Chemical Archives - C&I Engineering https://www.cieng.com/project_industry/chemical/ C&I Engineering Fri, 04 Feb 2022 14:57:31 +0000 en-US hourly 1 Urea Capacity Expansion https://www.cieng.com/projects/potash-urea-expansion/ Fri, 28 Jan 2022 19:07:38 +0000 https://www.cieng.com/?post_type=project&p=1409 This client sought to increase its urea capacity from 1,300 TPD to approximately 1,650 TPD to meet increasing market demand....

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]]> This client sought to increase its urea capacity from 1,300 TPD to approximately 1,650 TPD to meet increasing market demand. This is due primarily to its ability to reduce NOX emissions in diesel engines while achieving a 4% to 7% increase in gas mileage. Because of the economic opportunities realized by increasing production capacity, C&I conducted FEL-1 conceptual phase through Detailed Design, Start-up and Commissioning.

To accurately model the process changes, our team created a benchmark simulation of the entire Urea Unit. Creating a Hysys model was a challenge and had to be rigorously tested. Due to the unique chemistry of the process, the urea and ammonium carbamate components had to be created and regressed binary interaction parameters for multicomponent mixtures had to be developed. Our model was validated against a test run, providing confidence in the simulation of future operation. The process team used creativity to address the need for supplemental compressed CO2 gas feed by using liquid CO2 to support the overall capacity increase.

The existing unit was congested, requiring finesse in siting equipment and routing piping. This is where our expertise in retrofit design combined with the 3D modeling tool and laser scan set us up for a successful project. We were able to involve stakeholders in a constructability review early in the design process to locate several new pieces of equipment in an existing structure.

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]]> NOx Abatement https://www.cieng.com/projects/clariant-nox-abatement/ Wed, 29 Dec 2021 19:01:02 +0000 https://www.cieng.com/?post_type=project&p=1403 C&I assisted our client with specifying a SCR (selective catalyst reduction) system for removing NOx from rotary and belt calciners...

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]]> C&I assisted our client with specifying a SCR (selective catalyst reduction) system for removing NOx from rotary and belt calciners at a 95% or higher destruction efficiency. Defining the NOx emissions was challenging as the plant runs a variety of campaigns on each calciner resulting in several design cases used to characterize the NOx stream and establish a datasheet for the SCR unit. Several vendors and technologies were evaluated, and ultimately a system consisting of baghouse filters, natural gas burner, air fans, SCR catalyst reactor, exhaust stack, urea injection lance, mixers, and urea tank was chosen. Auxiliary equipment to the support the system included eductors for solids removal, air preheater to control header temperature, and a large collection header routed through the plant.

Utilizing our self-performed laser scan, the team was able to work with Operations, Construction and Maintenance to ensure the plant was able to use the existing NOx scrubber system while staging cut-over to the new system one calciner at a time, significantly reducing impacts to production.

C&I provided cost estimates for the FEL-3 and FEL-4 phases, procurement for instrumentation and engineered equipment, and construction packages for all upgrades.

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