The Improved ACES Urea Technology - Case Studies in China and Indonesia

Y. KOJIMA, H. MORIKAWA, E. SAKATA Toyo Engineering Corporation

8-1, Akanehama 2-chome, Narashino-shi, Chiba 275-0024, Japan Presented at Nitrogen 2003, 23 - 26 February, Warsaw, Poland INTRODUCTION
Toyo Engineering Corporation (TEC), a world leading engineering contractor and one of the three major urea technology licensors, first disclosed their R&D of an improved version of their ACES process at Nitrogen 99, Caracas, Venezuela [1]. TEC then announced the completion of the R&D and introduced the conceptual design of commercial scale Improved ACES (ACES 21) urea plant at Nitrogen 2000, Vienna, Austria [2], jointly with a partner of R&D, PT Pupuk Sriwidjaja (PUSRI), Indonesia Fig.1 shows the history of TEC urea processes since the development of partial recycle process in 1950s until the latest Improved ACES (ACES 21). Since its establishment 42 years ago, TEC has engineered and constructed, as of the end of 2002, 94 urea plants in 24 countries based on TEC own urea technologies, giving a quarter of the worlds total production capacity by the three major urea processes licensors. 14 of the 94 plants are based on CO2 stripping urea process ACES, including two Improved ACES (ACES 21) urea plants. The Improved ACES (ACES 21) is advantageous in low investment cost and low energy consumption for urea production. A major feature of this technology is that it reduces the number of equipment in the urea synthesis loop to simplify the system, which lessens construction costs with the installation of the reactor on the ground in CO2 stripping process (resultantly existing urea reactor can be re-utilized in revamp case). In addition, the operation conditions of synthesis section have been optimized under the lower operation pressure than the previous process. As a result, a remarkable reduction in energy consumption has been achieved. In 2002, TEC was awarded the contract for capacity expansion and energy saving project of the fertilizer plant in China. The capacity of this urea plant, built by TEC in 1976, will be increased from 1,620 mtpd to 2,460 mtpd with 30% saving of specific energy consumption. This project is scheduled to be completed in late 2003. The Improved ACES (ACES 21) technology is selected for this project, which is the largest in capacity to apply at a commercial plant. In the same year 2002, another project has been effectuated to build a 1,000 mtpd ammonia plant and a 1,725 mtpd urea plant in Indonesia. The urea plant also applies Improved ACES (ACES 21). The project is prospected to be completed in 2005. This paper reviews Improved ACES (ACES 21) technology with the two on-going urea projects in China and Indonesia in view of the process advantages and expected benefits.

THE ORIGINAL ACES PROCESS

The main concept of the original ACES Process was 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 (See Table I).

1960
TOTAL RECYCLE B TOTAL RECYCLE C TOTAL RECYCLE C-I TOTAL RECYCLE D ACES Improved ACES (ACES 21) SPOUT BED GRANULATION SPOUT - FLUID BED GRANULATION TARGET OF PROCESS IMPROVEMENT 100-500 T/D

1970
200-1137 T/D 180-1800 T/D

1980

1990

2000

200-1700 T/D 180-1760 T/D 1725-2460 T/D 100-470 T/D 750-2000 T/D MINIMIZE NH3 CONSUMPTION ENERGY CONSERVATION (MINIMIZE UTILITIES)..... POLLUTION PREVENTION..... PRODUCT QUALITY IMPROVEMENT.....

PLANT COST REDUCTION

FIG. 1: DEVELOPMENT HISTORY OF TEC UREA PROCESS

Table I TEC Urea Process Performance

TR-CI Synthesis Condition 250 Press. (Kg/cm2G) 200 Temp. (oC) (mol) 4 NH3 / CO2 mol) Conversion (%) 69 Utility Consumption / Ton-Urea Steam (tons) Import 22 Kg/cm2G 0.93 13 Kg/cm2G Export 5 Kg/cm2G Net 0.93 Power (kWh) 140

TR-D 250 200 4 69

ACES 175 190 4 68

Improved ACES ( ACES 21 ) 155 182 3.7 63

0.57 0.78 0.78 137 0.57 121

0.67 0.24 0.43 118

Note: Power consumption includes prilling tower with fluid bed cooler and dust scrubber

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 achieves 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 stripper with trays and falling film tubes efficiently decomposes and separates ammonium carbamate and excess ammonia in urea synthesis solution from the reactor. Fig. 2 shows the simplified flow diagram of the ACES Process synthesis section.

