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1
GROUP 8
NURUL HIDAYAH BINTI HASNAN 13343
NOR ASYIQIN BINTI ZAINAL ABIDIN 13294
MOHAMAD FARHAN BIN MOHAMAD ZAINI 13123
LOK CHEN CHUANG 13106MUHAMMAD IZZUDDIN BIN MOHAMMAD ZAKI 13239
ROSLI BIN MHM SAID 14680
SUPERVISOR: DR. NOORYUSMIZA YUSOFF
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CONCLUSION
PROCESS ECONOMICS AND COST ESTIMATION
WASTE TREATMENT
SAFETY AND LOSS PREVENTION
INSTRUMENTATION AND CONTROL
COMPARISON BETWEEN 3 PFD
CONCEPTUAL DESIGN ANALYSIS
LITERATURE REVIEW
INTRODUCTION
2
OVERVIEW OF PRESENTATION
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3
Introduction
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OBJECTIVE
Develop a plant design for an integrated plant for the
simultaneous production of ammonia and urea.
PROJECT BACKGROUND
Urea (NH2CONH2) is an essential nitrogen-rich
fertiliser to the agricultural industry.
The urea is synthesized from the ammonia and
carbon dioxide (CO2).
The plant capacity for the production of ammonia is
300 tonnes per day.
The maximum capacity of urea plant is 530 tonnes
per day.
4
INTRODUCTION
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5
PROCESS ROUTE
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6
Literature Review
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MARKET STUDY AND COST DATA
India ,15%
US , 14%
Brazil, 7%
Thailand, 7%
Others, 57%
Percentage of Global Fertilizers Imported by Countries
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MARKET STUDY AND COST DATA
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UREA & AMMONIA SELLING PRICE
Urea latest price as of May 2013 = RM 1039.05/tonnes
Ammonia latest price as reported on Jan 2013 = RM 1896/tonnes
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PRELIMINARY HAZARD ANALYSIS
Hazardous Events Identification:
Location Events
Ammonia Plant Major leak or rupture vessels of warm, pressurised liquid ammonia
Major leak of rupture vessels of refrigerated ammonia at -33C
Urea Plant Major leak or rupture urea reactor system (leading to ammonia release)
Several inherent safety aspects for consideration in designing plant that is
inherently safe:
Heat of reaction, temperature, and pressure
Hazardous substances
Chemical interaction
Inventory
Equipment safety
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PLANT LOCATION
i
i. Kerteh Integrated Petrochemical Complex, Terengganu
ii. Gebeng Industrial Estate, Kuantan, Pahang
iii. Tanjung Langsat Industrial Estate, Johor
The plant site should be ideally located where the cost of production and
distribution can be at a minimum level . .Also there has to be a good scope for
plant expansion and a conducive environment, safe living conditions for easy
plant operation.Shrinivas, P.K., 2009.
iii
ii
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PLANT LOCATION
SITE CONSIDERATION Gebeng Tanjung Langsat Kerteh
1. Location 3 4 5
2. Area Available 4 5 3
3. Land Price 5 2 4
4. Types of Industries Exist 5 5 5
5. Raw Material Supplier 5 5 5
6. Power Supply 4 2 5
7. Water Supply 5 3 48. Roadway Facilities 4 5 5
9. Port Facilities 4 5 2
10. Emergency and Safety Facilities 2 5 5
11. Airport 5 5 2
12. Incentives 4 5 4
13. Labour Supply 5 5 3
14. Competitor 5 1 3
15. Political and Government Decisions 1 5 3
16. Climate 2 5 2
Total Score 53 67 60
Percentage (%) 66.25 83.75 75
Ranking 3 1 2
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JUSTIFICATIONS
Specifically developed to cater to petrochemical industry and is well-
equipped with all the necessary infrastructure and service facilities.Has more than 3,000 acres of land available for lease at between RM14.00 to
RM30.00/ft2 compared to Gebeng Industrial Estate and Kerteh Integrated
Petrochemical Complex.
