Latest Urea Technology for Improving Performance and

Product Quality
by

EIJI SAKATA, Senior Process Engineer

TAKAHIRO Y ANAGAWA, Process Engineer

Technology & Knowledge Research Center

L T OYO ENGINEERING CORPORATION

TOKYO JAPAN
ABSTRACT
Toyo Engineering Corporation (TEC) has started licensing an advanced version of its ACES
urea process named “ACES 21”, being established based on a close collaboration with PT Pupuk
Sriwidjaja (PUSRI), Indonesia. ACES 21 is featured by ground level reactor and vertical
submerged carbamate condenser, combined with CO2 stripping technology, aiming at both plant
cost reduction and further energy saving from the original ACES process. TEC also owns the
granulation technology featured by unique Spout-Fluid Bed Granulator. A 2,000 mtpd urea
granulation plant using TEC granulation technology started operation successfully in 2000,
demonstrating its excellent performance.

This paper introduces the TEC’s latest urea technologies to improve plant performance and
product quality with the following features and references:
n Features of ACES 21 technology, remarkable plant cost reduction and energy saving, and
advantages in view of operation and maintenance
n A typical study to revamp a conventional solution recycle urea plant with ACES 21 for
capacity increase and energy saving, fully utilizing the existing urea reactor.
n Features of TEC granulation technology for improving product quality
n Recent commissioning experience in urea granulation plant based on TEC technologies.

1
INTRODUCTION
Toyo Engineering Corporation (TEC), a worldwide engineering contractor and one of three
major urea process licensers, has made continual efforts to improve the urea process as the
process licenser and the E-P-C contractor, and has contributed to the fertilizer industry by
supplying reliable, efficient and economical urea plants since its establishment 40 years ago.
TEC has engineered and constructed, as of the end of 2000, 93 urea plants and 10 urea
granulation plants based on TEC technologies, giving a quarter of the world’s total production
capacity by the three major urea processes licensors. Realizing the future technical demands for
the urea process technologies during the 21st Century, TEC has improved the existing ACES
Process to realize further reducing investment costs while maintaining all features of the ACES
Process. The improved process has been named the ACES 21 Process.

A 2,000 mtpd urea granulation plant which is the latest and the largest experience for TEC
started operation successfully in 2000, demonstrating its excellent performance with aqueous
urea solution feed. Some details of the project are outlined in the later sections in this paper.

THE ACES PROCESS

The main concept of the original ACES Process is to minimize energy input to the urea plant by
combining the features of solution recycle process and stripping process i.e. a high CO2
conversion and the highly efficient separation of unreacted materials. The ACES Process
drastically reduced steam consumption compared to Total Recycle Process.

The ACES Process, by ensuring NH3 to CO2 molar ratio (N/C ratio) of 4.0 and an operating
temperature of 190 °C in the reactor give CO2 conversion of 68%, the highest among modern
urea processes. The high CO2 conversion reduces the energy required for decomposition of
unconverted materials. The proprietarily designed tray-falling film Stripper efficiently
decomposes and separates ammonium carbamate and excess ammonia in urea synthesis solution
from the reactor. Fig. 1 shows the simplified flow diagram of the ACES Process synthesis
section.

2
 Fig. 1
ACES Process Synthesis Section

TO MP ABSORPTION
SCRUBBER

NO.1 & NO.2

REACTOR CARBAMATE
CONDENSER
FROM MP ABSORPTION
LP STM
+BFW
TO MP DECOMPOSITION
BFW
NH3
STRIPPER
MP STM

CO2
COND.

The unique heat integration between the synthesis section and downstream sections further
reduces energy requirement (See Fig. 2). MP steam is supplied to synthesis section to
decompose and separate excess NH3 and carbamate in the stripper. The stripped NH3 and CO2
gas mixture is sent to the carbamate condenser and the condensation heat is recovered by the two
parallel carbamate condensers. One is utilized for decomposition in the medium pressure section
and the other is for low pressure steam generation to be utilized in the low pressure and
evaporation sections. Condensation heat in medium pressure section is also utilized in
evaporation section. This multiple heat integration concept, originally invented and developed
by TEC, gives the most energy efficient urea process.

The ACES Process has been employed in 13 urea plants since its first application in 1983 (see
Table 1). Over last 10 years, 11 urea plants in 5 countries have employed this process.

