Latest Urea Technology for Improving Performance and Product Quality

by EIJI SAKATA, Senior Process Engineer TAKAHIRO Y ANAGAWA, Process Engineer

Technology & Knowledge Research Center

L T OYO ENGINEERING CORPORATION

TOKYO JAPAN

ABSTRACT
Toyo Engineering Corporation (TEC) has started licensing an advanced version of its ACES urea process named ACES 21, being established based on a close collaboration with PT Pupuk Sriwidjaja (PUSRI), Indonesia. ACES 21 is featured by ground level reactor and vertical submerged carbamate condenser, combined with CO2 stripping technology, aiming at both plant cost reduction and further energy saving from the original ACES process. TEC also owns the granulation technology featured by unique Spout-Fluid Bed Granulator. A 2,000 mtpd urea granulation plant using TEC granulation technology started operation successfully in 2000, demonstrating its excellent performance. This paper introduces the TECs latest urea technologies to improve plant performance and product quality with the following features and references: n Features of ACES 21 technology, remarkable plant cost reduction and energy saving, and advantages in view of operation and maintenance n A typical study to revamp a conventional solution recycle urea plant with ACES 21 for capacity increase and energy saving, fully utilizing the existing urea reactor. n Features of TEC granulation technology for improving product quality n Recent commissioning experience in urea granulation plant based on TEC technologies.

INTRODUCTION
Toyo Engineering Corporation (TEC), a worldwide engineering contractor and one of three major urea process licensers, has made continual efforts to improve the urea process as the process licenser and the E-P-C contractor, and has contributed to the fertilizer industry by supplying reliable, efficient and economical urea plants since its establishment 40 years ago. TEC has engineered and constructed, as of the end of 2000, 93 urea plants and 10 urea granulation plants based on TEC technologies, giving a quarter of the worlds total production capacity by the three major urea processes licensors. Realizing the future technical demands for the urea process technologies during the 21st Century, TEC has improved the existing ACES Process to realize further reducing investment costs while maintaining all features of the ACES Process. The improved process has been named the ACES 21 Process. A 2,000 mtpd urea granulation plant which is the latest and the largest experience for TEC started operation successfully in 2000, demonstrating its excellent performance with aqueous urea solution feed. Some details of the project are outlined in the later sections in this paper.

THE ACES PROCESS

The main concept of the original ACES Process is to minimize energy input to the urea plant by combining the features of solution recycle process and stripping process i.e. a high CO2 conversion and the highly efficient separation of unreacted materials. The ACES Process drastically reduced steam consumption compared to Total Recycle Process. The ACES Process, by ensuring NH3 to CO2 molar ratio (N/C ratio) of 4.0 and an operating temperature of 190 C in the reactor give CO2 conversion of 68%, the highest among modern urea processes. The high CO2 conversion reduces the energy required for decomposition of unconverted materials. The proprietarily designed tray-falling film Stripper efficiently decomposes and separates ammonium carbamate and excess ammonia in urea synthesis solution from the reactor. Fig. 1 shows the simplified flow diagram of the ACES Process synthesis section.

Fig. 1 ACES Process Synthesis Section

TO MP ABSORPTION NO.1 & NO.2 CARBAMATE CONDENSER LP STM +BFW BFW NH3 STRIPPER MP STM CO2 COND. FROM MP ABSORPTION TO MP DECOMPOSITION

SCRUBBER REACTOR

The unique heat integration between the synthesis section and downstream sections further reduces energy requirement (See Fig. 2). MP steam is supplied to synthesis section to decompose and separate excess NH3 and carbamate in the stripper. The stripped NH3 and CO2 gas mixture is sent to the carbamate condenser and the condensation heat is recovered by the two parallel carbamate condensers. One is utilized for decomposition in the medium pressure section and the other is for low pressure steam generation to be utilized in the low pressure and evaporation sections. Condensation heat in medium pressure section is also utilized in evaporation section. This multiple heat integration concept, originally invented and developed by TEC, gives the most energy efficient urea process. The ACES Process has been employed in 13 urea plants since its first application in 1983 (see Table 1). Over last 10 years, 11 urea plants in 5 countries have employed this process.

