method enables cleaning of 5. Electro-hydro-mechanical cleaning(EHMC); the full-length tube surface to bare metal. Using the 6. Hydrocleaning; TAB method toare thedescribed abrasive The cleaningdue methods in detailmedia below. heating up to 900 0C at the thermo-abrasive blaster outlet (Picture Thermo-abrasive blasting (TAB) 1) and1.high exhaust speed of the abrasive particles, a The TAB method is successfully applied for removal of the scales better surface cleaning is achieved (Picture 2) formed thanon the tube internal surface of the heaters at urea and ammonia plants during their operation standard and also for removal and asphaltene deposits of the heat-exchange when sandof fouling blasting methods are used. Beб) after the TAB tubes at petroleum plants. TAB method enables cleaning of the full-length tube sursides, the TAB method takes less time and abrasive face to bare metal. Using the TAB method due to the abrasive media heating up to after thecleaned TAB from rust by the TAB method 900 C at the thermo-abrasive blaster outlet (Picture 1) and high exhaust speed ofPicture 3 – Area of the lining б) weld-seam Picture 3 - Area of the lining weld-seam cleaned medium. The TAB method can be applied not only the abrasive particles, a better surface cleaning is achieved (Picture 2) than when in order to produce high-quality weld-seam during the urea synthesis reactor repair. sand blasting methods are used. Besides, the TAB method takes less time from rust by the TAB method in to by produce forstandard heat-exchangers cleaning, but for other equipPicture 3 – Area of the lining weld-seam cleaned order from rust the TAB method and abrasive medium. The TAB method can be applied not only for heat-exchangers cleaning, but for otheras equipment as well (Picture 3). high-quality weld-seam during the urea synthesis re- repair. ment cleaning well cleaning (Picture 3). in order to produce high-quality weld-seam during the urea synthesis reactor actor repair. 0
2. Vortex blasting The method is applied for removal of brittle scales. The operation principle of the vortex blasting is the following: at the air line outlet an air-eddy is formed with high rotational velocity where the abrasive sand is supplied (Picture 4). The sand is being thrown onto the heat-exchange tube walls with high-power pulse. The scales are broken away, grinded from the walls and blown out.
Picture 1 ذThermo-abrasive blaster
Picture 1 – Thermo-abrasive blaster
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3
3
ТНЫЙ
the vortex blasting is the following: at the air line outlet an air-eddy is formed with high rotational velocity where the abrasive sand is supplied (Picture 4). The sand is being thrown onto the heat-exchange tube walls with high-power pulse. The scales are broken away, grinded from the walls and blown out. JOINT STOCK COMPANY RESEARCH AND DESIGN INSTITUTE OF UREA ОТКРЫТОЕ АКЦИОНЕРНОЕ ОБЩЕСТВО И ПРОЕКТНЫЙ 3.«НАУЧНО-ИССЛЕДОВАТЕЛЬСКИЙ Chemical cleaning (JSC NIIK) ИНСТИТУТ КАРБАМИДА И ПРОДУКТОВ Chemical cleaning by ortophosphoric acid is applied ОРГАНИЧЕСКОГО СИНТЕЗА» in(ОАО case«НИИК») if the long heat-exchange tubes (over 6 m)
Studies & Researches
with small ID (under 10 mm) have deposits. Mechanical cleaning can result in tube perforation. The operation principle consists in washing of the Chemical cleaning acid soheat-exchange3.section with ortophosphoric for removal of brittle scales. The operation principle of lution. In highly acid medium partial dissolving of Chemical by ortophosphoric ac Picture –ذThe vortex blasting operation owing: at the air 44line outlet an air-eddy isprinciple formed with the deposits takes place, cleaning the undissolving deposits Picture The vortex blasting operation principle exchange tubes (over 6 m) with small ID (unde the abrasive sand is supplied (Picture 4). The sand is become loose and peel off as sludges. The cleaning September 2010 thethe specialists of R&D of Urea performed blasting InInSeptember 2010 specialists ofInstitute R&D can result in tubeofperforation. rate iscleaning being controlled by increase iron concenxchangeof tube walls with high-power pulse. TheInstitute scales the exchange tubes internal surface of distillation heaters at Acron (NovPicture 4 – The blasting operation principle ofheat Urea performed blasting ofvortex theMPheat exchange tration in the washing solution. When concentration The operation principle consists in wash gorod) with Snamprogetti technology before they were installed into the secondm the walls tubes and blown internalout. surface of MP distillation heaters at of iron ions is stable, theacid washing is beingInstoped. hand urea plant No. 5 ortophosphoric solution. highly acid med Acron with Snamprogetti Before (Novgorod) that, various companies tried to clean heat-exchangers by HPchemical waIn September 2010 thethetechnology specialists ofThe R&D Institute of Urea performed blasting cleaning method has been applied at become takes place, the undissolving deposits before they were installed into the second-hand urea ter supply and mechanically, but failed. urea plants for a long time and is widely used for of the heat exchange tubes internal surface of MP distillation heaters at Acron (NovThe No. specialists of R&D Institute of Urea applied the vortex blasting method plant 5 cleaningtube rate is being controlled inbydisincrease heat-exchange bundles ofinto the condensers which hadgorod) never been applied before. The statetooftechnology the heat exchange tubes inthey hea- were with Snamprogetti before installed the secondBefore that, various companies tried clean the heatsolution. concentration of ironand ions is stab ters pos. T-504 after the vortex blasting was satisfactory. The results of tillation the vortex sectionsWhen based on Tecnimont technology hand by urea plant No. 5 exchangers water blasting you can find inHP Picture 5. supply and mechanically, but The chemical cleaning method of the evaporation section based onhas been failed. Before that, various companies triedheat-exchangers to clean the heat-exchangers by HP wa- tube bun and is widely used for heat-exchange Snamprogetti technology. The specialists of R&D Institute of Urea applied the ter supply and mechanically, but failed. sections based on Tecnimont technology and vortex blasting method which had never been apThe specialists of R&D Institute of Urea applied the vortex blasting 4. Ultrasonic cleaning of the operating method unit plied before. The state of the heat exchange tubes section based on Snamprogetti technology. which had never been applied before. The state of the heat exchange tubes heaUltrasonic cleaning method is based on in excitation in heaters pos. T-504 after the vortex blasting was of ultrasonic small-amplitude vibrations heat-exters pos. vortex blasting satisfactory. The results of theinof vortex satisfactory. TheT-504 results after of the the vortex blasting you was 4. Ultrasonic cleaning the operating change equipment and in liquid heat transfer medican find in Picture blasting you5.can find in Picture 5. um. The vibrations Ultrasonic cleaning method is based prevent deposits vibrations on the heat surfacesequipme amplitude in exchange heat-exchange caused by liquid heat transfer medium; The vibrations blasting а) Heater Т-504(2) before the vortex b) Heater Т-504(2) after the vortexreduce thickness of the wall laminar layer which inblasting operation principle blasting, scales thickness – up to 4mm - prevent process. deposits on the heat excha tensifies the heat-exchange
5 – Results of the vortex blasting blasting specialists of R&DPicture Institute of Urea performed nternal surface of MP distillation heaters at Acron (Novchnology before they were installed into the second-
transfer medium; The wave propagation systems speciallyofdeveloped - reduce thickness the wall lamin for vibrations excitation and process. welded to the equipexchange
4 surface (for ex. to the tube-sheet side) enment outer sure introduction of ultrasonic waves into the heatThe wave propagation systems special equipment. In this case re-reflection and mpanies tried to clean the heat-exchangers by HP wa- exchange andare welded to the equipment outer (fo diffusion not typical for the method (Picture 6).surface It but failed. introduction of ultrasonic waves into the heat-e helps to achieve the required process effect when the D Institute of Urea applied the vortex blasting method method reflection diffusion arearenot typical is appliedand while the systems rather smallfor the m d before. The state of the heat exchange tubes in hea-b) Heater and not heavy and the power consumption is low. Т-504(2) after the vortex blasting а) Heater Т-504(2) before the vortex the required process effect when the method is Heater í-504(2) before theresults vortex blasting, scales ex blastinga)blasting, was satisfactory. The of the vortex scales thickness – up to 4mm small and not heavy and the power consumptio thickness ذup to 4mm
e 5.
Picture 5 – Results of the vortex blasting 4
Heaterí-504(2) Т-504(2) the vortex e vortex b) b) Heater afterafter the vortex blastingblasting Picture 5 ذ Results of the vortex blasting o 4mm
esults of the38vortex blasting
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а) Vibrations generator Picture 6 – Ultrasonic cleaning
b) moun wave gu
ypical for the method (Picture 6). It helps to achieve n the method is applied while the systems are rather wer consumption is low.
aning
Therefore special multi-edged drills with a centralizer and increased bearing area were developed to clean heat-exchangers of the 1st distillation stage which enable scales removal (Picture 7). ОТКРЫТОЕ АКЦИОНЕРНОЕ ОБЩЕСТВО «НАУЧНО-ИССЛЕДОВАТЕЛЬСКИЙ И ПРОЕКТНЫЙ ОТКРЫТОЕИАКЦИОНЕРНОЕ ИНСТИТУТ КАРБАМИДА ПРОДУКТОВ ОБЩЕСТВО «НАУЧНО-ИССЛЕДОВАТЕЛЬСКИЙ И ПРОЕКТНЫЙ ОРГАНИЧЕСКОГО СИНТЕЗА» ИНСТИТУТ КАРБАМИДА И ПРОДУКТОВ (ОАО «НИИК»)
JOINT STOCK COMPANY RESEARCH AND DESIGN INSTITUTE OF UREA JOINT STOCK COMPANY
RESEARCH AND DESIGN INSTITUTE OF UREA (JSC NIIK)
ОРГАНИЧЕСКОГО СИНТЕЗА» (ОАО «НИИК»)
(JSC NIIK)
b)b) mounting thevibrations vibrations generator onto mounting ofofthe generator onto wave guide guide wave In 2010 at ammonia sulphate unit K-2 at Azot (Cherkassy) the ultrasonic cleaning system was tested at circulation high-speed heater for ammonia sulphate pos. 5302/1. The test aimed at demonstration how to prevent adhering of ammonia sulphate crystals on the metal while the crystallization unit operating with over-5 saturated process solutions was running. During the ultrasonic cleaning the operation modes of the heater and ammonia sulphate circulation pump significantly changed: - the strength of current consumed by electric motor of the circulation pump reduced from 92 A to 80-82 A; - formation and increase of the crystals in the crystallizer intensified; - the temperature difference (“t) of ammonia sulphate solution before and after the heater reduced from 5-6! ë to 3~4oc which means optimization of the circulation process; - the system enabled reduction of the adhesive process in the unit. Based on the ultrasonic cleaning results Azot (Cherkassy) purchased three devices for ultrasonic cleaning. 5. Electro-hydro-mechanical cleaning (EHMC) The EHMC method is applied for removal of scales formed by the salts of various hardness and process scales in the tubes internal surface of condensers, boilers and various heaters. The EHMC method is based on torque transfer from electric or pneumatic unit by means of flexible shaft to a special device which goes through the tube breaking off and simultaneously washing away the scales making the internal tube surface absolutely clean and not damaging it. The advantage of the method is cleaning of fully choked tubes. Use of a standard two-edged drill with small bearing area results in damages of the tube internal surface, cut-ins which is unacceptable for film-type units. Besides, the scales in heat-exchangers of the 1st distillation stage at urea plants are very hard and standard drills are not used in such conditions.
Picture 7 – Standard dill VS multi-edge drill
7 – Standard dill VS multi-edge drill Picture 7Picture ذStandard VS multi-edge In 2010dill the heat-exchange tubes ofdrill HP stripper pos. E-201 at Odessa Port Plantthe (Ukraine) were cleaned methodpos. (Picture % of the In 2010 heat-exchange tubesbyof EHMC HP stripper E-2018).at30Odessa Portheat exchange tubes were cleaned due to the time limitations. the fact, Plant (Ukraine) were cleaned by EHMC method (Picture 8). Notwithstanding 30 % of the heat due to the achieved high heat-exchange efficiency, the plant capacity enhanced by exchange tubes were cleaned due to the time limitations. Notwithstanding the fact, 50 TPD (4 % increase). due to the achieved high heat-exchange efficiency, the plant capacity enhanced by 50 TPD (4 % increase).