3
 Fig. 2
heat Integration Scheme
NH3 CO2

REACTOR
HEAT RECOVERY
M.P. STEAM SECTION L.P. STEAM
(GENERATED)
UREA
NH3 + CO2 + H2O
MEDIUM PRESSURE
SECTION C.W.
UREA
NH3 + CO2 + H2O NH3 + CO2 + H2O
LOW PRESSURE
SECTION C.W.
UREA H2O
H2O
EVAPORATION
SECTION C.W.

WATER
UREA (BY-PRODUCT)
MELT

Table 1 Experience List of ACES Process

PLANT
CLIENT COUNTRY CAPACITY ON-STREAM
(MT/D)

1. KOREA FERTILIZER AND KOREA 600 MAY 1983

CHEMICALS CO.
2. FERTIBERIA S.L. SPAIN 750 OCT. 1988
3. UREA FERTILIZER FACTORY BANGLADESH 1,422 FEB. 1993
LTD.
4. P.T. PUPUK SRIWIDJAJA INDONESIA 1,725 MAR. 1994
5. P.T. PETROKIMIA GRESIK INDONESIA 1,400 MAY 1994
6. P.T. PUPUK SRIWIDJAJA INDONESIA 1,725 FEB. 1994
7. WEIHE CHEMICAL FERTILIZER CHINA 1,760 MAY 1996
8. WEIXIAN CHEMICAL FERTILIZER CHINA 180 JAN. 1997
9. PAK - AMERICAN FERTILIZER PAKISTAN 1,050 SEP. 1998
10. ENGRO CHEMICAL PAKISTAN LTD. PAKISTAN 1,755 OCT. 1998
11. CHAMBAL FERTILIZERS AND INDIA 2,350 OCT. 1999
CHEMICALS LTD.
12. P.T. PUPUK ISKANDAR MUDA INDONESIA 1,725 (2002)
13. P.T. PUPUK KUJANG INDONESIA 1,725 (2004)

4
THE ACES 21 P ROCESS
ACES 21 Process Concept
In CO2 stripping technology, the reactor, the largest and the heaviest vessel in urea plant, is
normally installed at 20-22 meter level so as to feed urea synthesis solution to the stripper by
gravity. If the reactor is installed on the ground level, civil and erection cost can be greatly
reduced. TEC and PUSRI jointly developed this process incorporating a unique two-stage
synthesis concept comprised by:

n A vertical submerged carbamate condenser, functioning as carbamate condenser, HP

scrubber and the primary urea reactor
n A vertical reactor to complete reaction from carbamate to urea, as the secondary reactor
n A vertical falling film type stripper to decompose and separate unreacted carbamate and
excess ammonia by CO2 stripping.
n A HP ejector motivated by HP liquid ammonia to supply driving force for the HP loop
circulation, so that the reactor is installed on the ground level and other HP vessels are laid-
out horizontally, as well as to increase N/C ratio in the reactor high enough so as to achieve
the high CO2 conversion.

ACES 21 Synthesis Section

Fig. 3 shows the ACES 21 Process synthesis section. The reactor, stripper, carbamate condenser
and ejector comprise the synthesis section as major equipment. Liquid ammonia is fed into the
reactor via the ejector. Most of the CO2 is fed to the stripper as stripping media and the rest is fed
to the reactor as a source of passivation air and a raw material for urea synthesis in the reactor.
Carbamate solution from the carbamate condenser is fed to the reactor after being pumped by the
ejector that is motivated by high pressure liquid ammonia. Urea synthesis solution leaving the
reactor is fed to the stripper. Stripped urea solution is sent to MP decomposition stage. The
stripped off gas is fed to vertical submerged-type carbamate condenser. NH3 and CO2 gas
condenses to form ammonium carbamate and urea in the shell side of the carbamate condenser.
The condensation heat is recovered to generate low pressure steam in the tube side. Packed bed
is provided at the top to absorb uncondensed NH3 and CO2 into recycle carbamate solution from
MP absorption stage. Inert gas from top of the packed bed is sent to MP absorption stage. The
driving force for liquid and gas circulation in the synthesis loop is mainly provided by the ejector,
while appropriate elevation of the carbamate condenser supplies additional driving force by
gravity.