The raw material can be obtain PETRONAS LNG, PETRONAS Gas Berhad or
Shell Gas BV.Power and water supply will be obtained from Tenaga Nasional Berhad,
Syarikat Air Johor Berhad and Centralized Utility Facilities PGB.
Source: Iskandar Regional
Development Authority
(IRDA), 2011
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Conceptual Design Analysis
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BATCH VS CONTINUOUSGUIDELINES BATCH CONTINUOUS
Production rate < 12.43 tonnes/day > 12.43 tonnes/dayPurpose Suitable for research
purposes
Suitable for mass
production (profit
purposes)
Lifetime of Product Short Long
Availability Product is a seasonalRaw material are limited
Product is a commodityRaw material are always
available
CONTINUOUS
Production rate: 530 tonnes/day forurea
Purpose: Generate profit
Lifetime: 20 years
Availability: Commodity
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PROCESS BLOCK DIAGRAM
Steam
Syngas
Carbon
Dioxide
Urea Granules
Pressure: 41 bar
Temperature: 400C
Pressure: 140 bar
Temperature: 180CPressure: 1 bar
Temperature: 115C
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Hydrogen Purification Unit
Carbon Dioxide [To Urea Production Unit]
Hydrogen
[To Nitrogen
Production Unit]
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Process step of Hydrogen Purification & theshift process:
18
HYDROGEN PURIFICATION
Source: (Bartholomew & Farrauto, 2011)
Process
Step
Reaction Catalyst Temperature
(C)
Pressure
(bar)
Water GasShift (HT) Cu 350 28
Water Gas
Shift (LT)CuO 250 26.5
Methanation Ni 330 27
2 2 2CO + H O H + CO
2 2 2CO + H O H + CO
2 4 2CO + 3H CH + H O
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Solvent absorption separation technologyremove CO2.
Solvent: Diethanol Amine (DEA)
Chemically stable.
Boiling point: 269C at 760mmHg.
Heat of Reaction: 1350 kJ/kg CO2.
Reduce the solvent degradation during
stripping and reduce solvent loss and
accumulation in the units. (A.E. Salako, 2005)
19
HYDROGEN PURIFICATION
Back to Process Flow Diagram
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Pressure Swing Adsorption(PSA)
PSA can be placed on-site which makes
N2readily available
During shutdown, less cost will be cut
More economical since amount of N2produced is less than 20,000 SCFH
("Introduction to Air Separation," 2013)
MEMBRANE
Least costly for repair and maintenance
Not good enough for certain processeswhere there must be 1 part per billion
(ppb) purity
Process flow rates up to 40,000 SCFH(the use of membrane is not necessary
for 40,000)
20
NITROGEN PRODUCTION
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21
Nitrogen Production Unit
Hydrogen [ From Hydrogen Purification Unit]
Ammonia Recycle
[From Ammonia
Synthesize Unit]
Feed to Ammonia Reactor [To
Ammonia Synthesize Unit]
Back to Process Flow Diagram
Nitrogen
Air
T = 200C
P = 15.5 bar
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22
Ammonia Synthesize Unit
Feed for Ammonia
Reactor
[From Nitrogen
Production Unit]
Ammonia Recycle
[ To Nitrogen Production Unit]
[To Urea Production Unit]
Purge
Liquid Ammonia
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23
AMMONIA SYNTHESIZE
Ammonia Synthesis (Haber-Bosch process) The reaction is reversible and exothermic
The reactor is a plug flow unit and assumed
to be isothermal with fixed conversion (Bike,Morari, & Grossmann, 1985).
