haldor topsoe, david james bray

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Boosting profitability for urea producers

6th GPCA Fertilizer Convention, Dubai, 14-16 September 2015

Integration of urea-formaldehyde production

2 Mission statement for GPCA Fertilizer convention

Innovating for growth: Ensuring an efficient and sustainable

future.

3

INNOVATION

IS CREATING RESULTS BY DOING NEW THINGS

4

Formaldehyde-based resins

Without formaldehyde-based resins

Utilized Wasted

63%

With formaldehyde-based resins

Utilized Wasted

95%

Source: American Chemistry Council 2015

Improving wood resources

5

Urea-Formaldehyde Concentrate Advantages in urea production

• Production • Improved anti-caking properties

• Increased crush strength

• Less powder formation

• More uniform size of particles

• No urea product discoloration

• End-user • Less urea lost due to wind

• Slower release of fertilizer

• Better utilisation of nitrogen

• Higher crop yields

• Better utilzation of natural gas

6

Co-production of UFC-85 fits in easily with Urea production Process steps

Feed purification

Primary reforming

Autothermal reforming

Natural gas

MeOH Formaldehyde

synthesis UFC-85 / AF

product

Air

Shift CO2 removal Methanation NH3 synthesis NH3 product

Urea synthesis

NH3

Urea product

Absorption

Form-aldehyde

UFC-85

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Integration of formaldehyde units in urea plants Topsoe has 25 years of experience

• Integration makes sense financially

• It allows for constant supply

• T/A’s can be easily coordinated

• Operation of the plants is easy and can use exiting man-power

• Fast installation and commissioning

• High degree of quality assurance

• Compact design

• Fully automatic operation

• Short payback time

8

The Topsoe UFC-85 Process Optimal performance

urea solution

Catalytic incinerator

Purified tail gas

Air

Blower

Pump

Methanol

After cooler

Evaporator/ Preheater

Recycle gas

Absorber

UFC Product

9

FK-100 The latest generation formaldehyde synthesis catalyst

• Higher selectivity

• Higher yields

• Lower by-product formation

• Operational flexibility

• Extended catalyst lifetime

• Chromium-free for safe handling

10

Integrated production of UFC-85 What to consider?

• New or existing urea plant?

• Prilling or granulation process?

• Daily quantity

• Local availability and price

• Opportunity for sale of surplus production

11

Methanol and Ammonia prices Price fluctuations make co-production an attractive option

0

200

400

600

800

1000

May/01 May/03 May/05 May/07 May/09 May/11 May/13 May/15

MIDDLE EAST METHANOL AND AMMONIA PRICES USD/ton

Source: Topsoe market research

• Highest profitability for co-production when MeOH > NH3

• UFC-85 manufacturing price is strongly correlated to the MeOH price

• Producers with fixed contract prices are generating larger profits

12

UFC-85 plant An investment in added value

Internal Rate of Return: 33%

Cost Gain

Price for plant and storage $18,000,000 -

0-12 months 0 $6,300,000

12-24 months 0 $6,300,000

24-36 months 0 $6,300,000

36-48 months 0 $6,300,000

48-60 months 0 $6,300,000

60-120 months 0 5 x $6,300,000

Net Present Value : $20,700,000

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Optimisation of UFC85 quality for improved production

Topsoe technical service improves product performance

• Challenge • Improving UFC85 to improve product at a

neighbouring consumer

• Too much Dimethyluron gave poor ‘glue’ performance

• Solution • Contacted Topsoe technical services for

analysis, sampling and recommendations.

• Absorber operation modified with respect to, i.e. recycle flows, pH and temperatures

• Outcome • Improved product quality; Dramatic reduction

in dimethyluron content

• Improved satisfaction from customer

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Before After

Dimethyloluron

Methylenediurea

N,N'-dimethylolurea

Oxymethylenediurea

Trimethylolurea

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Efficient removal of VOC’s from Formaldehyde plant

Reliable option to improve environmental performance

• Challenge • Reduce VOC emissions to comply with

environmental regulations

• Purge gas contains up to 2.2 vol% VOC’s

• Solution • Installed Topsoe CK-304 and CK-322 catalysts

• CK-322 has high performance in the hot-zone of the incinerator without using precious metals

• Outcome • VOC conversion > 99%

• Formaldehyde < 10 mg/Nm3

• Autothermal operation at both minimum and maximum operation

15

Chemanol An innovative company since 1991

• 18 expansion projects over 24 years

• Product portfolio

• Methanol

• Formaldehyde

• Derivatives

• Revenue • 2004: 60 mil USD

• 2013: 240 mil USD

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Chemanol and Topsoe Expansion projects over 23 years

67 MTPD

formaldehyde

1991

67 MTPD

formaldehyde

1993

120 MTPD

formaldehyde

1996

400 MTPD

formaldehyde

2008

Revamp

(117) MTPD

2002

Revamp

(117) MTPD

2004

Revamp

(220) MTPD

1998

700 MTPD

Methanol

2009

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Topsoe co-production references 16 units in operation

Source: Topsoe co-production reference list 2015

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Thank You To find out more or get in contact

www.topsoe.com

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