Fig. 2 heat Integration Scheme

NH3 CO2

REACTOR M.P. STEAM UREA NH3 + CO2 + H2O MEDIUM PRESSURE SECTION UREA NH3 + CO2 + H2O NH3 + CO2 + H2O LOW PRESSURE SECTION H2O EVAPORATION SECTION WATER (BY-PRODUCT) C.W. C.W. C.W. HEAT RECOVERY SECTION L.P. STEAM (GENERATED)

UREA H2O

UREA MELT

Table 1 Experience List of ACES Process

CLIENT
1. KOREA FERTILIZER AND CHEMICALS CO. 2. FERTIBERIA S.L. 3. UREA FERTILIZER FACTORY LTD. 4. P.T. PUPUK SRIWIDJAJA 5. P.T. PETROKIMIA GRESIK 6. P.T. PUPUK SRIWIDJAJA 7. WEIHE CHEMICAL FERTILIZER 8. WEIXIAN CHEMICAL FERTILIZER 9. PAK - AMERICAN FERTILIZER 10. ENGRO CHEMICAL PAKISTAN LTD. 11. CHAMBAL FERTILIZERS AND CHEMICALS LTD. 12. P.T. PUPUK ISKANDAR MUDA 13. P.T. PUPUK KUJANG

COUNTRY
KOREA SPAIN BANGLADESH INDONESIA INDONESIA INDONESIA CHINA CHINA PAKISTAN PAKISTAN INDIA INDONESIA INDONESIA

PLANT CAPACITY
(MT/D)

ON-STREAM
MAY 1983 OCT. 1988 FEB. 1993 MAR. 1994 MAY 1994 FEB. 1994 MAY 1996 JAN. 1997 SEP. 1998 OCT. 1998 OCT. 1999 (2002) (2004)

600 750 1,422 1,725 1,400 1,725 1,760 180 1,050 1,755 2,350 1,725 1,725

THE ACES 21 P ROCESS

ACES 21 Process Concept In CO2 stripping technology, the reactor, the largest and the heaviest vessel in urea plant, is normally installed at 20-22 meter level so as to feed urea synthesis solution to the stripper by gravity. If the reactor is installed on the ground level, civil and erection cost can be greatly reduced. TEC and PUSRI jointly developed this process incorporating a unique two-stage synthesis concept comprised by:
n n n n

A vertical submerged carbamate condenser, functioning as carbamate condenser, HP scrubber and the primary urea reactor A vertical reactor to complete reaction from carbamate to urea, as the secondary reactor A vertical falling film type stripper to decompose and separate unreacted carbamate and excess ammonia by CO2 stripping. A HP ejector motivated by HP liquid ammonia to supply driving force for the HP loop circulation, so that the reactor is installed on the ground level and other HP vessels are laidout horizontally, as well as to increase N/C ratio in the reactor high enough so as to achieve the high CO2 conversion.

ACES 21 Synthesis Section Fig. 3 shows the ACES 21 Process synthesis section. The reactor, stripper, carbamate condenser and ejector comprise the synthesis section as major equipment. Liquid ammonia is fed into the reactor via the ejector. Most of the CO2 is fed to the stripper as stripping media and the rest is fed to the reactor as a source of passivation air and a raw material for urea synthesis in the reactor. Carbamate solution from the carbamate condenser is fed to the reactor after being pumped by the ejector that is motivated by high pressure liquid ammonia. Urea synthesis solution leaving the reactor is fed to the stripper. Stripped urea solution is sent to MP decomposition stage. The stripped off gas is fed to vertical submerged-type carbamate condenser. NH3 and CO2 gas condenses to form ammonium carbamate and urea in the shell side of the carbamate condenser. The condensation heat is recovered to generate low pressure steam in the tube side. Packed bed is provided at the top to absorb uncondensed NH3 and CO2 into recycle carbamate solution from MP absorption stage. Inert gas from top of the packed bed is sent to MP absorption stage. The driving force for liquid and gas circulation in the synthesis loop is mainly provided by the ejector, while appropriate elevation of the carbamate condenser supplies additional driving force by gravity.