5
 Fig. 3
ACES 21 Process Synthesis Section

CARBAMATE REACTOR STRIPPER

CONDENSER

INERTS TO ABSORPTION STAGE

FROM ABSORPTION STAGE

MP STM
BFW LP
STM

S.C.
TO
LIQ. NH3 DECOMPOSITION
STAGE
CO2
EJECTOR

Vertical Submerged Carbamate Condenser

Vertical submerged design is employed for the carbamate condenser. From process view point,
this provides the following advantages:
(1) High gas velocity, appropriate gas hold up and sufficient liquid depth in the bubble column
promote mass and heat transfer;
(2) The appropriate number of baffle plates distribute gas bubbles in the column effectively
without pressure loss;
(3) A vertical design inevitably requires smaller plot area

Optimized N/C Ratio

In the ACES 21 Process, the N/C ratio in the carbamate condenser differs from that in the reactor.
A lower N/C in the carbamate condenser lowers vapor pressure, reducing vapor loss from the
carbamate condenser. A higher N/C ratio in the reactor raises CO2 conversion, reducing the heat
required for decomposition of carbamate in the stripper. Equilibrium vapor pressure becomes its
lowest level at around an N/C ratio of 3.0 at which the carbamate condenser is operated. The
reactor N/C ratio should be as high as possible to maximize CO2 conversion as far as its
operating pressure has appropriate excess pressure to that of the equilibrium.

Since different levels of N/C ratio are employed for the carbamate condenser and the reactor,
urea synthesis reaction takes place in two steps.

6
Advantages
Features and advantages of the ACES 21 Process are summarized below:

1. The horizontal layout of HP vessels has the following advantages compared to the vertical
layout.
(a) less HP piping and construction materials are used;
(b) easier erection using commonly available construction equipment and techniques;
(c) easier operation and maintenance

2. Combining the functions for carbamate formation, heat recovery, urea synthesis, and inert
gas scrubbing into one vertical submerged carbamate condenser has the following
advantages in comparison with conventional separate reactor and falling film carbamate
condenser:
(a) fewer and smaller sized HP vessels;
(b) a smaller heat transfer area for heat recovery;
(c) less HP piping and construction material are required

3. Simplified synthesis loop offers the followings advantages over conventional stripping
technologies:
(a) less HP piping and construction materials are required;
(b) easier operation and maintenance

4. Improved design for the reactor and the stripper give the following advantages in
comparison to conventional ones:
(a) less volume and weight for both the reactor and the stripper;
(b) easier reactor and stripper fabrication

5. Optimizing N/C ratios at different levels for the carbamate condenser and the reactor at
lower synthesis pressure results in the following advantages over the ACES Process:
(a) lower mechanical design pressure of HP vessels and rotating equipment;
(b) less energy consumption

TEC and PUSRI confirmed the combined effect of the above improvements, based on the one-
year demonstration with the pilot plant and the following engineering study for an industrial
scale plant, reduces the urea plant direct cost by approximately 10% and energy consumption by
5-20% from the original ACES process.

7
REVAMPING OF CONVENTIONAL SOLUTION RECYCLE UREA PROCESS
Revamping Technology Options
Table 2 shows the revamping technology options offered by TEC to improve plant efficiency and
product quality. Those options are so selected to meet the objectives for the revamp and/or
renovation project.

Table 2 REVAMPING TECHNOLOGY OPTIONS

Capacity Energy Product Environment Maintenance

Increase Saving Quality
ACES 21 P P
D PROCESS P P
GRANULATION PROCESS P P
VACUUM
CONCENTRATION P P P
PROCESS CONDENSATE
TREATMENT P
CENTRIFUGAL TYPE
HP ROTATING MACHINE P
ACOUSTIC GRANULATOR P
DUST SCRUBBER
P

L TOYO ENGINEERING CORPORATION

ACES 21 Process Features for Revamping

ACES 21 is also suitable for revamping conventional solution recycle urea plants in an efficient
way. For example, TEC’s Total Recycle C-Improved Process plant can be revamped to have 130
– 150% capacity of original nameplate together with 30 – 40 % saving of specific energy
consumption per metric ton of the product, simply adding a carbamate condenser, a stripper and
an ejector to the synthesis section. The ACES 21 revamp concept thus renovates conventional
less efficient urea plants to be the most advanced and efficient ones, owing to the following
features:

(1) ACES 21 adopts two-stage reaction with a vertical submerged condenser and a reactor. This
enables to increase the synthesis section capacity to 150% of original nameplate by re-
utilizing the existing reactor on the ground level without adding a new reactor, resulting in
great reduction of equipment cost;
(2) Horizontal lay-out of HP equipment greatly reduces erection and construction cost;
(3) Lowered synthesis pressure of 155 kg/cm 2G greatly reduces energy for raw material feed;
(4) Adoption of ACES 21 synthesis loop maximizes heat recovery in the synthesis section.

