Production of Urea Through ACES Process

Production of Urea Through ACES ProcessAdvanced Cost And Energy Saving ProcessProblem StatementTo synthesize urea by advanced cost and energy saving process

Urea Manufacturing Processes:General processes available for urea production are

Conventional Processes

Modern Processes

Conventional Processes:Once Through Process

Partial Recycle Process

Total Recycle ProcessModern ProcessesCO2 Stripping Process (Stamicarbon)

Ammonia Stripping Process (snamprogetti)

ACES ProcessWHY ONLY ACES?Stamicarbon ProcessSnamprogetti ProcessACES ProcessHigh production cost. High material of construction costHigh production costLow production costHigh energy costHigh energy cost/less energy recoveryLess energy cost/High energy recoveryLess treatment of pollutantsLess treatment of pollutantsLow environment pollution.Carbon dioxide used as stripping agent but NH3 in condenser which is more corrosiveNH3 is used as stripping agentCO2 is used as a stripping agent and carbamate solution in condenserLess number of recovery equipmentsDecomposersAbsorbersLess recovery of process fluids and heatRecovery equipments are greater in number i-eDecomposersAbsorbersEvaporatorsACES Advantages:Low Investment CostReduction of construction cost (Low Elevation and Compact Layout)Reactor on Ground LevelSimple synthesis loop and no gravity flowReduction of Equipment cost:Less number of equipment in synthesis loopLow Energy Consumption and running cost saving:The operation condition of synthesis section is optimized under the lower operation pressure than the previous process. As a result, a remarkable reduction in energy consumption is achieved.Easy Operation and High On-stream FactorForced flow of synthesis loop circulation by ejector and no gravity flowMaintenance Cost SavingMilder operating condition in synthesis loop (Less corrosion risk)Use of Duplex stainless steel

ACES Block Diagram

PFD ACES-21 PFD (TOYO JAPAN)

TOYOs Clients All Round The World

THANK YOU!BLOCK DIAGRAM OF UREA PLANTRaw Materials CO2 Gas / AmmoniaSynthesis SectionRecovery SectionPurification SectionProcess Condensate Treatment SectionTreated Process CondensateConcentration SectionPrilling SectionUrea Product To Bagging UnitTo Cooling TowerRecycle Carbamate SolutionUrea, Ammonia Carbamate, Ammonia & WaterUrea & WaterRecovered NH3 & COWater, small quantities as Urea Mist, NH3 & CO2NH3, Water, CO2Urea 98.8 Wt. %10