formaldehyde integrated production

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Information contained herein is our property and may not be used without our authority - Haldor Topsøe A/S Integrated Production of UFC-85 for Urea Fertiliser Conditioning by Carl-Vilhelm Rasmussen Haldor Topsøe A/S, Lyngby, Denmark Presented at the 12th Annual Technical Conference of the Arab Fertiliser Association (AFA) held on 5 – 8 October, 1999 in Casablanca, Morocco

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Urea Fertilizer Conditioning

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Page 1: Formaldehyde Integrated Production

Information contained herein is our property and may not be used without our authority - Haldor Topsøe A/S

Integrated Production of UFC-85

for

Urea Fertiliser Conditioning

by

Carl-Vilhelm RasmussenHaldor Topsøe A/S, Lyngby, Denmark

Presented at the 12th Annual Technical Conference of the Arab Fertiliser Association (AFA)held on 5 – 8 October, 1999 in Casablanca, Morocco

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Information contained herein is our property and may not be used without our authority - Haldor Topsøe A/S

Integrated Production of UFC-85for Urea Fertiliser Conditioning

IntroductionUrea is a nitrogen-containing chemical product that isproduced on a large-scale, world-wide basis. More than90% of the world production is destined for use as fer-tiliser. The product can be finished in the form of prills,granules or liquid fertiliser (solutions of urea and am-monium nitrate in water). For other areas of urea useplease refer to Appendix V.

67 MTPD (37 wt-% basis) conventional formaldehydeplant at Kaltim Fertiliser Plants, Bontang, Borneo,Indonesia. This plant is equipped with two absorbersystems for simultaneous production of UFC-85 andaqueous formaldehyde. An adiabatic post converter,increasing the production capacity to 80 MTPD (37wt-%), is seen under the tarpaulin to the far left in thephoto.

Urea is produced commercially from natural gas viaammonia and carbon dioxide.

Although prilling is in general the cheapest product fin-ishing technique, more and more customers are askingfor, or converting to, granular urea. The maximummean prill diameter obtainable with prilling is currentlyaround 2 mm, whereas granulation techniques can pro-duce grains of 5 mm or more in diameter.

Furthermore, having a more regular size than prilledurea, release is more constant and yields are more con-sistent.

Urea fertiliser, produced either in prills or in granules,shows a tendency to cake, i.e. to form lumps. The fac-tors contributing to the caking tendency are:

• hydroscopicity,• granule/prill size,• crystal restructuring and moisture content,• ambient conditions,• packaging, storage and transport conditions.

It is necessary to use some kind of additives in order tominimise caking in prilled or granular urea, particularlywhen the bulk urea storage facility has no humiditycontrol or when bulk urea is to be shipped long distan-ces.

The use of formaldehyde as anti-caking agent servesthe dual purpose of conditioning, as well as coating, ofurea granules/prills. It improves mechanical strength,moisture resistance and free-flowing characteristics tourea from a single point of injection in the productionprocess.

Formaldehyde as aConditioning/Coating AgentFull advantage of the benefits of the formaldehydeanti-caking system can be obtained whether the ureaproduction line uses the prilling or the granulationtechnology. Urea formaldehyde pre-condensate, UFC-85 (approx. 60 wt-% formaldehyde, 25 wt-% urea and15 wt-% water), can ideally be used for conditioning/coating prilled urea. UFC-85 can be directly injectedinto the urea melt, leaving the second stage of vacuumconcentration. The injection of UFC-85 in the ureamelt before prilling affords the added advantage ofpurer water streams from the evaporation sections.UFC-85 can also be introduced at the inlet to the 1ststage evaporation in the urea plant.

Granulated urea production requires UFC-85 for con-ditioning the urea granules. The solution is addeddirectly to the urea melt.

BenefitsThe main benefits obtained with the application offormaldehyde as anti caking agent are:

• Improved anti caking properties.

• Increased resistance to crushing of the urea prills andgranules.

• Less powder formation.

• More uniform size of particles.

• Investment costs for formaldehyde addition are low.See Appendix III and IV.

