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FERTIL-2 integrated ZERO effluent discharge and ammonia emissions design concept
Mr. MAJED ALSHEMEILIUrea-2 Operation Department Manager
FERTIL
Content
• FERTIL profile
• The design concept of FERTIL-2.
• Zero ammonia emission concept.
• Zero liquid discharge concept.
• Benefits achieved & Conclusion.
| Steering the Fertilizer Industry through Challenging Times
FERTIL Profile
Location Ruwais (250 Km west of Abu Dhabi)
Established 1980
Shareholders ADNOC 2/3 & TOTAL 1/3
Plants FERTIL 1 FERTIL 2
Established/Started Up Oct.1980 / Nov.1983 Nov. 2009 / June 2013
Products, Name plate
capacity
Ammonia (MT/Day) 1,300 2,000
Urea
(MT/Day)2,300 3,500
| Steering the Fertilizer Industry through Challenging Times
Plants Photos
FERTIL-1
FERTIL-2
change
| Steering the Fertilizer Industry through Challenging Times
FERTIL’s Commitments
Conserve energy, water and other resources for the future
Reduce industrial footprints
Leave a healthy environment
FERTIL Approach
towards Zero
Ammonia Emission
Concept
| Steering the Fertilizer Industry through Challenging Times
FERTIL-2 Flaring system Objective
• Improve HSE performance by making FERTIL-2 production units Zero ammonia emission units
o Improve Safety and avoid any risks caused by ammonia release during operation
o Improve working environment and eliminate nearby companies concerns about produced off-gases
| Steering the Fertilizer Industry through Challenging Times
FERTIL-2 Urea Flare for continuous sources:
Background
The released ammonia has the following impacts:
1. Safety concern on the working environment
2. Long term impact on employees’ health
3. Annoyance to the near by companies
| Steering the Fertilizer Industry through Challenging Times
Urea Flares Descriptions:
Main Flare designed for Discontinuous emissions as a result of the blow-off of PSV’s,
rupture disks of high pressure and low pressure sections with an emergency device tointroduce the required assist gas during emission.
Low-pressure Absorber Flare designed for continuous emission from the Low-
Pressure Absorber. The reason for the integration is that the governing cases require acomparable amount of nitrogen and natural gas insertion and the available pressure differfrom other flares. Designed for continuous off-gas flow of 2500m3/hr with 0.99% ammonia.
Utility Flare is designed for the continuous emission from the vent of the Process tanks.
The main consideration of the separation is the allowable atmospheric back pressure for thesmall flow cases. The addition of nitrogen is required in normal operating conditions to dilutethe oxygen concentration. Designed for continuous off-gas flow of 3400m3/hr with 1.34%
ammonia.
| Steering the Fertilizer Industry through Challenging Times
Current Urea-2 Flaring system arrangements
| Steering the Fertilizer Industry through Challenging Times
Current Ammonia-2 Flaring system arrangements
| Steering the Fertilizer Industry through Challenging Times
Current FERTIL-2 Flaring system arrangements
| Steering the Fertilizer Industry through Challenging Times
Environmental impact of continuous off-gases treatment
using flaring
Item Flaring system
NG gas used (MM Nm3/year) 15.5
CO2 emissions (ton/year) 35,047
NOx emissions (ton/year) 18
NOx emissions (ppmv) 160
ADNOC COP NOx emissions limit (ppmv) less than 186
FERTIL Approach
towards Zero Liquid
Discharge Concept
| Steering the Fertilizer Industry through Challenging Times
Zero Liquid Discharge Concept
o Existing evaporation ponds facilities at the site consist of two compartments .
o each with a 12,400 m3 capacity working in a parallel operation mode.
o The design envisions the possibility of taking one of the pond compartments offline for maintenance or cleaning while the other compartment remains operational.
o The ponds are designed to receive intermittent storm surface runoffs, firefighting flows from various areas of FERTIL and neutralized regeneration wastewater from the Demineralization plant.
o Amount of effluent discharge from DM unit neutralization pit ( 9 M3/Hr.) is design basis. In real it was more but with enhancement of running length of DEMIN and Mixed Bed polisher, the effluent discharge quality has been reduced and is less now ( Approx. 6 M3/Hr.).
| Steering the Fertilizer Industry through Challenging Times
Flow diagram of waste waster treatment
Waste water diversion pit
Waste water collection basin
CPI oil separator
Neutralization pitDemin. plant
B
A
Rain water buffer pit
Urea plant
Amm. plant
Utility
Sea Water
Evaporation Pond
9 Nm3/hr
Waste water from F-1
| Steering the Fertilizer Industry through Challenging Times
Evaporation pond location
Evaporation Pond
| Steering the Fertilizer Industry through Challenging Times
Benefits achieved & Conclusion:
• Fertil is committed to enhance the social responsibilities while protecting the environment and the community and has been achieved by implementing this concept of “Zero Effluent & Emission”,
• It is possible to avoid the release of liquid effluents produced in similar plants to the sea with the aim of protecting the healthy marine environment.
• The personal safety, in similar plants where ammonia is handled, can be enhanced by eliminating the release of ammonia fluid directly to the atmosphere while sustaining the highest responsibility towards the company staff & the surrounding community.
Thank You!www.gpca.org.ae