Producing tailor-made

urea granules of the

highest possible quality

Stamicarbon B.V.
Mercator 3 - 6135 KW Sittard,
The Netherlands.
P.O. Box 53 - 6160 AB Geleen,
The Netherlands.

Tel. +31 46 4237000

Fax. +31 46 4237001

communication@stamicarbon.com
www.stamicarbon.com

15-11-16 10:55

STAMI_LAUNCH_FINISH_Granulation_Design_WEB - NOV 2016 PAGE 1/3


What a good granulation design should offer:
• Large volumes of exportable granules
(uniform size, high crushing strength, low
caking tendency, and low dust content)
• Low formaldehyde content
• Low environmental emissions and ways to
reprocess the generated ammonium salts
• Easy to operate and a high on-stream time
• Possibility to add micro-nutrients to process
if required
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STAMI_LAUNCH_FINISH_Granulation_Design_WEB - NOV 2016
The main benefits: As the granules move through the granulation
Stamicarbon’s solution:
• Large reductions in formaldehyde addition section, their size steadily increases by layering
Our proven, state-of-the-art fluid-bed
compared to other fluid-bed granulation until they reach the required granule diameter.
granulation technology.
technologies, making it more cost effective Fluidization air is distributed over the granulation-
• Unprecedented uninterrupted run times, which and cooling sections, to maintain the fluidized bed
Stamicarbon’s fluid-bed granulation technology
exceeds 150 days before washing of the and to take away the generated crystallization heat.
has been selected over 15 times for commercial
granulator is required due to less dust formation The granules leaving the granulator pass a safety
scale plants, with capacities exceeding 3500 mtpd,
owed to the applied film spray nozzles screen (to remove lumps/agglomerates) and are
since its introduction less than 10 years ago.
• Unmatched, low dust and ammonia emissions transported by a bucket elevator to the main screens
The plants using this technology are operating at,
from the granulation vent stack, meeting where the granules are separated in three fractions.
or above, their original design capacity, and are
the most stringent environmental
producing superior products complying with
emission standards The on-spec product is cooled by a solid flow cooler
all required product quality standards.
• Lean design with minimum equipment and transported to storage. The coarse fraction,
requirement, resulting in reduced CAPEX after cooling and crushing, is sent back together
Innovative design
and less maintenance costs with the fines coming from the main screens to the
The key of the success of the Stamicarbon urea
• Low urea dust formation, resulting in a lower granulator as seed-material for further granulation.
granulation technology is the film spraying
wet-recycle, resulting in lower OPEX costs
characteristic of the nozzles. Film spraying requires
The fluidization and secondary air is exhausted
a minimum amount of formaldehyde, meaning that
from the granulator and sent to a dust/ammonia
it is more cost effective than other technologies and
How do we do it? scrubber, where urea dust and ammonia can be
it also decreases the amount of dust compared to
The source of the granulation is the fluid bed removed together or separately in a single scrubber
other fluid-bed granulation technologies, ensuring
granulator. In this fluid bed granulator, urea melt housing by circulating an acidified urea/salt
higher on-stream time (more than 150 days) due to
is introduced via multiple film spray nozzles and solution, which absorbs and dissolves both the dust
less down-time required for clean-ups.
deposited on the seed particles/granules in the and the ammonia.
Furthermore, Stamicarbon offers seamless
fluid bed. The Stamicarbon nozzles only require a
integration between the granulation plant and the
minimum amount of formaldehyde. A continuous Alternatively, if the scrubbing solution is acidified
urea melt and scrubbing technologies, meaning that
stream of secondary air is introduced via the air ring with sulfuric rather than nitric acid, the ammonium
the client or contractor has a one-stop-shop for the
installed around each spray nozzle and takes care of sulfate produced in the acidic scrubbing stage and
complete urea train.
the transport of the seeds/granules through the urea the urea solution from the dust scrubbing stage can
melt-film. be concentrated together in a separate evaporator
unit and then either routed to the urea granulator,
The fluid bed granulator is divided into multiple in which case the entire urea production then
granulation sections in which urea melt is contains approximately 0.05-0.1% S, or it can be
introduced via nozzles and some cooling sections processed in a separate finishing section to produce
in which the formed granules are cooled down, for UAS fertilizer with a higher S content (say 5%) as
further processing. a value-added by-product without producing any
waste streams.
PAGE 2/3
 Film-spraying nozzleFilm-spraying nozzle preferred aqueous solution
preferred aqueous solution
solid by-product solid by-product
no by-product no by-product
salt outlet salt outlet
combined separatecombinedcombinedseparateseparatecombinedcombinedseparateseparatecombined separate
dust and NH3 dust and NH3
scrubbing H2SO4 HNOscrubbing
3
H2SO4 H HNO
2
SO34 HHNO
2
SO34 HHNO
2
SO34 HHNO
2
SO34 H
HNO
2
SO34 HHNO
2
SO34 H HNO
2
SO34 HHNO
2
SO34 H
HNO
2
SO34 HNO3 H2SO4 HNO3
FILM SPRAYING FILM SPRAYING acid used acid used
LIQUID LIQUID
FILM FILM main urea main
urea urea urea
urea urea
urea urea urea urea
urea urea
urea urea
urea urea
urea urea urea urea urea
product product + AS + AN + AS + AN
AS + AN + AS + AN
0.2w% 0.2w% 0.2w% 0.2w% 0.2w% 0.2w% 0.2w%