In 2010 the heat-exchange tubes of HP stripper pos. E-201 at Odessa Port Plant (Ukraine) were cleaned by EHMC method (Picture 8). 30 % of the heat exchange tubes were cleaned due to the time limitations. Notwithstanding the fact, due to the achieved high heat-exchange efficiency, the plant capacity enhanced by 50 TPD (4 % increase). ОТКРЫТОЕ АКЦИОНЕРНОЕ ОБЩЕСТВО «НАУЧНО-ИССЛЕДОВАТЕЛЬСКИЙ И ПРОЕКТНЫЙ ИНСТИТУТ КАРБАМИДА И ПРОДУКТОВ ОРГАНИЧЕСКОГО СИНТЕЗА» (ОАО «НИИК»)
JOINT STOCK COMPANY RESEARCH AND DESIGN INSTITUTE OF UREA (JSC NIIK)
Picture 8 - heat-exchanged Cleaned heat-exchanged Picture 8 – Cleaned tubes of the stripper 6. Hydrocleaning The method is based on the water jet blow to the deposits. The water flow tubesfrom of the Hydrocleaning washes6.away the deposits the stripper metal surface. The method is generally used for cleaning of the mud deposits of any thickness in water recycle vessels (Picture 9).
8 – Cleaned heat-exchanged tubes of the stripper The method isPicture based Hydrocleaning on the 6.water jet blow to the deposits. The water flow washes away the deposits 7 from the metal surface. The method is generally used for cleaning of the mud deposits of any thickness in water recycle Picture 9 Cleaning of the heat-exchanger shell-side by HP water supplyby HP water supply Picture of the heat-exchanger shell-side vessels (Picture 9).9 – Cleaning
7
Conclusion: application on the Reasonable operation conditions enable the following: of various cleaning methods depending on the operation condi1) preservation of the heat-exchange tube internal surface which is very important tions enable forthe the following: film formation in vertical film-type heat-exchangers and has an impact on both process parameters and corrosion phenomenon; 1- preservation of the heat-exchange tube internal 2) removal of the deposits which is impossible with standard methods; 3) economic especially in case saving (cleaning surface which is benefits, very important forof steam the film forma-of HP stripper); 4) cost efficiency of the plant due to enhancement of the plant capacity caused by tion in vertical film-type heat-exchangers and has heat-exchange process improvement. an impact on both process parameters and corrosion phenomenon; 2- removal of the deposits which is impossible with standard methods; 3- economic benefits, especially in case of steam saving (cleaning of HP stripper); 4- cost efficiency of the plant due to enhancement of the plant capacity caused by heat-exchange process improvement. Conclusion: Reasonable application of various cleaning methods depending
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Studies & Researches
Phosphate Plant Yield Comparisons
Or, a recent paper HYPERLINK “http://www. aiche-cf.org/Clearwater/2010/Paper1/10.1.6.pdf” http://www.aiche-cf.org/Clearwater/2010/Paper1/ 10.1.6.pdf
Richard D. Harrison November 22, 2011
Outline
Gypsum Solids (wt %)
Estimated Range of P2O5 Loss to Gypsum Stacks A. Introduction - PegasusTSI Core Business Activities Manufacture of phosphoric acid produces from B. Estimate Range of P2O5 Losses to Gypsum Stacks Phosphate Plant Yield Comparisons November 22, 2011 5 to 6 tons of phosphogypsum for each ton of P2O5 C. Process Changes to Reduce Phosphate Losses: produced. Additionally, each ton of gypsum that is o Eliminate off-site discharges sent to the impoundment is only 67 weight % solids o Reduce phosphate flow to gypsum stack Estimated Range of P2O5 Loss to Gypsum Stacks initially, with the remaining 33% made up of process o Identify opportunities to recycle process water of phosphoric acid produces from 5 to 6 tons of phosphogypsum water that occupies the capillary space between the o Redirect fresh water make-up to gypsum stack Manufacture for each ton of P2O5 produced. Additionally, each ton of gypsum that is sent gypsum crystals (pore moisture). The older, lower to the impoundment is only 67 weight % solids initially, with the remaining 33% made up of process water the capillary space between theby strata dewater asthat theoccupies pore moisture is expressed D. Process Alternatives gypsum crystals (pore moisture). The older, lower strata dewater as the pore weight by of the theweight newer deposits above.above. TheThe folmoisture the is expressed of the newer deposits followinglowing graph shows the weight percent for a percent typical gypsum stackfor for a graph shows thesolids weight solids 1. Site selection and climate strata. gypsum stack for different strata. 2.Open Circuit Processes – no recovery of poredifferent typical moisture P2O5 85% 3. Closed Circuit Processes – some recovery of pore moisture P2O5 80% 4. Process Water Recycling 5. High Strength Fluoride Recycle 6. Improved Washing and/or Double Filtration 75% 7. Non-Contact Evaporator Condenser Cooling y = 0.0014x + 0.6625 8. Calcination 70% 9. Isothermal Phosphoric Acid Reactor Technology 10. Water Treatment Systems – EDR vs. RO E. References
65%
Introduction - Pegasus TSI Core Business Activities o o o o o o o o
60% 0
20
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Estimation of water soluble phosphate losses to the Process Studies three variables: gypsum stack depend on three variables: Identify & Compare Alternatives Concentration of water soluble P2O5 in the pore moisture solution Capital Cost Estimates (+/-) 50%, 30% & 10% 1. 2. Quantity of water acting as pore moisture 3. Quantity phosphogypsum produced per ton of P2O5 P2O5 producedin the pore 1. ofConcentration of water soluble Project Management moisture solution Front End Engineering 2. range Quantity water acting Detailed Engineering The typical of theseof three variables is: as pore moisture 3. Quantity of phosphogypsum produced per ton of Procurement 1. P2O5 concentration in gypsum slurry water is between 1% and 2.5% P2O5 produced Construction Management 2. Water acting as pore moisture is initially about 0.5 times gypsum weight Estimation of water soluble phosphate losses to the gypsum stack depend on
3. Gypsum weight per ton P2O5 is usually between 5 to 6, depending on ore
For more information on some the Pegasus TSI acTheRichard typical range of these three variables is: Copyright 2011 D. Harrison tivities please see our website at HYPERLINK “http://www.PegasusTSI.com” www. PegasusTSI.com
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Depth (feet)
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1. P2O5 concentration in gypsum slurry water is between 1% and 2.5% 2. Water acting as pore moisture is initially about 0.5
times gypsum weight 3. Gypsum weight per ton P2O5 is usually between 5 to 6, depending on ore Water soluble P2O5 lost to the gypsum stack initial pore moisture is therefore: Low
= 5 t gypsum/t P2O5 x 0.5 pore H2O/gyp. solids x 1% P2O5 = 2.5% Middle = 5.5 t gypsum/t P2O5 x 0.5 pore H2O/gyp. solids x 1.75% P2O5 = 5% High = 6 t gypsum/t P2O5 x 0.5 pore H2O/gyp. solids x 2.5% P2O5 = 7.5% The water soluble P2O5 in the gypsum stack can be accounted for in two different ways. If the facility is near the end of its life, then water discharges from the gypsum stack may have to be neutralized at significant expense for surface discharge. Alternatively, if the facility a going concern for the foreseeable future, any water discharges from expressed pore moisture can be recycled and the P2O5 value recovered.
For the purposes of this paper Phosphate Facility Yield will be defined as tons P2O5 sold as products / tons ore P2O5 brought on site. Using this definition it will be possible to achieve yields above 100% if future P2O5 losses to the gypsum stack are significantly reduced and P2O5 from the existing gypsum stack is reclaimed. Gypsum must be washed and transported to the gypsum stack with fresh water (0% P2O5) in order to minimize water soluble P2O5 losses to the gypsum stack. Due to water balance constraints, this ideal is not achievable without the installation of a second stage gypsum filtration system. The PegasusTSI team is fortunate to have been able to design a double filtration system for an phosphoric acid plant for a confidential client in the middle east. Please refer to the process schematic diagram on page 5 for a representation of a typical 1 MM ton P2O5 / year facility. The water balance shown is typical for a wet location like Florida that receives 137 +/- cm of rain per year. Phosphate Plant Yield Comparisons
Copyright 2011 Richard D. Harrison
The limiting ideal case is where all future P2O5 flow to the gypsum stack is eliminated, and all pore mois-
ture from past gypsum production recovered â&#x20AC;&#x201C; creating the possibility for P2O5 production to exceed P2O5 input for the facility while pore moisture from the prior gypsum stack is being reclaimed.
November 22, 2011
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Gypsum discharge practices include: slurry with sea water for discharge to the ocean, conveyor transport to rail cars or barges for transport to uses such as agricultural application, mine backfill, or ocean discharge. Additionally, some sites use belt conveyors for construction of gypsum fields. Please refer to the attached satellite photos of OCP’s Jorf Lasfar complex and GCT’s Sakhila plant for examples of open circuit gypsum disposal.
Studies & Researches Process Alternatives 1. Site Selection and Water Balance 22, 2011 Site selection has an important bearingNovember on phosphogypsum disposal techniques. Two general classes of plant sites are “dry” locations receiving less than 37 Process Alternatives cm of precipitation per year, and “wet” locations that 1. Site Selection and Water Balance receive 1 to 1.5 meters of precipitation per year. TypiSite selection has an important bearing on phosphogypsum disposal cal “dry”Two locations include plants in“dry” Morocco, Tunitechniques. general classes of plant sites are locations receiving less 37 cm ofSaudi precipitation per year, “wet” locations that receive 1 to sia,than Jordan, Arabia, andandAustralia. These plants 1.5 meters of precipitation per year. Typical “dry” locations include plants in do not usually employ gypsum slurry transport for Morocco, Tunisia, Jordan, Saudi Arabia, and Australia. These plants do not usually employ gypsumbecause slurry transport for gypsum disposalgreater because gypsum disposal evaporation is much evaporation is much greater than precipitation. than precipitation.
Phosphate Plant Yield Comparisons
The above photo shows the Jorf Lasfar plant in Morocco that uses seawater
for above process cooling and shows for gypsumthe slurryJorf transport to the ocean. The photo Lasfar plantThe in Moapproximate scale is 5 miles ( 8 kilometers) across the bottom of the photo. rocco that uses seawater for process cooling and for gypsum slurry transport to the ocean. The approximate scale is 5 miles ( 8 kilometers) across the botPhosphate Plant Yield Comparisons November 22, 2011 tom of the photo.
Phosphate Plant Yield Comparisons Copyright 2011 Richard D. Harrison
The above graphic from NOAA uses purple to show areas with less than 1 mm/day precipitation average, and aqua to display areas with 3.5 mm/day precipiMost “wet” average. locations that receive over consult 100 cm per the year inonline precipitation practice tation Please version slurry transport for gypsum stacking. Despite the water from rainfall, these of this paper at HYPERLINK “http://www.aiche“wet” locations also require significant input of either well water or river water tocf.org” maintain the water balance. www.aiche-cf.org for a color version of the graphics in this paper.
The above graphic from NOAA uses purple to show areas with less than 1 mm/day precipitation average, and aqua to display areas with 3.5 mm/day precipitation average. Please consult the online version of this paper at www.aiche-cf.org for a color version of the graphics in this paper.
