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P C S N i t r o g e N t r i N i D A D
Fact Seet
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PCS tndad a subsday f PashCp, s
sacally lcad sv h US gulf Cas,
h Cabban and Lan Amca. i s n fh wlds las nn cmplxs, wh
fu ammna plans and n ua plan n
165 acs f tndads shld ws cas.
i bnfs fm h cunys plnful and
favuably-pcd naual as.
th facly ulzs h ms advancd chnly
n h ndusy pduc ammna and ua
pducs. Ammna s mad n nnsluns f flzs. Nc acd s usd
mak synhc fbs, plascs, flzs and
mal amns, and ua s usd n flzs,
adhsvs and fd supplmns.
PCS tndad s an nal pa f PashCps
cnnud succss. in a hhly cmpv
ndusy, bn pa f a maj nnanal
cmpany lk PashCp bns sably whn
maks a vlal. Wh h dmand f
nn wn as h wlds fd ndsncas, PCS tndad s psd play a
cucal l n fdn h wld.
i als plays a val pa n nchn s nan.
th PCS Mdl Fam & Aculual rsuc
Cn was launchd n Fbuay 2009, wh
h bjcv f ann and achn h lcal
famn cmmuny hw pduc m by
usn h las chnly, an sysmsand spnsbl us f flz. in addn
suppn h cunys cnmc navs
and ducanal cmmuny, h cmpany
cnbus h scal and culual
dvlpmn f tndad and tba by
pvdn asssanc lcal slbands.
OUR PROFILE
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AmmoniA
PCS Trinidads ammonia complex consists of four
ammonia units producing approximately 2.4 million short
tons of ammonia annually. The utilities needed to run
these units include three cooling towers, three ammonia
storage tanks, steam, plant and instrument air support
and demineralized water for making steam.
Ammonia has a variety of uses, with its largest application
being as a nitrogen fertilizer. Ammonia is produced by
the reaction of nitrogen and hydrogen at elevated
temperatures and pressures in the presence of a catalyst.
Its three basic raw materials are air, natural gas and water.
The process of manufacturing anhydrous ammonia (NH3)
can be divided into eight basic steps:
1. Dsulphurzat
Natural gas feedstock is passed through a desulphurizerto remove any traces of the mineral, since sulphur
reduces the life of the catalyst in the downstream
processes.
2. Prary Rfrg
Steam (H2O) is mixed with natural gas, then heated and
passed over a catalyst to form hydrogen (H2), carbon
monoxide (CO) and carbon dioxide (CO2). The catalyst
promotes a reforming reaction through which the
natural gas is converted into these components.
3. Scdary Rfrg
Air is added to the secondary reformer in the necessary
proportion to create a ratio of three parts hydrogen (H2)
to one part nitrogen (N2). The oxygen (O
2) that is present
in the air reacts with un-reacted methane (CH4) to form
carbon dioxide (CO2) and water (H
2O). In addition to this
combustion of methane, the reactions that occur in the
primary reforming step continue in the secondary reformer.
SULPHUR REMOVAL REFORMING SHIFT CONVERSION, CO2 REMOVAL & METHANATION
1a 1b 2
3
Air
Steam
NaturalGas 4
5
7
CO2
6a 6b8
AmmoniA PRoCeSS FLoW DiAGRAm
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4. Shft Cvrs
Carbon monoxide formed in the primary and secondary
reforming steps is further reacted with steam to produce
hydrogen and carbon dioxide.
5. Carb Dxd RvalCarbon dioxide is removed from the gas stream by
absorption in a monodiethanolamine (MDEA) solution
or Benfield solution (a potassium carbonate solution).
The CO2
is then stripped from the absorbing solution
and some is used as feedstock in the production of
both urea and methanol. The stripped MDEA/Benfield
solution is then recycled.
6. mthaat
The gas stream now consists primarily of hydrogen
and nitrogen, plus small quantities of carbon oxides notremoved in the two preceding steps. Since carbon oxides
would poison the ammonia synthesis catalyst, it is necessary
to adjust the concentration to lower than 20 parts per
million (ppm). Carbon oxides are converted to methane
by reversing the steam reforming reaction.
