PRODUCTION DEPARTMENT

OPERATIONS MANUAL - AREA GENERAL

UREA GRANULATION PLANT 3.0 0
SUBJECT / TITLE Prepared by: Page:
3.0 : INTRODUCTION & DESIGN BASIS MM 2 of 4
Approved by: Date :
NUR 15/2/9

3.2 DESIGN BASIS

3.2.1 Production Capacity

The urea granulation unit have a net rated capacity of 1670 MTPD
of granulated urea.

The solid handling equipment of granulation unit is over designed

by about 20 to 30% above the effective operating conditions .

3.2.2 Production Specification (Expected)

a) Physical from Granulated V

b) Composition

- Nitrogen 46 to 46.2% wt. v

- Biuret 0.7% wt 'v
- Formaldehyde 0.45 to 0.55% wt. \1/

- Moisture 0.2% wt. for 2.5 mm granule -/

c) Product Size : 3.2 mm (95% b/w 2.3 and 4.5 mm).../"

d) Product Temperature 50°c J

e) Free Ammonia 60 to 80 ppm ./'

f) Crushing Strength 3 Kg (for 2.5 mm granule) /

g) Iron / oil 1 ppm / 3ppm max.

. v
~ If no oil in amUlonia to urea wet
part
 PRODUCTION DEPARTMENT Rev.
t
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 3.0 o
SUBJECT / TITLE Prepared by: Page:
3.0 : INTRODUCTION & DESIGN BASIS MM :30f4
Approved by:
3.2 : DESIGN BASIS NUR

3.2.3 Feed Stock Specifications And Utilities

V The raw material is melt urea from urea wet plant of following
analysis.
() P. ~11 r
Cone. Urea + Biuret 96 .10% b.w v--- CO.iif. ~ 'S("v;

Formaldehyde 200 to 300 ppm \,./

-?

Temperature

Free Ammonia 300 to 500 ppm V"

r-\
. \ . ',' • I
v'
\J\\
\\ .. The utilities which are used in granulation unit from urea wet
plant are as foHows.

Process condensate Temperature 40°C v

Low pressure steam 4.5 Kg/Cm2 abs. V

Medium pressure steam 9.0 Kg/Cm2 abs.\/

Glycoled water 49.6 % by volume, v '

temperature + 1°C

3.2.4 Ambient Condition For Design

Temperature 41°C (dry bulb) v

30 °C (wet bulb) v
v"
3.2.5 Urea Formaldehyde (UF-85)

UF -85 is used as anticaking ag.ent m granulation unit with

following specification. ''-.,''
\
Physical form Liquid v

Formaldehyde ~ 60 % \vt. v

Urea ~ 25 % wt.
v
/
Water ~ 15% wt. \i
 PRODUCTION DEPARTMENT Rev.
OPERATIONS MANUAL - AREA GENERA
UREA GRANULATION PLANT 3.0 0
SUBJECT / TITLE P r e pare d b y: Page :
3.0 : INTRODUCTION & DESIGN BASIS MM 4of4
A pprove d b y :
3.2 : DESIGN BASIS NUR

3.2.6 Emissions And Effluents

a) The urea dust emission level to the atmospher e at exit discharge

point shall not be exceed 30 mg / Nm::l of exh aust air durin g
normal operation of the unit.

b) The unit shall not discharge liquid effluent to the sewers during
normal operation of the unit.
 PRODUCTION DEPARTMENT C hapte r No. Rev. I' l'j
OPERATIONS MANUAL - AREA GENERAL
• UREA GRANULATION PLANT 4.0 0
SUBJECT / TITLE Prepared by: Page:
4.0 : GENERAL DESCRIPTION MM 1 of 1
Approved by: Date :
TABLE OF CONTENTS NUR 22/2/97 :

CHAPTER INDEX PAGE#.

4.1 INTRODUCTION 1
4.2 PHYSICO CHEMICAL ASPECTS OF
GRANULATION PROCESS 2
4.3 THE GRANULATOR 3
4.4 GRANULATION SECTION SOLID CIRCUIT 4-5
4.5 DUST EMISSION AND RECOVERY 6
 PRODUCTION DEPARTMENT Rev.
t
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 4.0 o
SUBJECT / TITLE Prepared by: Page:
4.0 : GENERAL DESCRIPTION MM lof6
Approved by: Date .
NUR 22/2/9

4.1 I INTRODUCTION

In the fluid bed process , granular urea is produced by spraying liquid

urea onto seed material in the fluidized state. The basic characteristics of
this process are

a) The liquid urea is concentrated solution and not a melt.

b) The spraying occurs in the core of a fluidized layer by means of a

large number of spray heads.

c) The particle size enlargement is achieved by accretion ...