Process step of Ammonia Synthesis
Source: (Bartholomew & Farrauto, 2011)
Process
Step
Reaction Catalyst Temperature
(C)
Pressure
(bar)
Ammonia
Synthesis
Ru 350-400C 41
Fe3O4 >450C 200
2N
2
Back to Process Flow Diagram
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24
UREA PRODUCTION
1streaction (Formation of carbamate):
2ndreaction (Formation of urea):
3rdreaction (Formation of Biuret):
molkJH
lCOONHNHgCOgNH
/84
)()()(2 4223
molkJH
OHCONHNHCOONHNH
/23
22242
molkJH
NHCONHCONHNHNHCO
/60
)(2 322222
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25
Urea Production Unit
[From Ammonia Synthesize Unit]
[From Hydrogen
Purification Unit]
Molten Urea
[ To Granulation Unit]
Back to Process Block Diagram
Ammonia
Water
Carbon Dioxide
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26
GRANULATION
Commercially, fertilizer urea can be purchased as prills or as a granulated material
(Curtis J. Overdahl, George W. Rehm, & Meredith, 1991).
Advantages Disadvantages
Cheaper Spoil the product quality
Involve only one single
process step, scaleable
to any capacity range
More prone to absorbing
moisture; make it hard to
handle.
Can also be used to
either increase or
reduce particle size,
Larger size urea prills
production requires very
tall prilling tower - high
capital investment
Easily damage when
handling and easily
converted to dust.
Both crushing and
impact strength of the
prill is less than for
granule
PRILLING
Advantages Disadvantages
Larger, harder, and
more resistant to
moisture and less
dusty. More suitable
for fertilizer blends.
Expensive
Three times harder
than prilled urea
Multiple processing
steps involved in
the process add
complexityHigh product quality
Has less fines and dust
when handled and
transported
Absorbs lesser
moisture
Environmental
friendly
GRANULATION
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27
Granulation Unit
Molten Urea
[From Urea
Production Unit]
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28
Comparison between 3 PFD
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29
COMPARISON BETWEEN 3 PFD
Description PFD 1 PFD 2 PFD 3
Catalyst used in ammonia
reactor
Iron fillings,
Fe3O4Ruthenium
Iron fillings,
Fe3O4
CO2feed input Stripper StripperStripper + Urea
reactor
Operatingcondition NH3
T (C) 400 400 400
P (bar) 200 41 200
Operating
condition Urea
T (C) 170 170 182
P (bar) 140 140 152
Conversion (%)Ammonia 25 32 25
Urea 68 68 63
ComplexityNo. Major
Operation Units18 18 19
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30
COMPARISON BETWEEN 3 PFD
PFD 1 PFD 2 PFD 3
Reactant (t/yr)
Syngas 113,170.71 113,170.71 113,170.71
Steam 57,071.52 57,071.52 57,071.52
Air 121,109.36 121,109.36 121,109.36
NH3 89,976.97 89,976.97 89,976.97
CO2 115,931.93 115,931.93 115,931.93
Product (t/yr)
Urea 159,555.76 159,555.76 159,223.62
O2 121,109.36 121,109.36 121,109.36
NH3 9,018.88 9,018.88 4,567.24
EP 1 RM 114.119 Million RM 114.119 Million RM 113.77 Million
EP 2 RM 207.719 Million RM 207.719 Million RM 207.37 Million
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31
JUSTIFICATION ON CHOSEN PFD
PFD 2 is selected since it meets thespecifications below:
Reactant required:
Syngas = 113,170.71 tonnes/yr
Steam = 57,071.52 tonnes/yr
Product:
Urea = 159,555.76 tonnes/yr
Ammonia = 9,018.88 tonnes/yr
Gross Profit:RM 207.719 Million
Catalyst: Ruthenium
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Before Heat Integration
32
Process Flow Diagram
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33
HEAT INTEGRATION
Objectives : To optimize the energy recovery byexchanging heat using process stream instead of utilities.