• No secondary spray coating treatment is necessary.

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• No solution preparation and handling equipment isrequired.

• No side product formation. Hence no operational pro-blems in the urea plant.

• The anti caking agent is mixed homogeneously in theproduced fertiliser.

• Urea solubility is not impaired.

• No urea product discoloration.

• Assured long life of treated urea particles – no lateralcrystal growth.

• No warehouse storage space required, but UFC-85and methanol tanks in case of on-site production ofUFC-85.

• No residual ammonia odour in the product, facilitat-ing unpolluted conveyor belt transport and warehousestorage.

Please refer to Appendix I for more specific advant-ages.

Recommended DosageThe injected formaldehyde or UFC-85 is applied in thefollowing concentrations relative to the urea product:

Prilled: approx. 0.25% formaldehyde by weight(as 100% formaldehyde)

Granulated: up to approx. 0.55% formaldehyde byweight (as 100% formaldehyde)

As can be calculated from the above, a typical 1000MTPD ammonia plant producing 1725 MTPD ureawill require per day:

Prilled: 4.3 TPD as 100% formaldehyde equal to 7TPD of UFC-85

Granulated: 9.5 TPD as 100% formaldehyde equal to16 TPD of UFC-85

FormaldehydeWorld-wide production/consumption of 37% formalde-hyde was nearly 18 million metric tons in 1996, aver-aging a value of USD 194/ton.

Most formaldehyde is consumed captively and demandis met mostly by regional suppliers.

Less than 2% of formaldehyde production is traded onthe international market, because of the cost of ship-ping formaldehyde solutions and because of the stabil-ity problems associated with storing formaldehyde forlong periods of time. Therefore, virtually all demand ismet by local producers within a 200 – 300 mile rangeof derivatives production sites.

Topsøe Experience ofFormaldehyde ProductionJointly with the Japanese company of Nippon KaseiChemical Co. Ltd., Haldor Topsøe A/S has in 1973 de-veloped a process for the production of formaldehydeby oxidation of methanol.

The process uses the so-called excess air principle. Theoxidation of methanol takes place over a catalyst com-posed of iron oxide and molybdenum oxide. This cata-lyst - denominated FK - is developed and produced byHaldor Topsøe A/S.

The advantages of the Haldor Topsøe/Nippon Kaseiprocess - as compared to other excess air processes -are mainly associated with the design of the absorptiontower and with the properties of the FK catalyst and itsinteraction with the design of the reactor.

The design of the absorption tower gives the followingadvantages

• The tail gas from the plant contains very little resi-dual methanol and formaldehyde.

• Even though the tail gas is very effectively scrubbed,the critical pressure drop over the tower is low.

The Topsøe FK catalyst is characterised by the followingadvantages

• The catalyst pellets are formed in a pressing process.This method gives high crush strength (above 90kg/cm2). Therefore, the catalyst is easy to handle andload into the reactor.

• The ring-shaped catalyst gives a low initial pressuredrop and a slow rate of pressure drop build-up. This isimportant for the power consumption of the plant. Fur-thermore, it gives a long lifetime of the catalyst. Thetypical lifetime is 18 months.

By addition of a Topsøe catalytic tail gas incinerator(CATOX), the formaldehyde plant can adhere to any en-vironmental standards.

Furthermore, if desired, any process condensate can beeliminated in the CATOX unit, whereby liquid effluentsare avoided.

Integrated ProductionVersus Purchase of UFC-85This decision and its economical advantages depend onvarious factors such as

• new or existing urea plant,

• prilling or granulation process,

• quantity of UFC-85 needed on a daily basis,

• availability and price of a local UFC-85 supply,

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• opportunities for sale or own use of surplus produc-tion of UFC-85 for production of derivatives.

If the urea producer can afford the investment, as esti-mated in Appendix IV, then the operating costs and theurea treatment costs, as estimated in Appendix III,ranging between 0.45 and 1.12 USD per ton of treatedurea from a UFC-85 package plant, would undoubtedlyprove to be competitive with any alternative anti-caking system or with the purchase of UFC-85. Thepurchase of UFC-85 would in addition to a higher costrequire extra storage capacity. See Appendix II abouthandling and storage of UFC-85.

