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2nd Annual GPCA Fertilizer Convention

Keeping your Urea Plant Operational when the Ammonia Plant is Down

CO2 Recovery (CDR) Plant IFFCO AonlaUnit (India)

CO2 Recovery (CDR) Plant IFFCO Phulpur Unit (India)

Masaki Iijima – Mitsubishi Heavy Industries Xxxxx xxxxx – Indian Farmers Fertilizer

2. MHI Flue Gas Recovery Process

Flow for MHI’s Advanced CO2 Capture Process

Flue Gas Outlet

Process Flow KM CDR Process®

CO2 Purity 99.9 %

ABSORBER STRIPPER (Regenerator)

C.W.

Cooling Tower Deep FGD C.W.

Flue Gas

Pre-treated Flue gas

C.W. Steam

Reboiler

Advantages of MHI’s CO2 Capture Process

Process Comparison MEA v KS-1 solvent

Evolution of MHI technology improvement

MHI’s Proprietary KS-1 Solvent MEA Solvent*1

Conventional MHI Process*2

MHI Improved MHI New Energy Process*2 Saving Process*3

Solution Circulation Rate

1

0.6

0.6

0.5

Regeneration Energy

1

0.8

0.68

0.62

Degradation of the Solvent

1

0.1

0.1

0.1

Solvent Loss

1

0.1

0.1

0.05

YES

NO

NO

NO

Corrosion Inhibitor Note *1 - Based on MHI’s Nanko pilot plant test data

*2 - Applied and proven on MHI commercial CO2 capture plants *3 – Based on MHI’s Nanko pilot plant test data – long term, reliable performance to be confirmed in a MHI commercial CO2 capture plant

Performance of MHI’s Improved Regeneration Process • Process Status: Commercialized • Process Features: Utilize lean solvent and steam condensate heat for regeneration inside the stripper


Utilize the semi lean solvent for the recovery of the lean solvent enthalpy

• Performance: 15% steam consumption reduction over MHI’s conventional process • Steam Consumption: *1.30 Ton Steam/Ton CO2 *Kcal/kg CO2 Recovered

Recovered CO2

Heat Recovery & Solvent Regeneration

Stripper

Note*: Steam 3 Bar G. Saturated

CO2

• Patent: Issues and pending in various countries • Further Improved Processes: MHI has developed further process improvements which reduce steam consumption. Currently preparing to release them to the market

Steam

Lean solvent Steam Condensate

Steam Consumption: 15% reduction compared to MHI conventional process ※ Steam = 3 BarG Saturated*2 Note*2: Steam = 3Bara can be applied

Commercial Scale Natural Gas CO2 Recovery – Ready to go!! Completed basic design for large single train PCC Plant Offering this plant on a commercial basis with guarantees Contract negotiation for several CCS & CO2-EOR commercial projects

Gas Boiler CO2 Capture Plant 3,000 t/d

Gas Turbine CO2 Capture & Compression Plant 3,000 t/d

MHI’s Commercial CO2 Capture Plants

MHI - Commercial CO2 Capture Plants Chemical Synthesis  World leading LARGE-SCALE post combustion CO2 capture technology licensor, with 8 commercial PCC plants in operation (from a variety of natural gas sources)  Largest operational post combustion CO2 capture plant in the world (450 tpd)

CO2 Recovery (CDR) Plant – IFFCO AonlaUnit (India)

CO2 Recovery (CDR) Plant – IFFCO Phulpur Unit (India)

1999

2005

2006

2006

2009

200 t/d Malaysia

330 t/d Japan

450 t/d India

450 t/d India

450 t/d India

Pre Commissioning

CO

ED T LE P M

2009

2009

2010

June - 2011

Q2 - 2012

450 t/d Bahrain

400 t/d UAE

240 t/d Vietnam

340 t/d Pakistan

450 t/d India

MHI Commercial CO2 Capture Plant Sites

33 9

2006 India (Aonla) 450 t/d

44

2006 India (Phulpur) 450 t/d

2011 Pakistan 340 t/d

22

2005 Japan 330 t/d

10 10

77

2012 India 450 t/d

2010 Bahrain 450 t/d

88

KEY

2010 Vietnam 240 t/d

Plants under operation Plant under commissioning

Plant under construction

66

2009 Abu Dhabi 400 t/d

55

2009 India 450 t/d

11

1999 Malaysia 200 t/d

CO2 Recovery Commercial Plant in Malaysia

Plant Outline Client

:

Solvent Capacity Use of CO2 Start up Feed Gas

: : : : :

PETRONAS Fertilizer (Kedah) Sdn Bhd KS-1 160T/D (200 T/D Max) Urea production October, 1999 Stream reformer flue gas

Process Description CO2 is recovered from flue gas of a steam reformer of on ammonia plant and delivered to CO2 compressor for urea synthesis. Recovered CO2 is used to increase urea production. The first commercial plant for flue gas CO2 recovery using this advanced technology has been operating in Malaysia since October 1999 for Urea production. Performance of the process is excellent in terms of low steam consumption, very low solvent degradation and low solvent loss.