"---- ~

d) Urea formaldehyde is added to the urea solution before spraying as a

~ ~
process aid and anticaking agen j

- -- - -- ----
 PRODUCTION DEPARTMENT
OPERATIONS MANUAL - AREA GENERAL
t
UREA GRANULATION PLANT 4.0 o
SUBJE CT / TITLE Prepared by: Page:
4.0 : GENERAL DESCRIPTION MM 201'1)

4.2 : PHYSICO CHEMICAL ASPECTS OF A pp rove d b y:

TI NUR

4.2 PHYSICO CHEMICAL ASPECT OF GRANULATION

PROCESS __ _

In gran ulator based on particle growth, three modes of particle SIze

enl argement exit.
* 1. Agglomeration i.e. adhering of several particles to one another by
solution acting as a binder. Agglomeration often leads to a non-
~------- ---- . ---- - -- -

homogeneous product, with rather poor mechanical properties .

',-:--
. - --

*~ Layering i.e. growth by addition of successive layer, and the seed

particles layering gives the so-called ~'. In the layerin g
process, a rather thick layer of solution occured at r egular intervals
which then is allowed to solidify between each "dip".
- - ~

* v1\.ccretion i.e. growth by continuous evaporation and separation of a

large' number of minute drops of the solution onto the initial par_ticle
seed of nucleus . Many granulators operate according to the several
gr anulation modes simultaneously./
Fluid bed granulators are the only ones that exclusively operate
accretion for particle build up .
This means that during the entire residence tim e in th e granulation
zone of the granulator, each nucleus repeatedly impacts sprays of tiny
urea drop s for growth is therefore progressive and uniform and is
concurrent to solution water evaporation. Accretion confers a fin e and
homogeneous structure and evaporates the highest water desorption
rate (dTying) of alL

In order to spray onto a large numb er of solid particles

simultaneou sly with no agglomeration , it is necess?ry to keep th em
apart. Fluidization is the 'mly method to avoid contact between
-'j.

particles over a long period of time , other method such as spraying on

a curtain of falling particles , allow intermittently sprayin g only.
 EPARTMENT
OPERATIONS MANUAL -AREA GENERAL
UREA GRANULATION PLANT 4.0 0
SUBJECT / TITLE Pre pared by: Page:
MM 3 of 6
4.0 : GENERAL DESCRIPTION
Approved by: Date :
R NUR 22/2/9

4.3 THE GRANULATOR

The granulator VB 631 is basically an empty vessel that contains

fluidized layer of urea particles.
The granulator consists of
* The perforated plate
* The lower casing
* The injection headers
* The upper casing)

----
Fluidization air deliver on the lower casing is evenly distributed by the
--
p erforated plate\, suspends the solids fine upper casing and is exhausted
. J'
at the top of the granulator. This air stream is urea dust laden and
proceeds to further treatment in the UD 651 granulator scrubber. v' 11" J.::.

t'The fluidized layer has a thickness of 0.5 to 2.0 m and is confined to the
lower p art of the upper casing which is vertically split in six sections.

The seed material is introduced into the first section of the upper casing
chamb er 1, where it is sprayed upon by urea solution . As granules move
from chamber 1 to chamber 2 and then 3, their size steadily increases by
..
accr etion to reach the required granule diameter at which the product
flows out at the granulator.

No more urea is being sprayed onto the granules in chamb er 4 to 6, they

only act as conditioning and cooling chambers.
*

The urea feed stock at granulator inlet is typically a 96% urea that also
con tains urea formaldehyde UF-85 as anticaking agent.

