prilled urea- a cost effective way to feed the world
DESCRIPTION
Prilled Urea- A Cost Effective Way to Feed the World. Sule Alabi Jonathan Arana Elizabeth Moscoso Oleg Yazvin Mentor: Dan Rusinak – Middough. Team Echo. Table of Contents. Purpose BFD Overview of Urea Plant Process Description Sinks & Loads Sizing and Costing Conclusion Q & A . - PowerPoint PPT PresentationTRANSCRIPT
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Prilled Urea- A Cost Prilled Urea- A Cost Effective Way to Feed the Effective Way to Feed the WorldWorld
Sule AlabiJonathan AranaElizabeth MoscosoOleg Yazvin
Mentor: Dan Rusinak – Middough
Team EchoTeam Echo
104/22/23
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Table of Contents•Purpose
•BFD Overview of Urea Plant
•Process Description
•Sinks & Loads
•Sizing and Costing
•Conclusion
•Q & A 2
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Purpose:◦ Convert shale gas
into a nitrogen-based fertilizer
Plant Location: ◦ Williston Basin
Reason for Location: ◦ Bakken Shale Gas
Formation
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Urea- Solution & Prill Urea has a high nitrogen content (47%)
Liquid Urea (72.0wt%) - Urea Ammonium Nitrate (UAN 32)
Prilled Urea (99.8wt%)- Controlled release fertilizer
Overall Reaction:
◦ Overall Exothermic: -120 BTU/mol
CO2 2NH 3 NH 2COONH 4
NH2COONH 4 Urea H2O
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Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
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Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
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Urea Production PlantConverts reactants into urea
◦ NH3 and CO2 from Nitrate Plant ◦ Produces 72 wt% Urea solution
Main Components of Plant◦ Reactor◦ Stripper◦ Decomposer◦ Scrubber◦ Absorber
Overall Reaction:CO2 2NH 3
NH 2COONH 4
NH2COONH 4 Urea H2O
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R-111
163
161
111
173
177
C-141
131
151
187
101
183
185
R-121
193
194 196
195
121
165
V-171
167 171
V-161
141
V-181
181
198
197
P-151
175
C-131
191
192
P-191
120
V-185
188
R-101
Urea PFDUrea PFD
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Urea Production Plant – Sinks & Urea Production Plant – Sinks & LoadsLoads
R-101
R-111
163
161
111
173
177
C-141
131
151
187
101
183
185
R-121
193
194 196
195
121
165
V-171
167 171
V-161
141
V-181
181
198
197
P-151
175
C-131
191
192
P-191
120
V-185
188
Unit Type Energy Utility Amount
Reactor Sink1,376
MMBtu/dayCooling Water
1.042 MMGal/day
Stripper Load1,199
MMBtu/day Steam 792 Tons/day
Decomposer Sink1,098
MMBtu/dayCooling Water
0.975 MMGal/day
Scrubber Sink984
MMBtu/dayCooling Water
0.829 MMGal/day
Compressor Load 200 HP Electricity3,576
KWH/day
Energy Saver
Sink
Load
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Urea Production Plant- AspenMass Balance
◦ No Convergence Recycle streams
◦ Attempted Solution Increased number of iterations- no change Cut recycle streams- Mass Balance Converged
Energy Balance ◦ No Values Given
No Ammonium Carbamate properties within Aspen data libraries
◦ Attempted Solutions Free energy of formation Heat of formation Heat of dissolution in water
◦ Pending Solutions Heat Capacity Component with similar properties
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Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
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Evaporation SectionEvaporation SectionMultiple-Effect Evaporation under
VacuumIncoming Urea Solution:
◦ 72% Urea, 28% WaterTwo evaporators required
◦ 1st Evaporator: 72% to 94.6% Urea
◦ 2nd Evaporator: 94.6% to 99.8% Urea
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Evaporator PFDEvaporator PFD
P-200
E-205
E-210
E-215
202
205
250210
220
213
230
225
227
200
215
P-220
207209
240 245
T-250
151
P-217
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Evaporator ProcessEvaporator ProcessTemp and Pressure are the main
operating parameters
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Importance of Vacuum Importance of Vacuum PressurePressureMinimization of Biuret (Poison)Lowering of Boiling Point for next
evaporation stageConsequently, reduces steam
load
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Evaporator- Sinks & LoadsEvaporator- Sinks & Loads
P-200
E-205
E-210
E-215
202
205
250210
220
213
230
225
227
200
215
P-220
207209
240 245
T-250
151
P-217
Unit Type Energy(MMBtu/day) Utility Amount
Evaporators Load 1,376 Steam 792 Tons/day
Condenser Sink 1,299 Cooling Water1.042
MMGal/dayEnergy Saver
Sink
Load
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Evaporator Aspen Evaporator Aspen SimulationSimulation
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Evaporator Equipment Costs & Evaporator Equipment Costs & SizingSizing
Particulars Evap1 Evap 2 CondenserHeat Duty (BTU/hr) 1.7X 10^7 8.7 X 10^6 ---
Area (sq. ft.) 718 563 30Fluid Urea Solution Urea Solution Cooling WaterPressure 510 mmHG Vacuum 735 mmHG Vacuum ---Flow Rate (TPD) 2,568 2,568 25,265Temp In (F) 221 202 93Temp Out (F) 202 211 107Total Direct Cost ($) 102,000 80,000 27,999
Equipment Cost ($) 173,000 136,000 8,000
Total Utility Cost ($) 66,000 52,000 6.46 MM