Copyright 2011 Richard D. Harrison
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Most “wet” locations that receive over 100 cm per year in precipitation practice slurry transport for gypsum stacking. Despite the water from rainfall, these “wet” locations also require significant input of either well water or river water to maintain the water balance. 2. Open Circuit – no recovery of gypsum effluent P2O5 Gypsum discharge practices include: slurry with sea water for discharge to the ocean, conveyor transport to rail cars or barges for transport to uses such as agricultural application, mine backfill, or ocean discharge. Additionally, some sites use belt conveyors for construction of gypsum fields. Please refer to the attached satellite photos of OCP’s Jorf Lasfar complex and GCT’s Sakhila plant for examples of open circuit gypsum disposal. 42
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November 22, 2011 7
The above shows plant The above photophoto shows the Sakhilathe plantSakhila in Tunisia that uses in beltTuniconveyors to transport gypsum railcars, or totoa transport gypsum fieldgypsum adjacent to sia that uses belttoconveyors tothe Mediterranean. A close-up of the same plant’s gypsum conveyor and gypsum railcars, or to a gypsum field adjacent to the Medifield is attached below. While gypsum can be conveyed by belt conveyer, experts such as Anwar Wissa havesame previously recommended slurry terranean. A Dr. close-up of the plant’s gypsum transport even for desert climates, please see http://www.aicheconveyor and gypsum field is attached below. While cf.org/Clearwater/2011/Paper1/11.1.5.pdf. The above photo shows the Sakhila plant in Tunisia that uses belt conveyors to transport can gypsum railcars, or by to abelt gypsum field adjacent to the gypsum be toconveyed conveyer, experts Mediterranean. A close-up of the same plant’s gypsum conveyor and gypsum such as Dr. Anwar Wissa have previously recomfield is attached below. While gypsum can be conveyed by belt conveyer, experts such as Dr. Anwar Wissa have previously recommended slurry mended slurry transport even for desert climates, transport even for desert climates, please see http://www.aichecf.org/Clearwater/2011/Paper1/11.1.5.pdf. please see
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Copyright 2011 Richard D. Harrison
Copyright 2011 Richard D. Harrison
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3. Closed circuits - lined gypsum stack systems – most “wet” locations Plants that operate a closed circuit process water and gypsum storage system use process water to slurry gypsum discharge from the filter for transport to the phosphogypsum landfill. Every ton of product P2O5 is accompanied with the generation of approximately 5 tonsPlant of Yield byproduct gypsum solids. November Accompanying Phosphate Comparisons 22, 2011 these gypsum solids are 2 to 3 tons of process water occupying the space between the gypsum crystals 3. Closed circuits - lined gypsum stack systems – most “wet” locations after filtration and stacking. Most plants operate with Plants that operate a closed circuit process water and gypsum storage system process to 2% use processwater water tobetween slurry gypsum1% discharge from P2O5, the filter forresulting transport to in phosphogypsum landfill. Every ton of product P O is accompanied with athe 2% to 6% loss of water soluble P2O5 with pore the generation of approximately 5 tons of byproduct gypsumthe solids. Accompanying these gypsumin solids are 2 to 3 tons of process water water accumulating the gypsum stack. occupying the space between the gypsum crystals after filtration and stacking.
largest consumptive uses include filter wash water and ball mill make-up water for wet rock grinding. These two applications account for approximately 409 m3/h and 136 m3/h respectively for a plant with 1 MM tons P2O5 / year capacity operating on 68% solids rock slurry. Two alternatives exist for using process water in the ore grinding area. The preferred solution is to specify materials of construction compatible with low pH (2 to 3 pH) operation. This allows water soluble P2O5 and accompanying fluosilicic acid to react with carbonates present in the phosphate ore to liberate CO2 gas. Typical phosphate ore contains 3% to 5% CO2.
a 2% to 6% loss of water soluble P O with the pore water accumulating in the The next picture shows the IFFCO plant in Paradeep, gypsum stack. India as an example of a plant operating with gypThe next picture shows the IFFCO plant in Paradeep, India as an example of a plantstacks operating (scale with gypsum 3.2 kmbottom). across bottom). sum 3.2stacks km(scale across
The least preferred method of enabling process water use for mill water addition is to add a neutralizing agent to the process water. The cost for ongoing purchase and transport of a neutralizing agent, along with the reduction in P2O5 capacity for the facility make the economics for this process inferior.
2
5
Most plants operate with process water between 1% to 2% P2O5, resulting in 2
5
5. High Strength Fluoride Recycle Processes Fluosilicic acid can be recovered for introduction into the ground ore storage area to further dissolve carbonates and liberate additional CO2 gas. Implementation of both process water addition to mill feed and FSA Phosphate Plant Comparisons Novemberincreased 22, 2011 addition toYield rock slurry storage will allow P2O5 production for a facility with a limited sulfuric 5. High Strength Fluoride Recycle Processes acid production capacity by neutralizing some of the carbonates in the incoming ore (Reference Fluosilicic acid can be recovered for introduction into the ground 5). ore storage area to further dissolve carbonates and liberate additional CO2 gas. Implementation of both process water addition to mill feed and FSA addition to rock slurry storage will allow increased P2O5 production for a facility with a limited sulfuric acid production capacity by neutralizing some of the carbonates in the incoming ore (Reference 5).
Phosphate Plant Yield Comparisons
November 22, 2011
The next photo shows a plant of approximately 1MM P2O5 t/year capacity with a gypsum stackcapacity (scale The next photo shows a plant of approximately 1MM P O t/year with 3.2 akm gypsum stack (scale 3.2 km across bottom). across bottom). 2
Copyright 2011 Richard D. Harrison
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PegasusTSI is pleased to be able to offer the most commercially successful fluoride recovery technology currently available, eighteen installations PegasusTSI is pleased with to be able to offer thesuccessful most commercially successful fluoride recovery technology currently available, with eighteen successful since 2007. Fluosilicic acid (FSA) recovery of 0.07 ton installations since 2007. Fluosilicic acid (FSA) recovery of 0.07 ton F per ton O are typical (Reference A 1 MM P(Reference O t/year facility can F Ptons per ton P2O5 are1).typical 1).produce A 1192MM F/day. P2O5 t/year facility can produce 192 tons F/day. 2
5
2
5
PegasusTSI FSA Recovery Process Cooling Water FSA Recovery Vessel
Evaporator with Cyclonic Entrainment Separator
To Vacuum System Barometric Condenser
Liquid
FSA Spray Nozzles
To Hotwell FSA Product
Make-up Water
FSA Recirculation Tank
4. Process water recovery (neutralized or as-is)
4. Process water recovery (neutralized or as-is)
The concentration of P2O5 in the process water can be reduced in part by maximizing the quantity of process water consumed in the process. The two
The concentration of P2O5 in the process water can be reduced in part by maximizing the quantity of process water consumed in the process. The two largest consumptive uses include filter wash water and ball mill make-up water for wet rock grinding. These two applications account for approximately 409 m3/h and 136 m3/h respectively for a plant with 1 MM tons P2O5 / year capacity operating on 68% solids rock slurry.
Two alternatives exist for using process water in the ore grinding area. The preferred solution is to specify materials of construction compatible with low pH (2 to 3 pH) operation. This allows water soluble P2O5 and accompanying fluosilicic acid to react with carbonates present in the phosphate ore to liberate CO2 gas. Typical phosphate ore contains 3% to 5% CO2. The least preferred method of enabling process water use for mill water
An additional benefit of implementing this strategy is that the barometric
water can then be isolated for final filter wash and gypsum slurry Ancondenser additional benefit of implementing this stratmake-up water. egy is that the barometric condenser water can then This FSA recovery technology has been retrofitted to fourteen existing well as beingfilter installedwash in the last new evaporators beevaporators, isolatedas for final andfourgypsum slurry designed and engineered by PegasusTSI. Additional information on this make-up water. technology can be found in the 2008 PegasusTSI presentation at the Jeddah AFA meeting that is archived on the AFA website.
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Copyright 2011 Richard D. Harrison
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Studies & Researches
One additional technique to improve gypsum crystal size is to operate with higher sulfate concentrations in the digester. The following graph from Reference 6 illustrates the significantly adverse impact that low sulfate digester conditions can have on gypsum crystal size and resulting wash rates.
This FSA recovery technology has been retrofitted to fourteen existing evaporators, as well as being installed in the last four new evaporators designed and engineered by PegasusTSI. Additional information on this technology can be found in the 2008 PegasusTSI presentation at the Jeddah AFA meeting that is archived on the AFA website. 6. Improved Washing and/or Double Filtration 7. Non-Contact Evaporator Condenser Cooling One opportunity to reduce P2O5 losses is to replace the process water that proceeds with the gypsum to Evaporator condenser heat exchangers are another itâ&#x20AC;&#x2122;s destination with fresh water. A 1 MM ton P2O5 Copyright 2011 Richard D. Harrison technology that our team has successfully imple/ year plant will require about 227 m3/h of water to mented in world-class phosphate fertilizer facilities. report as gypsum stack pore moisture. Reducing the This technology can be used to separate fresh evapoP2O5 content of the gypsum slurry water by 1% will rative cooling water from process condensate formed reduce P2O5 losses by 58.5 tons/day or 21,350 tons/ in a contact barometric condenser, and has been in year. The value of recovering this P2O5 is on the ongoing industrial use for more than 10 years. Conorder of $700/t * 21,350 t/year = $15MM/year. denser secondary heat exchangers offer an alternative to allow sea water for cooling while eliminating Additional to the immediate savings from reducing the transfer of phosphate and fluoride into the ocean P2O5 flow to pore moisture, some clients also may in climates where fresh water availability is limited. benefit by reduced escrow funds required to cover future closure costs. 8. Calcination The technology to permit fresh water to displace process water as pore moisture make-up is site specific. PegasusTSI will be pleased to facilitate the implementation of appropriate water processing technologies for your facility to enable the plant water balance to be controlled while allowing process water to be replaced with fresh water for pore moisture service. Our team has installed double filtration and other technologies for clients that are still in successful operation after more than 10 years of service. Another opportunity to improve filter washing is to feed scalped unground wet rock fines to the digester instead of 68% solids rock slurry. This will allow an additional 136 m3/h of filter wash for a 1 MM t/y P2O5 capacity plant. This alternative is ore and digester specific and is not practical for all facilities. One additional technique to improve gypsum crystal size is to operate with higher sulfate concentrations in the digester. The following graph from Reference 6 illustrates the significantly adverse impact that low sulfate digester conditions can have on gypsum crystal size and resulting wash rates.
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Some ores contain high concentrations of organic matter that dilutes chemical analysis. Calcination of these ores assists improving P2O5 yield in the following three ways: 1. Removes combustible organic matter and some carbonate CO2 2. Reduces the tons of gypsum solids (and pore moisture) per ton of P2O5 3. Produces a dry rock that allows more filter wash water to be introduced 9. Isothermal Phosphoric Acid Reactor Technology PegasusTSI is also pleased to offer the lowest capital cost phosphate reaction technology available on the market today. The improved single vessel reactor technology is the latest generation of ore digestion equipment that offers equivalent process performance at much lower capital and operating costs than competing technologies (Reference 8). This technology was used for the latest phosphoric acid reactor installation in the United States by Simplot in Wyoming, with vessel engineering by PegasusTSI (See Figure 1 next page).