8
Revamp Case Study
A revamp study to increase capacity to 150% of nameplate capacity and 30-40% energy
reduction for TEC Total Recycle C-Improved plants has been carried out. Fig. 4 shows a block
flow diagram for the overall revamped urea plant. The study result has shown positive feasibility
in view of profitability, environmental protection and energy saving. The following paragraphs
outline the modifications in each section.

Fig. 4
Block flow diagram
NH3 CO2

MODIFICATION OR
CO2 REPLACEMENT
NH3 FEED
COMPRESSION

MODIFICATION

SYSNTHESIS
(ACES 21)

MINOR MINOR
MODIFICATION MODIFICATION

PURIFICATION RECOVERY

NEW
CRYSTALLIZATION CONCENTRATION

NEW
PRILLING GRANULATION

1,725 T/D 875 T/D

UREA UREA

9
Outline of Revamp Schemes
1. Synthesis section and raw material feeding section
Fig. 5 shows process flow of the revamped synthesis section. Existing reactor is fully re-utilized
as ACES 21 reactor without relocation. Stripper, carbamate condenser and ejector are newly
added and NH3 pre-heater and CO2 compressor are modified or added.

Fig. 5
Revamped Synthesis Section
NEW EQUIPMENT
REACTOR STRIPPER CONDENSER HP DECOMPOSER

MP STEAM
TO LP DECOMPOSER

HP ABSORBER
TO NH3 CONDENSER
COND. FROM LP ABSORBER

BFW LP
STEAM

EJECTOR

CO2

NH3

CO2 COMPRESSOR NH3 PUMP CARBAMATE FEED

PUMP

Raw material feed equipments are evaluated as follows:

(i) CO2 compressor

Reduction of the discharge pressure from 250 Kg/cm 2G to 160 Kg/cm 2G greatly reduces
the energy for CO2 compression. In general, following two options are considered
practical to meet the increased capacity.
(a) Replace the existing reciprocating compressor(s) to new one centrifugal compressor
aiming maintenance free and oil free.
(b) Add a reciprocating compressor equivalent to the additional capacity aiming
minimum investment cost.

(ii) Turbine for CO2 compressor

Depending on the steam system, turbine for CO2 compressor may be required to be
modified to extraction-admission-condensing type to supply middle pressure steam for
HP stripper and to utilize low-pressure steam generated in ACES 21 condenser.

(iii) Ammonia pump

No modification is required and pumping energy is significantly reduced due to decrease
of required capacity. The existing pumps originally have sufficiently high discharge
pressure to supply motive energy for HP ejector

(iv) Carbamate pump

No modification is required and pumping energy is greatly reduced because required
capacity is same and discharge pressure is decreased from 250 Kg/cm 2G to 160 kg/cm 2G.

10
 (v) Hydrogen removal
Hydrogen removal unit is installed in the CO2 compression section to avoid flammable
condition in the synthesis section since passivation air requirement increases after
revamp.

2. Purification section
Purification section is utilized without major modifications. An additional pre-heater for HP
Decomposer, heated by 5 kg/cm 2G steam, is installed to utilize low pressure steam generated
after revamp.

3. Recovery section
Recovery section is utilized without major modifications. Additional stage for NH3 recovery
absorber is installed as the inert gas to high pressure recovery system increases due to increased
air supply for passivation and hydrogen removal.