The urea solution is finally pulverized by m eans of atomization air

through the spray h eads into the bed layer.
 Exhau6\-

l'l ~<
t
5eed material .In ~
(fine)
\

50luhon
.
Atomizing air
Gronul e6 our

. . tt-.
Fluldlza ton air
/

FLUID BED GRANULATOR

 PRODUCTION DEPARTMENT
OPERATIONS MANUAL - AREA GENERAL
• UREA GRANULATION PLANT 4.0 o
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4.0 : GENERAL DESCRIPTION MM 4 ofG
Approved by: Date .
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4.4 GRANULATION SECTION SOLID CIRCUIT

The UB 631 granulator receives the feedstock urea solution from the
UP-311 AJS urea melt pump located in the urea synthesis unit. Urea
formaldehyde UF-85 fed by means of metering pumps UP-621 AJS and
"*
added to the urea solution at the suction of the solution pump UP-311 AJS
at a rate of 4.5 to 5.5 Kg per ton of end product.
<f-

UP-311 AJS take care of efficiently mixing of both fluids for free flowing
product without further treatment.

The urea solution containing UF-85 solution at 96% concentration IS

\ J't.:. -
61st 1
! I ~spensed to the injection headers and sprayed by atomization all',
compressed by UK-611 atomization air blower)

The atomization air is ambient air that is heated after compression to

135°C in the steam heater UH ¥.-611.

, Fluidization air is supplied by the granulator fluidization air fan UK-615

\ ~
and sent to the granulator at about 40 °C.\The fluidization air ducts to the
)
granulation chambers are equipped with UR-615 AJBIC granulator
fluidization air heaters used for start-up conditions and fine adjustment
of bed temperature in the granulation zones.

Granular urea extracted by the granulator extractors UZ 631 AJB flows

through the safety screens US 631 AJB which screen off any lumps bigger
than 10 "mm. The lump fraction is let down in the recycle tank UT-655
and recycle back to urea solution tank UT-261. The recycle flow is
measured by FI-655.

The first fluid bed cooler UR -641 is a standard fluidized bed cooler.
A. mbient air supplied by the first cooler fluidization air fan UK-641 IS

used as cooling medium. In the event ambient air is particularly damp .

 PRODUCTION DEPARTMENT
OPERATIONS MANUAL - AREA GENERAL
• UREA GRANULATION PLANT 4.0 o
SUBJECT / TITLE Prepared b y: Page: I

4.0 : GENERAL DESCRIPTION MM 50fG

Approved by: Date:
4. NUR

cold or when the plant operates at low capacity. The first cooler air pre-
h eater UH-645 is used. Urea granules cooled down to the required
• -I<

intermediate temperature of around 70°C are lifted by the bucket

elevator UM 711 to the sieving section US-711 AlB vibrating screen
where they are classified in three fraction, oversize, undersize and on-
size . The on-size fraction is sent to final fluid bed cooler and thereafter to
storage.

The undersize fraction is recycled directly to the granulator, whereas the

oversize is first crushed in the roll mills UB-721 AlB before being fed back
to the granulator as seed material. The ratio oversize & undersize flow
rates to on-size flow rate is the solid recycle ratio and equal
1C
approximately 0.5. A start-up storage bin UT-635 is provided for start-up
and shut-down operation. In content is equal to the total content· of t~

-
whole granulation unit.

The on-size fraction is further cooled down in the final fluid bed cooler
UH-731, chilled air is used as cooling medium in the final fluid bed cooler,
chilling is carried out by cooling the air by means of glycol water in the
final cooler air chiller UH-735 and drying the air in the final cooler air
pre-heater UH-736. Final cooler fluidization air fan UK-731 supplies the
chilled air to the final cooler, at around 11°C.
""

The fluidization au of both coolers IS exhausted to the atmosphere

through the cooler scrubber UD-661 by means of the cooler scrubber
exhaust fan UK-661 to the stack.
 DUCTION DEPARTMENT
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 4.0 0
SUBJECT / TITLE Prepared by: Page:
4.0 : GENERAL DESCRIPTION MM 6of6
Approve d by: Date:
NUR

4.5 DUST EMISSION AND RECOVERY

There are two main locations where urea dust laden air originates from
the granulator and both fluidized bed coolers. In addition to those are the
various dedusting points i.e. bucket elevator top, roll crushers, vibrating
screens , discharge points on the conveyor belt FM-201 , that all merge
dedusting fan UK-655. The air exhausted from granulator UB-631
entrains around 3.5 - 4.5% of the plant output in the form of fine urea
'\(

dust (average particle 3~m). That gaseous stream is directed to the

granulator scrubber UD-651 , where it is efficiently cleaned by dilute urea
solution circulated by the UP-651 AJS and collected in the UT-651
granulator scrubber tank.

