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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