DIFF BW TOYO N SAIPEM.pptx

Feb 7, 2024Download as PPTX, PDF0 likes35 views

This document provides information about the synthesis loop equipment for the SAIPEM TOYO (ACES21) urea plant. It describes the reactor, stripper, condensers, separators, ejectors, and other major equipment. It also notes some differences between this plant and other typical urea plant process designs, such as the locations where CO2 and NH3 are fed to the loop and the use of a dehydrogenation column and additional anti-surge valves.

SYNTHASIS LOOP
EQUIPMENT NAME SAIPEM TOYO(ACES21)
REACTOR MOC : SHELL : CS+5mm LINING 25/22/2
Cr /Ni/Mo
INTERNALS/TRAYS : 25/22/2 Cr/Ni/Mo
DES T/P : 218/171
Volume : 250 m3
No. of Baffles : 16 (9 super cup trays
located at bottom +7 sieve trays located
at top )
CO2Conversion : 62 %
Outlet concentration:
NH3: 31.87 % CO2: 15.47 % UREA:32.99
% H2O:19.68 %
MOC : CS+25 CR DUPLEX SS
INTERNALS/TRAYS : 25 CR DUPLEX SS
DES T/P : 210/171
Volume : 212 m3
No. of Baffles : 5 (baffle spacing 3 meter)
CO2Conversion : 63 %
Outlet concentration:
NH3: 35.19 % CO2: 13.61 % UREA:32.47
% H2O:18.66 %
STRIPPER MOC : SHELL : CS+3mm C.A
TUBES IN : ZIRCONIUM
OUT : 25/22/2 Cr/Ni/MO
DES T/P (S-T) : 250/28-234/165
Outlet concentration:
NH3: 25.51 % CO2: 7.43 % UREA:43.12 %
MOC : STEAM SIDE : CS
UREA SIDE (TOP & BOTTOM DISH END) :
CS+DP28W
TUBE : DP28W
DES T/P (S-T) : 240/25-210/171
Outlet concentration:
NH3: 12.89 % CO2: 12.66 % UREA:49.31

SYNTHASIS LOOP
EQUIPMENT NAME SAIPEM TOYO(ACES21)
CARBAMATE CONDENSER Layout : horizontal
Numbers : 2
MOC : SHELL : CS+3mm C.A
TUBES : IN : ZIRCONIUM
OUT : 25/22/2 Cr/Ni/MO
DES T/P (S-T) : 195/8-220/165
Generating Steam pressures
E-1005A : P : 5.5 kg/cm2G T : 162 0C
E-1005B : P : 3.5 kg/cm2G T : 147 0C
Layout : vertical
Numbers : 1
MOC : SHELL : CS+25 CR DUPLEX SS
TUBES : IN : DP28W
OUT : 25/22/2 Cr/Ni/MO
DES T/P (S-T) : (210/171)-(200/8)
Generating Steam pressures
LP Steam
P : 5 kg/cm2G T : 158 0C
Outlet concentration:
NH3: 31.99 % CO2: 22.55 % UREA:26.40
% H2O:18.99 %
CARBAMATE SEPARATOR SHELL : CS+5mm LINING 25/22/2 Cr
/Ni/Mo
INTERNALS : 25/22/2 Cr/Ni/Mo
DES T/P : 185/165
THERE IS NO CARBAMATE SEPARATOR
CARBAMATE EJECTOR MOC : SS 316 Mod.U.G./SPINDLE HVD- MOC : SS316LUG

EQUIPMENT NAME SAIPEM TOYO(ACES21)
CO2 compressor and turbine Type : Integrally geared compressor (8
stages)
Make : MANTURBO
TURBINE
rated power : 14229 KW
Design T/P : 5450C /134 kg/cm2G
3700C /28 kg/cm2G
Type : four stage centrifugal compressor
Make : MITSUBISHI HEAVY INDUSTRIES
COMPRESSOR
TURBINE
rated power : 14264 KW
Design T/P : 4200C / 53.5kg/cm2G
CO2 Compressor turbine driving
steams
HP Steam
P : 110 kg/cm2G T : 5100C
EXTRACTION Steam (IP Steam)
P : 5.0 kg/cm2G T : 158 0C
MP Steam
P : 46.5 kg/cm2G T : 387 0C
IP Steam
P : 6.5 kg/cm2G T : 250 0C
LP Steam
P : 5.0 kg/cm2G T : 158 0C
EXTRACTION Steam
P : 21.0 kg/cm2G T : 301 0C
Prilling tower Height : 126 meter
Free fall height : 100
Height : 149 meter
Free fall height : 105

