Thyssenkrupp Ag · XETR:TKA
Thyssenkrupp — Nitrogen + Syngas 2012
25 slides from Thyssenkrupp's conference presentation, Feb 23, 2012
Slide 1: Emission control in urea plants in normal operation and upset cases
Emission control in urea plants in normal operation and upset cases – why so many different solutions? Martina Schmitz – Athens, 20 – 23 February 2012
Slide 2: Table of Content
Table of Content Emission Control in Urea Plants Table of Content 1. Introduction 2. Emissions during normal operation 3. Emissions from tank vents and safety valves 4. Emergency releases 5. Case studies 6. Résumé Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 3: International Requirements for Ammonia Emissions
Emissions during Normal Operation International Requirements for Ammonia Emissions IFC – International Finance Corporation (World Bank Group) Granulation Unit Prilling Unit 50 mg/Nm3 50 mg/Nm3 EFMA – European Fertilizer Manufacturer Association Granulation Unit Prilling Unit Vents 50 mg/Nm3 50 mg/Nm
Slide 4: Emission Points
1 Emissions during Normal Operation Emission Points Total : 4 - 6 kg/h NH3 80 – 90 kg/h NH3 Atm Absorber LP Absorber Off gas Steam from evaporation condensate Granulator to Process Process Scrubber Process water condensate water tank Synthesis off-gas Air from granulator Bleed to evaporation UREA SY
Slide 5: Acidic Scrubbing in Granulation Plant
2 Emissions during Normal Operation Acidic Scrubbing in Granulation Plant Nitric or sulphuric acid Acidic Part AN- or AS-solution Dust Part Process water Air from granulator Weak urea solution Granulator Scrubber Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 6: Acidic Scrubbing -> Purge Solution
Emissions during Normal Operation Acidic Scrubbing -> Purge Solution Nitric acid + NH3 -> Ammonium nitrate (AN) solution Liquid Fertilizer UAN solution Sulphuric acid + NH3 -> Ammonium sulphate (AS) solution Liquid Fertilizer AS crystals or pellets Incorporation in granules Emission control in urea
Slide 7: Acidic Scrubbing in Granulation Plant - Requirements
1 Emissions during Normal Operation Acidic Scrubbing in Granulation Plant - Requirements Acidic part Dust part Granulator Scrubber Solution purge Acid Tank Solution Tank Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 8: Acidic Scrubbing for Synthesis Vents
3 Emissions during Normal Operation Acidic Scrubbing for Synthesis Vents Atm Absorber Acidic Scrubber LP Absorber Nitric or sulphuric acid AN- / AS-solution Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 9: Flaring for Synthesis Vents
3 Emissions during Normal Operation Flaring for Synthesis Vents Nitrogen purge Nitrogen purge Atm Absorber NOx LP Absorber Flare Support gas Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 10: Flaring for Synthesis Vents - Consequences
3 Emissions during Normal Operation Flaring for Synthesis Vents - Consequences Nitrogen purge Nitrogen purge Atm Absorber NOx LP Absorber Flare Support gas NOx compared to NH3 has a negative environmental balance: Global warming potential Tropospheric ozone-forming potential Ozone-depletion Em
Slide 11: Tank Vents and Safety Valves: International Requirements
Emissions from Tank Vents and Safety Valves International Requirements IFC – International Finance Corporation (World Bank Group) Granulation Unit Prilling Unit 50 mg/Nm3 50 mg/Nm3 This requirement only applies to 95 % of the time that the plant is operating EFMA – European Fertilizer Manufacturer
Slide 12: Mitigating the Consequences
Emissions from Tank Vents and Safety Valves Mitigating the Consequences Vents from tanks Vent stack Acidic scrubbing Flaring Safety valves ammonia pump Flaring Safety valves carbamate Avoidance of PSV (design) Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 13: Main Safety Valves in Urea Plant
Emissions from Tank Vents and Safety Valves Main Safety Valves in Urea Plant HP Scrubber Pool Condenser Reactor Rectifying column Stripper NH3 CO2 Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 14: Main Safety Valves in Urea Plant
Emissions from Tank Vents and Safety Valves Main Safety Valves in Urea Plant HP Scrubber Pool Condenser PS PS PS Reactor Rectifying PS column PS Stripper PS NH3 CO2 Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 15: Overview Mitigating the Consequences
Emissions from Tank Vents and Safety Valves Overview Mitigating the Consequences Vents from tanks Vent stack Acidic scrubbing Flaring Safety valves ammonia pump Flaring Safety valves carbamate Avoidance of PSV (design) Avoidance of blowing (pressure switches) Vent stack Flaring Emi
Slide 16: Emergency Release
Emergency Release No international standards available, but neighbouring inhabitants? areas with frequent emissions? local authority requirements or company policy limits Event rare, but impact serious -> Risk evaluation Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Sch
Slide 17: Risk – Definition and Ranking
Emergency Release Risk – Definition and Ranking Risk = Frequency x Consequence Risk Ranking by Risk Matrix LOPA (Layer Of Protection Analysis) Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 18: Tube Rupture - Separator System
4 Emergency Release Tube Rupture - Separator System Emergency Separator HP Scrubber Pool Condenser Stripper Collection Tank Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 19: Tube Rupture - Absorber System
4 Emergency Release Tube Rupture - Absorber System Emergency Absorber water HP Scrubber Pool Condenser Stripper Collection Tank Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 20: Tube Rupture - Flare System
4 Emergency Release Tube Rupture - Flare System Emergency Flare HP Scrubber Pool Condenser Stripper Collection Tank Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 21: 'Zero Emission' Flaring System installed in Fertil Plant, Abu Dhabi
3 Case Studies ‚Zero Emission‘ Flaring System installed in Fertil Plant, Abu Dhabi LP Emergency Vent Ammonia Absorber Flare Flare Flare Flare Support Support Support gas gas gas Process water Process water PSVs, RD N2 Atm Absorber LP Absorber Buffer tanks N2 NH3 N2 N2 Tank vents Steam Process Proces
Slide 22: Acidic Scrubbing installed in Yara Plant, The Netherlands
3 Case Studies Acidic Scrubbing installed in Yara Plant, The Netherlands < 30 mg/Nm3 Atm Absorber Acidic Scrubber LP Absorber Nitric acid AN solution Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 23: Emergency System installed in Yara Plant, The Netherlands
PRU-999 04/00 Case Studies Emergency System installed in Yara Plant, The Netherlands HP Scrubber Emergency AI Absorber Consumers Turbine AI Vent Pool Condenser AI Urea Sol. Water Stripper Tank Tank Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 24: Emergency System installed in Safco 4 Plant, Saudi Arabia
PRU-999 04/00 Case Studies Emergency System installed in Safco 4 Plant, Saudi Arabia HP Scrubber Emergency Separator water Consumers Turbine Vent Pool Condenser Collection Stripper Tank Emission control in urea plants 20-23 Febr 2012 Nitrogen + Syngas, M. Schmitz
Slide 25: Any questions?
Any questions?