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Fertilizer Manufacturing Technologies: Product No. Product/ Technology Function Product
Fertilizer Manufacturing Technologies: Product No. Product/ Technology Function Product
Product
No.
Function
Product
F-1
Urea synthesis
Urea plant
F-2
F-3
Reformer
exhaust heat
recovery
Ammonia
Ammonia synthetic
synthesis
reactor
Ammonia
Ammonia synthetic
synthesis
reactor
CO conversion
H2 production
CO conversion reactor
CO oxidizing to
CO converter for
CO2
ammonia plant
Ammonia
manufacturing plant
integrated with power
generation plant
Heat recovery system
F-4
F-5
F-6
F-7
Coal gasification
F-8
Heat recovery
from
synthesized gas
Recovery of H2
from
synthesized gas
Power recovery
from highPressure water
Pre-reforming of
recovery system
F-9
F-10
F-11
natural gas
41 b
of ammonia plant
H2 recovery system of
Ammonia plant
Water turbine of
ammonia plant
Ammonia plant
F-1
Fertilizer/ Chemical
Process
Equipment of Urea
Outline of Product/Technology
(1) Function
Urea Production Technology
(2) Structure/System
A urea plant is composed of five sections such as urea synthesis, purification, recovery,
concentration and product forming section. A major feature of this technology is in the urea
synthesis section. The synthesis section contains a reactor, a stripper and a carbamate condenser.
Liquid ammonia is fed to the reactor via the HP Carbamate Ejector which provides the driving force
for circulation in the synthesis loop. The reactor is operated at an N/C ratio of 3.7, 182 C and 152
bar. Urea synthesis solution leaving the reactor is fed to the stripper where unconverted carbamate
is thermally decomposed and excess ammonia and CO2 are efficiently separated by CO2 stripping.
The stripped off gas from the stripper is fed to the Vertical Submerged Carbamate Condenser,
operated at an N/C ratio of 3.0, 180C and 152 bar. Ammonia and CO2 gas condense to form
ammonium carbamate and subsequently urea is formed by dehydration of the carbamate in the
shell side. Reaction heat of carbamate formation is recovered to generate 5 bar steam in the tube
side. A packed bed is provided at the top of the Condenser to absorb uncondensed ammonia and
CO2 gas into a recycle carbamate solution from the MP absorption stage. Inert gas from the top of
the packed bed is sent to the purification section
(3) Features
Ground Level Reactor: The sophisticated two-stage synthesis concept employing a Condenser
and an HP ejector enables the HP equipment in the synthesis section to be laid-out very compactly
in low elevation.
Less Corrosion: TOYO and Sumitomo Metal Ind., Ltd. (SMI) have jointly developed new duplex
stainless steel DP28W for urea plant. The biggest advantage of duplex stainless steel is the
excellent corrosion resistance and passivation property in urea-carbamate solution, which
enhances reliability of equipment and enables a reduction of the passivation air.
Clean Effluents: The liquid effluents from the urea plant contaminated with NH3, CO2 and urea
are processed in the process condensate stripper-urea hydrolyzer system. The process
condensate leaving the system is purified to 1 ppm of urea and 1 ppm of NH3. The exhaust air from
the prilling tower (or granulator) is scrubbed through a packed bed scrubber to reduce the urea dust
content to 30 mg/Nm3-air.
Easily revamp a conventional urea plant: Existing urea reactor can be re-utilized for
conventional solution recycle process or ammonia stripping process.
Energy Saving/ CO2 Emission Reduction
(1)Technical Features
The operation conditions of the synthesis section have been optimized under lower operation
pressure than in the previous process. As a result, a remarkable reduction in energy consumption
has been achieved.
(2)Energy Saving/CO2 Emission Reduction
This technology realizes 30% reduction of the energy consumption in a urea plant compared with the
total recycle process and 10-20% compared with the conventional stripping technology. As one of
example, the reduction of 550,000 kcal/ton of urea can be expected by modification of the total recycle
urea plant by this technology.
Information of Engineering Contractor
(1)Name of Company and DepartmentToyo Engineering Corp.
(2)Address
8-1,Akanehama,2-chome,Narasino-si,Chiba 275-0024 , Japan
(3)Contact to
HMorikawa
Tel
81-47-454-1526
Fax81-47-454-1536
E-mail
morikawa@pl.toyo-eng.co.jp
42 b
F-2
Outline of Product/Technology
(1) Function
It is a type of energy-saving technology using exhaust heat recovery in the reforming process of an
ammonia plant, in which exhaust heat emitted at the exit of the secondary reformer is used as a heat
source for the heat-absorbing reaction in the primary reformer.