Fig. 3 ACES 21 Process Synthesis Section

CARBAMATE CONDENSER REACTOR
INERTS TO ABSORPTION STAGE FROM ABSORPTION STAGE

STRIPPER

MP STM BFW LP STM S.C. LIQ. NH3 CO2 TO DECOMPOSITION STAGE

EJECTOR

Vertical Submerged Carbamate Condenser Vertical submerged design is employed for the carbamate condenser. From process view point, this provides the following advantages: (1) High gas velocity, appropriate gas hold up and sufficient liquid depth in the bubble column promote mass and heat transfer; (2) The appropriate number of baffle plates distribute gas bubbles in the column effectively without pressure loss; (3) A vertical design inevitably requires smaller plot area Optimized N/C Ratio In the ACES 21 Process, the N/C ratio in the carbamate condenser differs from that in the reactor. A lower N/C in the carbamate condenser lowers vapor pressure, reducing vapor loss from the carbamate condenser. A higher N/C ratio in the reactor raises CO2 conversion, reducing the heat required for decomposition of carbamate in the stripper. Equilibrium vapor pressure becomes its lowest level at around an N/C ratio of 3.0 at which the carbamate condenser is operated. The reactor N/C ratio should be as high as possible to maximize CO2 conversion as far as its operating pressure has appropriate excess pressure to that of the equilibrium. Since different levels of N/C ratio are employed for the carbamate condenser and the reactor, urea synthesis reaction takes place in two steps.

Advantages Features and advantages of the ACES 21 Process are summarized below: 1. The horizontal layout of HP vessels has the following advantages compared to the vertical layout. (a) less HP piping and construction materials are used; (b) easier erection using commonly available construction equipment and techniques; (c) easier operation and maintenance Combining the functions for carbamate formation, heat recovery, urea synthesis, and inert gas scrubbing into one vertical submerged carbamate condenser has the following advantages in comparison with conventional separate reactor and falling film carbamate condenser: (a) fewer and smaller sized HP vessels; (b) a smaller heat transfer area for heat recovery; (c) less HP piping and construction material are required Simplified synthesis loop offers the followings advantages over conventional stripping technologies: (a) less HP piping and construction materials are required; (b) easier operation and maintenance Improved design for the reactor and the stripper give the following advantages in comparison to conventional ones: (a) less volume and weight for both the reactor and the stripper; (b) easier reactor and stripper fabrication Optimizing N/C ratios at different levels for the carbamate condenser and the reactor at lower synthesis pressure results in the following advantages over the ACES Process: (a) lower mechanical design pressure of HP vessels and rotating equipment; (b) less energy consumption

2.

3.

4.

5.

TEC and PUSRI confirmed the combined effect of the above improvements, based on the oneyear demonstration with the pilot plant and the following engineering study for an industrial scale plant, reduces the urea plant direct cost by approximately 10% and energy consumption by 5-20% from the original ACES process.

REVAMPING OF CONVENTIONAL SOLUTION RECYCLE UREA PROCESS

Revamping Technology Options Table 2 shows the revamping technology options offered by TEC to improve plant efficiency and product quality. Those options are so selected to meet the objectives for the revamp and/or renovation project.
Table 2 REVAMPING TECHNOLOGY OPTIONS

Capacity Increase ACES 21 D PROCESS GRANULATION PROCESS VACUUM CONCENTRATION PROCESS CONDENSATE TREATMENT CENTRIFUGAL TYPE HP ROTATING MACHINE ACOUSTIC GRANULATOR DUST SCRUBBER

Energy Saving

Product Quality

Environment Maintenance

P P

P P P P

P P P P

P P

L TOYO ENGINEERING CORPORATION

ACES 21 Process Features for Revamping ACES 21 is also suitable for revamping conventional solution recycle urea plants in an efficient way. For example, TECs Total Recycle C-Improved Process plant can be revamped to have 130 150% capacity of original nameplate together with 30 40 % saving of specific energy consumption per metric ton of the product, simply adding a carbamate condenser, a stripper and an ejector to the synthesis section. The ACES 21 revamp concept thus renovates conventional less efficient urea plants to be the most advanced and efficient ones, owing to the following features: (1) ACES 21 adopts two-stage reaction with a vertical submerged condenser and a reactor. This enables to increase the synthesis section capacity to 150% of original nameplate by reutilizing the existing reactor on the ground level without adding a new reactor, resulting in great reduction of equipment cost; (2) Horizontal lay-out of HP equipment greatly reduces erection and construction cost; (3) Lowered synthesis pressure of 155 kg/cm 2G greatly reduces energy for raw material feed; (4) Adoption of ACES 21 synthesis loop maximizes heat recovery in the synthesis section.