12
Wyoming, with vessel engineering by PegasusTSI (See Figure 1 next page). Particulars of the Isothermal system performance relative to conventional Dihydrate (Prayon/DorrOliver/Jacobs) are:
Particulars of the Isother- Phosphoric Acid Reactor Comparison Conventional DH Isothermal DH 3 2 1 mal system performance Reactor + Filter Feed Tank Volume (M /T/D) Slurry Cooler Circulation (M3/h/T/D) 15 54.5 relative to conventional Phosphate Plant Yield Comparisons November 22, 2011 1.8 0.5 Dihydrate (Prayon/Dor- Cooler Temperature Change (C) Specific Power Consumption (kWH/T) 27 9 rOliver/Jacobs) are: Number Operating Motors
15
3
All of the Badger/Raytheon/Pegasus Isothermal MustangIsothermal Tampa Inc.phosphoric that later became PegasusTSI All of the Badger/Raytheon/Pegasus acid reactors that in 2007. Mustang Tampa, Inc. focused on project phosphoric acid reactors that have been built have have been built have been designed in Tampa, Florida. engineering services in lieu of process technology. Phosphate Plant Yield Comparisons been designed in Tampa, Florida. November 22, 2011 Subsequently, PegasusTSI has resumed offering engineering services for isothermal reaction systems. Since joining Mustang Tampa Inc. / PegasusTSI in 2006 I have had the opportunity to work on the last phosphoric acid reactor installed in the USA, the13 last Copyright 2011 Richard D. Harrison four evaporators installed in the USA, and eighteen of the last FSA recovery units installed in the USA, among other assignments. 10. Water Treatment Technology – EDR vs. RO PegasusTSI has recently worked with vendors to evaluate the applicability of electro dialysis reversal (EDR) technology for brackish water treatment Graphic from www.aiche-cf.org/Clearwater/1998/papers/98.1.1.pdf (Ref. 8) to compare with conventional reverse osmosis treatment. This technology offers a cost competitive Isothermal Reactor Installations List route for some water treatment applications. Power Graphic from HYPERLINK “http://www.aicheLocation – Owner No. Size (T/D) hp Dia. (m) Start consumption for EDR is about 1 kWh per m3 of waBakersfield California – American Fertilizer 1 25 1966 cf.org/Clearwater/1998/papers/98.1.1.pdf” Bartow Florida – Farmland 1 1,000 200 10.7 1971 ter. EDR offers very good water recovery of 94% Helm California – Valley Nitrogen 1 Engineers 255 100 7.9 1977 Historical note: Raytheon and ConstrucGraphic from www.aiche-cf.org/Clearwater/1998/papers/98.1.1.pdf (Ref. 8) for some applications. Additionally, the EDR unit Bartow Florida – USS AgChem 2 1,600 350 10.7 1982 Private torsSprings closed their Tampa office in1,300 1998,Private and effectively 1986 Rock Wyoming – Chevron 1 is more tolerant of free chlorine and other contamiLazaro Cardenas Mexico – Fertimex 2 1,500 1986 no longer offered the Isothermal Negev Israel – Rotem 1 1,000Reactor System to 1996 nants than most RO systems. Luzhai Guangxi Zhuang China – CNTIC 1 400 1998 the market. The staff that remained TampaPrivate formed 2012 Rock Springs Wyoming - Simplot 1 1,300 inPrivate Isothermal Reactor Installations List
Historical note: Raytheon Engineers and Constructors closed their Tampa office in 1998, and effectively no longer offered the Isothermal Reactor System to the market. The staff that remained in Tampa formed Mustang Tampa Inc. that later became PegasusTSI in 2007. Mustang Tampa, Inc. focused on project engineering services in lieu of process technology. Subsequently, PegasusTSI has resumed offering engineering services for isothermal reaction systems. Since joining Mustang Tampa Inc. / PegasusTSI in 2006 I have had the opportunity to work on the last phosphoric acid reactor installed in the USA, the last four evaporators installed in the USA, and eighteen of the last FSA recovery units installed in the USA, among other assignments.
Location – Owner
Bakersfield California – American Fertilizer Bartow Florida – Farmland Helm California – Valley Nitrogen Bartow Florida – USS AgChem Rock Springs Wyoming – Chevron Copyright 2011 Richard D. Harrison 14 Lazaro Cardenas Mexico – Fertimex Negev Israel – Rotem Luzhai Guangxi Zhuang China – CNTIC Rock Springs Wyoming - Simplot
No. 1 1 1 2 1 2 1 1 1
Size (T/D) 25 1,000 255 1,600 1,300 1,500 1,000 400 1,300
hp
Dia. (m)
200 100 350
10.7 7.9 10.7
Private
Private
Private
Private
Start 1966 1971 1977 1982 1986 1986 1996 1998 2012
References Historical note: Raytheon Engineers and Constructors closed their Tampa 1. 2. 3. 4. 5. 6. 7. 8. 9.
office in 1998, and effectively no longer offered the Isothermal Reactor Doug Belle -toInnovations in fluosilicic acid recovery technology - F.I. 224 - 2008 System the market. The staff that remained in Tampa formed Mustang John Cameron In Fertilizer Production - 1994Mustang Tampa, Inc. Tampa Inc.- Pollution that laterControl became PegasusTSI in 2007. Pierre Beckeron - Phosphates and Phosphoric Acid 2ndinEdition focused project engineering services lieu -of1989 process technology. Hossein Sepehri-Nik Fertilizer Technical Data Book 4th Edition – 1997 services for Subsequently, PegasusTSI has resumed offering engineering Lloyd Banning Fluosilicic Acid Acidulation of Phosphate Rock 1975 isothermal reaction systems. Since joining Mustang Tampa Inc. / PegasusTSI B. Moudgil/Univ. Florida/FIPR - Enhanced Filtration Phosphogypsum – 1995 in 2006 I haveofhad the opportunity to work on theoflast phosphoric acid reactor John Van Wazer Phosphorus andlast its Compounds - 1958 installed in the USA, and installed in –the USA, the four evaporators eighteen the last FSA units installed in the USA, - among Charles Feliceof- Raytheon - 21st recovery Century Phosphoric Acid Plant Designs 1998 other Dr.assignments. Anwar E. Z. Wissa, SC. D. - Phosphogypsum Transport and Disposal
Copyright 2011 Richard D. Harrison
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Studies & Researches
Topsøe solutions for sulphuric acid and ammonia plants Ayten Yılmaz Wagner (ayyw@Topsøe.dk) Henrik Larsen (hnl@Topsøe.dk)
Haldor Topsøe A/S, Denmark
Founded in 1940 on the brink of the Second World War, Dr. Haldor Topsøe started the company based on a commitment to heterogeneous catalysis. This has placed the company in the frontier of developing tomorrow’s catalysts for today. The company is governed by the notion that only through fundamental science can we continue offering our clients the best; and the past 70 years an on-going tale of improving catalysis. Topsøe has more than 70 years of experience in manufacturing VK catalysts, and today more than half of the world’s ammonia is produced over Topsøe ammonia synthesis catalyst. Topsøe has also contributed significantly to the development of efficient ammonia production technology. Today, approximately 50% of new ammonia plants use Topsøe ammonia technology. Topsøe’s ammonia technology can be used for both the design of new plants and for revamps of existing plants. This paper presents some of Topsøe’s catalyst and technology solutions for the sulphuric acid and ammonia plants. The outline of this paper is as below: - Part 1: Catalyst solutions for lower SO2 emissions and reduced pressure drop build-up in sulphuric acid plants - Part 2: Catalysts for improving ammonia production - Part 3: Advanced Reforming Technology for Ammonia Plants mercial sulphuric acid catalysts and thereby offers Part 1: Catalyst solutions for lower SO2 exceptionally high activity at low temperatures in emissions and reduced pressure drop strong gases. build-up in sulphuric acid plants
Marie Vognsen
Haldor Topsøe A/S, Denmark
1.1. Introduction In 1996 Topsøe introduced a caesium-promoted vanadium catalyst, VK69, designed for operation in the pass(es) after the intermediate absorption tower in double absorption plants. The high activity of VK69 opens opportunities for a more than 50% reduction in SO2 emissions from existing double-absorption plants or, alternatively, the acid production rate can be boosted by 15-20% without increasing SO2 emissions. Today, 15 years later, Topsøe has close to 100 installations with VK69. However, still more stringent regulations are being placed on the sulphuric acid industry to lower SO2 emissions. Topsøe has responded to these challenges by developing a new sulphuric acid catalyst designated VK-701 LEAP5™. This catalyst was introduced to the market in 2010. VK-701 LEAP5™ is based on a novel technology which circumvents the internal transport deficiencies of existing com46
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For many sulphuric acid plants the bottleneck for prolonged operating time between plant shutdowns is the requirement for screening of bed 1 due to increased pressure drop caused by deposition of dust from the feed gas. An improved protection against pressure drop buildup can be obtained by the use of a dust protection catalyst in the top of bed 1. In 2007 Topsøe introduced a new dust protection catalyst in the shape of a 25 mm Daisy. Installation of a 15 cm top layer of this unique VK38 dust protection catalyst results in a doubling of the operating time between screenings compared to the 12 mm Daisy. 1.2. Topsøe’s sulphuric acid catalysts – the VKseries VK38 VK38 is the classic all-round sulphuric acid catalyst. A high activity is provided in the entire range of operating conditions, and VK38 gives an excellent performance wherever placed in the converter.
The VK38 will operate continuously from 400°C to 630°C and peak temperatures as high as 650°C will not harm the catalyst. At the other end, the VK38 features an ignition temperature as low as 360°C for fresh catalyst, which leaves the operator with ample operational flexibility. Haldor Topsøe A/S – Nymøllevej 55 2800 Kgs. Lyngby - Denmark
VK48 VK48 is a high-vanadium version of the standard Topsøe solutions for sulphuric ammonia plants 3 / 25 VK38 catalyst andacid isand tailored for maximum activity 2011 in highly converted gasses, i.e. a high SO3/SO2 gas environment. Where the process gas contains large end, the VK38 features an ignition temperature low aspasses 360°C for fresh amounts of SO3, such as theaslast in acatalyst, single which leaves the operator with ample operational flexibility. absorption plant or the third pass of a 3+1 double VK48 absorption plant, VK48 has a 20-30% higher activity VK48 is a high-vanadium version of the standard VK38 catalyst and is tailored for maximum activity in highly gasses, i.e. a highhas SO /SO gas environment. than VK38. Theconverted higher activity been achieved Where the process gas contains large amounts of SO , such as the last passes in a notabsorption only byplant increasing the content, single or the third pass of avanadium 3+1 double absorption plant, but VK48also has a 20-30% higher activity than VK38. The higher activity has been achieved not only by by changing the composition of the active phase. increasing the vanadium content, but also by changing the composition of the active 3
2
3
phase.
VK69 is manufactured in a unique 9 mm Daisy shape. This provides a very high surface area, which is important for efficient SO2 conversion in the passes following the intermediate absorption tower. The high void fraction of the 9 mm Daisy shape ensures that this occurs while maintaining a low pressure drop. The extremely high activity of VK69 in the entire temperature range naturally provides a number of options for improved performance of existing double-absorption plants and in the design of new acid plants: - More than a 50% reduction in SO2 emission from existing double-absorption plants - The possibility of a significantly increased production without increasing SO2 emissions - Possibility for SO2 emissions from new or revamped plants of 50 ppm or less, eliminating the need for tail gas scrubbing Today VK69 is installed in close to 100 converters worldwide, and feedback from the users has clearly verified its advantages. The purpose of the major part of the VK69 installations is reduced SO2 emissions due to tightening of emission regulations and increased production rates while maintaining or improving the SO2 emissions.
Figure 1: Topsøe’s VK catalyst history in brief
Figure 1: Topsøe’s VK catalyst history in brief VK59 VK59 is a caesium-promoted catalyst developed especially for operation in medium to high strength SO2 gases at temperatures down to 370°C. This low temperature makes it possible to accommodate high SO2 concentrations inlet the first pass without exceeding the maximum outlet temperature of 630°C.
VK59 VK59 is a caesium-promoted catalyst developed especially for operation in medium to high strength InSO2 addition, the low at ignition temperature of just 320-330°C VK59 This very effective gases temperatures down to makes 370°C. lowin accelerating plant start-up, meaning faster and cleaner start-ups. The ability to start temperature makes it possible to accommodate high SO2 concentrations inlet the first pass without exceeding the maximum outlet temperature of 630°C. In addition, the low ignition temperature of just 320330°C makes VK59 very effective in accelerating plant start-up, meaning faster and cleaner start-ups. The ability to start from a very low temperature provides a significant extension of the period in which autothermal plant restart can occur after for instance an interruption of the feed gas supply. VK69 VK69 is developed for operation under low SO2 conditions following the inter-pass absorption tower in double absorption plants. It combines high vanadium content with a revised balance of its alkalimetal promoters.
