fydp slide presentation

8/13/2019 FYDP slide presentation

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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]


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



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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


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


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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