4. Finishing section
Finishing section revamp options can be categorized into the following schemes depending on
the prospective market conditions, environmental regulations and owners requirement:

i) Minimum Investment without Improving Product Quality and Pollution Abatement:

n Total production capacity is by prilled urea only. Crystallization section is utilized
without modification and new evaporators equivalent to the additional capacity (875
mtpd) are added. Existing prilling tower is utilized by modifying induced fans to
increase air flow rate and replacing distributors for prilling.
n As an alternative, the existing crystallization process can be converted to vacuum
evaporation process aiming at maintenance free and energy saving operation. The
existing crystallizer is utilized as a vacuum concentrator.

ii) Product Quality Improvement and Pollution Abatement for Additional Capacity by
Installing a Granulation Plant
n The existing crystallization section and prilling tower is utilized without modification.
New vacuum evaporation section and a granulation plant equivalent to the additional
capacity (875 mtpd) are newly installed.

iii) Product Quality Improvement and Pollution Abatement for Total Capacity by Installing a
Granulation Plant
n The existing crystallization process is totally converted to vacuum evaporation process.
Existing prilling tower is totally converted to granulation.

11
Process Performance and Economic Evaluation
Table 3 summarizes three typical revamp options. Case-1 needs the highest investment among
the three, however it provides the most simple steam system and the lowest operation and
maintenance cost, owing to the all centrifugalization of CO2 compressor. Case-2 shows the
second lowest investment, however it requires more complicated modification of steam system
and higher operation and maintenance cost than Case-1. Case-3 shows the lowest investment, so
long as 875 mtpd urea can be sold as 70% urea solution with appropriate margin to other plant.
Preliminary economic evaluation study has indicated that considerable steam saving by 0.4 T/T
achieved by ACES 21 concept and reasonable assumption of 20-30 US$ margin to net
production cost per metric ton of urea product will recover the investment within 3 – 5 years in
those three cases.

Table 3 Revamp Option

1,725 mtpd TR-CI 2,600 mtpd ACES 21

CASE-1 CASE-2 CASE-3

Replacement of Addition of
CO2 Compression Centrifugal Reciprocating
Compressor and Turbine Compressor
Synthesis ACES 21
Purification /Recover No Modification
Addition of Export 850 mtpd
Concentration 850 mtpd Evaporation Urea Solution
Addition of
Finishing 850 mtpd Granulation

Steam System Optimum Simple Complicated Complicated

Construction / Modification Simple Complicated Complicated
Operating / Maintenance Cost Low High Medium
Operation Flexibility High Medium Low

L TOYO ENGINEERING CORPORATION

12
Example of A Revamping Study
Typical revamping study to renovate a TEC TR-C urea plant with ACES 21 technology has been
recently carried out based on the conditions shown in Table 4. The case-2 is to convert prilling to
granulation.

Table 4 Study Cases

EXISTING CASE-1 CASE-2

Capacity 1300 MTPD 1300 MTPD 1300 MTPD
CO2 Booster Driver Back Turbine Extraction Admission Extraction Admission
Condensing Turbine Condensing Turbine
Synthesis TR-C ACES 21 ACES 21
Urea Reactor Titanium Re-lined with S.S Re-lined with S.S
lining with Baffle Plates with Baffle Plates
Finishing Crystallization Vacuum Evaporation Vacuum Evaporation

Product Forming Conventional Prilling with Spout-Fluid Bed

Prilling Acoustic Granulator Granulation
with Natural Draft + ID Fan
Dust Recovery Urea Solution Urea Solution Packed Bed
Spray Spray + Demister Dust Scrubber
Process Condensate None Hydrolyzer & Stripper Hydrolyzer & Stripper
Treatment

L TOYO ENGINEERING CORPORATION

Table 5 summarizes utility and energy consumption for each case. Energy consumption to
produce one metric ton of prilled or granulated urea is reduced by 0.36 – 0.40 Gcal. This drastic
energy reduction considerably improves the competitiveness of the urea plants.

Table 5 Performance Summary :

Utilities Consumption

EXISTING CASE-1 CASE-2

Steam (T/T)
Import 43 Kg/cm 2G x 385o C 1.67 1.14 1.13
12 Kg/cm 2G x 215o C 0.09 - -
Export 21 Kg/cm 2G x 318o C - -0.16 -0.16
12 Kg/cm 2G x 265o C -0.32 - -
Net 1.44 0.98 0.97

Electricity (kWh/T) 83 66 82

Energy (Gcal/T)
Steam 1.101 0.747 0.740
Electricity 0.204 0.162 0.201
Total 1.305 0.909 0.941
Saving Base 0.396 0.364
Note : 2475 kcal/kWh for Electricity.