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
VK-701 LEAP5™ Haldor Topsøe’s new sulphuric acid catalyst VK-701 LEAP5™ is developed and optimised for operation in converted strong gasses. At these conditions VK701 LEAP5™ shows significant activity advantages compared to existing potassium- and caesium-promoted catalysts. The major leap in activity for VK-701 LEAP5™ is primarily due to high fraction of vanadium in the active oxidation state V5+. At operating conditions several vanadium species are present; but only oxidation state V5+ is active in the catalytic cycle. The high V5+ level in VK-701 LEAP5™ has been brought about through physical as well as chemical changes compared to Topsøe’s existing catalysts. The increased content of vanadium in oxidation state V5+ results in a superior activity for VK-701 LEAP5™ compared to VK48 and VK59 throughout the entire temperature range. The high activity offered by VK-701 LEAP5™ presents new conversion Issue 61
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Studies & Researches opportunities for any single- and double-absorption Haldor Topsøe A/S – Nymøllevej 55 plants: 2800 Kgs. Lyngby - Denmark
Single absorption plants - reduce SO2 emissions by up to 40% by loading Topsøe solutions for sulphuric andpass ammonia plants VK-701 LEAP5™ in theacid final 2011
conversion is required, the first choice is to replace the VK38 in bed 4 with caesiumpromoted VK69, which is optimised for the final pass of double-absorption plants, and reduce the inlet temperature to 395°C. This cuts the SO2 emission to 100 ppm. Bed 3 Catalyst Inlet temperature, °C Outlet temperature, °C Conversion outlet bed 3, % 5 / 25 Bed 4 Catalyst Inlet temperature, °C Outlet temperature, °C
VK48 440 461 95.45
VK48 440 461 95.45
VK-701 LEAP5TM 423 447 96.43
VK38
VK69
VK69
Double absorption plants 425 395 395 442 413 409 - cut SO2 emissions by up to 70% in 3+1 plants by replacing thirdLEAP5™ and fourth passes with VK-701 high V5+ level the in VK-701 has been brought about through physical as well as Overall conversion, % 99.85 99.92 99.95 chemical changes Topsøe’s existing catalysts. LEAP5™ andcompared VK69 to respectively. SO2 in the stack, ppm 200 100 64 - cut SO2 emissions by up to 40% in 3+1 plants opThe increased content of vanadium in oxidation state V5+ results in a superior Tableactivity 1. Performance of VK69 and VK-701 LEAP5™ in a 3:1 double-absorption plant erating with VK69 by replacing the third pass with for VK-701 LEAP5™ compared to VK48 and VK59 throughout the entire temperature VK-701 LEAP5™ can2 be accomplishedcan by replacing the VK48 in bed further reduction in SO2 emission range. The high activity offered by VK-701 LEAP5™ presents new conversion AA further reduction in SO emission be accom3 with an equal amount of VK-701 LEAP5™ and operating the bed at an inlet -achieve as low as 50 ppm SO2 emission from existopportunities for any single- and double-absorption plants: plished byofreplacing VK48 inofbed 3 with an equal temperature 423°C. Due to the the higher activity the VK-701LEAP5™, the SO2 ing 3+1 plants content in the gas to bedLEAP5™ 4 is reduced to and 0.47%,operating and the overallthe conversion amount of feed VK-701 bed is Single absorption plants -design new plants with as little as 20-50 ppm SO2 increased to 99.95%. The 64 ppm SO 2 in the stack achieved with a combined VKat an inlet temperature of 423°C. Due to the higher - reduce SO2 emissions by up to 40% by loading VK-701 LEAP5™ in the final pass 701/VK69 loading corresponds to a 36% reduction compared to the VK48/VK69 emission activity of the VK-701LEAP5™, the SO2 content loading and as much as 68% reduction compared to a loading of conventional
catalyst 3 and 4. inVK48/VK38 the feed gasin beds to bed 4 is reduced to 0.47%, and Double absorption plants For- cut existing plants the reduced SO2 emissions SO2 emissions by up to 70% in 3+1 plants by replacing the third the and fourth overall conversion is increased to 99.95%. The achievable with VK69 and VK-701 passes with VK-701 LEAP5™ and VK69 LEAP5™ respectively. cata641.3.ppm SO2 in the stackwith achieved Industrial experience VK69 with a combined lysts- cut provide an attractive alternative to investing inVK69 by SO2 emissions by up to 40% in 3+1 plants operating with replacing VK•701/VK69 loading corresponds to a 36% reCase story 1 the third with VK-701 LEAP5™ scrubber. Even for a caustic orpass hydrogen peroxide In 1997, VK69 was installed to in the fourth pass of a large 1460loading MTPD sulphuric duction compared the VK48/VK69 andacid from existing 3+1 of plants - achieve as low as 50 ppm SO2 emission plants equipped with tail-gas scrubbing, the use plant in Asia. The plant burns elemental sulphur and has a 3+1 layout. In the middle of as much as 68% reduction compared to a loading of - design new plants with as little as 20-50 ppm SO2 emission 1997, the plant was met with a 100 ppm SO2 emission limit. A number of options for VK-701 LEAP5™ catalyst can be a cost-efficient
conventional VK48/VK38 bedsthe 3 installation and 4. of a improving the SO2 conversion efficiencycatalyst were studiedin including way to reduce consumption of chemicals for the caesium-promoted catalyst or the expansion of the plant with a fifth pass. It was For existing plants the reduced SO2 emissions achievable with VK69 and VK-701 scrubbing. calculated that throughexperience the high activity offered Topsøe’s VK69 catalyst, the LEAP5™ catalysts provide an attractive alternative to investing in a caustic or Industrial 1.3. withbyVK69 emission use limit could be met and the plant decided to choose this option. hydrogen peroxide scrubber. Even for plants equipped with tail-gas scrubbing, Casethestory 1 of VK-701 LEAP5™ catalyst can be a cost-efficient to reduce consumption of Example: Reduced emissions from a way double-abIn 1997, VK69 was installed in the fourth pass chemicals for the scrubbing. sorption plant
of a large 1460 MTPD sulphuric acid plant in Asia. The The SO2 emissions from an existing double-absorpplant burns elemental sulphur and has a 3+1 layout. Example: Reduced emissions from a double-absorption plant tion plant can be reduced by 50% loading VK69 in In by the50% middle of 1997, the plant was met with a 100 The SO2 emissions from an existing double-absorption plant can be reduced the final pass and even also VKloading VK69 in the final pass further and even by further by loading also loading VK-701 LEAP5™ in the emission limit. A number of options for ppm SO2 701 in the third pass. third LEAP5™ pass. improving the SO2 conversion efficiency were studied including the installation of a caesium-promoted Layout: 3:1 double-absorption plant catalyst or the expansion of the plant with a fifth SO2 source: Burning of elemental sulphur pass. It was calculated that through the high activFeed gas: 11% SO2, 10% O2 ity offered by Topsøe’s VK69 catalyst, the emission Catalysts in beds 1/2: VK38 / VK38 Conversion outlet bed 2: 88.5% limit could be met and the plant decided to choose this option. The performance of VK-701 LEAP5™ and VK69 The performance of VK-701 LEAP5™ and VK69 is compared to standard catalysts in 1. With standard potassium-promoted in bed1. 3 and VK38 in bed 4, the isTable compared to standard catalysts VK48 in Table With In the summer of 1997, the existing conventional overall conversion of the plant is 99.85%VK48 corresponding ppm SO2 in the stack standard potassium-promoted in bedto 200 3 and catalyst If higher in the fourth pass was replaced by 90.6 m3 gas. The feed gas to the fourth pass contains about 0.6% SO2 in this case. VK38 in bed 4, the overall conversion of the plant is VK69 catalyst. The volume of VK69 loaded was 99.85% corresponding to 200 ppm SO2 in the stack slightly less than the volume of the previous catalyst. gas. The feed gas to the fourth pass contains about A test run performed after the start-up showed a more 0.6% SO2 in this case. If higher conversion is rethan 60% reduction in the SO2 emission even though quired, the first choice is to replace the VK38 in bed the plant load had been increased slightly and the cat4 with caesium•promoted VK69, which is optimised alyst volume had been reduced. With the installation for the final pass of double-absorption plants, and of the high active VK69 catalyst in the fourth pass reduce the inlet temperature to 395°C. This cuts the the conversion requirement of 99.92% corresponding SO2 emission to 100 ppm. to less than 100 ppm was met with an optimum inlet Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
temperature to the fourth pass of 389°C.
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the volume of the previous catalyst. A test run performed after the start-up showed a catalyst performance is experienced during a 30 months period. In October 2010 a more than 60% reduction in the SO2 emission even though the plant load had been TOPGUN was performed at the plant showing SO2 emissions of 20 ppm at more than increased slightly and the catalyst volume had been reduced. With the installation of 90% production capacity. No catalyst work has been carried out since the start-up in the high active VK69 catalyst in the fourth pass the conversion requirement of 99.92% 2007, but it is scheduled to take place in the second quarter of 2011. corresponding to less than 100 ppm was met with an optimum inlet Later in 1997, a full fourth pass loading of temperature VK69 to the Design July TOPGUN July TOPGUN fourth pass of 389°C. catalyst was installed in the identical sister plant. 2008
2008
Later in the 1997,start-up a full fourth in pass1997 loadingboth of VK69 catalysthave was installed the identical Since plants beeninshut SO2, mole % 16.3 15.96 14.0 sister plant. down for catalyst screening several times. Also the Production, MTPD 2350 2300 2241 VK69 catalyst in the fourth passes has been screened Overall conversion, % 99.95 99.95 99.98 Sincenew the start-up in 1997 both plants have been shut down forIn catalyst and VK69 make-up catalyst added. the screening auSO2 emission, ppm 100 85 33 several of times. Also the catalyst in the fourth passes has been screened and new tumn 2009 theVK69 client still reported SO2 emissions VK69 make-up catalyst added. In the autumn of 2009 the client still reported SO2 below 100 ppm from both plants. Table 3. Plant performance since the initial start-up in 2007
2009
2010
15.6 2340 99.98 42
14.4 2208 99.99 20
emissions below 100 ppm from both plants.
