Green Granulation Technology - Ken Monstrey.pdf

w w w.greengranulation.com Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Ken Monstrey Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants 1. Introduction IN OTHER WORDS: GGT has drastically reduced the costs for building and operating a Urea Granulation Plant, without compromising on quality 20 – 40 % reduction How: CRG Process www.greengranulation.com 2 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Comparison with traditional processes Elevator Screener Screener F4 Elevator Crusher F3 Granulator Granulator Cooler Final Product Cooler F3 F2 Screener F2 Cooler Crusher Final Product F1 Final Product Traditional Granulation Process www.greengranulation.com F1 Seed belt CRG Process 3 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Comparison with traditional processes Traditional Granulation Process www.greengranulation.com  Lower building costs  Lower total investment costs  Facilitated operations  Lower power consumption CRG Process 4 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants ►  1.1. GGT company profile GGT Asia & GGT Europe Privately owned company Licensing granulation technology for nitrogen based fertilizers Urea business upon today: 9.720MTPD capacity commissioned 15.380MTPD capacity under construction www.greengranulation.com 5 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants ► 1.2. The CRG process features  Cold Recycle Granulation Process: Single step cooling  Granulator and cooler in-line  Smaller bucket elevator  -50% on crusher capacity  Smaller atomization air blower H: 28-32m www.greengranulation.com 6 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants ► 1.2. The CRG process features www.greengranulation.com Fig. GGT CRG PFD 7 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants 2. Innovations typical for CRG ► ► Reducing the total height of the building  Lowering building costs  Facilitating operation and maintenance Limiting the need for a strong weight bearing and vibration resisting building  ► No need for high Urea feed concentration  ► Lowering construction costs Low investment costs for the Urea Synthesis section Optimized Internal Dynamics in the fluidized bed and other power saving innovations  Reducing the power consumption www.greengranulation.com 8 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants ► 2.1. Reducing construction related investment  2.1.1. Height of the Building  2.1.2. Strength of the Building Fig. GGT Sprayer layout China Coal 2x2860MTPD www.greengranulation.com 9 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing construction related investments ► 2.1.1. Height of the urea granulation building  One single product Cooler, in-line with the Granulator  Only lifting the recycle stream  Combining screen feeder and safety screen in one device  Less equipment (coolers, fans, crushers)  Redesigning diverters Fig. GGT Granulator & Cooler Xinlianxin 1000MTPD Fig. Screen feeder with safety screen www.greengranulation.com 10 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing construction related investments ► 2.1.2. Strength of the urea granulation building  Vibrating screens and crushers located below the granulator (cfr. synchronized vibrations of all screens that need to be taken into account for strength calculation)  Highest load-bearing flow is the level of the granulator undercasing  Scrubbers located on ground level with integrated scrubber circulation tank www.greengranulation.com 11 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing construction related investments ► 2.1.2. Strength of the urea granulation building Fig. GGT 3D Deep Vacuum CRG Process www.greengranulation.com 12 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants ► 2.2. Reducing up-stream related investment Fig. GGT Urea melt feed headers China Coal 2x2860MTPD www.greengranulation.com 13 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing up-stream related investments ► Using low urea feed concentration  No influence on the product quality  One single evaporation step  Crystallization heat in the granulator is removed by evaporation of water reducing the need for air through the system  CRG process can be linked to a wide range of urea feed concentrations and to all currently existing synthesis processes  Single step cooling in relatively thick bed layer enables proper evaporation of moisture www.greengranulation.com 14 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants ► 2.3. Reducing the power consumption  2.3.1. Optimized