尿素装置增产改造技术交流课件

1、荷兰荷丰技术公司工程部1FUNGHAN ENGINEERING北京丰汉工程技术有限公司尿素装置增产节能改造Urea RevampUrea Revamp2尿素生产技术主要有水溶液全循环工艺和氨/CO2汽提工艺。该增产节能改造技术是在CO2汽提法尿素生产工艺以及大颗粒尿素造粒工艺的基础上完成的。Urea production technology is mainly about full circulation of the aqueous solution process and ammonia/CO2 stripping process. Our revamp technology is ma

2、inly applied to the CO2 stripping urea production technology and green granulation technology.Urea Revamp3CO2汽提法尿素合成工艺改造Urea Synthesis Revamp for CO2 Stripping Process4蒸发真空冷凝段废水处理段合成塔HP synthetic tower高压洗涤器HP Scrubber高压冷凝器 HP Carbamate Condenser脱氢反应器Dehydrogenation reactorCO2压缩机CO2 Compressor汽提塔一段蒸发

3、器Evaporation高压甲铵泵HP Carbamate Pump氨泵Ammonia Pump低压吸收塔LP Absorber精馏塔Rectify蒸发段低压段高压段熔融尿素去造粒装置HP synthesis stageLP stageEvaporation stageCO2汽提工艺流程示意简图CO2 stripping process flow schemeCO2 StripperMelting urea to granulation装置的特点plant features51. 高压氨泵和CO2压缩系统都有备机，可以满足扩产的需要。 Both high ammonia pumps and C

4、O2 compressor system have been prepared to meet expansion requirements.2. 高压循环系统设备成为瓶颈。增加该部分设备投资大。 In the expansion process, equipments in the high pressure stage is to be the bottleneck, which will cause a great investment if increase. 需要改造的装置一般都具有以下特点：Generally, the plant has the following feature

5、s. 丰汉工程建议方案 Funghan proposal6丰汉工程公司建议使用增加中压分解段的方式完成扩产改造的目的 Funghan propose to add a MP stage to complete expansion. 丰汉工程建议方案 Funghan proposal7尿素合成段增产改造的基本原则Basic principles for urea synthesis section revamp 尽量少动或不动高压段 as little as possible, even not revamp high pressure synthesis section改造后原装置仍可独立运行

6、 original plant can still operation independently after revamp尽可能的减少投资 as much as possible to reduce investment4. 节能降耗及减排 save energy and reduce emission丰汉工程建议方案Funghan proposal 8增加中压分解段的技术背景technical background of MP stage 最早水溶液全循环技术即有中压段 initial full circulation of the aqueous solution process tec

7、hnology has a MP stageCO2汽提引进中国后，有多种方案改进系统，增加中压段来增产改造是其中的一种方案 When ammonia stripping technology was introduced in to China, there are many proposals to improve the system, adding a MP stage to increase production is one of proposals.丰汉工程建议方案Funghan proposal 9增加中压分解段的技术背景technical background of MP st

8、age 3. 丰汉工程公司多年前即开始开发该技术 Funghan Engineering company began developing this technology many years ago.4. 在国内的改造中使用了该方案 In China, this proposal has been used in the revamp of some urea plant. 丰汉工程建议方案 Funghan proposal10增加中压段流程示意图PFS for adding MP stage蒸发真空冷凝段废水处理段汽提塔蒸发段低压段高压段熔融尿素去造粒装置HP synthesis stag

9、eLP stageEvaporation stage合成塔HP synthetic tower高压洗涤器HP Scrubber高压冷凝器 HP Carbamate Condenser脱氢反应器Dehydrogenation reactorCO2压缩机CO2 Compressor一段蒸发器Evaporation高压甲铵泵HP Carbamate Pump氨泵Ammonia Pump低压吸收塔LP Absorber精馏塔RectifyCO2 StripperMelting urea to granulation丰汉工程建议方案Funghan proposal 11蒸发真空冷凝段废水处理段中压甲铵冷

10、凝器MPCC中压分离器MP Separator汽提塔低压甲铵泵LP Carbamate pump中压汽提塔MP Stripper蒸发段低压段中压段高压段熔融尿素去造粒装置HP synthesis stageMP stageLP stageEvaporation stage增加中压段流程示意图PFS for adding MP stage高压洗涤器HP Scrubber高压冷凝器 HP Carbamate Condenser脱氢反应器Dehydrogenation reactorCO2压缩机CO2 Compressor一段蒸发器Evaporation高压甲铵泵HP CarbamatePump氨泵

11、Ammonia Pump低压吸收塔LP Absorber精馏塔RectifyCO2 StripperMelting urea to granulation合成塔HP synthetic tower丰汉工程建议方案Funghan proposal 12增加中压分解段的工艺流程概述PFS description of MP stage 从高压合成塔出来的尿素溶液经过绝压约20bar的闪蒸后，一部分被送入中压分离加热器中。在分离器中，在用于分离的9至12bar压力的高压蒸汽作用下，尿素/水溶液从大量未转化的氨和二氧化碳中被分离出来。中压分离器的分离段包含一个填料床层，以便在使用汽提加热器部分出来的废

12、蒸汽闪蒸后，进一步精馏液体。该床层有利于降低加热器的高压蒸汽损耗。Urea solution leaving the high-pressure autoclave is partly sent to the medium-pressure dissociation heater after being flashed at a pressure of about 20 bar absolute. In the dissociator the urea/ water solution is separated from the bulk of non-converted ammonia and