Some urea dust though in a much lower quantity and of a coarser nature
(average particle around 20 ~m) than the granulator is recovered from
. _ _~~---------lI'
-¥ -':---------.c

UT-661 cooler scrubber tank.

The dilute urea solution originating from the cooler scrubber operation is
used as scrubbing liquid to the granulator scrubber. The necessary
process water flow is introduced in the system via the cooler scrubber,
besides small amounts necessitated for flushing the demisters in both
scrubbers.

Granulator scrubber demister reqUIre continuous flushing, while the

cooler scrubber demister washing require on intermittent basis .

The concentrated granulator tank solution is recycled via the sump

UT-655 recycle tank to the urea wet plant. The recycle solution has a
con c. of around 45% urea.
'f
 EPARTMENT
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 5.0 0
SUBJECT / TITLE Prepared by: Page:
5.0 : DETAILED PROCESS DESCRIPTIO MM 1 of 1 '
Approved by:
T NUR

CHAPTER INDEX PAGE#.

5.1 THE UREA SOLUTION CIRCUIT 1-2

5.2 ATOMIZATION AIR CIRCUIT 3
5.3 FLUIDIZATION AIR CIRCUIT 4
5.4 THE SOLID CIRCUIT 5-6
5.5 PRODUCT COOLING CIRCUIT 7
5.6 AIR SCRUBBING SYSTEM 8 -9
5.6 .1 GRANULATOR EXHAUST STREAM CLEANING
5.6 .2 COOLER EXHAUST STREAM CLEANING
5.7 DEDUSTING SYSTEM 10
5.8 THE GRANULATOR DETAILS 11 - 12
5.9 UF-85 HANDLING SYSTEM 13
5.10 VARIOUS UTILITIES 14 - 15
5.10.1 STEAM
5.10.2 PROCESS WATER.
 ION DEPARTMENT
OPERATIONS MANUAL -AREA GENERAL
t
UREA GRANULATION PLANT 5.0 o
SUBJECT / TITLE Prepared by: Page:
5.0 : DETAILED PROCESS DESCRIPTIONt--_M_M__t-l_of_15--i1i
Approved by:
NUR

5.1 UREA SOLUTION CIRCUIT

The urea solution at 96% is delivered to the granulation unit battery limits at a
temperature of 13Q~
135 C by UP-311 AlS . Urea formaldehyde UF-85 is fed into
- \

the urea feed solution at UP-311 AlS suction at a rate of A 5 - 5JL Kg

formaldehyde per ton of urea product.

Under normal operating conditions, the feed solution from wet section flows
through the pressure control valve EY-631 to the distribution header and
further onwards to the spray nozzles.

The spray system consists in nine rows of hairpin like pipes onto which 21
vertical risers with atomization nozzles are fitted. Each row feature a separate
hand valve for on/off operation. During injection the control valve PV-631 is

-----
- - i

open to the main header wheres HIC-631 at the farther extremity of the
distribution header is closed.

The control valve onto the recycle line to the urea wet unit HIC-311 IS also
closed.

Where no urea solution injection takes place two situation many occur.

1. The feed solution through HIC-631 which is now openjl whereas all the
~

individual h eaders are shut, to the recycle tank UT-655. .J- (

II . The control valve PV-631 is closed, opening HIC-311 feed solution is recycled
to the urea wet unit UT-261 the urea storage tank.

The recycle tank UT-655 collects various streams i.e. solid lumps wash water
from scrubbers , urea solution etc. The sump solution concentration varies
between 40 % - 50 % and may reach 60% momentaneously . In case too large
quantities of solid arrive at a short time , heat and agitation are provided
through steam ejector UJ-G55.
 PRODUCTIONDEPARTMENT
PRODUCTION DEPARTMENT Chapter No. Re v.
Rev,
OPERATIONSMANUAL
OPERATIONS MANUAL- -AREA
AREAGENERAL
GENERAL
UREA
UREAGRANULATION
GRANULATIONPLANT
PLANT 5.0
5.0 00
SUBJECT/ /TITLE
SUBJECT TITLE Prepared by: Page:
Preparedby: Page:
5.0: DETAILED
5.0 : DETAILEDPROCESS
PROCESSDESCRIPTION
DESCRIPTION MM
MM 2 2ofof1515
Approved by: Date .
Approvedby: Date
5.1: :UREA
5.1 UREASOLUTION
SOLUTIONCIRCUIT
CIRCUIT NUR
NUR 26/2/9
26/2/97