SCRUBBER

TO MP ABSORPTION

REACTOR NO.1 C.C. STEAM BFW TO MP DECOMPOSITION NO.2 C.C.

FROM NH3-PUMP MP STEAM STRIPPER FROM CO2-COMP COND

FROM CARB.-PUMP

FIG. 2: ACES PROCESS SYNTHESIS SECTION Table II List of TEC ACES Urea Plant

CLIENT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

COUNTRY
KOREA SPAIN

PLANT CAPACITY (MT/D)

600 750 1,422 1,725 1,400 1,725 1,760 180 1,050 1,755 2,350 1,725 1,725 2,460

ON-STREAM
MAY 1983 OCT. 1988 FEB. 1993 MAR. 1994 MAY 1994 FEB. 1994 MAY 1996 JAN. 1997 SEP. 1998 OCT. O CT. 1998 DEC. 1999 (2003) (2005) (2003)

KOREA FERTILIZER AND CHEMICALS CO . CO. FERTIBERIA S.L. UREA FERTILIZER FACTORY LTD. P.T. PUPUK SRIW IDJAJA P.T. PETROKIMIA GRESIK P.T. PUPUK SRIW IDJAJA W EIHE CHEMICAL FERTILIZER W EIXIAN CHEMICAL FERTILIZER PAK - AMERICAN FERTILIZER ENGRO CHEMICAL PAKISTAN LTD. CHAMBAL FERTILIZERS AND CHEMICALS LTD. P.T. PUPUK ISKANDAR MUDA P.T. PUPUK KUJANG * SICHUAN CHEMICAL W ORKS LTD. *

BANGLADESH INDONESIA INDONESIA INDONESIA CHINA CHINA PAKISTAN PAKISTAN INDIA INDONESIA INDONESIA CHINA

* Improved ACES (ACES 21)

The unique heat integration between the synthesis section and downstream sections further reduces energy requirement (See Fig. 3). 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.

NH3

CO2

M.P. STEAM UREA NH3 + CO2 + H2O UREA NH3 + CO2 + H2O UREA H2O

SYNTHESIS HEAT RECOVERY SECTION

L.P. STEAM (GENERATED)

MEDIUM PRESSURE SECTION NH3 + CO2 + H2O LOW PRESSURE SECTION H2O EVAPORATION SECTION WATER (BY-PRODUCT)

C.W.

C.W.

C.W.

UREA MELT

FIG. 2: HEAT INTEGRATION CONCEPT OF ACES

THE IMPROVED ACES (ACES 21) PROCESS

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 PT Pupuk Sriwidjaja (PUSRI, Indonesia) have jointly improved the existing ACES process aiming at installing the reactor on the ground level, maintaining advantages of ACES process concepts based on proven CO2 stripping technology. The two stage synthesis concept in combination of Vertical Submerged Carbamate Condenser (VSCC) and the reactor is employed to enable the reactor be installed on the ground level and to simplify the synthesis loop. The forced circulation of the synthesis loop driven by HP carbamate ejector also makes the VSCC be installed on fairly low elevation.

Description of Improved ACES (ACES 21) Synthesis Section

Fig. 4 shows the Improved ACES (ACES 21) Process synthesis section consisting of a reactor, a stripper and a carbamate condenser. An HP carbamate ejector provides the driving force for circulation in the synthesis loop instead of gravity for the original ACES. Liquid ammonia is fed into the reactor via the HP ejector. Most of the CO2 with small amount of passivation air is fed to the stripper as a stripping medium and a raw material for urea synthesis, and the rest is fed to the reactor as a raw material and to passivate the reactor. The reactor is operated at N/C ratio of 3.7, 182 C and 155 Kg/cm2G. The CO2 conversion to urea is as high as 63% at the exit of the reactor. Carbamate solution from the carbamate condenser is also fed to the reactor after being pumped by the HP ejector that is motivated by high pressure liquid ammonia. Urea synthesis solution leaving the reactor is fed to the stripper where unconverted carbamate is thermally decomposed and

excess ammonia and CO2 are efficiently separated by CO2 stripping. Stripped urea solution is sent to MP decomposition stage to be purified further. The stripped off gas from the stripper is fed to Vertical Submerged Carbamate Condenser (VSCC), operated at N/C ratio of 3.0, 180C and 155 Kg/cm2G. Ammonia and CO2 gas condenses to form ammonium carbamate and subsequently urea is formed by dehydration of the carbamate in the shell side. Reaction heat of carbamate formation is recovered to generate 5 Kg/cm2G steam in the tube side. Packed bed is provided at the top of VSCC to absorb uncondensed ammonia and CO2 gas into recycle carbamate solution from MP absorption stage. Inert gas from the top of the packed bed is sent to MP absorption stage.