Pinch Technology Method
o
To determine the amount of heat recovery from theprocess plant.
o Use composite curve to identify amount of energy of
hot and cold utilities required as well as pinch
temperature.
o Software used - Sprint
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34
HEAT INTEGRATION
Composite Curve
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35
HEAT INTEGRATION
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After Heat Integration
36
Process Flow Diagram
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UtilityBefore Integration
(MW) After Integration(MW) Percentage UtilityReduced (%)
HOT 433.798 0 100.0
COLD 264.907 16.191 94.0
37
HEAT INTEGRATION
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38
Instrumentation & Control
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39
Safety and Loss Prevention
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40
Waste Treatment
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Economic Analysis
To determine the project is feasible or attractive enough forinvestment
To determine the profit or loss produced by the processplant design
41
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42
COST DATA
RM1039/tonneUrea
RM 1896/tonneAmmonia
RM 632/tonne
Oxygen RM455/tonneSyngas
RM 3/tonneSteam
RM 70/kWYearHot Utilities
RM 7.5/kWYearCold Utilities
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43
PROFITABILITY ANALYSIS
ECONOMIC POTENTIAL 1EP 1 = Product Value - Cost of Raw Materials
EP 1 = (Total Urea Produced)(Total Synthesis Gas + Steam Cost)
ECONOMIC POTENTIAL 2
EP 2 = Product Value - Cost of Raw Materials + By Product Value
EP 2 = (Total Urea Produced)(Total Synthesis Gas + Steam Cost) +
(Total 10 % of Ammonia + Oxygen Produced)
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ECONOMIC STUDIES
Economic Potential 1 (EP 1) Economic Potential 2 (EP 2)
Flowrate
(Tonne/ Day)
Product Raw Materials Product + Byproducts Raw Materials
Urea =
484 tonne/Day
Synthesis Gas =
343 tonne/Day
Steam =
173 tonne/Day
Urea =
483 tonne/Day
Ammonia =
273 tonne/Day
Oxygen =
367 tonne/Day
Synthesis Gas =
343 tonne/Day
Steam =
2173 tonne/Day
Cost
(RM/Year)
Product Raw Materials Product + Byproducts Raw Materials
Urea =
RM
165786414/Year
Synthesis Gas =
RM 51497200 Year
Steam =
RM 171329/Year
Urea =
RM 165786414/Year
Ammonia =
RM 17059634/Year
Oxygen =RM 76541116/Year
Synthesis Gas =
RM 51497200/ Year
Steam =
RM 171329/ Year
Economic
Potential
(RM/Year)RM 114 Millions/Year RM 208 Millions/Year
ECONOMIC ANALYSIS
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ECONOMIC ANALYSIS
ECONOMIC STUDIES
Economic Potential 3 (EP 3)
Before Heat Integration
Economic Potential 3 (EP 3)
After Heat Integration
Consumption (KW)
Hot Utility = 26249KW
Cold Utility = 42683KW
Total = 68932KW
Hot Utility = 0 KW
Cold Utility = 16197 KW
Total = 16193 KW
Cost (RM/Year)Total Hot + Cold Utility = RM
3,184,687/Year
Total Hot + Cold Utility = RM
121,445/Year
Economic Potential
(RM/Year) RM 204 Millions/Year RM 207 Millions/Year
EP 3 = EP 2Total Utility Cost
77 % Energy
Reduction
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Production of NH3 = 300 tonnes/day and Urea =480 tonnes/day
Specification of urea granulespurity, size
Gross Profit = RM 207 Millions/Year
46
CONCLUSION
Purity 98 wt%
Size 3.03.5 mm
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.washingtonpost.com/blogs/wonkblog/wp/2013/04/18/the-texas-fertilizer-plant-explosion-is-horrific-but-how-common-is-this/http://www.washingtonpost.com/blogs/wonkblog/wp/2013/04/18/the-texas-fertilizer-plant-explosion-is-horrific-but-how-common-is-this/http://www.washingtonpost.com/blogs/wonkblog/wp/2013/04/18/the-texas-fertilizer-plant-explosion-is-horrific-but-how-common-is-this/http://www.washingtonpost.com/blogs/wonkblog/wp/2013/04/18/the-texas-fertilizer-plant-explosion-is-horrific-but-how-common-is-this/http://www.washingtonpost.com/blogs/wonkblog/wp/2013/04/18/the-texas-fertilizer-plant-explosion-is-horrific-but-how-common-is-this/8/13/2019 FYDP slide presentation
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8/13/2019 FYDP slide presentation
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