Toprevent
To preventcrystallization
crystallizationininthe
thetank,
tank,the
the temperature
temperature must
must be
be capable
capable of
of
reaching80
reaching oS
80°C and
and is controlled by TIC-655
controlled by TIC-655 regulating
regulating the
the admission of lJi§
admission of LHS
steamtotoJU-655
steam JU-655..
~

Fromththe
From adjacentcompartment
e adjacent compartmentsolution
solutionisisdrawn
drawntotothe
the wet
wetplant
plant via
via pumps
pumps
UP-655AlS
UP-655 A/Surea
ureasolution
solution recycle
recyclepumps.
pumps.The
The recycle
recycle solution
solution flow
flowrate
rate isis set
set by
the level
the level control
control valve
valve LIC-655
LIC-655 and flow is monitored by FI-655.
flow is FI-655 .

Special
Sp care must
ecial care must be
be taken to
to avoid
avoid recycling of chloride
chloride containing
containing product
product or
other contamination
other contamination e.g.
e.g. oil.
oil.

Occasionallysome
Occasionally somevapours
vapourscan
can evolve
evolvefrom
fromrecycle
recycletank,
tank, they
they are vented
vented to
to
atmosphere by means
means of
of fume
.
extraction
extraction fan
fan UK-655.
UK-655
-.. .
 -
GRANULATOR SECTION

ITO GRAMJLATOR SC RUBBER

UREA DUST. AIR
.
106 °C

GRANULATOR SAFETY
GRANULATOR
- EXTRACTOR
. SCREENS 95 ° C
. TO FIRST FLUID BED COO LER

UB 631 UZ 631AB US 631AB

AM BIENT AIR ATOMIZATION AIR .

___ ML5 _.
ATOMIZATION AIR
M
L. MLS GRANULATOR
FL UIDIZATION
MLc;. GRANULATOR
FLUIDIZA TION AMBIENT AIR
BLOWER 97 °C HEATER AIR HEATER AIR FAN 41 °c
UK 611 UH 6!~ 135 OC . 1.58 KglCm2 49 ° C, 1.086 KglCm 1
UH 615ABC UH 615ABC

UF 85 t 96% UREA SOLUTION FROM WET UNIT

 PRODU CTIO N DEPARTMENT Chapte r' No. Rev.
t OPERATIONS MANUAL - AREA GENERA
UREA GRANULATION PLANT 5.0 0
SUBJECT / TITLE Pre pared by: Page:
5.0 : DETAILED PROCESS DESCRIPTION MM .3 of 15
Approved b y: Date:
5.2 : THE ATOMIZATION AIR CIRCUIT NUR 26/2/9 I

5.2 THE ATOMIZATION AIR CIRCUIT

The atomization air n ecessary to sh ape the urea solution spray into b ed is
delivered by the UK-611 atomization air blower at a temperature of 135
°C after post compression heating in th e UR-6ll atomization air beater.

The temperature is controlled via the control valve TV-63 1 regulating the
amount ofMLS steam through the heat exchanger DR-6ll.

Atomization air pressu re 0.5 5 Kg/Cm 2g and r esulting air flow rate are
set, safely away from the surge protection valve by RIC-611. The filter
US-6ll is provided to protect against sand wind.
 PRODUCTION DEPARTMENT Chapte r No. Rev.
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 5.0 0
SUBJECT I TITLE Prepared by: Page:
MM 4 of 15
5.0 : DETAILED PROCESS DESCRIPTION
A pproved by: Date
5.3 : THE FLUIDIZATION AIR CIRCUIT NUR 26/7/9

5.3 THE FLUIDIZATION AIR CIRCUIT

The fluidization air is supplied to the granulator by the UK-6I5

granulator fluidization air fan .

The fluidization air partly (about ,60%

- - of the total flow) h eated in the
granulator fluidization air heaters UR-6I5 AlBIC via control valves
TV-615 regulating the amount of MLS steam. These heaters UR-6I5
AlBIC are used during start-up or low load operation to increase the air
temperature to 100 °C to heat-up the granulator.

The air flow rate is set by pressure control valve PV-63I which keeps the

,---
top part of th e granulator upper casing under slight vacuum
WC}.
~-2~mm..

The fluidization air stream is divided up into six stream directed to the
corresponding lower casing compartments. Each branching duct is fitted
with flow meters FI-6I522 AlBIC , FI-6I523/24/25 giving relative
indication of flow rate to each ch amb er.

