Nearly Four Decades of Experience
Process and equipment for dust/ammoniaremoval from urea and ammonium nitrate
granulation systems
h dPROZAP - The Agenda
• About PROZAP
• Emmission control as a challenge for a plant owner
• CLEANING UNIT – one solution to all the issues
• What to do with the recovered product
• Why is the CLEANING UNIT unique
h
• 40 years of experience in design and engineering services
PROZAP - The Engineering Company
40 years of experience in design and engineering servicesfor chemical industry
• Highly qualified engineers and technical staff for professionalproject design and executionproject design and execution
• Resources to provide sophisticated and technologicallyadvanced design in all disciplines and a variety of accompanying servicesof accompanying services
• Customer oriented, tailoredengineering services
PROZAP Engineering Ltd
Al. Tysiaclecia P.P. 13
24-110 Pulawy, Poland
www.prozap.com.pl
Tel. +48 81 473 16 00
Fax +48 81 886 25 59
h l dPROZAP - Focus on Chemical Industry
Inorganic:
• Ammonia and methanol
• Nitric and sulphuric acids,
Organic:
• Caprolactam,
• Melamine,
• Ammonium nitrate,
• Urea,
• Mixed liquid fertilizers (UAN)
• Toluene diisocyanate (TDI)
• Polyol compounds,
• Bioethanol
• AdBlue
Environment protection units:p
• Prilling tower exit air dedusting,
• NOx removal from off-gases.
h f l
• Training of operating personnel
Phases of a plant project
g p g p• Plant operation and maintenance• Plant optimisation• Plant upgradingCommissioning
• Project Execution• Author’s Supervision• As-built DocumentationConstruction• Basic Engineering • Detail Engineering• Cost Control• ProcurementDesign• Market Study • Feasibility Study • Choice and transfer of technology• License Management• License Management• Cost EstimationProject Definition
f dMajor reference projects - domestic
• Ammonia• Urea• Melamine• Ammonium nitrate
C l tI t ti l P K id SA
Bałtycka Baza Masowa Lotos SA
Police SA
• Caprolactam• Peroxides• Sulphur and its compounds• Units based oil processing• NOx, SO2 , NH3 emission abatement
Anwil S.A.
Polfa Tarchomin SA
International Paper Kwidzyn SAMetalkoZachem S.A.
Z.Ch. LubońOrlen SA Boryszew SA
• Prill tower off- gas dedusting• Sulphuric acid• Nitric acid• Waste & Water treatment• Bulk and liquid fertilizer storage – inland and harbour
ZA Pulawy SA
KiZ.Ch.S. SiarkopolZ. Ch. Siarkopol
Organika Sarzyna
PCC RokitaWratislavia-Bio
Mostostal Puławy SA
Cersanit SA
• Bulk and liquid fertilizer storage – inland and harbour• Heat/power plants• Bioethanol
Polfa SAZA Kędzierzyn SA
Carbon Black Polska
Elektrownia Rybnik SA
M j f j tMajor reference projects - overseas
LithuaniaMethanol Plant
RussiaSulphuric Acid PlantCommercialCenter TagankaSwitzerland
AustriaUrea prilling towerCLEANING UNIT
South KoreaCaprolactam Plant
I di
SwitzerlandSteel structure
Saudi Arabia
IndiaHydroxylamine Plant
Urea prilling towerCLEANING UNIT
CLEANING UNIT
For dust/ammonia removalfrom urea and ammonium nitrate granulation systems
h llChallenges - emission
Urea and ammonium nitrate plants average emmissions:
Granulation method Unit Dust content Ammonia content
Urea and ammonium nitrate plants average emmissions:
content
Urea Prilling tower mg/Nm3 80-220 60-180
Urea Granulator g/Nm3 up to 12 90-180
l l / 3Urea Granulator Cooler g/Nm3 up to 4 traces
Ammonium Nitrate Prilling Tower mg/Nm3 80-160 40-120
Common environmentalregulations:
• 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 ammoniag pp g/
CLEANING UNIT systemCLEANING UNIT systemwith single-stage scrubbers
• Urea aqueous solution up
Recovered product
to 25 %wt concentration, if only dust is removed,
• Urea + ammonium sulphate aqueous solutionsulphate aqueous solution (UAS), or urea + ammonium nitrate aqueous solution (UAN) up to 25 %wt, in case of simultaneous removal of dust and ammonia.
CLEANING UNIT systemCLEANING UNIT system with double-stage scrubbers
Recovered product
Double-stage scrubbers – removingurea and ammonia separately (P1 and P2).
• First stage removes the urea dust.• Second stage removes ammonia.
f l d dWays of utilising recovered product
NH3
Liquid FertilizerUrea / Ammonium Nitrate
Aqueous Solution
H2OU / AN
CLEANINGUNIT
Urea / AN dust & ammonia
Urea / ANAquousSolution
Urea / AN dust & ammonia
Recycle to production
f l d dWays of utilising recovered product
Urea and Ammonium Sulphate Aqueous SolutionLiquid Fertilizer
H2O
CLEANINGUNIT
2
UASH2SO4 CrystallizationUNIT
Urea dust & ammonia
Recycle to production
f l d dWays of utilising recovered product
Urea and Ammonium Nitrate Aqueous SolutionLiquid Fertilizer
H O
CLEANING
H2O
UANHNO3
UNIT
Urea dust & ammonia
f l d dWays of utilising recovered product
Ammonium Sulphate Aqueous Solution
Liquid Fertilizer
H2O
CLEANINGUNIT
Power station / H2SO4 Plant
AS CrystallizationNH3
off-gases
Recycle to production
h k ?What makes CLEANING UNIT unique?
• Low pressure drop factor – energy saving
U i l i SO• Universal: urea, ammonia, SOx
• No limitation as to plant capacity, amount of off-gases and liquid/dust load
• Fits well new and old plantsp
h ?Why is CLEANING UNIT unique?
Pressure drop
Feature Sieve Tray Scrubber
Turbulaire CLEANING UNIT
Pressure drop
Pressure drop (Pa) 2794 35561 up to 800
Power consumption (KW/1000Nm3) Expected: 3,5 Expected: 4,5 1
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 (E )• 1MW ≈ €50 (European average)
KW/h KW/year €/year
1200 9 600 000 480 0001200 9,600,000 480,000
1 http://www.babcock.com/library/pdf/ps-420.pdf
h ?Why is CLEANING UNIT unique?Conventional Mesh Pad
Unlimited liquid
Crimped wire mesh Co-knit wire/fiberglass mesh
Unlimited liquidLoading capacity
p / g
CLEANING UNIT Action
h k ?What makes CLEANING UNIT unique?
resulting in reduced vessel size... resulting in reduced vessel size
Conventional scrubberPROZAP designed
Vessel equipped with MIST-MASTER®
Relative sizes of vessels designed for the same application
lPlacement options
On ground level On top of prilling tower
lConclusion
• Emmission control system can provide product for recycling or commercial use
• PROZAP’s CLEANING UNIT is state-of-the-art solution:
Hi h ffi i– High efficiency– Energy saving– Universal
• PROZAP has over 20 years of experience in implementing CLEANING UNIT systems
Decades of experience
Th kThank you
PROZAP Engineering Ltd
Al. Tysiaclecia P.P. 13
24-110 Pulawy, Poland
www.prozap.com.pl
Tel. +48 81 473 16 00
Fax +48 81 886 25 59