7. Aa Sythss
The synthesis gas contains a 3:1 ratio of hydrogen to
nitrogen. The gas is passed through dryers where any
remaining moisture is removed. The desiccant used in
the dryers consists mainly of an alumino-silicate zeolite(molecular sieve). The dried gas is then compressed in
the synthesis gas compressor. The compressed gas enters
the synthesis reactor where the ammonia synthesis
reaction occurs over an iron or ruthenium catalyst. The
gas leaving the synthesis reactor contains approximately
15 percent of ammonia which is condensed to liquid
ammonia in the following step refrigeration.
8. Rfrgrat ad Strag
The gases leaving the reactor are cooled to
approximately -33 C (-27.4 F) to liquefy the ammonia.
The liquid ammonia is pumped to storage tanks where
the temperature is maintained to keep it in a liquid state.
The uncondensed, un-reacted hydrogen and nitrogen arerecycled to the synthesis reactor, where they join fresh
incoming feed for ongoing reaction.
There are three insulated storage tanks which have
combined capacity of 110,000 short tons. From these
tanks, liquid ammonia is pumped to the Savonetta Pier,
where it is loaded into the export tankers. PCS Trinidad
has two ammonia loading facilities: one located at
Savonetta Pier Number 1 (SPN 1) south, and another
located at Savonetta Pier Number 2 (SPN 2) north. The
one located at SPN 1 south is rated at 1,000 metric tons
per hour, while the one located at SPN 2 north is rated
at 1,500 metric tons per hour.
The utilities provide the services, facilities and supplies
needed to operate the ammonia units including treated
water for boilers, cooling water (fresh and salt), air (for
instruments), steam, waste disposal and back-up
electricity. One of these units, the demineralizer, treats
fresh water (provided by WASA) to remove salts and
produce demineralized water for steam generation. Fresh
water is also used for cooling process equipment and is
itself cooled by seawater. The seawater is in turn cooledin the cooling towers and recirculated.
About 18 percent of the ammonia produced is supplied
to PCS Trinidads urea plant as its major raw material and
the rest is exported to other markets, mainly in North
America and western Europe.
NH3 SYNTHESIS & REFRIGERATION
9
Refrigeration
NH3 Productto storage
Catalyst/Absorbent Reactions
1. Desulphurizers (a) Cobalt/Nickel/Molybdenum (a) RS + H2
g R + H2S
(b) Zinc Oxide (b) H2S + ZnO g ZnS + H
2O
2. Primary Reformer Nickel (a) CH4
+ H2O g CO + 3H
2
(b) CO + H2O g CO
2+ H
2
3. Secondary Reformer Nickel (a) CH4
+ 2O2
g CO2
+ 2H2O
(b) CH4
+ H2O g CO + 3H
2
(c) CO + H2O g CO2 + H24. HTS Shift Converter Iron/Chromium CO + H
2O g CO
2+ H
2
5. LTS Shift Converter Copper/Zinc CO + H2O g CO
2+ H
2
6. a. CO2
Absorber MDEA/Benfield Solution
b. CO2
Stripper
7. Methanator Nickel (a) CO + 3H2
g CH4
+ H2O
(b) CO2
+ 4H2
g CH4
+ 2H2O
8. Mole Sieve Dryers Alumino-Silicate Zeolite
9. Ammonia Converter Iron/Ruthenium N2
+ 3H2
g 2NH3
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UReA
PCS Trinidads urea plant has a capacity of 2,260 short
tons per day of urea in granular form, which is suitable for
both direct application and for blending with other solid
fertilizers. The two main ingredients in the manufacture
of urea ammonia and carbon dioxide are both supplied
by the ammonia complex.
Urea is an organic chemical compound obtained from the
high pressure synthesis of ammonia and carbon dioxide.
It is a white, non-toxic, non-volatile compound which is
highly soluble in water, melts at 132.7 C (270.9 F),
is hygroscopic and can be handled manually. It is used
mainly as a fertilizer, supplying 46.6 percent nitrogen by
weight (the highest concentration of nitrogen available in a
solid material). It is also used as the chemical intermediate
in the manufacture of resins, varnishes, glues and other
adhesives, as a protein supplement for cattle feed, intoothpaste, plastics, fabric treatment and more.