The air exhausted from the granulator top is further treated into
granulator scrubber before being vented to the atmosphere via RIC-651
granulator scrubber exhaust fan. Its flow rate is controlled through the
control valve RIC- 651 on the suction side of the fan UK-65 1.
 PRODUCTION DEPARTMENT C h a pter No. R ev .
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 5.0 0
SUBJECT / TITLE Prepared by: Page:
5.0 : DETAILED PROCESS DESCRIPTION MM 5 of 15
Approved by: Date :
5.4 : THE SOLID CIRCUIT NUR 26/2/9 I

5.4 THE SOLID CIRCUIT

The granulated product is extracted from the granulator at 95 °C by

UZ-631 AlB granulated extractor which are follow ed by the US-631 AlB
safety screen, to the first fluid bed cooler UH-641. The safety screens
retain agglomerates or lumps and discharged in the recycle tank UT-655
for dissolution.

Urea granules cooled down to about 70°C and lifted by the bucket
elevator UM-711 split up into two streams to the sieves US-711 AlB
vibrating screen where granule selection occurs. Either sieve can be by-
passed with the same splitter when the operation load is reduced.

Proper distribution of the product over the two screen inlets is created for
screen feeders UZ-711 AlB.

From vibrating screen three fractions are separated.

a) The On-Size (End Product)

This one under normal operating condition flows VIa a splitter box
UZ-712 AlB diverter to the final fluid bed cooler UH-731. By means of
that box it can also be redirected to either the start-up bin UT-635 or
the final cooler by-pass duct, or the granulator UB-631 itself.

b) This Under Size (Fine)

This one under normal conditions , flows back to the granulator via the
diverter UZ-713 AlB splitter box. The flow can also be diverted to the
start-up bin or the recycle tank UT-655~~der ~~ -fr~~i~-?~~~e-~
Jfr-e;--;'~~la~e indication of individual screen~
~
 PRODUCTION DEPARTMENT C hapte r No . Rev.
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 5.0 0
SUBJECT / TITLE Pre pared by: Page:
5.0: D~'l IAILED PROCESS DESCRIPTION MM 6 0f1 5
Approved by: Date :
5.4 : THE SOLID CIRCUIT NUR 26/2/9/

c) The Over Size (Coarse)

This one normally goes as seed material to the granulator via the
crushers UB-721 AlB. It can overflow from the crusher feed hooper
UT-721 AlB to the recycle tank UT-655 . Qver size fracbon---fWw-r-a-te-
gives relative indication before the recycle inlet to the granulator.
 SAFETY FIRST FLUID VIBRATING FINAL FLUID
..- -
960/., UREA SOLUTION ..
FRO M WET PLANT ,-
~
GRANULATOR
-
95 ° C ..
SCREENS BED COOLER
70°C ..
SCREENS
ON SIZE ..
PRODUCT"" BED COOLER
50 ° C _

UF 85 GRANULAR UREA TO S

~
t UNDER SIZE PRODUCT
t lR AIRt

j~

ATO MIZATION AIR

----.-- --- ---
FLUIDIZATION AIR
CRUSHER
-
OVER SIZE PRODUCT
 PRODUCTION DEPARTMENT
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 5.0 o
SUBJECT / TITLE Prepared by: Page:
5.0: DETAILED PROCESS DESCRIPTION~_M_M_-+-7_0f_15~1
Approved by: Date .
NUR

5.5 PRODUCT COOLING CIRCUIT

The cooling of the urea granules down to the required temperature takes
place in a two fluid bed type coolers UH-641fUH-731. The product
discharged from the granulator flows by gravity to the first fluid bed
cooler where it is fluidized and cooled by the ambient air from the first
cooler fluidization air fan UK-641. The air flow rate is adjusted via the
hand valve (inlet guid,~ vane). In ca.s.£Lam.bi~ntl!ir is p,!!:rticularly cold or
damp, the first cooler air preheater UH-645 fed with LHS steam is used.
The first s..o..Qler treat both end. and recycle product and brings its
temperature to 70 ec (maximum).
The on-size (end product) only is further cooled down by means of chilled
air from final cooler fluidization air fan UK-731. The air flow rate is
adjusted via the hand valve (inlet guide vane) .

