Post on 05-Jan-2016
description
transcript
Sule AlabiJonathan Arana
Elizabeth MoscosoOleg Yazvin
Mentor: Dan Rusinak – Middough
Production of Prilled Urea
Clean Water from CHP Plant
Prilled Urea (99.3%)
Product
BFD of Urea & Prill Plant
"Dirty Water"
Rich in NH3, CO2 & Impurities
Cleaned Air Out
Urea Solution (72%)
Condensate Water
Solid Urea (99.3%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Production
PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
Urea Production Plant PFD
1
2
3
4
5
6
78 9
10
11
12
13
14
DECOMPOSERDECOMPOSER
water
Urea (72%)Solution
Un-reacted Gases
Urea Production Plant Calculations Some Assumptions:
Stream 1 2 3 4 5
NH3 Feed Gas Exit from Stripper Solution from Scrub Solution from Pool Gas Recycle to Scrub
Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons
Totals 77.31 1314.33 77.59 2441.84 140.00 3565.00 151.47 4430.96 10.50 234.30
Compounds
CO2 41.59 1829.84 10 440.00 18.57 817.14 2.06 90.79
NH3 77.31 1314.33 36.00 612.00 100 1700.00 75.97 1291.52 8.44 143.50
AC 15 1155.00 10.98 845.16
Urea 15.48 928.57
Water 15 270.00 30.48 548.57
Properties
Temperature 185oC 185oC 185oC 185oC 60oC
Pressure 140 Bar 140 Bar 140 Bar 140 Bar 1 Bar
Calculations:
Input Variables
CO2 input (tons) 1153.15
NH3 / CO2 Input Mole Ratio 2.95
Input CO2 Split into Reactor 0.90
Reactor
Extent of Reaction 1 Based on CO2 0.60
Extent of Reaction 2 Based on CO2 0.50
Fraction of CO2 that gets converted 1.00
Compound Mass Flow Rate IN (TPD)
Mass Flow Rate OUT (TPD)
Mole Flow Rate IN (ton mole/day)
Mole Flow Rate OUT (ton mole/day)
AC 506.7 12.5 6.5 0.13
Urea 1513.8 1893.5 25.2 31.6
Water 99.54 214.2 5.53 11.9
NH3 2.21 2.21 0.13 0.13
CO2 5.72 5.72 0.13 0.13
TOTAL 2128 2128 37.53 43.9
Q = 177 BTU/ton
Material & Energy Balance for Decomposer Unit
Basis:
1893 TPD of Urea produced
Composition of Urea 72%
Waste Water Treatment Plant PFD
13
31
32
33
Waste Water Treatment Plant Calculations
Assumptions: Basis of 50,000kg of
effluent sewer water 10 NH3 ppm specification
from EPA Assumed same PPM for
CO2 Inlet Water composition
from existing Indian Urea Plant
1% of recycle is vented to air
Calculations:
Stream 13 31 32 33
Total 532,066.00 477,245.34 50,000.00 4,820.66
Mass (kg) Balance
Components
CO2 38,084.00 37,703.11 0.05 380.84
NH3 45,332.00 44,878.63 0.05 453.32
Urea 4,985.00 4,935.15 0.00 49.85
Water 443,665.00 389,728.45 49,999.90 3,936.65
Mole (kmol) Balance
Component
CO2 865.55 865.54 0.00 216.39
NH3 2,666.59 2,666.59 0.00 666.65
Urea 83.08 83.08 0.00 20.77
Water 24,648.06 21,870.28 2,777.77 5,467.57
Total 28,263.27 25,485.50 2,777.78 6,371.37
Properties
Temperature 25oC 25oC 25oC 25oC
Pressure 1 bar 1 bar 1 bar 1 bar
Evaporator Unit PFD
15
16
26
25
24 17
2321
22
18
19
20
27
Condenser
Eductor
Evap1
Evap2
Storage Tank
Product Urea (99.8%)
H.P. Steam
Urea Solution (72%)
Streams 21, 26, 19:To Waste Water Treatment
Evaporator Unit Calculations Assumptions: Input Urea 1572.48 Tons
Input Water 611.52 Tons
wt% Water Evaporated 1 95%
wt% Water Evaporated 2 85%
wt% Water Condenses 65%
Input Steam 3 Tons
Calculations:Stream # 15 16 17 18 19
Urea (72%) to Tank Urea 72% Solution Water from Evap 1 Urea from Evap1 Steam from Evap 2
Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons
Totals 60.18 2184.00 60.18 2184.00 32.27 580.94 27.91 1603.06 32.27 580.94
Compounds
Urea 26.21 1572.48 26.21 1572.48 26.21 1572.48
Water 33.97 611.52 33.97 611.52 32.27 580.94 1.70 30.58 32.27 580.94
H.P. Steam
Properties
Temperature 80oC 80oC 110oC 95oC 80oC
Pressure 5 Bar 5 Bar 0.8 Bar 0.8 Bar 1 Bar
Cyclone
Screen
Bag House
Pump
Melting Furnace
Dehumidifier
Prilled Urea (99.8%)
Urea Melt (99.8%)
Prilling Tower
27
30
29
Air from Atm
Cleaned Air
28
Prilling Tower PFD
Prilling Tower Calculations
Assumptions: Mass flow rate of Prilled
Urea is 738.22 TPD According to the EPA the
allowed urea dust is 3.8 lb/ton of Prilled Urea. For ammonia dust the allowed emission is 0.87 lb/ton of Prilled Urea.
Stream 27 28 29 30
Urea Melt (99.8%)
Air From Atm
Prilled Urea (99.8%) Cleaned Air
Tons Tons Tons Tons
Totals 739.94 500 738.22 501.724
Component
Urea Melt 739.94 --- --- ---
Ammonia Dust --- --- --- 0.32
Urea Dust --- --- --- 1.40
Prilled Urea --- --- 738.22 ---
Air --- 500 --- 500
Properties
Temperature 185oC 25oC 25oC 25oC
Pressure 1 bar 1 bar 1 bar 1 bar
Calculations:
Estimated Economics
Materials Cost (Money We Spend) Amount Overall Cost
NH3 $521.00 Per Ton 891.07 Tons Per Day $464,247.47 Per Day
CO2 $15.00 Per Ton 1153 Tons Per Day $17,295 Per Day
Product Price (Money We Get) Overall Price
Urea to UAN $230.00 Per Ton 694.48 Tons Per Day $159,730.40 Per Day
Prilled $570.50 Per Ton 739.7 Tons Per Day $421,998.85 Per Day
Profit: $100,186.78 Per Day
Profit: $36,568,174.70 Per Year
Estimated Total Cost
2009- Q’atar built a 3,836 TPD Urea PlantPlant Cost: $610 Million Dollars.
Urea Plant Produces 1,384 TPD Using 6/10ths rule and 2010 Cost Index
Plant Cost: $389.4 Million Dollars.
About 10 years to break even
Questions?