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

prozap@prozap.com.pl

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

prozap@prozap.com.pl

www.prozap.com.pl

Tel. +48 81 473 16 00

Fax +48 81 886 25 59