TO MP ABSOPTION FROM CARB. PUMP CONDENSER (VSCC) VSCC)

STRIPPER REACTOR BFW LP STEAM EJECTOR FROM NH3-PUMP FROM CO2-COMP TO MP DECOMPOSITION MP STEAM

COND

FIG. 4: IMPROVED ACES (ACES 21) SYNTHESIS SECTION

Vertical Submerged Carbamate Condenser (VSCC)

The Vertical Submerged Carbamate Condenser (VSCC) functions to: (1) condense NH3 and CO2 gas from the stripper to form ammonium carbamate in the shell side; (2) synthesize urea by dehydration of ammonium carbamate in the shell side; (3) remove the reaction heat of ammonium carbamate formation by generating 5 Kg/cm2G steam in boiler tubes Advantages of the vertical submerged configuration of carbamate condenser are summarized as follows: High gas velocity, appropriate gas hold up and sufficient liquid depth in the bubble column promote mass and heat transfer, resulting in 30% reduction of heat transfer area from original ACES carbamate condensers; The appropriate number of baffle plates distribute gas bubbles in the column effectively without pressure loss; A vertical design inevitably requires smaller plot area.

Configuration of VSCC
Fig. 5 illustrates the configuration and the fluid flow pattern in VSCC. VSCC is categorized into a kind of

bubble column reactor with cooling tubes. VSCC consists of the condensation-reaction part in the main cylindrical shell and the scrubbing part at top. The condensation-reaction part has a U-tube bundle and baffle plates. A down flow pipe connects the scrubbing part and the condensation-reaction part so as to feed carbamate solution from the scrubbing part to the bottom chamber of the VSCC by gravity. Mixed gas from the stripper is introduced and distributed into the bottom compartment as small gas bubbles via a gas sparger. Carbamate solution is also introduced to the bottom compartment from the scrubbing part via the down-pipe as absorbent. From the bottom to the top of the condensation-reaction part, the mixed gas bubbles rise through the bundle of boiler tubes and partially condense, contacting with urea-carbamate solution. The condensation (carbamate formation) heat is removed by the boiler tubes in which saturated boiler water is circulated by a circulation pump. The shell side volume is sufficient to promote dehydration of ammonium carbamate to form urea.

GAS OUT

CARB. SOLUTION IN SCRUBBING PART

PACKED BED

GAS Flow LIQ. Flow

DOWN PIPE FROM SCRUBBING PART TO CONDENSATION & REACTION PART

DOWN PIPE FOR REACTION PRODUCT CONDENSATION & REACTION PART

U-TUBE BUNDLE

BAFFLE PLATES

UREA SYNTHESIS SOLUTION OUT

NH3+CO2 GAS IN LIQ. NH3 IN

BFW IN

BFW + STEAM OUT

FIG. 5: CONFIGURATION OF VSCC

Fig.6 shows a result of a computational fluid dynamic (CFD) analysis for gas bubbles and solution in a compartment of VSCC. The rising bubbles in the central tube bundle area agitates the urea-carbamate solution to circulate between the space among bristled boiler tubes and the surrounding open annular space near the wall, giving high mass transfer between the gas bubbles and the absorbent urea-carbamate solution and high heat transfer between the carbamate solution and the boiler tubes. The bubbles enters the compartment from holes provided among the tube holes on the lower baffle plate, then rise in the space among the bristled tubes and finally gather beneath the upper baffle plate to be re-distributed evenly as the form of small bubbles while passing through holes on the baffle plate. Urea-carbamate solution enters a compartment from an opening provided on each baffle plate, then circulates by being agitated by the rising bubbles and exits to the next compartment through the next opening provided on the next baffle plate. Such carbamate formation - heat removal - urea formation process cycle taking place in a compartment between two baffle plates repeats compartment-by-compartment from bottom to top, achieving high CO2 conversion to urea at the exit of VSCC and efficient heat recovery in VSCC. The urea-carbamate solution leaving the top compartment on the top baffle plate is extracted through a down-pipe to be fed to the HP ejector.

tube bundle area

open annular space

upper baffle plate

lower baffle plate

FIG. 6: CFD ANALYSIS IN VSCC

Mixed gas containing uncondensed ammonia and CO2 entrained by inert is introduced to the scrubbing part where the most of NH3 and CO2 is absorbed adiabatically into carbamate solution recycled from the downstream middle pressure section while contacting counter-currently in a packed bed. The mixed gas which is rich with inert after scrubbing is sent to middle pressure section for further treatment.