internal dynamics in the fluid bed  2.3.2. Deep vacuum in the granulator  2.3.3. Patented double temperature scrubbing system  2.3.4. Optimized ducting  2.3.5. High performance hydraulic urea melt sprayers  2.3.6. Flexibility by optional components Fig. Plant view www.greengranulation.com 15 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing power consumption ► 2.3.1. GGT Optimized internal dynamics in the fluid bed  Patented  Open spaces between the banks  Smoother circulation of granules  Bank arrangement eliminates need for thick layer bubbling bed bed level down to 600mm (total ∆P over bed + perforated plate)  Lower pressure of the fluidization air Fig. GGT Optimized internal dynamics www.greengranulation.com 16 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing power consumption ► 2.3.2. Deep vacuum in the granulator One step further… (under construction)  All fluidization air pulled through the system by the exhaust fan(s)  No need for a fluidization air fan  One single exhaust fan is possible (pressure drop)  Vacuum enables better evaporation of water in the spray area  When a fluidization air fan is needed for e.g. chiller on the cooler, GGT uses a fan with low pressure drop  Eliminating the heating of the fluidization air by the fan compression  Patent pending www.greengranulation.com 17 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing power consumption ► 2.3.3. Patented “Double temperature scrubbing”  Low pressure drop horizontal scrubbers ΔP 70mmWC  High concentration scrubber solution (55%)  Separate granulator scrubber and cooler scrubber  Use of Blue Fil high efficiency mist eliminators combining minimal pressure drop with low emission values  PM2.5 : +99,9% > 5µ ; +92% > 2,5µ Fig. Blue Fil by Mistrix-Benvitec www.greengranulation.com Fig. GGT “Double temperature scrubbing” 18 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing power consumption ► 2.3.4. Optimized ducting  Estimated saving in pressure drop due to optimized and minimized ducting: ca 100mmWC Fig. GGT Granulator in- and outlet Fig. Xinlianxin 1000MTPD www.greengranulation.com 19 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing power consumption ► 2.3.5. High performance hydraulic urea melt sprayers  In-house development  Hydraulic sprayer  Fine atomization, efficient evaporation of water  Low atomization air (0,3Barg)  Seed creation by the urea liquid sprayers only 50% of the crusher capacity Fig. GGT Hydraulic urea liquid sprayer Fig. Tianze 2x1500MTPD atomization air inlets www.greengranulation.com 20 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing power consumption ► 2.3.6. Flexibility by optional components  Alternative cooling means to boost the cooling capacity  Cooling plates making use of cooling water  AirSieve technology extracting fines from the cooler before total cooling  Optional chiller  Depending on ambient design conditions  Flexible components can be shut-off e.g. in winter time www.greengranulation.com 21 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reducing power consumption ► 2.3.6. Flexibility by optional components GGT Cooling Technology Combining Air and Water Cooling Air out Air out Granules Water in Water in Air in www.greengranulation.com Granules Water out Water out Air in Fig. GGT Cooling plate technology 22 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Reference list Commissioned Units Henan Xinlianxin Fertilizer Company Capacity: 1,000 MTPD - Started-up: 2014 – CRG process Shanxi Tianze Coal Chemical Group Capacity: 2 x 1,500 MTPD - Started-up: 2013 – CRG process Erdos China National Coal Group Capacity: 2 x 2,860 MTPD - Started-up: 2013 Units under Design / Construction Luoyang Junma Capacity: 600 MTPD - Contract: 2014 Jiangsu Linggu Capacity: 2,700 MTPD - Contract: 2014 Henan Junhua Capacity: 1,500 MTPD - Contract: 2014 Shandong Runyin Biochemical Co. Capacity: 2,000 MTPD - Contract: 2014 Inner Mongolia Manshi Capacity: 2 x 2,860 MTPD - Contract: 2014 Inner Mongolia Huajin Chemical Co. Capacity: 2,860 MTPD - Contract: 2013 www.greengranulation.com 23 Drastic Reduction in CAPEX and OPEX in Urea Granulation Plants Up-stream related investments www.greengranulation.com 24 CRG Process ► 2.1.2. Strength of the urea granulation building Fig. GGT 3D Deep Vacuum CRG Process www.greengranulation.com 25 w w w.greengranulation.com Thank you! In case of questions please feel free to contact us: Green Granulation Technology In het Midden 35 1422 PA Uithoorn The Netherlands Mob: E-mail: +32 486346037 [email protected] 26