1. 30,000 Ton
Melamine Plant
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17A Marlen Drive w Hamilton, NJ w USA Tel: (609) w Fax: (609)

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Overview
Brief Overview
Year Built: A Train: 1973 & B Train:1980
Year Shutdown: September 2006
Upgraded: 2002 major upgrade of equipment in both lines
Current Status: Under Nitrogen
Technology: Mitsui, Co., Ltd.
Production: A Train: 30 tpd & B Train: 60 tpd
Products Produced: Melamine
Operation Days: 300 days per year
Raw Materials: Prilled Urea, Molten Urea, Liquid Ammonia, Carbon Dioxide Gas, Hot Salt and Dowtherm-A
Utilities Consumed: Steam, Fuel and Electricity
Documentation: Available
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3. Process Description Process Flow
Urea feed is introduced to the melamine synthesis reactor (A-1) while urea is stored and maintained for reaction in the urea solution tank (B-16)
In the reactor (A-1), the catalyst is charged and the heated carrier gas goes through and forms catalyst fluidization. Owing to endothermic melamine forming reaction, it is necessary to keep the temperature between 350°C to 400°C in the reactor by a heating coil installed in the fluidizing bed of the catalyst to which the molten salt is introduced
As the reactants pass through the reactor, the molten urea is vaporized and reacted to melamine, carbon dioxide and ammonia
The melamine-rich effluent gas from the reactor is cooled down to about 320°C in the hot gas cooler (W-12A/B) and introduced to the hot gas filter (F-4A/B) where the by-products and catalyst dust carried out from the reactor (A-1) are separated
The product gas is cooled down again to about 210°C in the crystallizer (A-2) by contacting the gas effluent (140°C) and a very fine melamine particle is formed
The cyclone separator (F-6A/B) is used for the separation of the melamine product and consecutive cooling and packing system is installed for final treatment

4. Process Description Process Flow
The remaining gas from the cyclone separator (F-6A/B) is introduced to the urea washer (K-1) and cooled down to 140°C by contact with the spray of molten urea
The gas containing ammonia and carbon dioxide serves as a carrier gas in the melamine reaction and cooling medium in the crystallizer (A-2)
The temperature of the molten urea should be strictly controlled by the urea cooler system (W-14) for washing and cooling the gas
The molten urea is then mixed with the fresh urea feed in the urea storage tank (B-15)
The yield of melamine by the aformentioned whole treatment is over 90% (on the basis of dry and theoretical)

5. Process Description Off Gas Recovery
The off gas from the melamine plant, mixture of NH3, CO2, H20 and a small amount of inert gas is pressured by the off gas blower (V-8) and sent to the off gas absorber (B-18)
In the absorber (B-18), most of the NH3 and CO2 in the off gas is absorbed in water fed from the battery limit for the off gas absorber
The produced ammonium carbonate solution is then transferred to the battery limit by the off gas solution pump
In consequence of feeding, the ammonium carbonate solution to the existing urea plant shall be made to keep the designed production capacity of the urea plant

6. Process Description
Process Flow Diagram

7. Melamine Specifications
Process Description
Melamine Specifications
Shape: White Powder
Quality:  Purity: 99.9% min.  Moisture: 0.1% max.  Color: as APHA 20 max.  Iron: 1 ppm max.  Ash: 20 ppm max.  pH: 7.5 ~ 9.5  Ammeline + Ammelide: 0.01% max.
Reposed angle: 45° ~ 54°

8. Photos:

9. Contact Information:
MICHAEL JOACHIM
DIRECTOR, PLANTS DEPT.
Tele: (direct)
Mobile:
SANJEEV REGE
VP GLOBAL PLANT SALES
Tele: (direct)
Mobile:
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