Apart from being the most common and popular ureaanti-caking agent, UFC-85 or aqueous formaldehyde isalso a large chemical commodity, which may be attrac-tive to produce and perhaps sell locally for other reas-ons.

Appendix V lists areas of use for urea and formalde-hyde.

The considerations suggested above may lead to thedecision not only to build a formaldehyde plant forproduction of an amount of UFC-85 required daily forurea treatment at site, but also to build a plant with alarger capacity.

There may even be need for simultaneous productionof aqueous and urea formaldehyde solutions (UFC-85)in a dual absorber system.

This is all possible without much change to the processschemes.

Technical Description

Topsøe UFC-85 Package PlantThis technical description of a Topsøe package formal-dehyde plant is based on a capacity of 27 MTPD formal-dehyde (as 37 wt-%). The plant produces the equivalentamount of formaldehyde as urea formaldehyde pre-con-densate in any concentration up to 85 wt-% (UFC-85).

The plant consists of a free-standing absorber and three40 foot standard container modules. These are assembledand tested at our factory before delivery. They can betransported to the plant site by truck or ship, just likeother normal containers.

The modules are mounted on foundations provided be-fore the package plant is received at site. Two modulescontaining the process equipment are positioned verti-cally. The third module contains the rotating equipment,waste heat boiler and plate heat exchangers. This moduleis placed horizontally.

Once the modules have been received at site, only a fewfield welds and cable connections have to be made.

Meanwhile, the catalyst, heat transfer oil and absorberpacking are installed. The plant is ready to operate withinthree weeks.

17 MTPD UFC-85 Topsøe Package Plant at the POPKA Urea Project at Bontang,

East Kalimantan, Indonesia

Special features of the plant

• fast installation and commissioning,• few site preparations,• high degree of quality assurance,• compact design,• fully automatic operation,• a short pay-back time.

As an alternative to a plant supplied in modules, the UFCproduction unit may also be supplied in a conventionaldesign, where most of the installation work is carried outat site. This implies a longer construction period, but alsoa certain reduction of the purchasing price.

Process Description

Process Flow Diagram for a 17 MTPDTopsøe Urea Formaldehyde (UFC-85) Plant

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The plant will be laid out in accordance with the ProcessFlow Diagram shown on page 2.

Liquid methanol is pumped into an evaporator, where itis vaporised by condensing steam.

The gaseous methanol is mixed with air and recycle gas,which is circulated by the blower. The reaction mixturehas a methanol content of 8.4% by volume and an oxy-gen content of 10% by volume.

The mixture is preheated to 200ΕC in a process gasheater.

The preheated gas enters a reactor, in which it passesthrough approximately 2000 tubes containing Topsøemetal oxide catalyst type FK-2. The principal reaction,the catalytic oxidation of methanol into formaldehyde,occurs according to the equation:

CH3OH + 1/2O2 ? HCHO + H2O

The reaction is strongly exothermal, and in order tomaintain optimum temperature conditions and to limitthe formation of by-products, the heat of reaction has tobe removed during the reaction. This is done by heattransfer from the catalyst tubes to a bath of heat- stableboiling oil.

The oil vapours from the reactor are sent to an oil separa-tor and are then condensed in the process gas heater andin the air cooler for oil. All condensed oil is recycled bygravity to the reactor via the oil separator. In the oil sepa-rator the temperature of the return oil condensate is equi-librated with oil vapour, thus ensuring a uniform oil bathtemperature in the reactor.

The reactor effluent is cooled to 130ΕC in a waste heatboiler. Here all of the steam needed for methanol evap-oration is produced. The surplus steam is condensed in anair cooler for steam. All condensate is recycled by gravityto a steam boiler.

The formaldehyde-containing gas is passed on to an ab-sorber, where the formaldehyde is absorbed in urea solu-tion. The lower part of the absorber contains two packedbeds with packing made of 2" slotted stainless steel rings.The upper part of the absorber contains a section withvalve cap trays and one packed bed at the top.