CO2 Recovery Commercial Plant in India (Aonla)

Plant Outline Client Solvent Capacity Feed Gas

: : : :

Use of CO2 Start-up

: :

Indian Farmers Fertilizer Co. KS-1 Solvent 450 T/D Natural Gas and Naphtha Reformer Flue Gas Urea Production 2006

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOx is removed before entering the CO2 absorber.

CO2 Recovery (CDR) Plant IFFCO AonlaUnit (India)

CO2 Recovery Commercial Plant in India (Phulpur)

Plant Outline Client Solvent Capacity Feed Gas

: : : :

Use of CO2 Start-up

: :

Indian Farmers Fertilizer Co. KS-1 Solvent 450 T/D Natural Gas and Naphtha Reformer Flue Gas Urea Production 2006

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOx is removed before entering the CO2 absorber.

CO2 Recovery (CDR) Plant IFFCO Phulpur Unit (India)

CO2 Recovery Commercial Plant in India

Plant Outline Client

:

Solvent Capacity Feed Gas

: : :

Use of CO2 Start-up

: :

Nagarjuna Fertilizers and Chemicals Ltd. (NFCL) KS-1 Solvent 450 T/D Natural Gas and Naphtha Reformer Flue Gas Urea Production 2009

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOx is removed before entering the CO2 absorber.

CO2 Recovery Commercial Plant in Bahrain

Plant Outline Client (GPIC) Solvent Capacity Feed Gas

:

Gulf Petroleum Industries Co.

: : :

Use of CO2 Start-up

: :

KS-1 Solvent 450 T/D Natural Gas and Naphtha Reformer Flue Gas Urea & Methanol Production 2009

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOx is removed before entering the CO2 absorber.

CO2 Recovery Commercial Plant in Abu Dhabi

Plant Outline Client Solvent Capacity Feed Gas

: : : :

Use of CO2 : Start-up :

Ruwais Fertilizer Industries (FERTIL) KS-1 Solvent 400 T/D Natural gas Boiler & Steam Reformer flue Gas Urea Production 2009

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOX is removed before entering CO2 absorber. First MHI commercial plant to incorporate the New Energy Saving Process

CO2 Recovery Commercial Plant in Vietnam

Plant Outline Client Solvent Capacity Feed Gas

: : : :

Use of CO2 : Start-up :

PETROVIETNAM KS-1 Solvent 240 T/D Natural gas Boiler & Steam Reformer flue Gas Urea Production 2010

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOX is removed before entering CO2 absorber.

CO2 Recovery Commercial Plant in Pakistan

Plant Outline

Under Commissioning

Client Limited. Solvent Capacity Feed Gas

:

Engro Chemical Pakistan

: : :

Use of CO2 Start-up

: :

KS-1 Solvent 340 T/D Natural Gas and Naphtha Reformer Flue Gas Urea Production 2011

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOx is removed before entering the CO2 absorber.

CO2 Recovery Commercial Plant in India

Plant Outline

Under FEED Construction Completed

Client Chemicals Solvent Capacity Feed Gas

:

Use of CO2 Start-up

: :

: : :

Nagarjuna Fertilizers and Ltd. (NFCL) KS-1 Solvent 450 T/D Natural Gas Boiler and Naphtha Reformer Flue Gas Urea Production 2012

Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOx is removed before entering the CO2 absorber.

MHI’s CO2 Recovery Technology 1. World’s most advanced and comprehensive industrial R&D programs (commenced in 1990 and ongoing) 2. World’s largest operating post combustion CO2 capture plants (500 tpd) 3. World’s most energy efficient process – leading to reduced CAPEX & OPEX 4. MHI’s proprietary flue gas CO2 capture technology commercially applied since 1999 (8 plants under operation, 1 under commissioning and 1 under construction) 5. Coal Fired Power Plant CO2 Capture and Storage Project (500 tpd) in operation Alabama, USA 6. The ‘Complete Solution’ - hindered amine solvent “KS-1® ” with accompanying proprietary equipment 7. Applicable to large commercial power plants (MHI has comprehensive experience and a proven delivery record), biomass plants or CO2 intensive industries (steel, aluminum, etc.)