Corrosion Prevention
A small amount of liquid ammonia is fed into a small chamber at the bottom in order to dilute the corrosive carbamate solution. The dilution with ammonia reduces corrosion rate drastically in the bottom chamber, in particular tube to tubesheet weld joint part which is essential for safe operation and for prolonging the equipment lifetime. This corrosion prevention technology has been patented by TEC in major countries and areas worldwide.

Maintainability
Sufficient annular space for inspection and maintenance in the shell side is available between the U-tube bundle and the interior wall of the shell so that inspection and maintenance personnel can work and walk through. Tube thickness is precisely measured for full length of all the U-tubes from tube side by eddy current technique.

Optimum Selection of Synthesis Conditions

In the Improved ACES (ACES 21) Process, the N/C ratio in VSCC differs from that in the reactor. VSCC is operated at N/C ratio of 2.8 3.3 where the equilibrium vapor pressure of urea-carbamate solution gives the lowest. This optimum N/C selection allows relatively high temperature operation of VSCC, rendering efficient heat transfer between the shell and the tube and higher reaction rate of ammonium carbamate dehydration to form urea. The reactor N/C ratio is selected at around 3.7 to maximize CO2 conversion with

appropriate excess pressure to that of equilibrium (See Fig. 7). As inert gas fed to the reactor is only 1/5 of that of conventional CO2 stripping process, vapor fraction in the reactor decreases drastically and the reactor volume is fully utilized for urea synthesis reaction which takes place only in the liquid phase. Resultantly, high CO2 conversion of 63% is achieved in the reactor at relatively low temperature and pressure, i.e. 182 C and 155 Kg/cm2G. Since different N/C ratios are employed for the VSCC and the reactor, urea synthesis reaction takes place in two steps as shown in Fig. 8.

EQUILIBRIUM CONVERSION

80

200
IU M IB R I O N L I S U E Q N V ER CO
EXCESS PRESSURE

70

180 160 140 120 100

60

OPERATING PRESSURE

50
CONDENSER
N/C

REACTOR N/C

40 2 2.5 3

N/C

3.5

FIG. 7: SELECTION OF OPTIMUM N/C IN CONDENSER AND REACTOR

Low Elevation and Compact Layout

Fig. 9 represents a 3D graphic of Improved ACES (ACES 21) urea plant. The HP equipment in the synthesis section is laid-out very compactly in low elevation owing to the sophisticated two-stage synthesis concept with VSCC and HP ejector. The highest level in the synthesis section, that is the VSCC top, is only about 30 to 35 m, depending on the plant capacity and configuration, which significantly lower than even traditional total recycle urea process of which reactor is installed on the ground.

EQUILIBRIUM PRESS.

RIUM ILIB EQU SSURE PRE

80 70
C ON V E R S ION
EQUI LI BRI U M LI NE@ N/ C= 3 .7

60 50 40 30 20 10 0 0

EQUI LI BRI UM LI NE @ N/ C= 3 .0

REACTOR

CONDENSER (VSCC)

10 RESIDENCE 20 TIME 30

40

FIG. 8: CONVERSION VS. RESIDENCE TIME IN CONDENSER AND REACTOR

FIG. 9: 3D GRAPHIC REPRESENTATION OF IMPROVED ACES (ACES 21)

Advantages
As described in the previous sections, advantages of the Improved ACES (ACES 21) process over conventional processes are summarized below:

less HP piping and construction materials owing to lower elevation layout, fewer HP vessels and simplified synthesis loop; easier erection using commonly available construction equipment and techniques owing to low elevation layout and fewer and smaller HP vessels; easier operation supported by forced circulation by HP ejector, low elevation layout and fewer HP equipment easier maintenance owing to low elevation layout and fewer HP equipment smaller sized HP vessels by combining the VSCC and high efficiency reactor less energy consumption owing to optimized synthesis conditions and proprietarily designed VSCC, reactor and stripper.