1.4. Dust protection The alkali-metal promoted vanadium catalyst acts as Before VK69 After VK69 Dust protection a1.4. very effective dust filter due to the “fly-paper” efCatalyst loading bed 4, litres 97,000 90,600 fect of the pyrosulphate complex is present as to The alkali-metal promoted vanadium catalyst acts as a that very effective dust filter due Production, MTPD 1460 1490 atheliquid theof the microscopic pores theascatalyst “fly-paper”ineffect pyrosulphate complex that isof present a liquid in theat Conversion exit bed 3, % 94.7 94.4 microscopic pores of the catalyst at operating temperatures. Observations from operating temperatures. Observations from indusTemperature inlet bed 4, °C 440 389 industrial applications have shown that part of the liquid melt migrates from the catalyst trial applications have shown that part of the liquid Overall conversion, % 99.79 99.92 into themigrates accumulated dust, making sticky as well.into The dust pass largely melt from theitcatalyst theparticles accumulated SO2 exit bed 4, ppm 260 97 unhindered through it thesticky layer of inert or ceramic bodies particles normally placedpass on top of dust, making asrocks well. The dust the bed. Most of the dust is normally trapped in the upper 5-10 cm of the catalyst, largely unhindered through the layer of inert rocks Table 2. Plant performance prior to and after installation of VK69 in the fourth pass plugging the gas normally passage so thatplaced screening on of thetop bed becomes oreventually ceramic bodies of the necessary bed. to relieveof highthe pressure dropisbuild-up. Most dust normally trapped in the upper Case story 2 Case story 2 An Asian sulphuric acid producer operates a 2350 MTPD sulphuricaacid2350 plant based on5-10 cm of the catalyst, eventually plugging the gas An Asian sulphuric acid producer operates The sensitivity plugging and pressure of dropthe build-up in abecomes catalyst bed bynecesdust-laden off-gases from smelting of metals ores. The plant has a 3+2 layout (intermediate passage sotothat screening bed MTPD sulphuric acid plant based on off-gases from gas depends on the bed void fraction and how the dust is distributed. The penetration absorption located after the third pass). The catalyst loading was tailored to meet a sary to relieve high pressure drop build-up. smelting of metals ores. The plant has a 3+2 layout conversion goal of 99.95% corresponding to less than 100 ppm SO2 exit the last pass depth increases with the size of the catalyst particles because the relative surface area
(intermediate absorption located after the third pass). is lower. based on a feed gas composition of 14.2% SO2 and 11.6% O2 inlet the first pass. In The sensitivity to plugging and pressure drop buildThe catalyst loading was tailored to meet a converJuly 2007 Topsøe’s VK38/VK48 catalysts were loaded in the upper four passes up in a catalyst bed by dust-laden gas depends on sion goal of 99.95% corresponding less Topsøe has developed an improved dust protection catalyst in the shape of a large 25 including a top-layer of VK59 catalyst in the first pass.to In the fifththan pass 95100 m3 of the bed void fraction and how the dust is distributed. mm Daisy. This super Daisy catalyst combines the effect of a larger void fraction for ppm SO2 thewas last pass based onthe a feed gas comTopsøe’s VK69exit catalyst loaded in order to meet high conversion requirement.The penetration depth increases with the size of the higher dust capacity and the effect of a lower specific surface area for improved dust position of 14.2% SO2 and 11.6% O2 inlet the first catalyst particles because the relative surface area is distribution. pass. In July Topsøe’s VK38/VK48 catalystsfluctuations Most sulphuric acid 2007 plants feeding on off-gases from metal ores experience lower. in the gas flow rateinand composition. This ispasses also the reality in the present plant and were loaded the upper four including a topconsequently variations in the conversion level are experienced. However, the trend in layer of VK59 catalyst in the first pass. In the fifth Topsøe has developed an improved dust protection pass 95 m3 of Topsøe’s VK69 catalyst was loaded in catalyst in the shape of a large 25 mm Daisy. This order to meet the high conversion requirement. super Daisy catalyst combines the effect of a larger void fraction for higher dust capacity and the effect Information contained herein is confidential; it may not be used for any Information contained herein is confidential; it mayacid not be used for any purpose other than for which it has been issued, and may not be used by Most sulphuric plants feeding on off-gases from of a lower specific area for improved dust purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøesurface A/S. or disclosed to third parties without written approval of Haldor Topsøe A/S. metal ores experience fluctuations in the gas flow distribution. rate and composition. This is also the reality in the present plant and consequently variations in the conInstallation of a 15 cm top layer in the first bed enables the plant to double the production time between version level are experienced. However, the trend catalyst screenings compared to the 12 mm Daisy. in the operating data received from the plant shows stable performance of the Topsøe VK catalyst with With more than 80 installations, VK38 in the shape SO2 emissions in the range of 20-80 ppm and no of 25 mm Daisy has proven to be an unmatched sodeterioration of the catalyst performance is experilution for plants suffering from rapid pressure drop enced during a 30 months period. In October 2010 a build-up due to dust in the feed gas. Both metalTOPGUN was performed at the plant showing SO2 lurgical plants and plants based on sulphur burning emissions of 20 ppm at more than 90% production have increased operating time between screenings capacity. No catalyst work has been carried out since and thereby, reduced the number of expensive shutthe start-up in 2007, but it is scheduled to take place downs for catalyst screening. in the second quarter of 2011. Issue 61
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Studies & Researches
Haldor Topsøe A/S – Nymøllevej 55 Installation of a 15 cm top layer in the first bed enables the plant to double the 2800 Kgs. Lyngby - Denmark production time between catalyst screenings compared to the 12 mm Daisy.
1.5. Industrial experience with 25 mm Daisy for
Part 2: Catalysts for improving ammonia
With more than 80 installations, VK38 in the shape of 25 mm Daisy has proven to be dust protection Case story an unmatched solution for plants suffering from rapid pressure drop build-up due toproduction A gas. European sulphuricplants acid producer operates a solutions 1330burningfor sulphuric acid and ammonia plants Topsøe dust in the feed Both metallurgical and plants based on sulphur have increased operating time between andon thereby, reduced the number MTPD sulphuric acid screenings plant based off-gases from Anja Nielsen 2011 of expensive shutdowns for catalyst screening. smelting of metals ores. The plant has a 2+2 layout.
11
Haldor Topsøe A/S, Denmark
1.5.
In October 2008, a with 150 25 mm top layerforofdust VK38, 25 Industrial experience mm Daisy protection
2.1. Introduction
Part 2: Catalysts for improving ammonia production
The low temperature shift (LTS) catalyst is one of Case story mm Daisy was installed in the top of the first pass. Anjacatalysts Nielsen in ammonia plants. The purpose of theoperates dust protection layer was toacid ex-plant based A European sulphuric acid producer a 1330 MTPD sulphuric the most important on off-gases from of metals ores. The plant has a 2+2 layout. Haldor Topsøe Denmark tendsmelting the period between screenings. Even small changes in A/S, its performance may have significant impact on operational costs. In this paper demonstrate some of these impacts.
In October 2008, a 150 mm top layer of VK38, 25 mm Daisy was installed in the top of 2 shows pressure drop development we will the first pass.Figure The purpose of thethe dust protection layer was to2.1. extend across the period Introduction bed 1 for the operations cycle prior to the installation between screenings.
Theoperation low temperature shift (LTS) catalyst is one of the most importantTopcatalysts in of the dust protection layer as well as the The close cooperation between the industry,
Figure 2 shows the pressure drop bed 1 in for the the operations ammonia Even changes in its have significant impac cycle with the 25development mm Daisyacross installed topplants. of cycle søe’ssmall R&D Division andperformance the catalystmay manufacturing prior to the installation of the dust protection layer as well as the operation cycle with In this paper we will demonstrate some of these impacts. on operational costs. the first bed. facility has resulted in the development of Topsøe’s the 25 mm Daisy installed in the top of the first bed.
LK series of LTS catalysts. For more than three de-
The close cooperation between the industry, Topsøe’s R&D Division and the catalys cades, Topsøe’s LK series has acquired leading posimanufacturing facility has resulted in the development of Topsøe’s LK series of LTS tion due to features such as superior activity, rugcatalysts. For more than three decades, Topsøe’s LK series has acquired leading ged mechanical strength and rugged unmatched resistance position due to features such as superior activity, mechanical strength and towards poisons. This is an outstanding combination unmatched resistance towards poisons. This is an outstanding combination which h whichthe hasmost made Topsøe the on most made Topsøe LK series widely soldLK LTSseries catalysts thewidely market.
120 Prior to installing 25 mm Daisy 25 mm Daisy installed
Pressure drop across 1st bed
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sold LTS catalysts on the market.
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Months of operation Figure 2. Actual pressure drop development for operation with and without the 25 mm Daisy
Figure 2. Actual pressure drop development for operation with and without the 25 mm Daisy
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
The figure clearly illustrates that the installation of 25 mm Daisy has significantly reduced the rate of pressure drop build-up.
Topsøe Others
The 25 mm Daisy has been in operation for more 1. Global market share – Topsøe LTS catalyst than two years and for this period no pressure drop marketFigure Figure 1. Global share – Topsøe LTS catalyst build-up has been observed. Without the 25 mm in Topsøe LTS catalysts, LK-821-2 and LK-823, both Topsøe LTS catalysts, LK-821-2 and LK-823, both possess the same high activity a the top of first bed the pressure drop had increased possess the same high activity and unmatched resisunmatched resistance towards poisoning. As an added benefit, LK-823 is promoted more than 5 times after two years of operation. tance towards poisoning. As an added benefit, LK-
order to improve selectivity and this has resulted in significant reduction of methano
Consequently, the number of time-consuming and expensive shutdowns for catalyst screening is reduced and at the same time significant savings in blower energy result from the lower pressure drop.
823 is promoted in order to improve selectivity and this has resulted in significant reduction of methanol by-product formation. With the introduction of the low-methanol LTS catalyst, LK-823, Topsøe has provided the fertiliser industry with an effective and industrially proven technology, enabling achievement of even the most stringent reductions in methanol emissions.
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
50
Issue 61
The lower CO leakage achieved with Topsøe LK-821-2 low shift catalyst in the Indian ammonia plant translates into a gain in production of an additional 21,000 MT of ammonia over a period of 6 years. Based on the current ammonia price this corresponds to an additional earning of USD 7 million.
2.2. Performance benefits with Topsøe LTS catalysts
0.50
Topsøe LSK/LK-821 installed in Plant 2 Catalyst 1 installed in Plant 2 Series2
0.45
LTS CO leakage, mole % dry
The superior activity of Topsøe LTS catalysts makes it possible to operate the LTS reactor at a lower temperature level. Due to the exothermic character of Haldor Topsøe A/S – Nymøllevej 55 the -water 2800 Kgs. Lyngby Denmark gas shift reaction and the restrictions in the equilibrium, the CO leakage from the LTS will be lowered. A lower temperature level will also have Topsøe solutions for sulphuric a positive effect acid on and the ammonia catalystplants lifetime due to less 2011 sintering of the Cu crystals.
1000 MTPD Ammonia Plants LTS CO Leakage History
0.40 0.35 0.30 0.25
More than 21,000 MT of Ammonia
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Figure 3: Difference in CO leakage and corresponding produc-
Case story 1 Figure 3: Difference in CO leakage and corresponding production gain tion gain by-product formation. With the introduction of the low-methanol LTS catalyst, LK-823, In order to quantify the benefits of having a more Topsøe has provided the fertiliser industry with an effective and industrially proven active LTS catalyst and thereby lower CO concentechnology, enabling achievement of even the mosta stringent reductions in methanol2.3. Benefits of reducing methanol-by-product2.3. Benefits of reducing methanol-by-product-formation emissions. tration outlet the LTS converter, the following case formation The low-methanol LTS catalyst, LK-823, is today widely used in the industry as it is story of performance benefits from operating with a desirable to minimise methanol by-product formation for several reasons: 2.2. Performance benefits Topsøe LTS catalysts lower CO leakage willwith be presented. The low-methanol LTS catalyst, LK-823, is today The superior activity of Topsøe LTS catalysts makes it possible to operate the LTS - Methanol emissions regulated as to protect the environment widely usedare in being the industry it is desirable to mireactor atThe a lower temperature level. Due to exothermic character of the gas case story illustrates thethetypical improvement in- water Methanol by-product formation consumes valuable hydrogen nimise methanol by-product formation for several shift reaction and the restrictions in the equilibrium, the CO leakage from the LTS will - Methanol may react to form amines causing odour problems plant performance of having Topsøe LTS catalyst. be lowered. A lower temperature level will also a have a positive effect on the catalystreasons: lifetime due to less Cu crystals. The casesintering story ofisthe taken from a 1,000 MTPD Indian- Process condensate quality can be affected
- CO2 quality can affect downstream processes
ammonia plant. The plant operated with a competi-
- Methanol emissions are being regulated to protect
Case story 1 tor catalyst for a period 6 years. Thecatalyst charge was Case story 2 environment In order to quantify the benefits of having of a more active LTS and thereby a the The methanol by-product formed over theconsumes LTS catalystvaluable has the adverse lower COreplaced concentration outletTopsøe the LTS converter, the following case story of undesired with LK-821-2 low temperature - Methanol by-product formation effect hydrogen being consumed to form the methanol. performance from operating with a lower CO leakage presented. shiftbenefits catalyst which today, 7 years later,willisbestill in of valuable hydrogen
Methanol may react to form amines causing odour From the development in the CO level The caseoperation. story illustrates the typical improvement in plant performance of ilhaving a - LK-823 By installing the methanol by-product formation is greatly reduced as illustrated lustrated Figure 1, itis can seen thatMTPD thereIndian areinammonia no Topsøe LTS catalyst.in The case story takenbe from a 1,000 figure 4. problems plant. Thesigns plant operated with the a competitor for a period of 6 years.in The charge -Process condensate quality can be affected indicating need ofcatalyst replacing the catalyst was replaced with Topsøe LK-821-2 low temperature shift catalyst which today, 7 years -CO2 quality can affect downstream processes the near future. Actually, it is expected to last for at later, is still in operation. From the development in the CO level illustrated in Figure 1, it least another 2-3 years. can be seen that there are no signs indicating the need of replacing the catalyst in the near future. Actually, it is expected to last for at least another 2-3 years. Case story 2 The undesired methanol by-product formed over the LTS catalyst has the adverse effect of valuable hyHaldor Topsøe A/S – Nymøllevej 55 2800 Kgs. Lyngby - Denmark drogen being consumed to form the methanol.
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
1000 MTPD Ammonia Plants LTS CO Leakage History 0.50
Topsøe LSK/LK-821 installed in Plant 2
LTS CO leakage, mole % dry
0.45
Catalyst 1 installed in Plant 2 Load [%]
0.40 0.35 136
0.30
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137
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By installing LK-823 the methanol by-product 14 for/ 25 mation is greatly reduced as illustrated in figure 4.
