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23rd AFA Int.’l Technical Conference & Exhibition June 29 – July 1, 2010 Ramada Plaza Tunis Hotel, Tunisia

Ammonia and Urea processing: AdBlue and other environmental care related applications

Maria Skorupka President & CEO, PROZAP Engineering Ltd

Poland

6/10/2010

SSmart, Investor Friendly, I F i dl Environmental Care Ammonia and Urea processing

PROZAP Engineering Ltd. Agenda

• About PROZAP • CLEANING UNIT: Urea, Ammonium Nitrate ‐ emission control • AdBlue plant • Power Plant Flue‐Gas Desulphurization • Conclusion

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PROZAP The Engineering Company • 40 years of experience in design and engineering services for chemical industry • Highly qualified engineers and technical staff for professional project design and execution • Resources to provide sophisticated and technologically advanced design in all disciplines and a variety of accompanying services and a variety of accompanying services • Customer oriented, tailored engineering services PROZAP Engineering Ltd Al. Tysiaclecia P.P. 13 24‐110 Pulawy, Poland

Tel. +48 81 473 16 00 Fax +48 81 886 25 59

prozap@prozap.com.pl www.prozap.com.pl

PROZAP Focus on Chemical Industry • Ammonia and methanol A i d th l

• Caprolactam, C l t

• Sulphuric and Nitric acid,

• Melamine,

• Ammonium nitrate,

• Toluene diisocyanate (TDI)

• Urea,

• Polyol compounds,

• Mixed liquid fertilizers (UAN)

• Bioethanol

• AdBlue Environment protection units: • Ammonium Nitrate/ Urea Prilling tower and granulator exit air dedusting, • SOx / NOx removal from off‐gases, • Flue Gas Desulphurisation.

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Specialty Services At every stage of a project life‐time • Training of operating personnel • Plant operation and maintenance • Plant optimisation • Plant upgrading

Commissioning

• Project Execution • Author’s Supervision • As‐built Documentation

Construction

Design

• Basic Engineering • Detail Engineering • Cost Control Cost Control • Procurement

Project Definition

• Market Study • Feasibility Study • Choice and transfer of technology • License Management • Cost Estimation

Major Reference Projects Domestic Bałtycka Baza Masowa

Lotos SA

Police SA

International Paper Kwidzyn SA Zachem S.A. Metalko Anwil S.A. Z.Ch. Luboń

Orlen SA

Boryszew SA Polfa Tarchomin SA

Mostostal Puławy SA

ZA Pulawy SA Cersanit SA

KiZ.Ch.S. Siarkopol PCC Rokita

Z. Ch. Siarkopol p

W i l i Bi Wratislavia‐Bio

Organika Sarzyna ZA Kędzierzyn SA Elektrownia Rybnik SA

Carbon Black Polska

Polfa SA

• • • • • • • • • • • • • • •

Ammonia Urea Ad Blue Ad Blue Sulphuric acid Sulphur and its compounds Nitric acid NOx, SO2 , NH3 emission abatement Prill tower off‐ gas dedusting Melamine Ammonium nitrate Caprolactam Peroxides Units based oil processing Waste & Water treatment Bulk and liquid fertilizer storage – inland and harbour • Heat/power plants • Bioethanol

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Major Reference Projects Overseas Russia Lithuania

Sulphuric Acid Plant Commercial Center Taganka

Methanol Plant

Switzerland

South Korea

Steel structure

Caprolactam Plant

Austria Urea prilling tower CLEANING UNIT

India Hydroxylamine Plant

Saudi Arabia Urea prilling tower CLEANING UNIT

Key Partners Overseas

 Achema

 Khimtekhnologya

 Agro Linz

 Lurgi Zimmer

 Air Liquide

 Marsulex

 BECO Engineering Company

 Petrochemishe Anlagen

 Casale Group

 Rhodia Chemie

 Chematur Engineering Group

 Samsung Engineering

 Evonik Carbon Black

 Saudi Arabia

 Gea Messo AG

 Sulzer Chemtech

 GSFC

 Tecnimont

 Intergraph

 ZAO Polus

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Environment care Is it a must?

• Regulations • The Company’s Image • Quality of our life: work & residential environment

Recent Projects Ammonia and Urea Processing

Recent projects • CLEANING UNIT: Urea prill‐ tower emission control in Middle East • AdBlue plant • Power Plant flue‐gas Power Plant flue gas desulphurization

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CLEANING UNIT Urea prill‐tower emission control in Middle East

CLEANING UNIT Challenges ‐ emission Urea and ammonium nitrate plants average emmissions: Granulation method

Unit

Dust content

Ammonia content

mg/Nm3

80‐220

60‐180

Urea Granulator

g/Nm3

up to 12

90‐180

Urea Granulator Cooler

g/Nm3

up to 4

traces

mg/Nm3

80‐160

40‐120

Urea Prilling tower

Ammonium Nitrate Prilling Tower Common environmental regulations: • •

Urea Dust 50 – 80 mg/Nm3 Ammonia 50‐80 mg/Nm3

Clean air from CLEANING UNIT contains: • •

approx. 25 mg/Nm3 of dust approx. 25 mg/Nm3 of ammonia

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CLEANING UNIT Utilizing recovered product Urea and Ammonium Sulphate Aqueous Solution Urea and Ammonium Sulphate Aqueous Solution

H2O H2SO4

CLEANING UNIT

UAS

Crystallization lli i

Urea dust & ammonia

CLEANING UNIT Why is it so unique?