PROCESS PERFORMANCE
Table III shows consumption of raw materials and utilities of typical 3,000 to 3,500 mtpd plant based on Improved ACES (ACES 21) combined with TEC Spout-fluid Bed Granulation. The optimized synthesis conditions and well contrived heat integration reduces energy consumption 5 to 10% even from original ACES, which has been one of the most energy efficient urea processes in the world.

Table III Specific Consumption Figures of TEC Improved ACES (ACES 21) Urea Plant Combined with TEC Spout-Fluid Bed Granulation
Unit CO2 Compressor NH3 Pump Carbamate Pump NH3 CO2 Steam Import (42 Kg/cm2G x 380 C) Steam Import (22 Kg/cm2G x 300 C) Steam Export (5 Kg/cm2G saturated) Net Steam Consumption C.W. (T=10C) Power (process) Power (granulation) ton ton ton ton ton ton m3 kWh kWh Notes: 1) unit: per metric ton of final granular urea product 2) Final granular urea product includes 0.25 wt% moisture and 0.45 wt% formaldehyde. Configuration 1 Steam Turbine Steam Turbine Steam Turbine 0.563 0.731 0.90 none none 0.90 86 9 24 Configuration - 2 Steam Turbine Electric Motor Electric Motor 0.563 0.731 0.80 none none 0.80 81 22 24 Configuration 3 Electric Motor Electric Motor Electric Motor 0.563 0.731 none 0.67 0.24 0.43 52 106 24

ON-GOING UREA PROJECTS WITH IMPROVED ACES (ACES 21) Technological Revamp Project in China
In April 2002, TEC was awarded a contract for capacity expansion and energy saving project of the fertilizer plant of Sichuan Chemical Works (Group) Ltd. (SCW) in China of which existing 1,620 mtpd urea plant was built by TEC in 1976. Table IV outlines the project profile. The project is now being executed in close collaboration among TEC, SCW and Chengda Chemical Engineering Corporation of China (CCECC). The revamped plant is scheduled to be commissioned in late 2003. The Improved ACES (ACES 21) technology is selected for this project.

Table IV Sichuan Chemical Works Ltd. Project Data

Plant Capacity : 2,460 MTPD (revamp) Location : Process : Scope of Work Sichuan Province, China TEC Improved ACES (ACES 21) + Vacuum Evaporation TEC: CCECC: SCW: License & BDP + Critical Equipment Supply Detailed Engineering Procurement, Construction,Commissioning

Contract Date : February 2002 Effective Date : April 2002 Mechanical Completion : ( 2003 )

The major objectives of the project are: to increase production capacity from 1,620 mtpd to 2,460 mtpd (50% increase) with minimum investment to reduce energy consumption by 30% with advanced energy saving technologies to receive carbamate solution from melamine plants in efficient manner to minimize ammonia consumption to achieve long-term safe operation to protect environment with modern pollution abatement technology

Table V summarize the technological revamp features of the project and Fig. 10 shows a process block diagram after the revamp. The revamp outline is described in the following paragraphs:

Table V Technological Features of Sichuan Chemical Works Ltd. Project

REVAMPING 2,460 MTPD Capacity CO2 Compression New Centrifugal Compressor Synthesis Improved ACES Urea Reactor Re-lined with 25Cr22Ni2Mo S.S. + Baffle Plates Finishing Crystallization Vacuum Evaporation +Granulation / Prilling +Granulation / Prilling Waste Water None Hydrolyzer Treatment & Stripper Carbamate Solution Yes Yes from Melamine Plant

EXISTING 1,620 MTPD Centri. Centri. Booster + Recipro. Recipro. Compressor TR-CI Titanium

NH3
NH3 FEED

CO2
REPLACED TO CENTRIFUGAL CO2 COMPRESSION MACHINE

REVAMP

SYNTHESIS (Improved ACES) MINOR MODIFICATION

MINOR MODIFICATION

PURIFICATION

RECOVERY

MODIFICATION VAC.EVAPORATION

NEW INSTALLATION

550 T/D UREA

GRANULATION / PRILLING

MELAMINE OFF GAS TREATMENT SYSTEM

MELAMINE PLANTS & OTHER UREA PLANT

1,910 T/D UREA

FIG. 10: PROCESS BLOCK DIAGRAM FOR REVAMPED PLANT

CO2 Compression
The CO2 compression unit, originally traditional combination of a centrifugal booster compressor and a reciprocating compressor, is converted to a centrifugal CO2 compressor driven by an extraction-admission-condensing turbine.