(2) Structure / System
Hydrocarbon/steam
mixture feeding
Heat insulation
material
Improved
(3) Contact to
Tel
Fax
E-mail
43 b
F-3
Ammonia synthesis
Outline of Product/Technology
(1) Function
It is an energy-saving-type reactor that has a heat exchanger in the reactor for the synthetic process in
the ammonia plant, in which heat exchange takes place between some of the cold gas yet to undergo
reaction and the gas under reaction (heat-generating reaction) to control the reaction temperature
appropriately; in this way, the gas temperature at the exit of the reactor is elevated and its heat is thus
recovered efficiently.
(2) Structure / System
Inlet
Catalyst layer
Cooling
gas inlet
Exit
Catalyst layer
Intermediate
cooling equipment
Improved
Synthetic reactor of the indirect cooling type with a high conversion rate
(3) Features
In the conventional ammonia synthetic reactor of the quench type, reaction heat was removed in such a
way that hot gas under reaction was cooled directly by the gas yet to undergo reaction. The
disadvantages of the quench-type synthetic reactor were that (1) the ammonia concentration elevated
by synthesis was diluted and (2) the temperature at the exit of reactor was lowered. In order to improve
these points, the indirect cooling-type synthetic reactor was developed.
In the new development, its temperature is elevated to 450 - 500C from the conventional 300C. In this
way, energy can be recovered by high-pressure steam and heated steam.
Effect on Energy Saving
The temperature at the exit of the indirect cooling reactor is 450 - 500C over 300C of the conventional
type, and the reaction heat can be efficiently used to generate high-pressure steam and hot steam.
Thermal energy of 0.14 x 10-6 (kcal/t - NH3) can be recovered in the form of steam.
Information of Manufacturer
(1) Name of Company and Department
(2) Address
(3) Contact to
Tel
Fax
E-mail
44 b
F-4
Fertilizer & chemicals
Primary
bypass
Secondary
bypass
Gas exit
Gas inlet
Improved
(3) Contact to
Tel
Fax
E-mail
45 b
F-5
CO conversion
Outline of Product/Technology
(1) Function
It is a heat exchanger incorporating-type reactor that recovers reaction heat by conducting the CO
conversion reaction in one stage in the ammonia plant.
(2) Structure / System
Steam
Circulating
water
Gas inlet
Gas exit
Improved
CO conversion reactor
(3) Features
The gas at the exit of the secondary reformer contains about 13% CO. In the present technology, an
isothermal reactor of the low-temperature one-stage type is employed to improve the H2 conversion
rate, that is, improvement of the raw material primary unit.
Carbon monoxide, CO, undergoes a conversion reaction of CO + H2O CO2 + H2 to obtain H2. This
reaction has an advantage at lower temperatures from the standpoint of chemical equilibrium; therefore,
a low-temperature one-stage reaction is used. Its reactor (isothermal CO conversion reactor) has a
complicated structure as it has a heat exchanger. A point to be noted is that only copper is needed as a
catalyst and only a small amount of it is necessary. In the past, the following two stages were used: (1)
high-temperature conversion in which the reaction took place at 370 - 430C in an adiabatic reactor
filled with an Fe - Cr catalyst, and (2) low-temperature conversion in which the reaction took place at
200 - 230C in an adiabatic reactor filled with a Cu catalyst. However, in the present technology, an
isothermal reactor is used in which the conversion reaction takes place at about 250C in one stage.
The reactor recovers the heat generated by CO conversion reaction by means of an incorporated heat
exchanger that generates medium-pressure steam.
Energy Saving/ CO2 Emission Reduction
Fuel consumption can be saved at 0.1 x 106 kcal/t - NH3.
Information of Manufacturer
(1) Name of Company and Department
(2) Address
(3) Contact to
Tel
Fax
E-mail
46 b
F-6
CO Oxidizing Reactor
CO oxidizing
Outline of Product/Technology
(1) Function
In the present reactor used in the CO conversion process in an ammonia plant, reaction (CO + H2O
CO2 + H2) takes place at two stages at high and low temperatures, and CO is then oxidized in air with a
Pd catalyst to obtain CO2.