Total Maintenance Cost ($)
5000 3800 3,000
Total ($) Operating Cost 1.1 MM 860,000 1.2 MM18
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Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water
Treatment Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
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Prill SectionPrill SectionConverts Urea Melt into PrillMain Components
◦ Prill Tower ◦ Screen◦ Cyclone◦ Bag House◦ Heater◦ Dehumidifier
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Prill PFDPrill PFDD-320
P-310
M-370
E-375
310
P-305
315
S-350
F-330
350
B-360
320
330
360398
345
325
P-316
370
355
390
210
397
395
301
375
380
F-360
342344
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Prill Sinks & LoadsPrill Sinks & LoadsD-320
P-310
M-370
E-375
310
P-305
315
S-350
F-330
350
B-360
320
330
360398
345
325
P-316
370
355
390
210
397
395
301
375
380
F-360
342344
Unit Type Energy(MMBtu/day) Utility Amount
Heater Load 1,298 Steam ~1 Tons/day Energy Saver
Sink
Load
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Prill Section Cost and Prill Section Cost and SizingSizingResearch yielded a previously done
mathematical simulation of prilling tower◦From simulation data, airflow and size for
our prilling tower were obtained◦Cost for prilling tower will be
approximated by a similar capacity storage tank
Cyclone and bag house sizing in progress due to potential redesign of prilling tower
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Potential Redesign of Prilling Tower
Standard Oil Patent Filed in 1978
Uses co-current airstream and fluidized bed
Benefits:◦Less dust
emissions◦Smaller tower
required24
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Cooling Water from CHP Plant
Prilled Urea (99.8%)
Product
BFD of Urea & Prill PlantBFD of Urea & Prill Plant
Air Out
Urea Solution (72%)
Condensate Water with NH3, CO2 & Impurities
Solid Urea (99.8%)
Output NH3 Purge & Urea Solution
To Amm. Nitrate & UAN Plants
Urea Productio
n PlantWaste Water Treatment
Plant
Evaporator Unit
Inlet NH3 & CO2
from NH3 Plant
CO2 & NH3 Recycled Gas
Air In
Prilling Tower
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Waste Water Treatment Waste Water Treatment PlantPlant For every ton of urea produced 0.3 tons of waste water is produced
Co-Current thermal hydrolysis of urea with steam Main Components:
◦ 1stDesorber ◦ Hydrolyzer ◦ 2ndDesorber◦ 2 HX
Overall Reaction: Reverse of Urea Plant
Overall Endothermic: +58 BTU/mol
Urea H2O NH 2COONH
NH 2COONH NH 3 CO2
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Waste Water Treatment Waste Water Treatment PlantPlant
Waste Water Content:◦2- 9 wt% Ammonia◦0.8- 6 wt% CO2◦0.3-1.5 wt% Urea
Simple discharge is a waste of resources and environmentally harmful
Ammonia is hazardous, toxic, and volatile
Urea promotes algae growth and hydrolyses slowly
EPA Emission Requirements: 10 ppm27
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WWTP ProcessWWTP Process
E-401
D-421
400
E-411
410
415
450
E-421
S-445
490
494
P-401
496
492
498455
E-441
P-411
483
430
D-431
445
420
475
480
440
499
485
405
470
465
185
210
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WWTP Sinks & LoadsWWTP Sinks & Loads
Unit Type Energy(BTU/HR) Utility Amount
Condenser Sink 34,538Cooling Water 5400Gal/day
Heat Exchanger Sink 280,000
Cooling Water 8100Gal/day
Hydrolyzer Load -1.03*10^7 Steam 354TPD
E-401
D-421
400
E-411410
415
450
E-421
S-445
490
494
P-401
496
492
498455
E-441
P-411
483
430
D-431
445
420
475
480
192
499
485
405
470
465
Energy Saver
Sink
LoadLoadLoad
Sink
Load
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WWTP Aspen SimulationWWTP Aspen Simulation
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WWTP Equipment SizingWWTP Equipment SizingUnit
Total Direct Cost ($)
Equipment Cost ($) Area (sq. Ft.)
Heat Duty (BTU/hr)
Condenser 43,300 8000 7 34,538Heat Exchanger 1 55,900 9400 47 280,000Heat Exchanger 2 54,200 9400 43 183,000
Hydrolyzer 260,100 81200 --- -1.03 X 10 ^7
Desorber 1 122800 35100 --- .0012
Desorber 2 98200 15300 --- 0
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WWTP Equipment Costs WWTP Equipment Costs Total Project Capital Cost 2.25
MillionTotal Operating Cost 1.2 MillionTotal Utilities Cost $42,000/yr
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Daily EconomicsDaily Economics
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Materials Cost (Money We Spend) Amount Overall Cost
NH3 $521.00 Per Ton 891.07 Tons Per Day $464,000 Per Day
CO2 $15.00 Per Ton 1153 Tons Per Day $17,300 Per Day
Product Price (Money We Get) Overall Price
Urea to UAN $230.00 Per Ton 836 Tons Per Day $159,700 Per Day
Prilled $570.50 Per Ton 793 Tons Per Day $422,000 Per Day
Profit: $100,000 Per Day
Profit: $37 Million Per Year
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ConclusionConclusion
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• Total Plant Cost: $400 Million• Produce 793 TPD of Prilled Product• Produce 836 TPD of Urea melt for
UAN Plant • Numerous Instances of Efficient
Energy Usages.• Aspen Simulation: Great Start
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Thank youQuestions?
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