The end product temperature is 50 ee, because less pro~ to caking when
cold. However provision has been made to by-pass the final fluid bed
cooler as a temporary step to avoid plant shut down during maintenance
job on final cooler fluidization air fan.

In final cooler, the ambient air is first dried out by condensation of a

portion of its moisture in the final cooler air chiller UH-735 and
thereafter slightly reheated in the final cooler air preheater UH-736. The
moisture condensate is separated in the final cooler air demister US-735.
Air reheating is carried out to prevent moisture pick-up by the granules
while in the cooler.

The air chiller UH-73?.is fed with glycol water cooled at ~ C by heating
liquid ammonia from the ammonia storage. The air heater UH -736 is fed
with LHS steam. Level of the product in the coolers is adjusted by means
of an overflow :yeir adjusted manually.
 ..
SCREENING AND COOLING SECTION

TO COOLER SCRUBBER TO COOLEB SCBIlBBE.

~
74 vC 49 °C

95 ° C _
URE A GRANULES -
FIRST FLUID BED
COOLER
UH 641
70 ° c ..
VIA ELEVATOR (UM 711j
VIBRATING
SCREENS
US 711AB
70 ° C
ON SIZE PRODUCT --
FINAL FLUID BED
COOLER
UH 731
so oc ...
UREA PRODUCT TO Sr'I5"R AGE
FR OM GRANULATOR (UREA GRANULES)

•
41 ° C . 1 045 Kg/Cm' 11 ° C
OVER SIZE PRODUCT , UNDER SIZE PRODUCT
FINAL COOLER
FIRST COOLER CRUS HER , - -
FLUIDIZATION AIR
~. --
8 °C

---- ~. FLUIDIZATION AIR FAN AIR

AIR FAN UB 721AB TO GRANULATOR AS SEED MATERIAL UK 731
UK 641
 PRODUCTION DEPARTMENT Rev.
OPERATIONS MANUAL - AREA GENERAL
UREA GRANULATION PLANT 5.0 o
SUBJECT / TITLE Prepared by: Page:
5.0 : DETAILED PROCESS DESCRIPTIONr-.-_M_M_. . .8_of_15--.1
.
Approved by: Date '
5.6 : AIR SCRUBBING SYSTEM NUR 0113/9/

5.6 AIR SCRUBBING SYSTEM

5.6.1 Granulator Exhaust Stream Cleaning

The air exhausted from the granulator contains some urea dust and
for that reason is cleaned in a scrubber before being emitted to the
atmosphere.

(The dust ladden aIr IS sprayed to saturation with dilute urea

solution from the cooler scrubber tank, ~tream scrubber inlet to
<!YQicL clogging of the air ducts, it then enters radially to the
scrubber, where it is continuously sprayed with the recirculating
urea solution(The air flow is accelerated towards the bottom of the
scrubber, where urea is collected by impingeme~~ on the liquid
bath. The air is centrally discharged and mist elimination IS

accomplished with the centrifugal action of a set ofvaneJ

The droplets are returned into the liquid by gravity through

internal descending pipe.

In order to avoid any droplet entrainment which would

automatically lower scrubber efficiency because being urea solution
droplets , a final mesh demister is installed on top of the scrubber.
The demister is flushed with a small flow of process water to avoid
clogging.

(The clean air is thereafter exhausted through granulator scrubber

'- exhaust fan UK-651 to atmosphere. The air flow rate is adjusted
via the control valve HIC-621 at suction ofllK-651)

The scrubbing water is collected in the gTanulator scrubber tank

UT-651
~ -=w:;..
is partly recirculated as scrubbing solution to the scrubber
sprayers and remaining pumped to the recycle tank UT-655.
 I

PRODUCTIONDEPARTMENT
PRODUCTION DEPARTMENT IChapter
Chapter No.
No. Rev.
Rev.
OPERATIONS MANUAL
OPERATIONS MANUAL--AREA
AREAGENERAL
GENERAL
UREAGRANULATION
UREA GRANULATION PLANT
PLANT 5.0
5.0 00
SUBJECT // TITLE
SUBJECT TITLE
Prepared by: Page:
Prepared by: Page:
MM 9 ofof 15
5.0 : DETAILED PROCESS DESCRIPTION
5.0 : DETAILED PROCESS DESCRIPTION MM 9 15
Approved by: Date:
Approved by: Date :
5.6::AIR
5.6 AIRSCRUBBING
SCRUBBING SYSTEM
SYSTEM NUR
NUR 0113/97
01/3/97