Topsøe solutions for sulphuric acid and ammonia plants
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Figure 2: Development in CO leakage over Figure 2: Development intime CO
leakage over time
The lower CO leakage achieved with Topsøe LK821-2 low shift catalyst in the Indian ammonia plant translates into a gain in production of an additional 21,000 MT of ammonia over a period of 6 years. Based on the current ammonia price this corresponds to an additional earning of USD 7 million.
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
100
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Figure 4: Reduction in methanol-by-product-formation
The methanol values in figure 4 are taken from actual industrial operation and are here benchmarked against our LK-821-2. The methanol formation across LK-823 is only about one eight of LK-821-2. A very important aspect of LK-823 is that the low methanol by-product-formation has been achieved while maintaining the same high activity, poisoning resistance and 51 Issue 61 stability as for LK-821-2. In other words, LK-823 will yield the same shift conversion and catalyst lifetime as LK-821-2. The benefits of lowering the methanol by-product formation can be calculated and in
Studies & Researches The methanol values in figure 4 are taken from actual industrial operation and are here benchmarked against our LK-821-2. The methanol formation across LK-823 is only about one eight of LK-821-2. A very important aspect of LK-823 is that the low methanol by-product-formation has been achieved while maintaining the same high activity, poisoning resistance and stability as for LK-821-2. In other words, LK-823 will yield the same shift conversion and catalyst lifetime as LK-821-2. The benefits of lowering the methanol by-product formation can be calculated and in this case story a standard 1500 MTPD ammonia plant is used as basis. In order to evaluate the benefits of Topsøe LK-823 it is important to note that the methanol loss will greatly depend on the specific plant layout and the temperature in the separator. However, the numbers in this case story is based on a plant layout where the condensate, including the methanol, will be recycled back to the reformer. Thus, the methanol loss is only depending on the temperature in the separator which thereby determines the fraction of methanol leaving the plant from the CO2 absorber. For a temperature range in the separator of 70 degC to 120 degC the methanol loss through the CO2 absorber would correspond to a loss of ammonia production of 0.6 – 3.0 MTPD. With current ammonia prices this translates into a value of 350,000 – 1,000,000 USD over a five year period.
Part 3: Application of the Haldor Topsøe Exchange Reformer in Ammonia Plants Pat A. Han, Søren G. Thomsen Haldor Topsøe A/S, Denmark
Paper Abstract Haldor Topsøe A/S (Topsøe) supplies a full range of reforming technologies which also includes heat exchange reforming technology. The Haldor Topsøe Exchange Reformer (HTER) technology is applicable to many technologies such as syngas, hydrogen, methanol, and ammonia. This paper describes how this technology is adopted in an ammonia plant and what benefits can be offered to the ammonia industry. For a new ammonia plant, implementing the HTER reduces the size of 52
Issue 61
the primary reformer and due to high reforming temperature still retains a low methane slippage, which is crucial for ammonia production. Various options are available for a capacity increase in the front-end of an ammonia complex. Out of these, convective gas heated reforming stands out as an attractive option from both a technical as well as a cost effective perspective. The Haldor Topsøe Exchange Reformer (HTER) technology is a proven revamp option where a capacity increase of 20 - 25% can easily be achieved, while the methane leakage is retained at a low level. The HTER technology has now been in successful commercial operation since early 2003. A full size industrial unit has been revamped with an HTER installed downstream of an Autothermal Reformer (ATR), this has resulted in a 33% increase in reforming capacity. 3.1. Introduction Steam reforming is the dominant technology for producing hydrogen or hydrogen rich synthesis gas for example for ammonia production. Feedstock may range from natural gas to kerosene. Topsøe supplies a full range of reforming technologies, all based on decades of intensive R&D in the relevant areas and evaluations of actual plant operation. Topsøe’s most recent reforming technology is the Haldor Topsøe Exchange Reformer (HTER). HTER operates in series or parallel with another reformer(s) and draws the necessary heat of reaction from the effluent gas from this source. It has already been commercialised in combination with an autothermal reformer at Sasol’s large facility in Secunda, South Africa, for conversion of coal to liquid fuels and other refined hydrocarbon products. The implementation of HTER at Sasol Synfuels is described in the paper [1], and shortly repeated here. HTER in combination with a tubular reformer for a 206,000 Nm3/h Hydrogen plant is in the design phase and will become reality within a few years. Application of HTER in ammonia plants in combination with a tubular reformer and a secondary reformer is also very well suitable. This application will be described in more details in this paper. It is shown how HTER for ammonia plants can increase the reforming capacity in existing plants with up to 25% or for a given capacity for a new plant, how
steam reforming rather than for raising less valuable steam. In this way, a significant capacity increase can be achieved and at the same time the carbon and hydrogen efficiencies of the process are improved and, as a third and very important benefit, the hydrogen/CO/CO2 ratio of the syngas can be controlled to match the stoichiometry of the downstream processes much better.
HTER reduces the size of the primary reformer. of the downstream processes much better. Figure 1 is a sketch of the reformer section of the The recent development of HTER for ammonia Figure 1 ofis a sketch of the reformer section of the Sasol Synfuels plant prior to the Sasol Synfuels plant prior to the revamp. fers a very high reforming temperaturerevamp. resulting in low methane slippage without operating at high steam to carbon ratio (S/C). A low methane slippage is crucial for ammonia plants as the methane will otherwise end up in the ammonia synthesis affecting the rate of reaction. The overall S/C in the ammonia plant with both primary/secondary reformer and HTER is kept at the same level as for conventional plants with only primary/secondary reformer. The low methane slippage is obtained with HTER, withProduct flow out increasing the outlet temperature from primary rate 100% reformer because the required process air is still introduced in the secondary reformer (which leads to a lower methane slip from the secondary reformer), Figure 1: Layout of reforming to revamp section prior to revamp Figure 1:section Layoutprior of reforming whereas only part of the feedstock passes through The layout is quite conventional with the high level The layout is quite conventional with the high level heat of syngas being cooled in a primary and secondary reformer. heat of syngas being cooled in a steam generating
steam generating waste heat boiler placed downstream the oxygen fired ATR. One of Haldor Topsøe A/S – Nymøllevej 55 waste heat boiler placed downstream the oxygen 2800limitations Kgs. Lyngby -to Denmark the the process in the Sasol plant is the waste heat boiler inlet 3.2. First Industrial Experience with HTER fired ATR. One of the limitations to the process in the temperature as well as the duty. Both are stressed to or beyond the original design Sasol plant is the waste steam heat boiler inlet temperature capacity and in order to protect the boiler, is used to quench the gas before the as well as the duty. Both are stressed to or beyond to the boiler. This is obviously not optimal from an energy perspective. Sasol Synfuels successfully operates a entrance very large Topsøe solutionsthe for original sulphuricdesign acid and ammoniaand plants capacity in order
facility in Secunda, South Africa, for conversion of 2011 coal to liquid fuels and other refined hydrocarbon products. One of the important process steps on the way to the final products is the reforming section in which a methane rich gas is converted to syngas on the basis of autothermal reforming using Topsøe’s burner technology. Sasol operates 16 parallel autothermal reformers (ATRs), each with a capacity equivalent to a syngas production for a 900 to 1025 MTPD ammonia plant.
to protect the boiler, steam is used to quench the gas before the entrance to the boiler. This is obviously not optimal from an energy perspective.
19 / 2
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be used by or disclosed to third parties without written approval of Haldor Topsøe A/S.
Product flow
r ate 133% Sasol Synfuels is actively pursuing opportunities for reforming capacity increase, in particular, opportunities that allows capacity increase without an increase Figure 2: Layout of reforming section revamped with an HTER in oxygen consumption. This is achievedFigure with2: the Layout of reforming section revamped with an HTER in parallel with the ATR in parallel with the ATR Haldor Topsøe Exchange Reformer (HTER) techA more efficient process would be feed-effluent heat A more efficient process would be feed-effluent heat exchange at high temperatures nology, where the sensible heat from the ATR effluexchange at inside high temperatures reducing the oxygen reducing the oxygen required the reformer or, more attractively, increasing the required reformer or, more reforming attractively, ent is effectively utilised for steam reforming rather product total syngas flow byinside drivingthe additional endothermic reaction with the increasing total issyngas product flow driving highway, level aheat. This processthe concept depicted in Figure 2, by where the HTER taking than for raising less valuable steam. In this additional endothermic reforming reaction with the revamp care of the additional reforming is installed in parallel with the ATR. This significant capacity increase can be achieved and at scheme was chosen the Sasol Synfuels project. highfor level heat. This process concept is depicted in the same time the carbon and hydrogen efficiencies Figure 2, where the HTER taking care of the addiof the process are improved and, as a thirdThe andrevamped very unit wasreforming started up is early 2003 and an extensive fullATR. scale 22-month tional installed in parallel with the long demonstration run was performed at Sasol to prove the viability of the concept. important benefit, the hydrogen/CO/CO2 ratio of the This revamp scheme was chosen for the Sasol SynThe ATR/HTER pair has been in operation since and meets all expectations. syngas can be controlled to match the stoichiometry fuels project.
Since the initial start-up, there have been no unforeseen stops that were related to the HTER, and the HTER has been in continuous operation with the exception of planned 53 Issue 61 shut-downs and the period of by-pass operation. This has led to a high availability factor (97%).
Studies & Researches The revamped unit was started up early 2003 and an extensive full scale 22-month long demonstration run was performed at Sasol to prove the viability of the concept. The ATR/HTER pair has been in operation since and meets all expectations. Since the initial start-up, there have been no unforeseen stops that were related to the HTER, and the HTER has been in continuous operation with the exception of planned shut-downs and the period of by-pass operation. This has led to a high availability factor (97%). The HTER has been shut down at a number of predetermined occasions for inspection. The main purpose of these inspections has been to verify the mechanical integrity given the high material temperatures experienced in this piece of equipment and to examine for signs of corrosion, viz. metal dusting. It has been concluded from these inspections that the HTER is performing well and the projected life-time of the HTER internal has been confirmed. As an additional benefit, these inspections have served to confirm the maintainability of the HTER, and they have given valuable experience in shutting down and restarting the ATR/HTER pair. During the test run, it was shown that the predicted capacity increase and conversion of the revamped unit was reached – in fact, there was some additional capacity in the unit compared to the expected figures of a 33% capacity increase. Likewise, the pressure drops have been found to be stable and well within the anticipated values. Since this new equipment was built into the plant as a full scale industrial unit with no prior pilot scale or side stream operating experience, the operators were anxious to learn how the reformer pair behaved under industrial conditions with whatever up•stream and down-stream fluctuations that could be anticipated. It was found that the ATR/HTER pair was easily operable, however, slightly more sensitive to fast cut-back of the feed or the oxygen than the stand-alone ATRs. Based on the successful experience with HTER, Sasol Synfuels plans to implement HTER in additional syngas lines. The HTER technology is not only suited for syngas preparation for Coal to Liquids or Gas to Liquids facilities, with minor adaptations it is equally suited to boost the capacity of a methanol or an ammonia producing facility. This option will be discussed further at the end of this paper. 54
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3.3. HTCR Technology Another reforming technology supplied by Topsøe is the Haldor Topsøe convection reformer (HTCR). HTCR is based on predominantly convective reforming and combines the functions of the radiant and waste heat sections of the conventional reformer in one relatively small piece of equipment [2]. The HTCR is available with capacities up to approximately 15,000 Nm3/h of hydrogen. With a special arrangement using two HTCR reactors operating in tandem, plants with capacities of 30,000 Nm3/h can be designed. A first generation of the HTCR reformer was introduced to the industry in 1992. This design has since been used for 22 industrial applications. An updated design was introduced to the industry in 2003 and four units have been sold. The design is based on the use of bayonet tubes, approximately 10 m long. Each bayonet tube is surrounded by a flue gas guiding tube. The HTCR reactor consists of a vertical, refractory lined vessel containing the tube bundle with several bayonet tubes. Through the many HTCR applications, the bayonet tube principle for heat exchange reforming is now well established. 3.4. Application of HTER in Ammonia Plants In the above case for Sasol, the HTER is placed downstream of an ATR, but the HTER is equally well suited to be located after a secondary reformer or even downstream a stand-alone tubular reformer. The technology is thus interesting in many business areas such as hydrogen production, methanol production, GTL/CTL and ammonia production. In this section, we shall be looking specifically into the HTER option for ammonia plants – both as a revamp option or as an alternative to the classical layout for a grass-root plant. Figure 3 is a sketch of a traditional ammonia plant front-end (reforming only) with a tubular primary reformer and an air fired secondary reformer followed by a Waste Heat Boiler (WHB). This unit can be revamped with an HTER in parallel (HTER-p) to the primary reformer as is shown in Figure 4.
e 3 is a sketch of a traditional ammonia plant front-end (reforming only) with a ar primary reformer and an air fired secondary reformer followed by a Waste Heat (WHB). This unit can be revamped with an HTER in parallel (HTER-p) to the ry reformer as is shown in Figure 4.