Ammonia Feed
Ammonia feed pumps, originally three running and one stand-by configuration will become two running and two stand-by without any modification owing to process renovation from traditional total recycle process to CO2 stripping process which does not require liquid ammonia recycle, resulting in remarkable reduction of electric power consumption.

Carbamate Feed
Existing centrifugal carbamate feed pumps will have minor modification to its impeller so as to meet with reduced discharge pressure after revamp (existing 260 Kg/cm2G is reduced to 160 Kg/cm2G).

Synthesis
Existing titanium-lined Urea Reactor has been re-lined with 25Cr-22Ni-2Mo steel and equipped with baffle plates to be re-utilized after the revamp without relocation. A stripper, a carbamate condenser (VSCC type) and an HP ejector are added to comprise a new synthesis loop having 50% more capacity than the existing production capacity. See Fig. 11. The N/C ratios in the synthesis section is continuously monitored with a special density meter to control it at optimum.

REACTOR

STRIPPER

CONDENSER(VSCC)
TO HP ABSORBER COOLER

MP STEAM

COND.

NEW STRIPPER CARBAMATE CONDENSER HP EJECTOR CO2 COMPRESSOR MODIFICATION NH3 PREHEATING REACTOR CARBAMATE PUMP
BFW LP STEAM TO PURIFICATION SECTION

EJECTOR

NH3 PREHEATER

CO2 NH3 FROM HP ABSORBER COOLER

CO2 COMPRESSOR

NH3 PUMP

CARBAMATE FEED PUMP

FIG. 11: REVAMPED SYNTHESIS SECTION WITH IMPROVED ACES

Purification and Recovery

The existing middle pressure and low pressure sections are fully re-utilized with minor modifications and addition of MP preheater and LP precondenser.

Finishing
The existing crystallization process is converted to vacuum evaporation process which minimizes ammonia

loss and improves operability and maintainability. The existing crystallizer is fully re-utilized as pre-concentrator (vacuum concentrator). Existing vacuum generation unit is converted to surface condenser system. 96 wt% urea solution is produced as the feed to the existing granulation unit and an export to other urea plant and melamine plants.

Process Condensate Treatment

Process Condensate Treatment section is newly installed to condense water vapor that contains small quantity of urea, ammonia and CO2 from evaporation section and clean its condensate by hydrolyzing urea and recover ammonia and CO2. The system contributes to eliminating the pollutants from urea plant and to improving the ammonia consumption.

Kujang-1B Project in Indonesia

In the same year 2002, another project has been effectuated to build a 1,000 mtpd ammonia plant and a 1,725 mtpd urea plant in Indonesia. The ammonia plant is based on conventional KBR technology and the urea plant applies the Improved ACES (ACES 21). The project is prospected to be completed in 2005. The plant owner, PT Pupuk Kujang, is an Indonesian state owned company located in West Java and a member of PT Pupuk Sriwidjaja (PUSRI) holding company who has been the partner of TEC in R&D of Improved ACES (ACES 21). Table VI outlines the Kujang-1B project.

Table VI

Project Data for Kujang-1B Project

Plant Owner : Plant Location : Plant Capacity : Ammonia Process : Urea Process : Scope of Work :

PT Pupuk Kujang Cikampek, Cikampek, West Java, Indonesia Ammonia 1,000 MTPD Urea 1,725 MTPD KBR Conventional TEC Improved ACES (ACES 21) License & EPC (LSTK)

Mechanical Completion : ( 2005 )

The plant will be the most advanced urea plant in Indonesia based on the following technical features: simple, compact and low energy urea plant with Improved ACES (ACES 21) technology. real-time N/C monitoring in synthesis loop easy operation and free of maintenance with all centrifugal CO2 compression, ammonia feed, and carbamate feed driven by steam turbines based on proven technologies supported by abundant experiences.

zero emission and zero effluent with TEC proprietary dust scrubber for prilling tower and process condensate treatment system

APPROACH TO MEGA-CAPACITY PLANT

TEC announced that single train 3,500 mtpd unit based on original ACES combined with TEC Spout-Fluid Granulation process is technically feasible and economically advantageous in Gulf Nitrogen 2002 [3] and in Nitrogen 2001 [4] respectively. The Improved ACES (ACES 21) is more suitable for mega-capacity plant than conventional stripping urea processes owing to its important features, i.e. less and smaller HP equipment and low elevation and compact layout. Fig. 12 shows the comparison of sizes and weights of HP equipment of 3,500 mtpd original ACES and Improved ACES (ACES 21). As shown in Fig. 12, the reactor height and weight is only about half of conventional ACES and the heaviest in erection weight is carbamate condenser (VSCC type) which is 75% of that of the reactor of original ACES. Needless to say, those features give great advantages in equipment fabrication, transportation and erection.