Revamp Case Study A revamp study to increase capacity to 150% of nameplate capacity and 30-40% energy reduction for TEC Total Recycle C-Improved plants has been carried out. Fig. 4 shows a block flow diagram for the overall revamped urea plant. The study result has shown positive feasibility in view of profitability, environmental protection and energy saving. The following paragraphs outline the modifications in each section.

Fig. 4 Block flow diagram

NH3 CO2
CO2 COMPRESSION
MODIFICATION OR REPLACEMENT

NH3 FEED

MODIFICATION

SYSNTHESIS (ACES 21)

MINOR MODIFICATION

MINOR MODIFICATION

PURIFICATION

RECOVERY

NEW

CRYSTALLIZATION

CONCENTRATION

NEW

PRILLING

GRANULATION

1,725 T/D UREA

875 T/D UREA

Outline of Revamp Schemes 1. Synthesis section and raw material feeding section Fig. 5 shows process flow of the revamped synthesis section. Existing reactor is fully re-utilized as ACES 21 reactor without relocation. Stripper, carbamate condenser and ejector are newly added and NH3 pre-heater and CO2 compressor are modified or added. Fig. 5 Revamped Synthesis Section
NEW EQUIPMENT REACTOR STRIPPER CONDENSER HP DECOMPOSER

MP STEAM TO LP DECOMPOSER

HP ABSORBER
TO NH3 CONDENSER COND. FROM LP ABSORBER BFW LP STEAM

EJECTOR

CO2 NH3 CARBAMATE FEED PUMP

CO2 COMPRESSOR

NH3 PUMP

Raw material feed equipments are evaluated as follows: (i) CO2 compressor Reduction of the discharge pressure from 250 Kg/cm 2G to 160 Kg/cm 2G greatly reduces the energy for CO2 compression. In general, following two options are considered practical to meet the increased capacity. (a) Replace the existing reciprocating compressor(s) to new one centrifugal compressor aiming maintenance free and oil free. (b) Add a reciprocating compressor equivalent to the additional capacity aiming minimum investment cost. (ii) Turbine for CO2 compressor Depending on the steam system, turbine for CO2 compressor may be required to be modified to extraction-admission-condensing type to supply middle pressure steam for HP stripper and to utilize low-pressure steam generated in ACES 21 condenser. (iii) Ammonia pump No modification is required and pumping energy is significantly reduced due to decrease of required capacity. The existing pumps originally have sufficiently high discharge pressure to supply motive energy for HP ejector (iv) Carbamate pump No modification is required and pumping energy is greatly reduced because required capacity is same and discharge pressure is decreased from 250 Kg/cm 2G to 160 kg/cm 2G.
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(v) Hydrogen removal Hydrogen removal unit is installed in the CO2 compression section to avoid flammable condition in the synthesis section since passivation air requirement increases after revamp. 2. Purification section Purification section is utilized without major modifications. An additional pre-heater for HP Decomposer, heated by 5 kg/cm 2G steam, is installed to utilize low pressure steam generated after revamp. 3. Recovery section Recovery section is utilized without major modifications. Additional stage for NH3 recovery absorber is installed as the inert gas to high pressure recovery system increases due to increased air supply for passivation and hydrogen removal. 4. Finishing section Finishing section revamp options can be categorized into the following schemes depending on the prospective market conditions, environmental regulations and owners requirement: i) Minimum Investment without Improving Product Quality and Pollution Abatement: n Total production capacity is by prilled urea only. Crystallization section is utilized without modification and new evaporators equivalent to the additional capacity (875 mtpd) are added. Existing prilling tower is utilized by modifying induced fans to increase air flow rate and replacing distributors for prilling. n As an alternative, the existing crystallization process can be converted to vacuum evaporation process aiming at maintenance free and energy saving operation. The existing crystallizer is utilized as a vacuum concentrator.

ii) Product Quality Improvement and Pollution Abatement for Additional Capacity by Installing a Granulation Plant n The existing crystallization section and prilling tower is utilized without modification. New vacuum evaporation section and a granulation plant equivalent to the additional capacity (875 mtpd) are newly installed. iii) Product Quality Improvement and Pollution Abatement for Total Capacity by Installing a Granulation Plant n The existing crystallization process is totally converted to vacuum evaporation process. Existing prilling tower is totally converted to granulation.

