2nd Annual GPCA Fertilizer Convention

Keeping your Urea Plant Operational when the

Ammonia Plant is Down

CO2 Recovery (CDR) Plant CO2 Recovery (CDR) Plant

IFFCO AonlaUnit (India) IFFCO Phulpur Unit (India)

Masaki Iijima – Mitsubishi Heavy Industries

Xxxxx xxxxx – Indian Farmers Fertilizer
2. MHI Flue Gas Recovery Process
Flow for MHI’s Advanced CO2 Capture Process

Flue Gas
Process Flow Outlet
CO2 Purity 99.9 %
KM CDR Process®

ABSORBER

STRIPPER
C.W.
(Regenerator)

Cooling Tower
Deep FGD

C.W.
Flue Gas
C.W.
Pre-treated Flue gas
Steam

Reboiler
Advantages of MHI’s CO2 Capture Process

Process Comparison Evolution of MHI technology improvement

MEA v KS-1 solvent

MHI’s Proprietary KS-1 Solvent
Conventional MHI Improved MHI New Energy
MEA Solvent*1 MHI Process*2 Process*2 Saving Process*3

Solution Circulation Rate 1 0.6 0.6 0.5

Regeneration Energy 1 0.8 0.68 0.62

Degradation of the Solvent 1 0.1 0.1 0.1

Solvent Loss 1 0.1 0.1 0.05

Corrosion Inhibitor YES NO NO NO

Note
*1 - Based on MHI’s Nanko pilot plant test data
*2 - Applied and proven on MHI commercial CO2 capture plants
*3 – Based on MHI’s Nanko pilot plant test data – long term, reliable performance to be confirmed in a MHI commercial CO2 capture plant
Performance of MHI’s Improved Regeneration Process

• Process Status: Commercialized

• Process Features:
Utilize the semi lean solvent for the
Utilize lean solvent and steam condensate heat recovery of the lean solvent enthalpy
for regeneration inside the stripper
• Performance: Recovered CO2
15% steam consumption reduction over MHI’s
conventional process
Heat Recovery
• Steam Consumption: & Stripper
*1.30 Ton Steam/Ton CO2 Solvent
*Kcal/kg CO2 Recovered Regeneration
Note*: Steam 3 Bar G. Saturated
CO2 Steam
• Patent:
Issues and pending in various countries
Lean solvent
• Further Improved Processes:
MHI has developed further process Steam Condensate
improvements which reduce steam
consumption. Currently preparing to release
them to the market
Steam Consumption: 15% reduction compared to MHI conventional process
※ Steam = 3 BarG Saturated*2
Note*2: Steam = 3Bara can be applied
Commercial Scale Natural Gas CO2 Recovery – Ready to go!!

Completed basic design for large single train PCC Plant

Offering this plant on a commercial basis with guarantees
Contract negotiation for several CCS & CO2-EOR commercial projects

Gas Boiler Gas Turbine

CO2 Capture Plant CO2 Capture & Compression Plant
3,000 t/d 3,000 t/d
MHI’s Commercial CO2 Capture Plants
 MHI - Commercial CO2 Capture Plants
Chemical Synthesis

 World leading LARGE-SCALE post combustion CO2 capture technology licensor,

with 8 commercial PCC plants in operation (from a variety of natural gas sources)
 Largest operational post combustion CO2 capture plant in the world (450 tpd)

CO2 Recovery (CDR) Plant – CO2 Recovery (CDR) Plant –

IFFCO AonlaUnit (India) IFFCO Phulpur Unit (India)

1999 2005 2006 2006 2009

200 t/d Malaysia 330 t/d Japan 450 t/d India 450 t/d India 450 t/d India

Pre
Commissioning
T ED
PLE
M
CO

2009 2009 2010 June - 2011 Q2 - 2012

450 t/d Bahrain 400 t/d UAE 240 t/d Vietnam 340 t/d Pakistan 450 t/d India
MHI Commercial CO2 Capture Plant Sites

33 2006 India (Aonla) 44 2006 India (Phulpur)

450 t/d
450 t/d

2011 Pakistan
9 340 t/d 22 2005 Japan
330 t/d

10 2012 India
10 450 t/d

77 2010 Bahrain
450 t/d

KEY 88 2010 Vietnam

240 t/d

Plants under operation

Plant under commissioning

66 2009 Abu Dhabi
400 t/d
55 2009 India
450 t/d
11 1999 Malaysia
200 t/d
Plant under construction
CO2 Recovery Commercial Plant in Malaysia

Plant Outline
Client : PETRONAS Fertilizer
(Kedah) Sdn Bhd
Solvent : KS-1
Capacity : 160T/D (200 T/D Max)
Use of CO2 : Urea production
Start up : October, 1999
Feed Gas : Stream reformer flue gas