PROCESS SIDE DIFFERENCES
SAIPEM TOYO(ACES21)
Passivation air to CO2 compressor Added at 1st stage suction Added at 2nd stage suction
Dehydrogen column NOT THERE Is at CO2 compressor 2nd stage
CO2 feed to synthasis loop Total CO2 fed to UREA REACTOR 18 % of total CO2 fed to Reactor
82 % of total CO2 fed to stripper
NH3 feed to synthasis loop Total NH3 fed to UREA REACTOR NH3 fed to UREA REACTOR and
CARBAMATE CONDENSER
Passivation air from Passivation air
compressor to stripper
Added at bottom dish end NOT THERE
As 82% of CO2 along with passivation air
added at stipper bottom
Number of Anti surge control valves 1
SV-1(8th Discharge to 1st suction)
2
UV-151 (3rd suction to 1st suction)
UV-152 (4th Discharge to 3rd suction)
CO2 to LP Decomposer NOT THERE Is there from 1st stage discharge of CO2
compressor

PROCESS SIDE DIFFERENCES
SAIPEM TOYO(ACES21)
Urea solution tank location Urea solution can be divert from 1st vacuum
section upstream and urea melt pump
discharge
And same can be lined up to 1st vacuum
section upstream through Urea solution
recovery pumps
During normal operation urea solution is
in line from urea solution tank to vacuum
concentration section.
Urea solution can be divert from urea
melt pump discharge to urea solution
tank in case of vacuum section fail
Heat recovery MP Decomposer vapors routed to vacuum
pre concentrator
HP Decomposer and Carbamate
condenser vapors are routed to heater for
1st vacuum concentrator
MP NG added to MP Condenser shell inlet line NOT THERE
Process condensate section Distillation column vapors along with
hydrolyzer vapors routed to Ammonia
preheater
Process condensate stripper vapors along
with hydrolyzer vapors routed to
LP decomposer shell side

This document summarizes the key equipment and process parameters for the Saipem Toyo ACES21 urea synthesis loop. It describes the materials of construction, design temperatures and pressures, conversion rates and outlet concentrations for the reactor, stripper, condensers, and other major equipment. It also outlines some of the differences between this process and others, such as additional passivation air injection points and the inclusion of a dehydrogenation column. The energy requirement per ton of urea produced is listed as well.

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DIFF BW TOYO N SAIPEM.pptx

3. SYNTHASIS LOOP EQUIPMENT NAME SAIPEM TOYO(ACES21) REACTOR MOC : SHELL : CS+5mm LINING 25/22/2 Cr /Ni/Mo INTERNALS/TRAYS : 25/22/2 Cr/Ni/Mo DES T/P : 218/171 Volume : 250 m3 No. of Baffles : 16 (9 super cup trays located at bottom +7 sieve trays located at top ) CO2Conversion : 62 % Outlet concentration: NH3: 31.87 % CO2: 15.47 % UREA:32.99 % H2O:19.68 % MOC : CS+25 CR DUPLEX SS INTERNALS/TRAYS : 25 CR DUPLEX SS DES T/P : 210/171 Volume : 212 m3 No. of Baffles : 5 (baffle spacing 3 meter) CO2Conversion : 63 % Outlet concentration: NH3: 35.19 % CO2: 13.61 % UREA:32.47 % H2O:18.66 % STRIPPER MOC : SHELL : CS+3mm C.A TUBES IN : ZIRCONIUM OUT : 25/22/2 Cr/Ni/MO DES T/P (S-T) : 250/28-234/165 Outlet concentration: NH3: 25.51 % CO2: 7.43 % UREA:43.12 % MOC : STEAM SIDE : CS UREA SIDE (TOP & BOTTOM DISH END) : CS+DP28W TUBE : DP28W DES T/P (S-T) : 240/25-210/171 Outlet concentration: NH3: 12.89 % CO2: 12.66 % UREA:49.31

