POT Trinidad Fact Sheet

7/28/2019 POT Trinidad Fact Sheet

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P C S N i t r o g e N t r i N i D A D

Fact Seet


2/8

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OUR PROFILE


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AmmoniA

PCS Trinidads ammonia complex consists of four

ammonia units producing approximately 2.4 million short

tons of ammonia annually. The utilities needed to run

these units include three cooling towers, three ammonia

storage tanks, steam, plant and instrument air support

and demineralized water for making steam.

Ammonia has a variety of uses, with its largest application

being as a nitrogen fertilizer. Ammonia is produced by

the reaction of nitrogen and hydrogen at elevated

temperatures and pressures in the presence of a catalyst.

Its three basic raw materials are air, natural gas and water.

The process of manufacturing anhydrous ammonia (NH3)

can be divided into eight basic steps:

1. Dsulphurzat

Natural gas feedstock is passed through a desulphurizerto remove any traces of the mineral, since sulphur

reduces the life of the catalyst in the downstream

processes.

2. Prary Rfrg

Steam (H2O) is mixed with natural gas, then heated and

passed over a catalyst to form hydrogen (H2), carbon

monoxide (CO) and carbon dioxide (CO2). The catalyst

promotes a reforming reaction through which the

natural gas is converted into these components.

3. Scdary Rfrg

Air is added to the secondary reformer in the necessary

proportion to create a ratio of three parts hydrogen (H2)

to one part nitrogen (N2). The oxygen (O

2) that is present

in the air reacts with un-reacted methane (CH4) to form

carbon dioxide (CO2) and water (H

2O). In addition to this

combustion of methane, the reactions that occur in the

primary reforming step continue in the secondary reformer.

SULPHUR REMOVAL REFORMING SHIFT CONVERSION, CO2 REMOVAL & METHANATION

1a 1b 2

3

Air

Steam

NaturalGas 4

5

7

CO2

6a 6b8

AmmoniA PRoCeSS FLoW DiAGRAm


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4. Shft Cvrs

Carbon monoxide formed in the primary and secondary

reforming steps is further reacted with steam to produce

hydrogen and carbon dioxide.

5. Carb Dxd RvalCarbon dioxide is removed from the gas stream by

absorption in a monodiethanolamine (MDEA) solution

or Benfield solution (a potassium carbonate solution).

The CO2

is then stripped from the absorbing solution

and some is used as feedstock in the production of

both urea and methanol. The stripped MDEA/Benfield

solution is then recycled.

6. mthaat

The gas stream now consists primarily of hydrogen

and nitrogen, plus small quantities of carbon oxides notremoved in the two preceding steps. Since carbon oxides

would poison the ammonia synthesis catalyst, it is necessary

to adjust the concentration to lower than 20 parts per

million (ppm). Carbon oxides are converted to methane

by reversing the steam reforming reaction.

7. Aa Sythss

The synthesis gas contains a 3:1 ratio of hydrogen to

nitrogen. The gas is passed through dryers where any

remaining moisture is removed. The desiccant used in

the dryers consists mainly of an alumino-silicate zeolite(molecular sieve). The dried gas is then compressed in

the synthesis gas compressor. The compressed gas enters

the synthesis reactor where the ammonia synthesis

reaction occurs over an iron or ruthenium catalyst. The

gas leaving the synthesis reactor contains approximately

15 percent of ammonia which is condensed to liquid

ammonia in the following step refrigeration.

8. Rfrgrat ad Strag

The gases leaving the reactor are cooled to

approximately -33 C (-27.4 F) to liquefy the ammonia.

The liquid ammonia is pumped to storage tanks where

the temperature is maintained to keep it in a liquid state.

The uncondensed, un-reacted hydrogen and nitrogen arerecycled to the synthesis reactor, where they join fresh

incoming feed for ongoing reaction.

There are three insulated storage tanks which have

combined capacity of 110,000 short tons. From these

tanks, liquid ammonia is pumped to the Savonetta Pier,

where it is loaded into the export tankers. PCS Trinidad

has two ammonia loading facilities: one located at

Savonetta Pier Number 1 (SPN 1) south, and another

located at Savonetta Pier Number 2 (SPN 2) north. The

one located at SPN 1 south is rated at 1,000 metric tons

per hour, while the one located at SPN 2 north is rated

at 1,500 metric tons per hour.

The utilities provide the services, facilities and supplies

needed to operate the ammonia units including treated

water for boilers, cooling water (fresh and salt), air (for

instruments), steam, waste disposal and back-up

electricity. One of these units, the demineralizer, treats

fresh water (provided by WASA) to remove salts and

produce demineralized water for steam generation. Fresh

water is also used for cooling process equipment and is

itself cooled by seawater. The seawater is in turn cooledin the cooling towers and recirculated.

About 18 percent of the ammonia produced is supplied

to PCS Trinidads urea plant as its major raw material and

the rest is exported to other markets, mainly in North

America and western Europe.