Process Description
CO2 is recovered from flue gas of a steam reformer of on
ammonia plant and delivered to CO2 compressor for urea
synthesis. Recovered CO2 is used to increase urea
production.
The first commercial plant for flue gas CO2 recovery using this
advanced technology has been operating in Malaysia since
October 1999 for Urea production.
Performance of the process is excellent in terms of low steam
consumption, very low solvent degradation and low solvent
loss.
CO2 Recovery Commercial Plant in India (Aonla)

Plant Outline
Client : Indian Farmers Fertilizer Co.
Solvent : KS-1 Solvent
Capacity : 450 T/D
Feed Gas : Natural Gas and Naphtha
Reformer Flue Gas
Use of CO2 : Urea Production
Start-up : 2006

Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOx is removed before entering the CO2
absorber.
CO2 Recovery (CDR) Plant
IFFCO AonlaUnit (India)
CO2 Recovery Commercial Plant in India (Phulpur)

Plant Outline
Client : Indian Farmers Fertilizer Co.
Solvent : KS-1 Solvent
Capacity : 450 T/D
Feed Gas : Natural Gas and Naphtha
Reformer Flue Gas
Use of CO2 : Urea Production
Start-up : 2006

Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOx is removed before entering the CO2
absorber.
CO2 Recovery (CDR) Plant
IFFCO Phulpur Unit (India)
CO2 Recovery Commercial Plant in India

Plant Outline
Client : Nagarjuna Fertilizers and
Chemicals Ltd. (NFCL)
Solvent : KS-1 Solvent
Capacity : 450 T/D
Feed Gas : Natural Gas and Naphtha
Reformer Flue Gas
Use of CO2 : Urea Production
Start-up : 2009
Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOx is removed before entering the CO2
absorber.
CO2 Recovery Commercial Plant in Bahrain

Plant Outline
Client : Gulf Petroleum Industries Co.
(GPIC)
Solvent : KS-1 Solvent
Capacity : 450 T/D
Feed Gas : Natural Gas and Naphtha
Reformer Flue Gas
Use of CO2 : Urea & Methanol Production
Start-up : 2009
Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOx is removed before entering the CO2
absorber.
CO2 Recovery Commercial Plant in Abu Dhabi

Plant Outline
Client : Ruwais Fertilizer Industries (FERTIL)
Solvent : KS-1 Solvent
Capacity : 400 T/D
Feed Gas : Natural gas Boiler
& Steam Reformer flue Gas
Use of CO2 : Urea Production
Start-up : 2009

Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOX is removed before entering CO2 absorber.

First MHI commercial plant to incorporate the

New Energy Saving Process
CO2 Recovery Commercial Plant in Vietnam

Plant Outline
Client : PETROVIETNAM
Solvent : KS-1 Solvent
Capacity : 240 T/D
Feed Gas : Natural gas Boiler
& Steam Reformer flue Gas
Use of CO2 : Urea Production
Start-up : 2010

Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOX is removed before entering CO2 absorber.
CO2 Recovery Commercial Plant in Pakistan

Plant Outline
Client : Engro Chemical Pakistan
Limited.
Solvent : KS-1 Solvent
Capacity : 340 T/D
Feed Gas : Natural Gas and Naphtha
Reformer Flue Gas
Under Use of CO2 : Urea Production
Commissioning Start-up : 2011
Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOx is removed before entering the CO2
absorber.
CO2 Recovery Commercial Plant in India

Plant Outline
Client : Nagarjuna Fertilizers and
Chemicals Ltd. (NFCL)
Solvent : KS-1 Solvent
Capacity : 450 T/D
Feed Gas : Natural Gas Boiler and Naphtha
Reformer Flue Gas
Under
FEED Use of CO2 : Urea Production
Start-up : 2012
Construction
Completed Process Description
CO2 is recovered from steam reformer flue
gases. CO2 is compressed and then used for
urea synthesis. Flue gas is cooled and then
SOx is removed before entering the CO2
absorber.
MHI’s CO2 Recovery Technology

1. World’s most advanced and comprehensive industrial R&D programs

(commenced in 1990 and ongoing)

2. World’s largest operating post combustion CO2 capture plants (500 tpd)

3. World’s most energy efficient process – leading to reduced CAPEX & OPEX

4. MHI’s proprietary flue gas CO2 capture technology commercially applied since
1999 (8 plants under operation, 1 under commissioning and 1 under construction)

5. Coal Fired Power Plant CO2 Capture and Storage Project (500 tpd) in operation
Alabama, USA

6. The ‘Complete Solution’ - hindered amine solvent “KS-1® ” with accompanying

proprietary equipment

7. Applicable to large commercial power plants (MHI has comprehensive experience

and a proven delivery record), biomass plants or CO2 intensive industries (steel,
aluminum, etc.)
Flue Gas CO2 Recovery for Urea Production
Flue Gas CO2 Recovery for Urea Production