30% Saving 28% Saving

L TOYO ENGINEERING CORPORATION

13
TEC GRANULATION PROCESS
TEC has developed own granulation technology so called Spout-Fluid Bed Granulation since the
early 1980s. In the year 2000, a 2,000 mtpd urea granulation plant which is the latest and the
largest experience for TEC started operation successfully, demonstrating its excellent and
reliable performance with aqueous urea solution feed.

Table 6 Experience List of TEC Granulation Process

OWNER LOCATION CAPACITY ON

(MTPD) STREAM

1) Mitsui Toatsu Chemicals, Inc. Chiba, Japan 50 1975

2) Petrochem Ltd. Kapuni, New Zealand 470 1983
3) Mitsui Toatsu Chemicals, Inc. Osaka, Japan 100 1983
4) SKW Piesteritz GmbH Piesteritz, Germany 1,200 1995
5) Petrochem Ltd. Kapuni, New Zealand 750 1997
6) SKW Piesteritz GmbH Piesteritz, Germany 500 1998
7) Ningxia Chemical Works of CNPC Ningxia China 1,740 1999
8) P.T. Pupuk Iskandar Muda North Aceh, Indonesia 1,725 (2002)
9) Lutianhua Group Inc. Sichuan, China 2,000 2000
10) Zhanyi Fertilizer Plant Yunnan,China 600 (2002)

14
Process Description
Figure 6 shows a typical flow diagram of TEC Urea Granulation Process. The Urea Granulation
process consists of following three sections.
• granulation section
• recycle and product cooling section
• dust removal and recovery section

Fig.6: TEC urea granulation process flow diagram

Aqueous urea solution from urea plant is fed to the granulator to enlarge recycle particles in the
granulator. In the granulator, the granules are dried and cooled simultaneously. The granulator is
operated at 110-115ºC and at slightly negative pressure. Enlarged urea particles are cooled to
about 90ºC in the after-cooler inside the granulator to be transported to the recycle section.

The discharged granules are separated into three sizes, product, small and large size by the
screen. Product size granules are further cooled below 60ºC in the product cooler to be sent to
the urea storage or bagging facility. Large size granules are crushed by the crusher. The crushed
particles and smaller size particles from the screen are recycled to the granulator as seed.

Urea dust contained in the exhaust air from the granulator and the product cooler is scrubbed in
the dust scrubber by contacting counter currently with aqueous urea solution. The urea dust
content in the exit air of the dust scrubber is 30 mg/Nm3 or less. Urea recovered in the dust
scrubber, approximately 3-4 % of production rate, is recycled to the urea plant as 45 wt% urea
solution.

Any other urea granulation processes available in the world have similar flow schemes, however
characteristics and performance of the process strongly depend upon the granulator design. The
features of TEC Urea Granulation Process are given below:

15
(i) High Energy Efficiency:
n No requirement of compressed atomizing air for granulator reduces power consumption;
n Seed circulation at moderately high temperature (= 90ºC) minimizes cooling air
requirement and heat removal in the process;
n Optimal bed depth minimizes pressure loss in the granulator;
n Uniquely designed low pressure drop dust scrubber minimizes power consumption of
induced fan(s)

Table 7 shows a typical steam and power consumption of TEC Urea Granulation Process.

Table 7
Typical specific utilities consumption

Steam (MT/MT) 0 – 0.03

Power (kWh/T) 23 – 25 (Fluid Bed Cooler)
19 – 21 (Bulk Flow Cooler)
Note: ambient temperature = 30 - 35ºC

In the case that water cooled bulk flow cooler is applied for product cooling instead of fluidized
bed cooler, the power consumption is further reduced by about 4 kWh/MT. Since its first
application in 1993, TEC has been ready to apply the both options in granulation plant design,
i.e. the bulk flow cooler and the fluidized bed cooler considering site conditions, energy cost and
client’s requirement.

(ii) High Product Quality

n Rapid cooling of granules in the granulator with minimum residence time reduces biuret
formation to negligibly small;
n Efficient drying in the granulator reduces granule moisture low enough to increase
product hardness;
n Optimal combination of spouted bed and fluidized bed produces round and uniform
granules.

Table-8 shows typical quality of the granules produced by TEC Urea Granulation Process.

Table 8
Typical product quality

Total Nitrogen 46.3wt%

Biuret 0.7wt%
Moisture 0.25wt%
Formaldehyde 0.45wt%
Size (2-4mm) 95wt%
Hardness 3.5kg at 3mm

(iii) Low Urea Dust Emission

n Optimal spouted bed air velocity minimizes dust formation in the granulator.
n Uniquely designed low delta-P dust scrubber proven through application to twelve
prilling towers and seven urea granulators reduces urea dust to less than 30 mg/Nm3.