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Process Performance and Economic Evaluation Table 3 summarizes three typical revamp options. Case-1 needs the highest investment among the three, however it provides the most simple steam system and the lowest operation and maintenance cost, owing to the all centrifugalization of CO2 compressor. Case-2 shows the second lowest investment, however it requires more complicated modification of steam system and higher operation and maintenance cost than Case-1. Case-3 shows the lowest investment, so long as 875 mtpd urea can be sold as 70% urea solution with appropriate margin to other plant. Preliminary economic evaluation study has indicated that considerable steam saving by 0.4 T/T achieved by ACES 21 concept and reasonable assumption of 20-30 US$ margin to net production cost per metric ton of urea product will recover the investment within 3 5 years in those three cases.
Table 3 Revamp Option
1,725 mtpd TR-CI 2,600 mtpd ACES 21 CASE-1
CO2 Compression Synthesis Purification /Recover Concentration Finishing

CASE-2

CASE-3

Replacement of Addition of Centrifugal Reciprocating Compressor and Turbine Compressor ACES 21 No Modification Addition of 850 mtpd Evaporation Addition of 850 mtpd Granulation

Export 850 mtpd Urea Solution

Steam System Optimum Simple Construction / Modification Simple Operating / Maintenance Cost Low Operation Flexibility High

Complicated Complicated High Medium

Complicated Complicated Medium Low

L TOYO ENGINEERING CORPORATION

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Example of A Revamping Study Typical revamping study to renovate a TEC TR-C urea plant with ACES 21 technology has been recently carried out based on the conditions shown in Table 4. The case-2 is to convert prilling to granulation.
Table 4 Study Cases EXISTING 1300 MTPD Back Turbine TR-C Titanium lining Crystallization CASE-1 CASE-2 1300 MTPD 1300 MTPD Extraction Admission Extraction Admission Condensing Turbine Condensing Turbine ACES 21 ACES 21 Re-lined with S.S Re-lined with S.S
with Baffle Plates with Baffle Plates

Capacity CO2 Booster Driver Synthesis Urea Reactor Finishing Product Forming

Vacuum Evaporation

Vacuum Evaporation

Conventional Prilling with Spout-Fluid Bed Prilling Acoustic Granulator Granulation with Natural Draft + ID Fan Dust Recovery Urea Solution Urea Solution Packed Bed Spray Spray + Demister Dust Scrubber Process Condensate None Hydrolyzer & Stripper Hydrolyzer & Stripper Treatment

L TOYO ENGINEERING CORPORATION

Table 5 summarizes utility and energy consumption for each case. Energy consumption to produce one metric ton of prilled or granulated urea is reduced by 0.36 0.40 Gcal. This drastic energy reduction considerably improves the competitiveness of the urea plants.
Table 5 Performance Summary : Utilities Consumption EXISTING Steam (T/T) Import 43 12 Export 21 12 Net Kg/cm 2G x 385o C Kg/cm 2G x 215o C Kg/cm 2G x 318o C Kg/cm 2G x 265o C 1.67 0.09 -0.32 1.44 83 CASE-1 1.14 -0.16 0.98 66 CASE-2 1.13 -0.16 0.97 82

Electricity (kWh/T) Energy (Gcal/T) Steam Electricity Total Saving

Note : 2475 kcal/kWh for Electricity.

1.101 0.204 1.305 Base

0.747 0.162 0.909 0.396

0.740 0.201 0.941 0.364

30% Saving 28% Saving

L TOYO ENGINEERING CORPORATION

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TEC GRANULATION PROCESS

TEC has developed own granulation technology so called Spout-Fluid Bed Granulation since the early 1980s. In the year 2000, a 2,000 mtpd urea granulation plant which is the latest and the largest experience for TEC started operation successfully, demonstrating its excellent and reliable performance with aqueous urea solution feed.