The heat of the solution - as well as the sensible and lat-ent heat of the reaction gas - is removed in the lower bedsby re-circulated solution, which is externally cooled inproduct absorber coolers. Simultaneously, the major partof the formaldehyde is absorbed. Having passed the twopacked beds, the gas stream enters the tray section in theupper part of the absorber, where most of the remainingformaldehyde and methanol are removed from the gas bycounter-current washing with urea solution. In the toppacked bed maximum cooling is applied, and from thisstage the excess water is also drawn. See below.

The purified gas leaving the absorber is split into recyclegas, which is recycled back by the re-circulation blower,and tail gas, which is vented after further purification bya catalytic incinerator.

The absorption system is made from stainless steelthroughout. Also the bottom of the reactor, as well as theequipment between the reactor and the absorber, aremade of stainless, at least for all parts in contact with thereactor effluent gas. The choice of this material is madeto avoid corrosion and to obtain maximum purity of theproduct.

Catalytic Tail GasIncinerator (CATOX)The scrubbed tail gas is heated to approx. 250ΕC in aheat exchanger. At this temperature the gas enters an in-cineration reactor. Here the Topsøe type CKM-22 cata-lyst makes the combustible compounds - CO, CH30H,HCHO and (CH3)2O - burn with the O2 present in the tailgas. Thereby the gas temperature increases to approx.480ΕC. The hot gas leaving the incinerator is sent to thevent.

Excess water from the absorber is taken via a pump to thebattery limits. If so desired, the excess water may beevaporated in a separate heat exchanger within the UFC-85 unit and then mixed with tail gas for cleaning in thecatalytic incinerator.

As a result, the formaldehyde plant is completely neutraltowards the environment.

Operation of the Plant

InstrumentationThe plant is equipped with all necessary measuring andcontrol systems to ensure safe operation without continu-ous supervision by operators.

Normal OperationThe plant is easily controlled by regulating the methanolflow, the re-circulation flow and the air flow. The opti-mum reaction temperature, which is practically indepen-dent of the plant capacity, is controlled by the heattransfer oil pressure. This is regulated once in a while byadjusting the pressure controller at the inlet to the aircooler for oil.

Plant Turn-down Capacity and On-stream FactorThe turn-down capacity of the plant is 40% of the nameplate capacity.

The expected on-stream availability of the plant is mini-mum 350 days per year.

Recommended ManpowerWe recommend one full-time supervisor, who may takecare of other plants as well. Typically, supervisionwould take place from a central control room at thefertiliser plant.

Design BasisReference is made to Appendix VI.

Plant Lay-outThe modular design lay-out of the UFC-85 plant isshown on page 4 and 6.

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Scope of Supply

GeneralThe formaldehyde plant comprises a complete packagewith all the necessary equipment within the batterylimits. The plant is ready for production after connectionto the customer’s piping system.

All piping, valves, equipment and instrumentation is sup-plied pre-assembled, insulated or painted and ready forconnection to the customer's piping and foundations.

Cables for electric motors and instruments are suppliedpre-installed in cable trays.

Furthermore, the following items are included

• one full charge of FK-2 and CKM-22 catalyst,• special tools as required,• lighting of platforms and equipment,• control system (if not part of the urea fertiliser plant).

Erection at SiteThe package formaldehyde plant is erected at site in onlythree weeks, provided that foundations and paving areready to receive the plant. All instruments, valves andcontrol loops, as well as rotating equipment, are testedbefore transportation to the site.

First the absorber and the modules are placed on thefoundations and are aligned and bolted together.

17 MTPD UFC-85 Package PlantLay-out/Assembly Drawing

17 MTPD UFC-85 Conventional Plantat Petronas Kedah in Malaysia

with Topsøe Process, Constructed and Designedby Mitsubishi Heavy Industries.

Then the top section of the absorber is welded to the bot-tom section and the transport fixations are removed.

