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Successful Applications of CasaleTechnology to Grass-Roots
Plants
By
Sergio Panza
CASALE GROUP
[email protected]
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ammonia plant of the 20s
ammonia plant of the 21 century
Drops of historyDrops of history
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CASALE GROUPCASALE GROUP
AMMONIA PLANTS
UREA PLANTS
METHANOL PLANTS
HYDROGEN PLANTS
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UREA PLANT
Presentation outlinePresentation outline
CONCLUSIONRECENT PROJECTS
TECHNOLOGIES FOR GRASS ROOTPLANTS
AMMONIA PLANT
METHANOL PLANT HYDROGEN PLANT
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Standard Ammonia processStandard Ammonia process
Axial-Radial bed
3 bed 2 interchanger converter
Waste Heat BoilerNH3 WASH
High Efficiency Burner
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High Efficiency Secondary Reformer Burner
Standard Ammonia processStandard Ammonia process
Minimize equipment size and guarantees high reliability:
Superior mixing in the flame
Short flame lengths
Homogeneous conditions at catalyst bed inlet
Low pressure drop
Protection of burner and lining against hightemperatures
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Axial-Radial Shift Converters
Standard Ammonia processStandard Ammonia process
Longer catalyst life stable pressure drop high resistance to
poison and water carryover
Low CO slip
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Ejector ammonia wash system
Standard Ammonia processStandard Ammonia process
Minimize energy consumption of:
circulator refrigeration compressor
Syngas is dried
Pressure recover on
the sygas
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Standard Ammonia processStandard Ammonia process
Axial-Radial Synthesis Converters
3 Bed 2 Interchanger configuration:
high thermodynamic efficiency and
catalyst volume utilization
minimizing energy consumption
minimizing equipment size
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Waste Heat Boiler design
Standard Ammonia processStandard Ammonia process
All ferritic parts kept at lower
temperature:
No risk of nitrading
High reliability
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Performances
Standard Ammonia processStandard Ammonia process
S/C ratio : 2.9 CO slip from LTS : < 0.3% vol.
CO2 slip from absorber : < 300 ppm vol.
Ammonia conversion : 20%
Low investment
Low energy consumption : 6.7 Gcal/MT
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MEGAMMONIAMEGAMMONIA processprocess
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Performances
High capacity in a single line : > 4000 MTD
Low capex
Low energy consumption : 6.6 Gcal/MT
MEGAMMONIAMEGAMMONIA processprocess
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SPLIT FLOW LOOP process
High EfficiencyTrays
High EfficiencyHydrolyser
FullCondenser
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High Efficiency Trays
SPLIT FLOW LOOP process
Enhanced heat & masstransfer
High liquid/vapor mixing
High conversion efficiency
Minimize reactor size
Minimize energy consumption
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Two-phase flow in tubes
High exch. coefficient
Urea is formed
Submerged condenser
Internal circulation
Full Condenser TM design
SPLIT FLOW LOOP process
Minimize equipment size
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SPLIT FLOW LOOP process
High Efficiency Hydrolyser
Complete cleaning ofprocess condensate
Divided into 2 parts forhighest hydrolysisefficiency
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high CO2 conversion(63.5 % @ N/C 3.2, H/C 0.45)
high stripping efficiency
low amount of unreacted to thedownstream sect.
SPLIT FLOW LOOP process
Performances
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Performances
Steam:tot process cons. (24bar) 750 kg/MT
NH3 consumption: 568 kg/MT
CO2 consumption: 735 kg/MT
Electricity consumption: 22 kWh/MT
SPLIT FLOW LOOP process
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Standard Methanol processIMC Converter
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IMC Converter
Standard Methanol process
No tube sheet
Plate cooled pseudo
isothermal converter
Highest reaction rateprofile is followed
Maximum efficiency
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Performances
Standard Methanol processStandard Methanol process
S/C ratio : 2.5 to 3.0 Methanol loop pressure : 80 bar
Methanol conversion : 7 %
Low investment
Low energy consumption : 6.9 Gcal/MT
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Advanced Methanol processAdvanced Methanol process
ATRBurner
2 bedIMC Converter
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ATR Converter Design
Advanced Methanol processAdvanced Methanol process
High conversion efficiency
Superior combustion obtainedby perfect mixing of O2 and gas
Soot free operation
Flexible and reliable design
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Advanced Methanol processAdvanced Methanol process
2 Bed IMC Converter
IMC bed design arranged in
2 bed configuration
One bed cooled by
process gas Second bed cooled by
boiling water
Large capacities in a singlevessel
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Performances
High capacity in a single line : > 7000 MTD
Low capex
Low energy consumption : 6.7 Gcal/MT
MEGMETHANOLMEGMETHANOL processprocess
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Standard Ammonia processStandard Ammonia process --
ImplementationImplementation
1 plant 2050 MTD in op. in Iran (RPC) since 2008
1 plant 2050 MTD in advanced implement. stage
3 plants 2050 MTD under basic design
RPC plant
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In operation since 2003 in a1500 MTD plant located inUkraine
One plant under construction
SPLIT FLOW LOOP process - Implementation
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Standard & Advanced Methanol processesStandard &
Advanced Methanol processes -- ImplementationImplementation
Standard process:2 plants (1350 & 1650 MTD) in op. in
Russia
Advanced process:
1 plant 7000 MTD under implementation in Iran
Russian methanolplant
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ConclusionsConclusions
Through continuous technological evolutionCasale developed
innovative processes for
ammonia, urea and methanol grass-root plants
Casale can now design world scale fertilizer andmethanol plants
responding also to futuredemands in terms of capacity
This place Casale in the unique position to ownproprietary
technologies for the design of all the3 products, ammonia, urea and
methanol
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For further information:[email protected]
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Methanol Plant Of The 60Methanol Plant Of The 60ss
RIO TERCEROMEOH PLANT
(ARGENTINA) 1962
MeOH ConverterDistillation columns