Flue Gas CO2 Recovery for Urea Production

Flue Gas CO2 Recovery for Urea Production In ammonia and urea plants, the CO2 produced by the reforming process and the CO2 recovered from the flue gas reformer or boiler are fed together to the urea synthesis section as feed stock. 1. Maximize Urea Production 2. Minimize Reconstruction 3. Reduce CO2 Emission Natural Gas

Flue Gas

Steam

Fuel

Primary Reformer

CO2 Recovery Air

Secondary Reformer

CO2

CO Shift

CO2

CO2 Removal

H2 N2

Ammonia Urea Synthesis NH Synthesis 3

Urea

Typical Ammonia and Urea Plant When synthesizing ammonia and urea from natural gas, ammonia is always in excess and there is a shortage of CO2. Therefore in a conventional ammonia/urea plant: 1. Excess hydrogen is used as fuel for the steam reformer and the ammonia and CO2 production is adjusted for urea production 2. Excess ammonia is sold or used for other purposes, other than urea.

CH4 + Air

NH3 + CO2

CO(NH2)2

Typical Ammonia and Urea Plant (Lean Gas Case)

CO2 2,588 T/D

Process Natural Gas Fuel Natural Gas

Ammonia Unit

Urea: 1,765 T/D

Urea Unit

Urea: 1,765 T/D

NH3 2000 T/D

NH3 Storage H2 for Fuel

Urea Unit

10,000T

Flue Gas CO2 Recovery to Optimize Urea Production

As stated before, when synthesizing ammonia and urea from natural gas, ammonia is always in excess and there is a shortage of CO2. Therefore, by recovering CO2 from flue gas and adjusting the ammonia and CO2 ratio, urea production can be maximized.

=

more product

Flue Gas CO2 Recovery

Urea ready for sale

Flue Gas CO2 Recovery to Maximize Urea Production (Lean Gas Case)

CO2 2,588 T/D Partial Flue Gas

CO2 2,910 T/D

CO2 Recovery 322 T/D

Process Natural Gas Fuel Natural Gas

Ammonia Unit

Urea Unit

Urea: 1,765 T/D + 220 T/D

Urea Unit

Urea: 1,765 T/D + 220 T/D

NH3 2000 T/D + 249 T/D

NH3 Storage 10,000T

During Ammonia Plant Trip or during Start Up Preparation, Urea Production can be Maximized

In

Ammonia and Urea plants, an ammonia liquefaction plant is usually installed to adjust the ammonia and CO2 ratio for urea production



If a large flue gas CO2 recovery plant is installed at the steam reformer, even during an ammonia plant trip or during start up preparation, urea production can still be maximized using the liquefied ammonia and the recovered CO2.

LESS DOWN TIME – MORE PRODUCT

During Ammonia Plant Trip or during Start Up Preparation, Urea Production can be Maximized (Two Ammonia Train, Lean Gas Case) CO2 2,588 T/D → 0 T/D

817 T/D

Urea Unit

Process Natural Gas Fuel Natural Gas

Urea: 0

Ammonia Unit Urea Unit

NH3 Storage

Urea: 1,114 T/D

10,000T

CO2 2,588 T/D 322 T/D

Flue Gas CO2 Recovery

1139 T/D

Process Natural Gas Fuel Natural Gas

Ammonia Unit

Urea Unit

Urea: 1,765 T/D + 220 T/D

Urea Unit

Urea: 1,765 T/D + 220 T/D

NH3 2000 T/D + 249 T/D

NH3 Storage 10,000T

Three Ammonia Train Case, If One Ammonia Plant Trips or during Start Up Preparation, All Urea Plants can be Operated (Lean Gas Case)

Process Natural Gas Fuel Natural Gas

815 T/D

Ammonia Unit

NH3 Storage

815 T/D

Urea Unit Urea Unit

Urea: 1,111 T/D

Urea: 1,111 T/D

10,000T CO2 2,588 T/D

1,456 T/D

Process Natural Gas Fuel Natural Gas

Ammonia Unit

NH3 2000 T/D + 249 T/D 1,456 T/D

NH3 Storage

Urea Unit

Urea: 1,765 T/D + 220 T/D

Urea Unit

Urea: 1,765 T/D + 220 T/D

Urea Unit

Urea: 1,765 T/D + 220 T/D

Urea Unit

Urea: 1,765 T/D + 220 T/D

10,000T Flue Gas

CO2 Recovery

CO2 2,278 T/D

CO2 2,588 T/D 1,456 T/D

Process Natural Gas Fuel Natural Gas

Ammonia Unit

NH3 2000 T/D + 249 T/D 1,456 T/D

NH3 Storage 10,000T

Thank You, Further Information Thank You,Questions Questions& & Further Information