Table 6 Experience List of TEC Granulation Process

OWNER 1) Mitsui Toatsu Chemicals, Inc. 2) Petrochem Ltd. 3) Mitsui Toatsu Chemicals, Inc. 4) SKW Piesteritz GmbH 5) Petrochem Ltd. 6) SKW Piesteritz GmbH 7) Ningxia Chemical Works of CNPC 8) P.T. Pupuk Iskandar Muda 9) Lutianhua Group Inc. 10) Zhanyi Fertilizer Plant LOCATION CAPACITY ON (MTPD) STREAM 50 470 100 1,200 750 500 1,740 1,725 2,000 600 1975 1983 1983 1995 1997 1998 1999 (2002) 2000 (2002)

Chiba, Japan Kapuni, New Zealand Osaka, Japan Piesteritz, Germany Kapuni, New Zealand Piesteritz, Germany Ningxia China North Aceh, Indonesia Sichuan, China Yunnan,China

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Process Description Figure 6 shows a typical flow diagram of TEC Urea Granulation Process. The Urea Granulation process consists of following three sections. granulation section recycle and product cooling section dust removal and recovery section Fig.6: TEC urea granulation process flow diagram

Aqueous urea solution from urea plant is fed to the granulator to enlarge recycle particles in the granulator. In the granulator, the granules are dried and cooled simultaneously. The granulator is operated at 110-115C and at slightly negative pressure. Enlarged urea particles are cooled to about 90C in the after-cooler inside the granulator to be transported to the recycle section. The discharged granules are separated into three sizes, product, small and large size by the screen. Product size granules are further cooled below 60C in the product cooler to be sent to the urea storage or bagging facility. Large size granules are crushed by the crusher. The crushed particles and smaller size particles from the screen are recycled to the granulator as seed. Urea dust contained in the exhaust air from the granulator and the product cooler is scrubbed in the dust scrubber by contacting counter currently with aqueous urea solution. The urea dust content in the exit air of the dust scrubber is 30 mg/Nm3 or less. Urea recovered in the dust scrubber, approximately 3-4 % of production rate, is recycled to the urea plant as 45 wt% urea solution. Any other urea granulation processes available in the world have similar flow schemes, however characteristics and performance of the process strongly depend upon the granulator design. The features of TEC Urea Granulation Process are given below:

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(i) High Energy Efficiency: n No requirement of compressed atomizing air for granulator reduces power consumption; n Seed circulation at moderately high temperature (= 90C) minimizes cooling air requirement and heat removal in the process; n Optimal bed depth minimizes pressure loss in the granulator; n Uniquely designed low pressure drop dust scrubber minimizes power consumption of induced fan(s) Table 7 shows a typical steam and power consumption of TEC Urea Granulation Process. Table 7 Typical specific utilities consumption
Steam (MT/MT) Power (kWh/T) Note: ambient temperature = 30 - 35C 0 0.03 23 25 (Fluid Bed Cooler) 19 21 (Bulk Flow Cooler)

In the case that water cooled bulk flow cooler is applied for product cooling instead of fluidized bed cooler, the power consumption is further reduced by about 4 kWh/MT. Since its first application in 1993, TEC has been ready to apply the both options in granulation plant design, i.e. the bulk flow cooler and the fluidized bed cooler considering site conditions, energy cost and clients requirement. (ii) High Product Quality n Rapid cooling of granules in the granulator with minimum residence time reduces biuret formation to negligibly small; n Efficient drying in the granulator reduces granule moisture low enough to increase product hardness; n Optimal combination of spouted bed and fluidized bed produces round and uniform granules. Table-8 shows typical quality of the granules produced by TEC Urea Granulation Process. Table 8 Typical product quality
Total Nitrogen Biuret Moisture Formaldehyde Size (2-4mm) Hardness 46.3wt% 0.7wt% 0.25wt% 0.45wt% 95wt% 3.5kg at 3mm

(iii) Low Urea Dust Emission n Optimal spouted bed air velocity minimizes dust formation in the granulator. n Uniquely designed low delta-P dust scrubber proven through application to twelve prilling towers and seven urea granulators reduces urea dust to less than 30 mg/Nm3.