The process of manufacturing granular urea can be
divided into five steps:
1. Hgh-Prssur/Sythss
Liquid ammonia and gaseous carbon dioxide in a ratio of
3.6:1 are fed to a reactor where they form ammonium
carbamate, which rearranges (or dehydrates) to form urea
and water. Since the reaction does not go to completion,
the un-reacted carbon dioxide and ammonia are subsequently
stripped off, condensed and recycled to the reactor.
2. mdu Prssur Purfcat
The urea solution leaving the high-pressure synthesis
system is expanded and heated in the Medium Pressure
Decomposer. Additional un-reacted ammonia, together
with carbon dioxide and water vapour, is recovered and
recycled to the reactor.
3. Lw Prssur Purfcat
The urea solution from the Medium Pressure Decomposer
is again expanded and heated at an even lower pressure
in the Low Pressure Decomposer. A carbonate solution
containing ammonia and carbon dioxide in water is recycled
to the reactor via the medium pressure purification
recovery system.
4. evaprat
The urea solution then flows through the flash separatorand the vacuum separator where it is flashed and heated
to a molten 96 percent urea solution (urea melt). The
evaporated water is condensed and fed to the wastewater
treatment system, where traces of ammonia, carbon
dioxide and urea are removed, leaving a condensate
suitable for use in the steam generation system.
HIGH PRESSURE/SYNTHESIS LOOP MEDIUM PRESSURE LOOP LOW PRESSURE LOOP
Ammonia
3
4 5
1
2
Carbon Dioxide
Water from WasteWater Treatment
UReA PRoCeSS
FLoW DiAGRAm
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5. Graulat
In this final step, 0.5 percent of urea formaldehyde is
added to the urea melt. It acts as an anti-caking agent by
helping to restrict the tendency of the urea granules to
absorb moisture. In the granulator, the solution is then
sprayed upwards into a bed of seed granules, which iskept fluidized with warm air. Hot air is injected along with
molten urea, to atomize the urea melt into a fine spray.
This spray accretes on the seed granules, which fall to the
bottom of the fluidizing bed and are moved along by the
warm fluidizing air. The granules are cooled and screened
to ensure they meet market specifications. Undersized and
crushed oversized granules are recycled for use as seed.
The granular urea is then sent to the bulk warehouse
(which has a capacity of 70,000 short tons) where it is
stored under controlled temperature and humidity. Ninety-five percent is transported along conveyor belts to the pier
where it is loaded into the holds of dry cargo vessels at
approximately 550 short tons per hour. Major markets
include the United States, Canada and Latin America,
but some sales are also made to India and China. The
remaining five percent is bagged for sale to local and
regional markets.
EVAPORATION GRANULATION STORAGE & HANDLING Reactions
1. Ammonia Receiver
2. Reactor (a) 2NH3
+ CO2
g NH4CO
2NH
2
(b) NH4CO
2NH
2g NH
2CONH
2+ H
2O
3. Stripper
4. Medium Pressure
Decomposer
5. Low Pressure
Decomposer
6. Flash Separator
7. Urea Solution Tank
8. Vacuum Separator
9. Granulator
VACUUMSYSTEM
Water to WasteWater Treatment
Urea Formaldehyde
6 89
7
Hot Air
Bulk Warehouse
PCS TRiniDAD iS one oF THe WoRLDS
LARGeST niTRoGen ComPLeXeS, WiTH
FoUR AmmoniA PLAnTS AnD one UReA
PLAnT on 165 ACReS oF TRiniDADS
SHeLTeReD WeST CoAST.
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As h wlds las pduc, by capacy, f h h
pmay plan nuns pash, phspha and nn
PashCp has bul a lbal puan f qualy and
svc. ou pducs sv h dffn maks: flz,
fd and ndusal. All h nuns a mpan h
flz ndusy, wh phspha bn h bs play n
h fd mak. in h ndusal mak, phspha and
nn pducs play h maj l.
POTAShCORP
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For further information please contact:
PCS NITROGEN TRINIDAD
Mdanan Dv, P.o. Ba 201, Pn Lsas indusal esa
Cuva, tndad, Ws inds
Phn: (868) 636-2205 Fax: (868) 636-2052
emal: [email protected].
www.pashcp.cm Mach 2012
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