The solution
The solution concentration
concentrationinin granulator
granulator scrubber
scrubber tank
tank is
controlled
controlledby
by density
density measuremat
measuremat DIC-651
DIC-651 .. The
' _
The concentration
concentration
22lIiiIC:

about
--
about 45%
45%isisadjusted
adjusted via
coolerscrubber.
cooler scrubber.
via the
the flow
flowrate
rate of
of dilute
dilute urea
urea solution from
from

The high
The high temperature
temperature alarm
alarmT.1 .15123 at the scrubber
Tk65123 scrubber air exhaust
exhaust
gives also
gives also an
an indication
indication of too high concentration
too high concentration of the scrubber
scrubber
solution.
solution.

5.6.2 Cooler
5.6.2 Cooler Exhaust
Exhaust Stream Cleaning
Cleaning

The air exhausted

The exhausted from
from both cooler
cooler also
alsocontains
contains urea
urea dust through
through
in smaller quantities and
and of
of coarser
coarser nature. Never the less the
the air
air
needs to be cleaned before being emitted
before being emitted to
to the atmosphere.
atmosphere.

Cooler scrubber
Cooler scrubber UD-661
UD-661 isis the
the wet
wet type
type scrubber.
scrubber. Its features
features also
also aa
cylindrical shell with radial
cylindrical shell
~
radial gas
gas inlet
inlet and
andtop
topvertical
verticaldischarge.
discharge.
~

The top
top demister
demisterisissprayed
sprayedwith
withprocess
processwater
watertotoavoid
avoidclogging.
clogging.

The
The cleaned
cleaned air
air is
is exhausted
exhausted through
through cooler
cooler scrubber
scrubber exhaust
exhaust fan
fan
UK-661 to the atmosphere. The air flow
UK-661 to rate is manually
flow rate manually adjustable
adjustable
by
by means
means of
of inlet
inlet guide
guide vanes.
vanes .The
Thecooler
cooler scrubber
scrubbertank
tankUT-661
UT-6Glisis
located
located underneath itit and
andreceives
receives process
process water
waternecessary
necessaryfor
for
water
water balance
balanceof
ofthe
thecomplete
complete granulation
granulationsystem.
system .

The
The dilute
dilute urea
ureasolution
solutionisiscirculated
circulatedtotothe
thescrubber
scrubberby
bymeans
meansofof
cooler
cooler scrubber
scrubber circulation
circulation pumps
pumps UP-661
UP-661 A/S.
AlS . Normally
Normally its
its
concentration
concentrationvaries
variesfrom
from1%
1%to
to 3%
3% only. !Y2A'fJ 71-

-- giA,
 ..

AIR SCRUBBING SECTION

Ii ATMOSPHERE

STACK
~--

UX 670

Ir--..
GRANULATOR
SCRUBBER - COOLER
SCRU BBER
~ IR + UREA DUST FROM DEDUSTING SYSTEM

-
AIR + UREA DUST FROM GRANULATOR UD 651 UD 661
-
_ AIR + UREA DUST FROM FIRST&FINAL COOLER

PROCESS CONDENSATE FROM TANK(U T 431 )

.r , t ,

GRANULATO R COOLER
COARSE&LUMPS SC RUBBER TANK SCRUBBER TANK
FROM SAFETY SCREENSI
CRUSHERI VIBRATING SCREENS . , UT 651 UT 661
If
RE CYC LE TANK

45% UREA SOl UTION TO'WET PART

UT 655
 PRODUCTION DEPARTMENT
OPERATIONS MANUAL - AREA GENERAL 1\
UREA GRANULATION PLANT 5.0 0
SUBJECT / TITLE Prepared by: Page:
5.0 : DETAILED PROCESS DESCRIPTION MM 10 of 15
Approved by: Date :
5.7: DEDUSTING SYSTEM NUR 0113/9

5.7 DEDUSTING SYSTEM

The purpose of dedusting circuit is to collect urea dust at the locations
where dust generation is likely to occur.

Those location are typically:

1. The elevator top

II. The roll crushers

III .The vibrating screens

IV. The discharge points on the belt conveyor FM-201

The dedusting is catered for by the dedusting fan UK-665 of which flow
rate is regulated by hand valves at each suction point. The air flow is
directed to the cooler scrubber UD-661 for cleaning.