Meanwhile catalyst is loaded into the reactors, heat trans-fer oil is filled into the oil tank and the absorber packingis installed.

After that the piping between the modules is connectedby welding and by means of distance pieces. Also thecustomer's piping is connected.

When the power supply has been established and cablesbetween the modules have been rolled out and connected,the plant is ready for commissioning.

Capacity IncreaseIf the UFC-85 or formaldehyde production capacity of anexisting facility should later need to be increased, Topsøecan offer unique, affordable and convenient solutions.

The APCBy adding an Adiabatic Post Converter (APC), the capa-city of an existing formaldehyde plant can be enhancedup to 25% without major modifications or costs exceptfor the APC itself. The APC utilises a monolithic typeTopsøe FKM catalyst, which does not significantlyincrease the pressure drop in the plant. This concept hassuccessfully been installed and operated at the formalde-hyde plant of Kaltim in Indonesia.

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The Adiabatic Post Converter (APC) Installedat the Formaldehyde Plant of Kaltim, Indonesia

(67 to 80 MTPD Capacity Increase)

The Series ReactorBy adding another reactor placed in series with theexisting reactor, plant capacity can competitively beincreased by 50% without other major changes in theplant.

If also the existing absorber system is modified, thisoption may offer up to 80% capacity increase withoutactually increasing the process flow in the plant, but theformaldehyde gas concentration at the inlet to the absor-ber system.

This concept has successfully been installed and operated

at the plant of Saudi Formaldehyde Chemical CompanyLimited in Saudi Arabia.

SummaryThe package formaldehyde plant was developed by Top-søe some years ago, with special focus on the formalde-hyde consumers among nitrogen producers.

At various urea plants the high CIF cost of imported for-maldehyde or other anti-caking agents could be avoidedby producing formaldehyde in a self-operated formalde-hyde plant located adjacent to the urea plant. UFC-85,containing 60 wt-% formaldehyde, 25 wt-% urea and thebalance water, can easily be produced by diverting sidestream of urea solution from the urea plant to the forma-ldehyde plant absorber tower. Thereafter the UFC-85product stream is reintroduced to the urea process prior toprilling or granulation.

So far, this has lead to two projects. One 17 MTPD UFC-85 plant for the Petronas Kedah urea project in Malaysiaand one for the POPKA urea project at Bontang, EastKalimantan (Borneo) in Indonesia.

Both plants are based on the same process scheme asdescribed in this paper. The Petronas Kedah plant hasbeen constructed as a conventional plant at site during theconstruction phase of the fertiliser plant, whereas thePOPKA UFC-85 package plant has been constructed inaccordance with the principles indicated in this paper andwas shipped to the customer pre-assembled. In total 21commercial units have been built with an additional 2units under construction.

Appendix III is a cost survey for formaldehyde treatmentof urea. Appendix IV offers an indication of the approxi-mate turnkey investment cost of a package formaldehydeplant as well as to large conventional plants.

The economics of integrated production of UFC-85 forurea fertiliser conditioning depend on many factors, asdealt with in this paper. We hope that it will contribute tothe process of evaluating the possibilities.

Topsøe has Supplied all Formaldehyde and UFC-85 Units at the Complex of Saudi Formaldehyde Chemical CompanyLimited at Jubail in Saudi Arabia. The Total Installed Capacity Exceeds 350 MTPD (37 wt-% Basis).

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Appendix I

Specific Advantages of the Use of Urea Formaldehyde Concentrate (UFC-85)for Urea Anti-caking Application

• Use of urea formaldehyde as anti-caking agent serves the dual purpose of conditioning as well as coating urea prills. Itimproves mechanical strength, moisture resistance and free flowability characteristics to urea from a single pointof injection. No surface spray coating by surfactants (Uresoft) or inert powders is necessary, even if urea is to beexported over long distances to overseas clients.

• The conditioned/treated urea product is completely soluble, unlike urea treated with surfactant/inert materials.