4. SYNTHASIS LOOP EQUIPMENT NAME SAIPEM TOYO(ACES21) CARBAMATE CONDENSER Layout : horizontal Numbers : 2 MOC : SHELL : CS+3mm C.A TUBES : IN : ZIRCONIUM OUT : 25/22/2 Cr/Ni/MO DES T/P (S-T) : 195/8-220/165 Generating Steam pressures E-1005A : P : 5.5 kg/cm2G T : 162 0C E-1005B : P : 3.5 kg/cm2G T : 147 0C Layout : vertical Numbers : 1 MOC : SHELL : CS+25 CR DUPLEX SS TUBES : IN : DP28W OUT : 25/22/2 Cr/Ni/MO DES T/P (S-T) : (210/171)-(200/8) Generating Steam pressures LP Steam P : 5 kg/cm2G T : 158 0C Outlet concentration: NH3: 31.99 % CO2: 22.55 % UREA:26.40 % H2O:18.99 % CARBAMATE SEPARATOR SHELL : CS+5mm LINING 25/22/2 Cr /Ni/Mo INTERNALS : 25/22/2 Cr/Ni/Mo DES T/P : 185/165 THERE IS NO CARBAMATE SEPARATOR CARBAMATE EJECTOR MOC : SS 316 Mod.U.G./SPINDLE HVD- MOC : SS316LUG

5. EQUIPMENT NAME SAIPEM TOYO(ACES21) CO2 compressor and turbine Type : Integrally geared compressor (8 stages) Make : MANTURBO TURBINE rated power : 14229 KW Design T/P : 5450C /134 kg/cm2G 3700C /28 kg/cm2G Type : four stage centrifugal compressor Make : MITSUBISHI HEAVY INDUSTRIES COMPRESSOR TURBINE rated power : 14264 KW Design T/P : 4200C / 53.5kg/cm2G CO2 Compressor turbine driving steams HP Steam P : 110 kg/cm2G T : 5100C EXTRACTION Steam (IP Steam) P : 5.0 kg/cm2G T : 158 0C MP Steam P : 46.5 kg/cm2G T : 387 0C IP Steam P : 6.5 kg/cm2G T : 250 0C LP Steam P : 5.0 kg/cm2G T : 158 0C EXTRACTION Steam P : 21.0 kg/cm2G T : 301 0C Prilling tower Height : 126 meter Free fall height : 100 Height : 149 meter Free fall height : 105

6. PROCESS SIDE DIFFERENCES SAIPEM TOYO(ACES21) Passivation air to CO2 compressor Added at 1st stage suction Added at 2nd stage suction Dehydrogen column NOT THERE Is at CO2 compressor 2nd stage CO2 feed to synthasis loop Total CO2 fed to UREA REACTOR 18 % of total CO2 fed to Reactor 82 % of total CO2 fed to stripper NH3 feed to synthasis loop Total NH3 fed to UREA REACTOR NH3 fed to UREA REACTOR and CARBAMATE CONDENSER Passivation air from Passivation air compressor to stripper Added at bottom dish end NOT THERE As 82% of CO2 along with passivation air added at stipper bottom Number of Anti surge control valves 1 SV-1(8th Discharge to 1st suction) 2 UV-151 (3rd suction to 1st suction) UV-152 (4th Discharge to 3rd suction) CO2 to LP Decomposer NOT THERE Is there from 1st stage discharge of CO2 compressor

7. PROCESS SIDE DIFFERENCES SAIPEM TOYO(ACES21) Urea solution tank location Urea solution can be divert from 1st vacuum section upstream and urea melt pump discharge And same can be lined up to 1st vacuum section upstream through Urea solution recovery pumps During normal operation urea solution is in line from urea solution tank to vacuum concentration section. Urea solution can be divert from urea melt pump discharge to urea solution tank in case of vacuum section fail Heat recovery MP Decomposer vapors routed to vacuum pre concentrator HP Decomposer and Carbamate condenser vapors are routed to heater for 1st vacuum concentrator MP NG added to MP Condenser shell inlet line NOT THERE Process condensate section Distillation column vapors along with hydrolyzer vapors routed to Ammonia preheater Process condensate stripper vapors along with hydrolyzer vapors routed to LP decomposer shell side

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