NH3 SYNTHESIS & REFRIGERATION

9

Refrigeration

NH3 Productto storage

Catalyst/Absorbent Reactions

1. Desulphurizers (a) Cobalt/Nickel/Molybdenum (a) RS + H2

g R + H2S

(b) Zinc Oxide (b) H2S + ZnO g ZnS + H

2O

2. Primary Reformer Nickel (a) CH4

+ H2O g CO + 3H

2

(b) CO + H2O g CO

2+ H

2

3. Secondary Reformer Nickel (a) CH4

+ 2O2

g CO2

+ 2H2O

(b) CH4

+ H2O g CO + 3H

2

(c) CO + H2O g CO2 + H24. HTS Shift Converter Iron/Chromium CO + H

2O g CO

2+ H

2

5. LTS Shift Converter Copper/Zinc CO + H2O g CO

2+ H

2

6. a. CO2

Absorber MDEA/Benfield Solution

b. CO2

Stripper

7. Methanator Nickel (a) CO + 3H2

g CH4

+ H2O

(b) CO2

+ 4H2

g CH4

+ 2H2O

8. Mole Sieve Dryers Alumino-Silicate Zeolite

9. Ammonia Converter Iron/Ruthenium N2

+ 3H2

g 2NH3


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UReA

PCS Trinidads urea plant has a capacity of 2,260 short

tons per day of urea in granular form, which is suitable for

both direct application and for blending with other solid

fertilizers. The two main ingredients in the manufacture

of urea ammonia and carbon dioxide are both supplied

by the ammonia complex.

Urea is an organic chemical compound obtained from the

high pressure synthesis of ammonia and carbon dioxide.

It is a white, non-toxic, non-volatile compound which is

highly soluble in water, melts at 132.7 C (270.9 F),

is hygroscopic and can be handled manually. It is used

mainly as a fertilizer, supplying 46.6 percent nitrogen by

weight (the highest concentration of nitrogen available in a

solid material). It is also used as the chemical intermediate

in the manufacture of resins, varnishes, glues and other

adhesives, as a protein supplement for cattle feed, intoothpaste, plastics, fabric treatment and more.

The process of manufacturing granular urea can be

divided into five steps:

1. Hgh-Prssur/Sythss

Liquid ammonia and gaseous carbon dioxide in a ratio of

3.6:1 are fed to a reactor where they form ammonium

carbamate, which rearranges (or dehydrates) to form urea

and water. Since the reaction does not go to completion,

the un-reacted carbon dioxide and ammonia are subsequently

stripped off, condensed and recycled to the reactor.

2. mdu Prssur Purfcat

The urea solution leaving the high-pressure synthesis

system is expanded and heated in the Medium Pressure

Decomposer. Additional un-reacted ammonia, together

with carbon dioxide and water vapour, is recovered and

recycled to the reactor.

3. Lw Prssur Purfcat

The urea solution from the Medium Pressure Decomposer

is again expanded and heated at an even lower pressure

in the Low Pressure Decomposer. A carbonate solution

containing ammonia and carbon dioxide in water is recycled

to the reactor via the medium pressure purification

recovery system.

4. evaprat

The urea solution then flows through the flash separatorand the vacuum separator where it is flashed and heated

to a molten 96 percent urea solution (urea melt). The

evaporated water is condensed and fed to the wastewater

treatment system, where traces of ammonia, carbon

dioxide and urea are removed, leaving a condensate

suitable for use in the steam generation system.

HIGH PRESSURE/SYNTHESIS LOOP MEDIUM PRESSURE LOOP LOW PRESSURE LOOP

Ammonia

3

4 5

1

2

Carbon Dioxide

Water from WasteWater Treatment

UReA PRoCeSS

FLoW DiAGRAm


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5. Graulat

In this final step, 0.5 percent of urea formaldehyde is

added to the urea melt. It acts as an anti-caking agent by

helping to restrict the tendency of the urea granules to

absorb moisture. In the granulator, the solution is then

sprayed upwards into a bed of seed granules, which iskept fluidized with warm air. Hot air is injected along with

molten urea, to atomize the urea melt into a fine spray.

This spray accretes on the seed granules, which fall to the

bottom of the fluidizing bed and are moved along by the

warm fluidizing air. The granules are cooled and screened

to ensure they meet market specifications. Undersized and

crushed oversized granules are recycled for use as seed.

The granular urea is then sent to the bulk warehouse

(which has a capacity of 70,000 short tons) where it is

stored under controlled temperature and humidity. Ninety-five percent is transported along conveyor belts to the pier

where it is loaded into the holds of dry cargo vessels at

approximately 550 short tons per hour. Major markets

include the United States, Canada and Latin America,

but some sales are also made to India and China. The

remaining five percent is bagged for sale to local and

regional markets.

EVAPORATION GRANULATION STORAGE & HANDLING Reactions

1. Ammonia Receiver

2. Reactor (a) 2NH3

+ CO2

g NH4CO

2NH

2

(b) NH4CO

2NH

2g NH

2CONH

2+ H

2O

3. Stripper

4. Medium Pressure

Decomposer

5. Low Pressure

Decomposer

6. Flash Separator

7. Urea Solution Tank

8. Vacuum Separator

9. Granulator

VACUUMSYSTEM

Water to WasteWater Treatment

Urea Formaldehyde

6 89

7

Hot Air

Bulk Warehouse

PCS TRiniDAD iS one oF THe WoRLDS

LARGeST niTRoGen ComPLeXeS, WiTH

FoUR AmmoniA PLAnTS AnD one UReA

PLAnT on 165 ACReS oF TRiniDADS

SHeLTeReD WeST CoAST.


7/8

As h wlds las pduc, by capacy, f h h

pmay plan nuns pash, phspha and nn

PashCp has bul a lbal puan f qualy and

svc. ou pducs sv h dffn maks: flz,

fd and ndusal. All h nuns a mpan h

flz ndusy, wh phspha bn h bs play n

h fd mak. in h ndusal mak, phspha and

nn pducs play h maj l.

POTAShCORP


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For further information please contact:

PCS NITROGEN TRINIDAD

Mdanan Dv, P.o. Ba 201, Pn Lsas indusal esa

Cuva, tndad, Ws inds

Phn: (868) 636-2205 Fax: (868) 636-2052

emal: [email protected].

www.pashcp.cm Mach 2012

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POT Trinidad Fact Sheet