Presentation on theme: "MAXIM FERD OAO GIAP, MOSCOW, RUSSIA VASIL GRANCHAROV"— Presentation transcript:
150% CAPACITY INCREASE OF AN – 72 PLANT UTILIZING THE ORIGINAL PRILLING TOWER MAXIM FERDOAO GIAP, MOSCOW, RUSSIAVASIL GRANCHAROVNEOCHIM PLC, DIMITROVGRAD, BULGARIA
250 % CAPACITY INCREASEFeatures of a typical AN – 72 plant:Design capacity 1360 MT/DayOne - stage neutralization in reactors operating under atmospheric pressure.One - stage evaporation under atmospheric pressure in air current.
350 % CAPACITY INCREASEAmmonium nitrate melt is pumped from the ground level to the top of the prilling tower. Steel - made prilling tower with a rectangular cross - section is employed. The fluidized bed cooler is placed outside the prilling tower.
450 % CAPACITY INCREASEAir coming from the evaporator and the prilling tower, together with the steam exiting the secondary steam recovery system, undergo scrubber treatment prior to being vented to the atmosphere.
550 % CAPACITY INCREASEThere are a total of 19 AN – 72 plants built in the period 1977 – 1987, all of them in the FSU countries and a single one outside the FSU, built in Dimitrovgrad, Bulgaria, and operated by Neochim PLC.
1050 % CAPACITY INCREASE Replacement of the three fans supplying air to Engineering decisions for the prilling tower include:Replacement of the three fans supplying air tothe tower’s bottom and the six exhaust fans atthe top of the tower by new ones with totalcapacity 30 % greater than this of the originalones.Replacement of the original 3 static granulatorsby 2 vibro - granulators with a rotating basket,aiming at a narrower size distribution and to agreater - extent elimination of dust carryoutexpected as a result of the increased airvelocity in the tower’s cross - section.
1150 % CAPACITY INCREASE Engineering decisions for the prilling tower include:Increase of the filter surface of the sixscrubbers at the tower’s top by 10 % and useof three - layer packs of filtrating material withdifferent layer characteristics.Washing of the frontal filter pack’s surface withfinely - spread secondary steam condensate .
1250 % CAPACITY INCREASE Engineering decisions for the prilling tower include:Introduction of preliminary purification of thesecondary steam and air from the evaporatorsin a separate scrubber prior to the steam airstream being fed to the tower’s scrubbers.Introduction of additional ammonia air coolingat the second stage of the fluidized bed cooler.
1350 % CAPACITY INCREASE Engineering decisions for the “wet” part include:Addition of a new neutralizer identical to theexisting ones, an evaporator with modifieddesign, and of all necessary equipment for theiroperation.
14First neutralization in the “new” wet part carried out 50 % CAPACITY INCREASEProject MilestonesJune 1st 2007First earth movedFirst neutralization in the “new” wet part carried outJune 16th 2008July1st 2008Plant at full swing
1650 % CAPACITY INCREASEComparison of the plant’s major operational parameters before and after the revamp.ItemBefore revampAfter revampAmmonia214.0 Kg/MT211.5 Kg/MTNitric acid780.0 Kg/ MT777.3 Kg/ MT17 Bar Steam0.236 T/MT0.181 T/MTPower20 kW/MT22.9 kW/ MTAN emission exit towerLess than 70Mg/NM312.8 Mg/NM3Ammonia emission exit towerLess than 20 Mg/Nm35.4 Mg NM3Granulometry73% between 2-3 mm90% between 2-3 mm95 % between 1-4 mm99 % between 1-4 mmMaximum achieved capacity1550 MT/Day2350 MT/Day
1750 % CAPACITY INCREASE Better consumption figures were achieved The improved granulometry allowed bypassing the originally installed sieve section and thus discontinuing reprocessing of off spec material.Emission levels for both AN and ammonia were reduced to BAT levels.Capacity increase of more than 70 %, based on name plate, and more than 50 %, based on best log, was achieved.
1850 % CAPACITY INCREASE 50 % CAPACITY INCREASE CONCLUSIONS Proven now commercially, is the possibility to increase the production capacity of a typical AN – 72 plant, from 1360 MT/Day(name plate) to 2350 MT/Day utilizing the existing prilling tower and keeping the AN and ammonia emissions at BAT levels.The revamp leads to an Improvement of both Ammonia and Nitric acid consumption figures.Better product granulometry is also achieved.Capex for such a revamp is significantly lower than that needed for the addition of the same incremental capacity using the existing AN – 72 design or the known granulation process.CONCLUSIONS