16
TEC Spout-Fluid Bed Granulator
Figure 7 shows a schematic diagram of TEC Spout-Fluid Bed Granulator. The granulator
consists of spouted beds and fluidized bed on the perforated plate, spray nozzles and air duct
manifolds. Each spouted bed has one spray nozzle. Recycle urea granules are enlarged while
passing through the spouted beds and the fluidized bed. Aqueous urea solution ( > 95wt% ) is
sprayed into the spouted beds through pressure spray nozzles.

Fig. 7: TEC spout-fluid bed granulator

Vigorous mixing in the spouted bed gives round and uniform granules. Since air introduced for
spouting and fluidizing not only removes urea solidification heat but also evaporates water
contained in the sprayed aqueous urea droplets and granules, the urea granules are dried to less
than 0.25wt% moisture content at the exit of the granulator. Owing to the drying effect in the
granulator, cost and energy consumption in the urea process plant can be reduced.

Industrial scale granulator has multi-stage spouted bed arrangement, therefore the granulator is
simply scaled-up by increasing the number of the spouted beds.

17
Equipment Layout
Figure 8 shows a bird’s-eye view of a typical 1,700 mtpd TEC Urea Granulation Process plant.
As can be seen, the building for granulator and other solid handling equipment is very compact.

Fig. 8: 3-D graphic representation of TEC granulation plant

TEC Urea Granulation Process has alternative layout options, i.e. the dust scrubber can be
installed on the top to reduce the plot area. This option can be attractive for the case that
available area is very limited, for example, the case for prill tower conversion to granulation.
Four granulation plants have employed this layout.

Large Scale Granulation Plants in China

Two large scale urea granulation plants based on TEC technology, of which respective
nameplate capacity is 1,740 mtpd and 2,000 mtpd, have been commissioned in China in 1999
and 2000. Both plants have single train TEC Spout-Fluid Bed Granulator designed to receive
aqueous urea solution as feed. The both plants are designed to be capable to produce either 2-4
mm product or 5-8 mm product, depending upon the market demand. In the 2,000 mtpd unit
project for Lutianhua Group Inc., (LTH) which aimed at the total conversion of existing prilling
tower to granulation, the following advantages have been demonstrated:
• 2,000mtpd production with aqueous urea solution feed
• Remarkably low urea dust emission (= 5 mg/Nm3) by uniquely designed dust scrubber
• Low production cost owing to low utilities consumption
• Easy and smooth start-up in large capacity unit

18
 Fig. 9 LTH 2,000 mtpd granulation plant

This project came into effect in May 1999. TEC supplied the process design package and
proprietary equipment as process licenser. China Wuhuan Chemical Engineering Corporation
(CWCEC) carried out detail engineering and LTH performed procurement and construction.
Owing to the efficient project coordination and cooperation among TEC, CWCEC and LTH, the
plant started operation in July 2000, within only 14 month after the effective date of contract.
Some details of the project are introduced below.

Operation history
The plant went into operation in the beginning of July 2000 and the plant load reached 100%
very smoothly. Performance test run was completed in October 2000. Performance test was
postponed due to a repair work of bucket elevator and urea prill production required by market
reason. Maximum daily capacity reached 107% in October 2000. The plant has operated
successfully producing good quality product for both export and domestic use.

CONCLUSION
TEC, the only urea process licenser that covers by itself all the proven essential technologies, i.e.
urea synthesis, prilling, granulation and pollution abatement, has improved the ACES urea
process to establish the most advanced urea process “ACES 21” cooperating with PUSRI. TEC
Spout-Fluid Bed Granulation Process has been adopted in 8 revamps and 2 grass roots plants.
Several revamp studies have proved that conventional urea plant can be revamped to be the most
competitive one with ACES 21 technology and Spout Fluid Bed Granulation in very efficient
way. The recent successful commissioning of a large scale granulation plants further promotes
prilling tower conversion to granulation aiming at drastic improvement of product quality. The
TEC-PUSRI ACES 21 and TEC Spout-Fluid Bed Granulation provide the most realistic solution
to improve efficiency and product quality of conventional urea plants.

19