Pressure drop Feature

Sieve Tray Scrubber

Turbulaire

CLEANING UNIT

2794

35561

up to 800

Expected: 3,5

Expected: 4,5

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Pressure drop (Pa) Power consumption (KW/1000Nm3) Input data for calculations:

• Energy consumption by 1 CLEANING UNIT: 1KW/1000Nm3 • Inlet flow to emission control: 1 200 000 Nm3/h • Operation period: 8000h/year • 1MW ≈ €50 (European average)

1

KW/h

KW/year

€/year

1200

9,600,000

480,000

http://www.babcock.com/library/pdf/ps-420.pdf

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CLEANING UNIT Urea prill‐tower emission control in Middle East Project at a glance • Start‐up in mid 2009 • Goal: reduction of emission of ammonia and urea dust • Scope of work: – – – – – –

General Concept Basic Design Basic Design Detail Engineering Supply of key equipment Supervision Training of personnel

CLEANING UNIT Urea prill‐tower emission control in Middle East Project results Item

Before

After

Dust content

~ 300 mg/Nm3

25 mg/Nm3

Ammonia

~ 200 mg/Nm3

25 mg/Nm3

Other applications • Granulator exit‐air cleaning ‐ concentration of product solution – up to 45% • Ammonium Nitrate plants

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AdBlue Plant Top Priority: Superb Product Quality

AdBlue Plant Why AdBlue?

  

Fossil Fuel → NOx → Environment deterioration SCR/SNCR to reduce NOx emission SCR/SNCR to reduce AdBlue – reagent for the reaction  4NO + 4NH3 + O2 → 4N2 + 6H2O  2NO2 + 4NH3 + O2 → 3N2 + 6H2O  NO + NO2 + 2NH3 → 2N2 + 3H2O

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AdBlue Plant What is AdBlue?

AdBlue: 

32 5% aqueous urea solution 32.5% aqueous



Non‐toxic



Odourless and colourless liquid



Freezing‐point (crystallization) at ‐11°C



At temperature exceeding 30°C decomposes with emission of ammonia



Used in modern diesel engines equipped with SCR catalysts



Ammonia released from AdBlue reduces NOx emission to a minimum

AdBlue Plant Product Quality

AdBlue product requirements (ISO 22241)            

Density at 20°C Refractive index 20°C Alcalinity as NH max.

Biuret max.

Aldehyde max.

Insoluble max.

Phosphorate max.

Calcium max.

Iron max.

Copper max.

Zinc max.

Chromium max.

1.087 – 1.093 1.3814 – 1.3843 0.2% 0.3% 5 mg/kg 20 mg/kg 0.5 mg/kg  0.5 mg/kg  0.5 mg/kg  0.2 mg/kg  0.2 mg/kg  0.2 mg/kg

Nickel max.

Aluminium max.

Magnesium max.

Sodium max.

Potassium max.

0.2 mg/kg 0.5 mg/kg 0.5 mg/kg 0.5 mg/kg 0.5 mg/kg

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AdBlue Plant Reference Project Client: ZA Pulawy S.A. Location: Pulawy, POLAND Job Description: •

Civil Engineering

•

Environment protection approvals

•

Detail Engineering

•

Phase 1: 30,000 mtpy

•

Environment Impact Report

•

Phase 2: 100,000 mtpy

Power Plant Flue‐gas Desulphurisation

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Power Plant Flue‐gas Desulphurisation PROZAP’s experience in removing dust / ammonia from urea and ammonium nitrate plants applied in a new field – Flue Gas Desulphurization I In progress: supervision over a desulphurization project based on Marsulex i i d l h i ti j tb d M l technology and know‐how • A novel and commercially viable process for flue gas desulfurization • Ammonia as reagent • > 98% SO2 removal efficiency • Product ‐ commercial grade ammonium sulfate • High (99+%) system reliability • Commercially proven in full scale for over 10 years: plants in U.S., Canada and P.R.C. • No waste sludge • Minimal / no waste water

Power Plant Flue‐gas Desulphurisation Best opportunity profile • Fuel sulfur content 2% or higher Fuel sulfur content 2% or higher • Access to domestic or export market for AS fertilizer product • Unit size 100 to 1000 megawatts (or equivalent source gas flow rate) • Access to economic source(s) of anhydrous or aqueous ammonia Method applicable in power stations using various types of fuel: types of fuel: • Crude Oil • Natural Gas • Heavy Crude Oil / Mazut • Coal

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Power Plant Flue‐gas Desulphurisation Ammonia and Limestone WFGD Process Comparison

Power Plant Flue‐gas Desulphurisation Basic reactions in the desulphurization process: SO2 + 2NH3 + H2O → (NH4)2SO3 (NH4)2SO3 + 1/2 O2 → (NH4)2SO4

Capital cost of the AS‐FGD approach is typically in the range of 30 to 40% over that of limestone FGD if a fertilizer plant is included FGD if a fertilizer plant is included.

If the fertilizer plant is outsourced on a Build, Own, Operate and Maintain (BOOM) basis, the AS‐FGD capital cost can be less than that of conventional limestone, as the reagent system is greatly simplified and the dewatering system is eliminated from the Owner’s scope.

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Smart, Investor Friendly, Environmental Care Conclusion

• Emmission control system can provide product for recycling or commercial use • PROZAP’s state‐of‐the‐art solutions: – High efficiency – Energy saving – Universal

• New FGD technology, smart, especially suitable for sites where ammonia is available

Thank you Ammonia and Urea processing: AdBlue and other environmental care related applications

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