Because of higher S/C in the process gas, there are less severe conditions with regards to metal dusting in HTER for ammonia compared to HTER for syngas. This will result in very long lifetime and again minimises use of special resistant material.
or Topsøe A/S – Nymøllevej 55 0 Kgs. Lyngby - Denmark
psøe solutions for sulphuric acid and ammonia plants
1
Figure 3: A plant traditional ammonia plant front-end 3: A traditional ammonia front-end
Process and design-wise Topsøe has many years of experience and more than 25 references with the design of bayonet tubes for reforming from our HTCR technology. The obvious advantage of HTER for ammonia is be22 / 25 sides the reduction in primary reforming duty that it offers a very high reforming temperature. A high reforming temperature results in a low methane slippage even with a S/C ratio at the same level as used in a traditional primary reformer for ammonia. The overall S/C ratio used in the front-end with HTER is Haldor same Topsøe A/Sas – Nymøllevej the in the55 traditional front-end for ammonia. 2800 Kgs. Lyngby - Denmark
In the case with HTER (Figure 4), it shall be noted that the outlet temperature from primary reformer is not higher in theacid traditional Topsøe solutionsthan for sulphuric and ammonia case plants (Figure 3).
23 / 25
2011
For a given capacity, HTER reduces the size of primary reformer for two reasons. Firstly, because part of the reforming duty is transferred to the HTER. temperature results in a low methane slippage evenreformer with a S/C ratio at the same level Secondly, because the secondary will perure 4: Ammonia plant front-end including an HTER-p as used in a traditional primary reformer for ammonia. The overall S/C ratio used in the form better, as the total amount of process air, which Figure 4: Ammonia plant front-end including an HTER-p front-end with HTER is the same as in the traditional front-end for ammonia. e parallel option can be executed in two ways: either the effluent from the secondary is determined by the ammonia capacity, is fed to the ormer (or ATR) is mixed with the reformed gas coming out of the HTER catalyst bed secondary reformer and only part of the feedstock The parallel option can be executed in two ways: In the case with HTER (Figure 4), it shall be noted that the outlet temperature from ore cooling of the combined product gas takes place, or the two streams are cooled passes the secondary reformer. When thetheeffluent from secondary reformer primaryofreformer is not higher than in the traditional case the (Figuresecondary 3). parately and either mixed at exit. Both waysthe have their advantages, and(or the selection reformer operates with a higher ratio of process air ATR) is mixed with the reformed gas coming out of ion depends on the circumstances. For the revamp case at Sasol Synfuels, the first gas,HTER the exit temperature will increase and the HTER bedabefore the comion was chosen. In other catalyst cases where low CH4cooling leakage of is crucial such as into Forprocess a given capacity, reduces the size of primary reformer for two reasons. the gas production for product ammonia,gas thetakes second option thetwo moststreams attractive. Firstly,methane because partslip of thedecrease. reforming duty is transferred to the HTER. Secondly, bined place, oristhe are because the secondary reformer will perform better, as the total amount of process air, cooled separately and mixed at the exit. Both ways e HTER design can be made to accommodate both the above options and otherwise which is determined by the ammonia capacity, is fedfor to the an secondary reformer and To illustrate a revamp situation ammonia have their advantages, and the selection of option deoptimised to suit the process requirements in the best possible way. The main only part of the feedstock passes the secondary reformer. When the secondary plant, a comparison between a base case and the repends on the circumstances. For the revamp case at tures of the HTER will in all cases be the same as those demonstrated industrially reformeratcase operates a higher of process to process gas, the temperature vamp iswith made in ratio Table 1. Asaircan be seen, a exit 25% Sasol Synfuels, the first option was chosen. In other Sasol Synfuels Gas Reforming Plant. The HTER suited for an ammonia plant will will increase and the methane slip decrease. in reforming capacity and equivalent amwhere a lowtubes CH4that leakage is crucial as in returnincrease made up of cases a number of double are furnished withsuch a bayonet tube. monia production can be achieved by introduction e heat transfer is laidproduction out in such afor way that only athe very limitedoption surfaceisarea will be syngas ammonia, second To illustrate a revamp situation for an ammonia plant, a comparison between a base of the HTER. It is noted that this capacity increase bjected to metal conditions, and consequently, the use of special resistant the dusting most attractive. case and the revamp case is made in Table 1. As can be seen, a 25% increase in terials can be minimised. could equally well be translated into an unchanged The HTER design can be made to accommodate both reforming capacity and equivalent ammonia production can be achieved by introduction capacity and a correspondingly smaller load on the the above options and otherwise be optimised to suit of the HTER. It is noted that this capacity increase could equally well be translated into cause of higher S/C in the process gas, there are less severe conditions with primary reformer. the process requirements in compared the best to possible way. an unchanged capacity and a correspondingly smaller load on the primary reformer. ards to metal dusting in HTER for ammonia HTER for syngas. This will The main features of the HTER will in all cases be ult in very long lifetime and again minimises use of special resistant material. Base HTER Change the same as those demonstrated industrially at the SaCase Revamp Case cess and design-wise Topsøe has many years of experience and more than 25 sol Synfuels Gas Reforming Plant. The HTER suited erences withfor thean design of bayonet for made reforming from our HTCR Dry product flow, kNm3/hr 280 351 +25% ammonia planttubes will be up of a number oftechnology. Equivalent NH3 production, MTPD 2225 2800 +25% double tubes that are furnished with a bayonet return e obvious advantage of HTER for ammonia is besides the reduction in primaryCH4 leakage 0.44 0.38 transfer is laid out in such aAway orming duty tube. that it The offersheat a very high reforming temperature. high that reforming Steam production in syngas WHB 100% 90% only a very limited surface area will be subjected to metal dusting conditions, and consequently, the use Table 1: Key figures for the base case and the same ammonia plant revamped with an HTER. of special resistant materials can be minimised.
contained herein is confidential; it may not be used for any er than for which it has been issued, and may not be used by to third parties without written approval of Haldor Topsøe A/S.
tion contained herein is confidential; it may not be used for any e other than for which it has been issued, and may not be used by osed to third parties without written approval of Haldor Topsøe A/S.
The steam production in the syngas WHB is lowered by 10% only, but it should be emphasised that the total steam production inIssue the plant61(including the ammonia 55 loop) is essentially unchanged. This means that it will not be necessary to upgrade the steam system in the plant, which will save both time and investment cost for the revamp. It
Studies & Researches The steam production in the syngas WHB is lowered by 10% only, but it should be emphasised that the total steam production in the plant (including the ammonia loop) is essentially unchanged. This means that it will not be necessary to upgrade the steam system in the plant, which will save both time and investment cost for the revamp. It can also be noted that the methane slip is kept around the original level in order to keep the inert level in the Haldor Topsøe A/S – Nymøllevej 55 2800 Kgs. Lyngby - Denmark loop unchanged.
that there is no need for any special start-up system, because the HTER is easily heated up and put on-stream together with the primary and secondary reformers.
3.5. Conclusion Topsøe has successfully demonstrated technologies within heat exchange reforming. Haldor Topsøe Exchange Reformer (HTER) has been in successful operation at the Sasol Synfuels plant in Secunda, South Africa, for more than 3 years. The HTER, which is a full scale plant, has been operating on The above case clearly demonstrates that the HTER Topsøe solutions for acid andas ammonia plants option for an 24 / 25 a commercial basis for the entire period. Through technology issulphuric attractive a revamp 2011 more than 25 HTCR applications, the bayonet tube ammonia plant. The HTER is, however, also an atprinciple for heat exchange reforming is now well tractive solution for a new grass-root plant. In Table established. 2, a comparison is made between the conventional for a new grass-root plant. In Table 2, a comparison is made between the conventional based front-end and the HTER based front-end for based front-end and the HTER based front-end for the reforming section. HTER is a promising technology which is attractive the reforming section. not only in a synthetic fuels plant or hydrogen plant. Conventional HTER The HTER is very well suited for ammonia and ofPrimary reformer, No. of tubes 350 276 fers a very high reforming temperature. Even with Secondary reformer diameter, mm 5000 4600 an overall steam to carbon ratio kept at the same CH4 leakage, dry mole% 0.80 0.40 level as for new conventional ammonia plants, the Total steam production, t/h 552 462 HTER solution results in a reduced methane slipTable 2: Conventional vs. HTER based front-end for a new plant based on 3300 MTPD ammonia page which is crucial for ammonia production. production.
As such, the ofbenefit introducing HTER can As such, the benefit introducingof an HTER can either be an harvested in terms of a significantbe capacity increase if an or as an option to either harvested inexisting termsplantofis arevamped, significant capacminimise the size of the primary reformer in a new plant and thereby save capital cost ity increase if an existing plant is revamped, or as and improve operability of the plant. An additional benefit for a new ammonia plant is an to minimise theconsumption size of isthe primary re-virtually that option the steam production and the steam partially balanced, i.e. former in a newThis plant savefor capital cost no steam import/export. wouldand be of thereby particular interest a stand-alone ammonia plant. improve operability of the plant. An additional and benefit for a new ammonia plant is that the steam In the revamp option, the mechanical layout needs special consideration based on the production andinthe steam actual available space the plant. Often itconsumption is possible to locate is the partially HTER next to the balanced, i.e.andvirtually steam import/export. secondary reformer re-route the exitno transfer line to the bottom of the HTER. The combined exit gas from is led back tointerest the existing WHB, without This would be theofHTER particular for preferably a standmoving any equipment in the front-end. It should be noted that there is no need for any alone ammonia plant. special start-up system, because the HTER is easily heated up and put on-stream together with the primary and secondary reformers.
As the example in this paper has demonstrated, significant increases in ammonia production can be achieved if an ammonia plant with a traditional front-end layout is revamped with the HTER technology. Likewise, it has been shown that a new plant can be designed with a smaller and less costly primary reformer when an HTER is installed from the beginning. 3.6. References [1] Thomsen, S. G., Han, P. A., Loock, S., and Ernst W.: “The First Industrial Experience with the Haldor Topsøe Exchange Reformer” AIChE Ammonia Safety Symposium, Vancouver, 2006.
In the revamp option, the mechanical layout needs special consideration based on the actual available 3.5. Conclusion space in the plant. Often it is possible to locate the Topsøe has successfully demonstrated technologies within heat exchange reforming. [2] Dybkjær, I., Madsen, S. W.: “Compact HydroHTER next to the secondary reformer and re-route Haldor Topsøe Exchange Reformer (HTER) has been in successful operation at the gen Plants” Hydrocarbon Engineering, November the transfer line South to the of3the Sasolexit Synfuels plant in Secunda, Africa,bottom for more than years.HTER. The HTER, which iscombined a full scale plant, has been on a commercial basisled for the entire 2004. The exit gas operating from the HTER is back period. Through more than 25 HTCR applications, the bayonet tube principle for heat to the existing WHB, preferably without moving exchange reforming is now well established. any equipment in the front-end. It should be noted HTER is a promising technology which is attractive not only in a synthetic fuels plant or hydrogen plant. The HTER is very well suited for ammonia and offers a very high 56 Issue 61
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