by-product by-product
UAS aq UAN aq AS aq UAS
AN aq
aq UAN
UAS aq
s UAN
AS aqs AN
AS aq
s UAS
AN ss UAN
nones none
AS s none
AN s none none none none

evaporation no evaporation
no no no yes
no yes
no yes
no yes yes yes yes yes yes yes yes
section section
FLUID BED FLUID BED required required

finishing no finishingno
no no yes
no yes
no yes
no yes yes
no yes
no yes
no no no no no
FLUIDIZATION AIR FLUIDIZATION AIR FLUIDIZATION AIR FLUIDIZATION AIR section section
required required

present yes present yes

yes yes yes yes yes yes yes yes
Stamicarbon Stamicarbon
portfolio portfolio

HIGH VELOCITY UREA MELT HIGH

HIGHVELOCITY
VELOCITY UREA MELT HIGH VELOCITY
HOT AIR HOT AIR
HOT AIR HOT AIR

GASES/AIR GASES/AIR CONDENSER CONDENSER

Did you know? Did you know? LIQUIDS LIQUIDS

GASES/AIR GASES/AIR CONDENSER CONDENSER
• Stamicarbon offers a high-efficiency
• Stamicarbonscrubbing
offers a high-efficiency scrubbing LIQUID (± 45% UAS) LIQUID (± 45% UAS) SEPARATOR SEPARATOR
LIQUIDS LIQUIDS
technology which allows high
technology
submicronwhich
particulate
allows high submicron particulate UREA SOLUTION/MELT/SLURRY UREA SOLUTION/MELT/SLURRY
STACK
STEARN
STACK
STEARN
LIQUID (± 45% UAS) LIQUID (± 45% UAS) SEPARATOR SEPARATOR
SOLID UREA SOLID UREA COARSE COARSE CONDENSATE EVAPORATOR CONDENSATE EVAPORATOR
matter and efficient ammonia
matter
collection,
and efficient
while ammonia collection, while UREA SOLUTION/MELT/SLURRY UREA SOLUTION/MELT/SLURRY
STEAM/WATER STEAM/WATER STEARN STEARN
producing concentrated blowdown
producingstreams,
concentrated
known blowdown streams, known SOLID UREA COOLER
SOLID UREA COOLER STACK
CONDENSATE
STACK
EVAPORATOR CONDENSATE EVAPORATOR
UREA/AMMONIUM-SOLUTION (UAS) UREA/AMMONIUM-SOLUTIONCOARSE
(UAS) SCREEN COARSE SCREEN
as The MicroMistTM VenturiasScrubber:
The MicroMistTM Venturi Scrubber: STEAM/WATER CRUSHER
STEAM/WATER CRUSHER
ELEVATOR ELEVATOR

COOLER COOLER UREA MELT PUMP UREA MELT PUMP

[www.stamicarbon.com/micro-mist-venturi-scrubber]
[www.stamicarbon.com/micro-mist-venturi-scrubber] UREA/AMMONIUM-SOLUTION (UAS) UREA/AMMONIUM-SOLUTION (UAS)
FINES SCREEN
ELEVATOR
FINES SCREEN
ELEVATOR
CRUSHER CRUSHER PROCESS WATER PROCESS WATER
CW CW
UREA MELT PUMP UREA MELT PUMP
FINES FINES
• Stamicarbon can offer its•customers
Stamicarbontailor-
can offer its customers tailor- CW
COOLER
CW
COOLER PROCESS WATER PROCESS WATER
UREA GRANULES UREA GRANULES DUST SCRUBBER DUST SCRUBBER
made schemes for reprocessing
made both
schemes
Ammonium
for reprocessing both Ammonium GRANULATOR GRANULATOR
COOLER COOLER
Sulfate (AS) as well as Ammonium
Sulfate (AS)
Nitrate
as well
(AN)as Ammonium Nitrate (AN) UREA GRANULES UREA GRANULES DUST SCRUBBER DUST SCRUBBER
GRANULATOR GRANULATOR
salts generated by the ammonia
salts generated
acidic scrubbing
by the ammonia acidic scrubbing RECYCLE RECYCLE

processes: [www.stamicarbon.com/
processes: [www.stamicarbon.com/
FORMALDEHYDE
RECYCLE FORMALDEHYDE
RECYCLE
ammonia-salt-rework-design]ammonia-salt-rework-design]
UREA UREA
FORMALDEHYDE FORMALDEHYDE

• Stamicarbon can convert •itsStamicarbon

granulation can
into convert its granulation into UREA UREA

a multi-functional granulation
a multi-functional
process, whichgranulation process, which
can produce urea granules canwithproduce
higher AS
urea granules with higher AS
concentrations or which allows
concentrations
the additionorofwhich allows the addition of
selected micro-nutrients: selected micro-nutrients:
[www.stamicarbon.com/ammonia-salt-rework-design]
[www.stamicarbon.com/ammonia-salt-rework-design]

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