• As UFC-85 is injected in the urea melt, there is no contamination of process condensate and purer waste streams areobtained from the evaporation/concentration sections. The entire quality of process condensate can be recycled to theD.M. water unit for demineralised water production. Purer process condensate also eliminates the possibility ofcontamination of cation/anion resins in the D.M. water unit. These are considerable economic advantages.

• Injection of UFC-85 in the urea melt reduces the load on the evaporation sections in terms of the total throughput.

• By addition of UFC-85 in the urea melt, the total residence time is reduced. Moreover, urea formaldehyde is acomplex, which does not convert to free formaldehyde. Therefore, there is no possibility of formation of intra-molecular ring closure products of methylene diurea. The problem of precipitation of ring compounds in the 1ststage evaporator/2nd stage evaporator and resultant choking of prilling buckets can be completely eliminated. Thisdecidedly is a notable operational advantage.

• In case of some prilled urea plants, it is possible to curb urea carry-over losses into the waste water system leadingto a decrease in the load on the hydrolyzer.

• Less powder formation.

Further Advantages in Comparison to the Use of Other Anti-caking Agents

• Investment costs are low (see Appendix III).

• No secondary spray coating treatment is necessary.

• Operating costs and urea treatment costs are low, among other things due to the saving in water/steam requirements(see Appendix IV).

• No solution preparation and handling equipment required.

• Addition of anti-caking agent can be accurately controlled.

• No by-product formation. Hence no operational problems in the urea plant.

• The anti-caking agent is mixed homogeneously in the produced fertiliser.

• No urea product discolouration.

• Assured long life of particles – no lateral crystal growth.

• No warehouse storage space required. No residual ammonia odour in the product facilitating unpolluted conveyor belttransport and warehouse storage.

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Appendix II

Handling/Storage of UFC-85

The shelf life of the UFC-85 product is almost unlimited, as long as the following conditions aremet.

• The UFC-85 concentrate should be maintained at a temperature not less than 0ΕC in order toavoid excessive viscosity and gel precipitation and at not more than 45ΕC in order to avoidpolymers/ formic acid formation.

• The pH level should be near 7.0 to prevent the formation and precipitation of higher molecularurea formaldehyde compounds, lower molecular urea compounds, transparent resins or even insol-uble condensation products. The pH level can be controlled by the addition of caustic soda to thestorage tank.

Among the common materials of construction suitable for handling and storing UFC-85 concentrateat temperatures up to 60ΕC are aluminium 2S and stainless steel (304, 316 and 405). Since somecontamination results when aluminium is used, stainless steel or stainless clad steel is generallypreferred for tanks.

Fibre reinforced plastic (FRP) tanks can also be used.

Storage tanks should be provided with a recirculation pump, caustic soda addition system, a canopyto prevent direct exposure to sunlight, and a shell cooling system/insulation depending on localambient conditions etc.

Appendix III

Cost Survey for Formaldehyde Treatment of Urea

Cost per ton of treated urea*

Formaldehyde plantcapacity 37 wt-% basis

Cost per ton of37% formaldehyde

0.2%100% formaldehyde

addition

0.5%100% formaldehyde

additionMTPD USD USD USD

27 120.58 0.45 1.1267 97.11 0.32 0.81

120 91.77 0.30 0.76

* In the cost calculation the formaldehyde added to the urea is set off at a price of USD 100.00 permetric ton.

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Appendix IVTopsøe Formaldehyde Plant Estimated Investment and Production Costs

Variable Costs

Consumption UnitCost per unit

USD

Consumption perton of 37%

formaldehyde

Cost per ton of 37%formaldehyde

USD

Methanol (1

Electricity (1

Catalyst (formaldehyde)Catalyst (incineration)Cooling water (1

(Process water (1 & 3

kgkWhkgkgm3

m3

0.140.05

0.013.00

42670

450.378

59.643.502.800.400.45

1.10)

Total variable costs USD/t 66.79

Fixed Costs

Description Unit

27 t/day37% formaldehyde,

package unit

67 t/day37% formaldehyde,skid mounted plant

120 t/day37% formaldehyde,conventional plant

Annual production(350 days/year)