In ammonia and urea plants, the CO2 produced by the reforming process and the
CO2 recovered from the flue gas reformer or boiler are fed together to the urea
synthesis section as feed stock.
1. Maximize Urea Production
2. Minimize Reconstruction
3. Reduce CO2 Emission

Natural Gas
Flue Gas
Steam

Primary CO2
Fuel
Reformer Recovery

CO2 CO2
Air

Secondary CO2 Ammonia Urea Urea

CO Shift
Reformer Removal Synthesis NH Synthesis
3

H2 N2
Typical Ammonia and Urea Plant

When synthesizing ammonia and urea from natural gas, ammonia is always in
excess and there is a shortage of CO2. Therefore in a conventional
ammonia/urea plant:
1. Excess hydrogen is used as fuel for the steam reformer and the ammonia
and CO2 production is adjusted for urea production
2. Excess ammonia is sold or used for other purposes, other than urea.

CH4 + Air NH3 + CO2 CO(NH2)2

Typical Ammonia and Urea Plant (Lean Gas Case)

CO2 2,588 T/D

Urea Urea: 1,765 T/D

Process Natural Gas Unit
Ammonia NH3 2000 T/D
Fuel Natural Gas Unit

Urea Urea: 1,765 T/D

Unit
NH3
Storage
H2 for Fuel
10,000T
Flue Gas CO2 Recovery to Optimize Urea Production

As stated before, when synthesizing ammonia and urea from natural gas,
ammonia is always in excess and there is a shortage of CO2.
Therefore, by recovering CO2 from flue gas and adjusting the ammonia and CO2
ratio, urea production can be maximized.

=
more product

Flue Gas CO2 Recovery Urea ready for sale

Flue Gas CO2 Recovery to Maximize Urea Production
(Lean Gas Case)

CO2 2,588 T/D CO2 2,910 T/D

Partial
Flue Gas CO2
Recovery
322 T/D

Urea Urea: 1,765 T/D + 220 T/D

Process Natural Gas Unit
Ammonia NH3 2000 T/D + 249 T/D
Fuel Natural Gas Unit

Urea Urea: 1,765 T/D + 220 T/D

Unit
NH3
Storage

10,000T
During Ammonia Plant Trip or during Start Up Preparation, Urea
Production can be Maximized

In Ammonia and Urea plants, an ammonia liquefaction plant is usually installed to
adjust the ammonia and CO2 ratio for urea production
 If a large flue gas CO2 recovery plant is installed at the steam reformer, even
during an ammonia plant trip or during start up preparation, urea production can
still be maximized using the liquefied ammonia and the recovered CO2.

LESS DOWN TIME – MORE PRODUCT

 During Ammonia Plant Trip or during Start Up Preparation, Urea
Production can be Maximized (Two Ammonia Train, Lean Gas Case)

CO2 2,588 T/D → 0 T/D

817 T/D

Urea: 0
Urea
Process Natural Gas Unit
Ammonia
Fuel Natural Gas Unit

Urea Urea: 1,114 T/D

NH3 Unit
Storage

10,000T

CO2 2,588 T/D

Flue Gas 322 T/D

CO2 1139 T/D
Recovery

Urea Urea: 1,765 T/D + 220 T/D

Process Natural Gas Unit
Ammonia NH3 2000 T/D + 249 T/D
Fuel Natural Gas Unit

Urea Urea: 1,765 T/D + 220 T/D

NH3 Unit
Storage

10,000T
Three Ammonia Train Case, If One Ammonia Plant Trips or during Start
Up Preparation, All Urea Plants can be Operated (Lean Gas Case)

Urea Urea: 1,111 T/D

Process Natural Gas Unit
Ammonia 815 T/D
Fuel Natural Gas Unit
Urea: 1,111 T/D
Urea
NH3 815 T/D
Unit
Storage
10,000T
CO2 2,588 T/D

1,456 T/D Urea: 1,765 T/D + 220 T/D

Process Natural Gas Urea
Ammonia NH3 2000 T/D + 249 T/D Unit
Fuel Natural Gas
Unit
1,456 T/D
Urea Urea: 1,765 T/D + 220 T/D
NH3 Unit
Storage
10,000T
CO2 CO2 2,278 T/D
Flue Gas Recovery

CO2 2,588 T/D

1,456 T/D
Urea Urea: 1,765 T/D + 220 T/D
Process Natural Gas
NH3 2000 T/D + 249 T/D Unit
Ammonia
Fuel Natural Gas Unit
1,456 T/D
NH3 Urea Urea: 1,765 T/D + 220 T/D
Unit
Storage
10,000T
Thank You,
Thank You,Questions
Questions& &
Further Information
Further Information