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TEC Spout-Fluid Bed Granulator

Figure 7 shows a schematic diagram of TEC Spout-Fluid Bed Granulator. The granulator consists of spouted beds and fluidized bed on the perforated plate, spray nozzles and air duct manifolds. Each spouted bed has one spray nozzle. Recycle urea granules are enlarged while passing through the spouted beds and the fluidized bed. Aqueous urea solution ( > 95wt% ) is sprayed into the spouted beds through pressure spray nozzles.

Fig. 7: TEC spout-fluid bed granulator

Vigorous mixing in the spouted bed gives round and uniform granules. Since air introduced for spouting and fluidizing not only removes urea solidification heat but also evaporates water contained in the sprayed aqueous urea droplets and granules, the urea granules are dried to less than 0.25wt% moisture content at the exit of the granulator. Owing to the drying effect in the granulator, cost and energy consumption in the urea process plant can be reduced. Industrial scale granulator has multi-stage spouted bed arrangement, therefore the granulator is simply scaled-up by increasing the number of the spouted beds.

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Equipment Layout Figure 8 shows a birds-eye view of a typical 1,700 mtpd TEC Urea Granulation Process plant. As can be seen, the building for granulator and other solid handling equipment is very compact.

Fig. 8: 3-D graphic representation of TEC granulation plant

TEC Urea Granulation Process has alternative layout options, i.e. the dust scrubber can be installed on the top to reduce the plot area. This option can be attractive for the case that available area is very limited, for example, the case for prill tower conversion to granulation. Four granulation plants have employed this layout.

Large Scale Granulation Plants in China Two large scale urea granulation plants based on TEC technology, of which respective nameplate capacity is 1,740 mtpd and 2,000 mtpd, have been commissioned in China in 1999 and 2000. Both plants have single train TEC Spout-Fluid Bed Granulator designed to receive aqueous urea solution as feed. The both plants are designed to be capable to produce either 2-4 mm product or 5-8 mm product, depending upon the market demand. In the 2,000 mtpd unit project for Lutianhua Group Inc., (LTH) which aimed at the total conversion of existing prilling tower to granulation, the following advantages have been demonstrated: 2,000mtpd production with aqueous urea solution feed Remarkably low urea dust emission (= 5 mg/Nm3) by uniquely designed dust scrubber Low production cost owing to low utilities consumption Easy and smooth start-up in large capacity unit

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Fig. 9

LTH 2,000 mtpd granulation plant

This project came into effect in May 1999. TEC supplied the process design package and proprietary equipment as process licenser. China Wuhuan Chemical Engineering Corporation (CWCEC) carried out detail engineering and LTH performed procurement and construction. Owing to the efficient project coordination and cooperation among TEC, CWCEC and LTH, the plant started operation in July 2000, within only 14 month after the effective date of contract. Some details of the project are introduced below. Operation history The plant went into operation in the beginning of July 2000 and the plant load reached 100% very smoothly. Performance test run was completed in October 2000. Performance test was postponed due to a repair work of bucket elevator and urea prill production required by market reason. Maximum daily capacity reached 107% in October 2000. The plant has operated successfully producing good quality product for both export and domestic use.

CONCLUSION
TEC, the only urea process licenser that covers by itself all the proven essential technologies, i.e. urea synthesis, prilling, granulation and pollution abatement, has improved the ACES urea process to establish the most advanced urea process ACES 21 cooperating with PUSRI. TEC Spout-Fluid Bed Granulation Process has been adopted in 8 revamps and 2 grass roots plants. Several revamp studies have proved that conventional urea plant can be revamped to be the most competitive one with ACES 21 technology and Spout Fluid Bed Granulation in very efficient way. The recent successful commissioning of a large scale granulation plants further promotes prilling tower conversion to granulation aiming at drastic improvement of product quality. The TEC-PUSRI ACES 21 and TEC Spout-Fluid Bed Granulation provide the most realistic solution to improve efficiency and product quality of conventional urea plants.

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