Approx. cost of turnkeyprocess plant (1

10 years depreciation time,8% p.a. annuity loan

Maintenance 2% of plantcost

4 x 3-time operators (1

Total fixed costs

t/y

USD

USD/y

USD/y

USD/y

USD/y

9,450

2,800,000

417,281

56,000

35,000

508,281

23,450

4,000,000

596,116

80,000

35,000

711,116

42,000

6,000,000

894,174

120,000

35,000

1,049,174

Total fixed costs USD/t 53.79 30.32 24.98

Production Cost USD/t 120.58 97.11 91.77

Production cost excludingdepreciation

Price of importedformaldehyde (1

Saving (profit)

Saving (profit)

USD/t

USD/t(CIF)

USD/t

USD/y

90.95

260.00

169.05

1,597,519.00

80.05

260.00

179.95

4,219,828.00

77.48

260.00

182.52

7,665,840.00

Pay-back time (2 years 1.75 0.95 0.78

(1 Cost depending on local conditions and on the USD/EUR exchange rate.(2 Assuming that the total production can be utilised and set off against a similar import of formaldehyde.(3 In case of UFC-85 production, no process water is required.

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Appendix V

Areas of Use for Urea

• Fertiliser.

• Raw material for urea formaldehyde resins production in the adhesives and textile industries.

• Raw material for melamine production.

• Supplementary substitute protein source in feed stuffs for cattle and other ruminants.

• Other miscellaneous products such as de-icing agent for roads and airport runways.

Areas of Use for Formaldehyde

• Adhesive resins for the wood making industry, especially for particle board.

• Raw materials for surface coatings (paints).

• Curable moulding materials for plastic articles (acetals).

• Impregnating resins for coatings etc.

• Paper auxiliaries.

• Textile auxiliaries.

• Binders for foundry sand.

• Binders for fibre mats, e.g. mineral wool.

• Binders for abrasive materials, e.g. sandpaper.

• Binders for friction linings, e.g. brake pads.

• Foamed resins for building insulation, mining, soil improvement, miscellaneous.

• Rubber auxiliaries.

• Disinfectant and preservative.

• Infection inhibitor in sugar production.

• Intermediate for chemicals.

• Complexing agent, e.g. for EDTA (ethylene diamine tetraacetic acid and NTA (nitrilotriacetic acid)

• Synthesis base for- 1,4 butanediol- polyoxymethylenes- pentaerythritol- methylene diphenyl diisocyanate- hexamethylene tetramine- complexing agents

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Appendix VITypical Design Basis of a Topsøe UFC-85 Plant

Raw Materials

Feedstock methanol: methanol grade A or similar

UreaSolution: wt-% 60 - 70 in waterTemperature: ΕC 60 – 70Pressure: 4.0 kg/cm2g

Product Urea Formaldehyde (UFC-85)Formaldehyde content: % 60.00Urea: % 25.00Methanol content (typical): % 0.21Formic acid content: % 0.05Balance: water

Waste Streams

Tail Gas (tail gas incinerator included)Pressure: atmosphericComposition,- HCHO: vol-% < 0.0010- CO: vol-% < 0.0100- (CH3)2O: vol-% < 0.0010

Excess Water (if not eliminated in a CATOX unit)Temperature: ΕC 34Pressure: kg/cm2g 2.0

Utilities

ElectricityVoltage: V 380 ACPhases: 3Frequency: Hz 50

Cooling WaterTemperature inlet/outlet: ΕC 30/40Pressure inlet/outlet: kg/cm2g 4/2

Process WaterTemperature: ΕC 30Pressure: kg/cm2g 4Quality: demineralised

NitrogenPressure: kg/cm2g 5

Instrument AirPressure: kg/cm2g 6Quality: clean and dryDew point at pressure: ΕC 10 below minimum ambient temperature

Climatic ConditionsTemperature rangemin./max.: ΕC to be specified

Classification of EquipmentThe entire production area of the formaldehyde plant is to be classified as explosion hazardous area, zone 2, group IIA,class T1, as per IP safety code and IEC Recommendations.