(2) Structure / System
Secondary
reformer
Steam
High-temperature Low-temperature
conversion
conversion
Material
Air
Primary reformer
Methanator
Purge gas
Ammonia
synthetic
process
CO oxidation reactor
Product ammonia
Carbon oxide removal
Improved
(3) Contact to
Tel
Fax
E-mail
47 b
F-7
Outline of Product/Technology
(1) Function
It is an energy-saving-type manufacturing system in which a coal thermal power generator is integrated
into an ammonia plant.
(2) Structure / System
Unimproved
Natural gas
Coal
Reforming
process
CO
conversion
Ammonia
synthesis
Gasification
CO
conversion
Ammonia
synthesis
Improved
Power
generation
Improved
(3) Contact to
Tel
Fax
E-mail
48 b
F-8
Heat recovery
Ammonia plant
Outline of Product/Technology
(1) Function
It is an energy-saving system, in which energy is recovered by using the heat of the gas at the exit of
the synthesized gas compressor for preheating methanator feed gas in the ammonia plant.
(2) Structure / System
Methanator
CO conversion reaction
Change
To the
methanator
Change
Mist
separator
Gas exit
Improved
Heat recovery system from the gas at the exit of the synthesized gas compressor
(3) Features
In the past, the gas at the exit of the synthesized gas compressor was cooled by the cooling water-type
heat exchanger. In the present technology, heat is recovered by methanator feed gas, in which the
temperatures of the methanator at the inlet and exit elevate, the amount of boiler feed waters heat
recovered at the exit of the methanator increases, and more steam is generated.
Note that, in this technology, the temperature at the CO low-temperature conversion reactor inlet
elevates and a problem occurs regarding temperature control; therefore, some of boiler feed water is
directly injected into the process gas to cool it by the evaporation heat of the water.
Energy Saving/ CO2 Emission Reduction
Heat can be recovered in the form of steam by 0.046 x 106 kcal/t - NH3.
Information of Manufacturer
(1) Name of Company and Department
(2) Address
(3) Contact to
Tel
Fax
E-mail
49 b
F-9
Recovery of H2
Ammonia plant
Outline of Product/Technology
(1) Function
It is an energy-saving system using membrane separation technology for an ammonia plant, in which
hydrogen in the purge gas that is separated in the synthetic process is recovered and returned to the
synthetic process.
(2) Structure / System
Material mixed gas
Transmitted gas
Non-transmitted gas
CH4N2
Other gas
Improved
(3) Contact to
Tel
Fax
E-mail
410 b
F-10
Power recovery
Ammonia plant
Outline of Product/Technology
(1) Function
It is a high-pressure turbine that recovers power from high-pressure water in CO2 gas-absorbing liquid
in the CO2-removing process in an ammonia plant.
(2) Structure / System
Feed gas
Acidic gas
Reaction
tower, etc.
Purified gas
Flash tank
Power recovery turbine
Absorbing
tower
To low-pressure
Flow control
tower
Pump
Clutch
Water
wheel
Improved
(3) Features
In the CO2-removing process, a large amount of absorbing liquid is fed to the top of absorbing tower at a
pressure of about 30 kg/cm2 in order to remove about 15% of the CO2 contained in the coarse
synthesized gas produced in the reforming process and CO conversion process. In the past, absorbing
liquid that had absorbed CO2 passed through a pressure reduction valve (30 kg/cm2 to 1 kg/cm2) and
then fed to the regenerating tower.
In the present technology, a power recovery turbine is used instead of a pressure reduction valve to
utilize it for driving the water feed pump of the absorbing liquid. In the past, an external energy source
such as electric power or steam was used to drive the pump, but with the present technology, such an
external energy source is not necessary because energy obtained by pressure reduction in the process
is utilized.
Energy Saving/ CO2 Emission Reduction
Steam consumption can be saved at 0.04 x 10-6 kcal/t - NH3.
Note: Driving by the conventional steam turbine is assumed.
Information of Manufacturer
(1) Name of Company and Department
(2) Address
(3) Contact to
Tel
Fax
E-mail
411 b
F-11
Ammonia plant
Outline of Product/Technology
(1) Function
It is an energy-saving process in the ammonia-manufacturing process, in which a prereformer is set in
the reforming process.
(2) Structure / System
Primary reformer
Smoke path gas
Fuel
Gas/steam
Preheater of
combustion air
Steam generation/overheating
Reforming gas
Prereformer
Improved
(3) Contact to
Tel
Fax
E-mail
412 b