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Fact Sheet
OUR PROFILE
PCS Trinidad a subsidiary of PotashCorp, is strategically located to serve the US Gulf Coast, the Caribbean and Latin America. It is one of the worlds largest nitrogen complexes, with four ammonia plants and one urea plant on 165 acres of Trinidads sheltered west coast. It benefits from the countrys plentiful and favourably-priced natural gas. The facility utilizes the most advanced technology in the industry to produce ammonia and urea products. Ammonia is made into nitrogen solutions for fertilizers. Nitric acid is used to make synthetic fibers, plastics, fertilizers and metal treatments, and urea is used in fertilizers, adhesives and feed supplements. PCS Trinidad is an integral part of PotashCorps continued success. In a highly competitive industry, being part of a major international company like PotashCorp brings stability when markets are volatile. With the demand for nitrogen growing as the worlds food needs increase, PCS Trinidad is poised to play a crucial role in feeding the world. It also plays a vital part in enriching its nation. The PCS Model Farm & Agricultural Resource Centre was launched in February 2009, with the objective of training and teaching the local farming community how to produce more by using the latest technology, irrigation systems and responsible use of fertilizer. In addition to supporting the countrys economic initiatives and educational community, the company contributes to the social and cultural development of Trinidad and Tobago by providing assistance to local steelbands.
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. Desulphurization
Natural gas feedstock is passed through a desulphurizer to remove any traces of the mineral, since sulphur reduces the life of the catalyst in the downstream processes.
2. Primary Reforming
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. Secondary Reforming
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 (O2) that is present in the air reacts with un-reacted methane (CH4) to form carbon dioxide (CO2) and water (H2O). In addition to this combustion of methane, the reactions that occur in the primary reforming step continue in the secondary reformer.
1a
1b
2 3 5
6a 6b
Steam
4. Shift Conversion
Carbon monoxide formed in the primary and secondary reforming steps is further reacted with steam to produce hydrogen and carbon dioxide.
6. methanation
The gas stream now consists primarily of hydrogen and nitrogen, plus small quantities of carbon oxides not removed 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. Ammonia Synthesis
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.
Catalyst/Absorbent
(a) Cobalt/Nickel/Molybdenum (b) Zinc Oxide Nickel Nickel
Reactions
(a) RS + H2 g R + H2S (b) H2S + ZnO g ZnS + H2O (a) CH4 + H2O g CO + 3H2 (b) CO + H2O g CO2 + H2 (a) CH4 + 2O2 g CO2 + 2H2O (b) CH4 + H2O g CO + 3H2 (c) CO + H2O g CO2 + H2 CO + H2O g CO2 + H2 CO + H2O g CO2 + H2
3. Secondary Reformer
4. HTS Shift Converter 5. LTS Shift Converter 6. a. CO2 Absorber b. CO2 Stripper 7. Methanator 8. Mole Sieve Dryers 9. Ammonia Converter
(a) CO + 3H2 g CH4 + H2O (b) CO2 + 4H2 g CH4 + 2H2O N2 + 3H2 g 2NH3
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, in toothpaste, plastics, fabric treatment and more. The process of manufacturing granular urea can be divided into five steps:
4. evaporation
The urea solution then flows through the flash separator and 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.
1. High-Pressure/Synthesis
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.
3 4 2
1
5
Carbon Dioxide
5. Granulation
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 is kept 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. Ninetyfive 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. 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.
EVAPORATION
Water to Waste Water Treatment VACUUM SYSTEM
GRANULATION
STORAGE & HANDLING 1. Ammonia Receiver 2. Reactor 3. Stripper 4. Medium Pressure Decomposer 5. Low Pressure Decomposer 6. Flash Separator 7. Urea Solution Tank 8. Vacuum Separator 9. Granulator
Reactions
(a) 2NH3 + CO2 g NH4CO2NH2 (b) NH4CO2NH2 g NH2CONH2 + H2O
Urea Formaldehyde
P otas h corp
As the worlds largest producer, by capacity, of the three primary plant nutrients potash, phosphate and nitrogen PotashCorp has built a global reputation for quality and service. Our products serve three different markets: fertilizer, feed and industrial. All three nutrients are important to the fertilizer industry, with phosphate being the biggest player in the feed market. In the industrial market, phosphate and nitrogen products play the major role.
Mediterranean Drive, P.O. Bag 201, Point Lisas Industrial Estate Couva, Trinidad, West Indies Phone: (868) 636-2205 Fax: (868) 636-2052
Email: info@pcsnitrogen.co.tt www.potashcorp.com
March 2012