Reactor
510 tons

Condenser

Stripper

380 tons 330 tons 220 tons 330 tons 280 tons

ACES Improved ACES

ACES

Improved ACES

ACES Improved ACES

FIG. 12: SIZE AND WEIGHT OF HP EQUIPMENT OF 3,500 MTPD PLANT

In erecting HP equipment, the low elevation layout with smaller vessels is quite favorable. For example, Fig. 13 illustrates HP equipment erection with crane, comparing between Improved and conventional ACES. As can be seen, boom length, height and lifting capacity of crane can be remarkably reduced. Studies by TEC in cooperation with a construction contractor have indicated that about 30% reduction of crane cost can be expected.

Original Original ACES ACES

Improved Improved ACES ACES

FIG. 13: ERECTION OF HP EQUIPMENT WITH CRANE

FUTURE DEVELOPMENT FOR ALTERNATIVE CONFIGURATION

The Improved ACES (ACES 21) synthesis loop is comprised by a vertical submerged carbamate condenser (VSCC), a vertical cylindrical urea reactor, vertical falling film type stripper, and HP carbamate ejector. Now TEC can offer alternatives to the currently offered two-stage synthesis concept. Fig. 14 shows one of alternatives composed by a vertical unified urea reactor-condenser, a stripper and a HP carbamate ejector. The urea reactor-condenser is a vertical tower partitioned into two sections, upper section is the condensing part with cooling tubes and lower section is the reaction part with baffle plates. The reactor-condenser simply combines the functions of VSCC and reactor into one tower. Therefore, the process is not substantially different from current configuration comprised by separate VSCC and the reactor. Patent applications for this alternative configuration were filed including some process variations together with that for current Improved ACES (ACES 21) in major countries and areas worldwide. The alternative configuration gives the following advantages: less HP piping by unifying reactor and HP condenser less equipment cost by eliminating two HP hemispherical heads less structure because the reactor-condenser can be a self-supporting tower

Based on the above discussions, it is suggested that the alternative configuration is also attractive if fabrication, transportation and erection are not so problematic. In particular, it would be more favorable and feasible for the medium or small sized units.

TO MP ABSORPTION FROM CARB. PUMP REACTORCONDENSER BFW+STEAM

BFW STRIPPER MP STEAM

EJECTOR FROM NH3-PUMP FROM CO2-COMP

COND

TO MP DECOMPOSITION

FIG. 14:

ALTERNATIVE SCHEME FOR IMPROVED ACES

CONCLUSION
Intensive efforts by TEC and PUSRI after completion of R&D of Improved ACES (ACES 21) in 2000 has realized two large-scale commercial projects in China and Indonesia two years later. The two projects are being executed in close collaboration of TEC and PUSRI as licenser, plant owners and engineering firms in China and Indonesia to be completed in 2003 and 2005. Successful completion of the project in China will be an epoch of urea process technology, i.e. the urea plant revamped with Improved ACES (ACES 21) CO2 stripping technology utilizing an existing reactor to achieve 50% capacity increase and 30% energy saving. The Kujang-1B project in Indonesia will be a milestone for a most advanced urea plant with high reliability, low investment and low energy consumption. TEC is the only urea process licenser having urea synthesis, prilling, granulation and pollution abatement technology of full commercial status. TEC will continue contributing to fertilizer industry by developing urea process, engineering and construction of urea plants with TEC-PUSRI Improved ACES (ACES 21) technology and TEC Spout-Fluid Bed Granulation.

References
1. H. Moriawa et al, ACES Process for the 21st Century, Nitrogen 99 2. Y. Kojima et al, Development of the ACES 21 Process, Nitrogen 2000 3. H. Morikawa et al, Mega-capacity Urea Plants TECs Approach, Gulf Nitrogen 2002 4. G. Nishikawa et al, Large Scale Urea Granulation Plants based on TEC Technology, Nitrogen 2001