13、 carbon dioxide by using reduced high-pressure steam at a pressure of 9 to 12 bar for the dissociation. The separator of the medium-pressure dissociator contains a packed bed in order to rectify the liquid after flashing by using the off-vapor leaving the heater part for stripping. This bed has a po

14、sitive effect on the high-pressure steam consumption of heater.丰汉工程建议方案Funghan proposal 13增加中压分解段的工艺流程概述PFS description of MP stage 来自中压分离加热器中的尿素溶液，温度要控制在160 至165C，并被引到一台中压汽提塔中。为了把甲铵生成的N/C摩尔比控制在约2.3mol/mol的数值上，需要向这个中压段加入二氧化碳。在这台中压汽提塔中，这些二氧化碳用作汽提剂，以降低从中压汽提塔进入现有低压循环段的被汽提尿液的N/C摩尔比。The urea solution lea

15、ving the medium-pressure dissociation heater is controlled at a temperature of 160 to 165 C and discharged to a medium-pressure stripper. Carbon dioxide is added to this medium-pressure section in order to control the N/C molar ratio of the formed carbamate at a value of about 2.3 mol/mol. In the me

16、dium-pressure stripper this carbon dioxide is being used as a stripping agent to decrease the N/C molar ratio of the stripped urea solution leaving MP stripper to existing low-pressure recirculation section.丰汉工程建议方案Funghan proposal 14增加中压分解段的工艺流程概述PFS description of MP stage 来自中压分解分离器和中压汽提塔的气体，与在现有低

17、压循环段生成的甲铵一起，被送到一台浸没式的中压甲铵冷凝器中。在这台浸没式冷凝器中，气体被最大程度的冷凝。放出的冷凝热由一个冷却水调节系统吸收。The vapor leaving the medium-pressure dissociation separator and the medium-pressure stripper are sent together with the carbamate formed in the existing low-pressure recirculation section to a submerged medium-pressure carbamate

18、 condenser. In this submerged condenser the vapors are condensed at a maximum. The released condensation heat is dissipated in a tempered cooling water system.丰汉工程建议方案Funghan proposal 15增加中压分解段的工艺流程概述PFS description of MP stage 含水约20%（重量比）温度控制在约105C的的中压甲铵，将被现有的高压甲铵泵送到合成段，该甲铵泵分别通向高压洗涤器和高压甲铵冷凝器。The me

19、dium-pressure carbamate, containing about 20 wt % water will be controlled at a temperature of about 105 C. This carbamate is sent to synthesis section via the existing high-pressure carbamate pumps, where it is split to the high-pressure scrubber and to the high-pressure carbamate condenser. 丰汉工程建议

20、方案Funghan proposal 16增加中压分解段的工艺流程概述PFS description of MP stage 来自中压再冷凝器的、含有未转化氨和二氧化碳的惰性气体，被引入现有的4bar吸收塔和/或现有的低压循环段中的低压甲铵冷凝器中。The inert, containing non-condensed ammonia and carbon dioxide, leaving the medium-pressure after condenser is discharged to the existing 4 bar absorber and/or to the low-pres

21、sure carbamate condenser in the existing low-pressure recirculation section.丰汉工程建议方案 Funghan proposal序号No.设备名称Equipment Description状态Status1中压分离器Medium-Pressure Separator新建 New 2中压 CO2 汽提塔Medium-Pressure CO2 Stripper新建New3中压分解加热器Medium-Pressure Heater新建New4中压甲氨冷凝器Medium-Pressure Carbamate Condenser新

22、建New5中压甲氨冷凝器循环水冷却器Circulation water cooler for MPCC新建New6其他，视装置情况而定Others, depending on the device.新建/改造New/Modify17新增的设备表New Equipment List 大颗粒造粒部分改造 Revamp for Granulation18大颗粒造粒部分改造Revamp for Green Granulation Process装置的特点plant features191. 造粒机的造粒能力成为增产的一大瓶颈。 The capacity of granulator will be a

23、bit problem for the expansion revamp.2. 产量增加后没有足够的冷却系统降温，使产品温度过高。 There is no enough cooler system to cool down the products. 需要改造的装置一般都具有以下特点：Generally, the plant has the following features. 丰汉工程建议方案Funghan proposal 20 丰汉工程建议方案Funghan proposal 21 增加造粒喷头，以满足增产的需要。Add new granulation sprayer to meet

24、the capacity requirement.增加新冷却器，以弥补冷却系统的不足。Add new cooler to compensate for cooling system capacity.同时，为新增冷却器配备尾气洗涤系统及风机，不影响原洗涤系统的运行。At the same time, we will add new scrubber system for the new cooler.视设备能力情况，增加/改造斗提、筛分系统.Considering the equipment capacity to add or revamp elevator and screen.丰汉工程建

25、议方案 Funghan proposal序号No.设备名称Equipment Description状态Status1造粒机Granulator改造 Modify 2流化床冷却器Fluid Bed Cooler新建New3洗涤系统（含洗涤器和引风机）Scrubber and Exhaust Fan新建New4斗提机Elevator改造Modify5筛分机Screen新建/改造New/Modify22新增/改造的设备表New/Modify Equipment List 改造实例介绍 revamp practice introduction23尿素装置改造实例介绍Revamp practice introduction of Urea plant.改造实例介绍 revamp practice introduction24装置改造前设计能力1000吨/天（年产30万吨) Design capacity is 1000mtpd (annua