FERTIL-2 integrated ZERO effluent discharge and ammonia emissions design concept

Mr. MAJED ALSHEMEILIUrea-2 Operation Department Manager

FERTIL

Content

• FERTIL profile

• The design concept of FERTIL-2.

• Zero ammonia emission concept.

• Zero liquid discharge concept.

• Benefits achieved & Conclusion.

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FERTIL Profile

Location Ruwais (250 Km west of Abu Dhabi)

Established 1980

Shareholders ADNOC 2/3 & TOTAL 1/3

Plants FERTIL 1 FERTIL 2

Established/Started Up Oct.1980 / Nov.1983 Nov. 2009 / June 2013

Products, Name plate

capacity

Ammonia (MT/Day) 1,300 2,000

Urea

(MT/Day)2,300 3,500

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Plants Photos

FERTIL-1

FERTIL-2

change

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FERTIL’s Commitments

Conserve energy, water and other resources for the future

Reduce industrial footprints

Leave a healthy environment

FERTIL Approach

towards Zero

Ammonia Emission

Concept

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FERTIL-2 Flaring system Objective

• Improve HSE performance by making FERTIL-2 production units Zero ammonia emission units

o Improve Safety and avoid any risks caused by ammonia release during operation

o Improve working environment and eliminate nearby companies concerns about produced off-gases

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FERTIL-2 Urea Flare for continuous sources:

Background

The released ammonia has the following impacts:

1. Safety concern on the working environment

2. Long term impact on employees’ health

3. Annoyance to the near by companies

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Urea Flares Descriptions:

Main Flare designed for Discontinuous emissions as a result of the blow-off of PSV’s,

rupture disks of high pressure and low pressure sections with an emergency device tointroduce the required assist gas during emission.

Low-pressure Absorber Flare designed for continuous emission from the Low-

Pressure Absorber. The reason for the integration is that the governing cases require acomparable amount of nitrogen and natural gas insertion and the available pressure differfrom other flares. Designed for continuous off-gas flow of 2500m3/hr with 0.99% ammonia.

Utility Flare is designed for the continuous emission from the vent of the Process tanks.

The main consideration of the separation is the allowable atmospheric back pressure for thesmall flow cases. The addition of nitrogen is required in normal operating conditions to dilutethe oxygen concentration. Designed for continuous off-gas flow of 3400m3/hr with 1.34%

ammonia.

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Current Urea-2 Flaring system arrangements

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Current Ammonia-2 Flaring system arrangements

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Current FERTIL-2 Flaring system arrangements

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Environmental impact of continuous off-gases treatment

using flaring

Item Flaring system

NG gas used (MM Nm3/year) 15.5

CO2 emissions (ton/year) 35,047

NOx emissions (ton/year) 18

NOx emissions (ppmv) 160

ADNOC COP NOx emissions limit (ppmv) less than 186

FERTIL Approach

towards Zero Liquid

Discharge Concept

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Zero Liquid Discharge Concept

o Existing evaporation ponds facilities at the site consist of two compartments .

o each with a 12,400 m3 capacity working in a parallel operation mode.

o The design envisions the possibility of taking one of the pond compartments offline for maintenance or cleaning while the other compartment remains operational.

o The ponds are designed to receive intermittent storm surface runoffs, firefighting flows from various areas of FERTIL and neutralized regeneration wastewater from the Demineralization plant.

o Amount of effluent discharge from DM unit neutralization pit ( 9 M3/Hr.) is design basis. In real it was more but with enhancement of running length of DEMIN and Mixed Bed polisher, the effluent discharge quality has been reduced and is less now ( Approx. 6 M3/Hr.).

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Flow diagram of waste waster treatment

Waste water diversion pit

Waste water collection basin

CPI oil separator

Neutralization pitDemin. plant

B

A

Rain water buffer pit

Urea plant

Amm. plant

Utility

Sea Water

Evaporation Pond

9 Nm3/hr

Waste water from F-1

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Evaporation pond location

Evaporation Pond

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Benefits achieved & Conclusion:

• Fertil is committed to enhance the social responsibilities while protecting the environment and the community and has been achieved by implementing this concept of “Zero Effluent & Emission”,

• It is possible to avoid the release of liquid effluents produced in similar plants to the sea with the aim of protecting the healthy marine environment.

• The personal safety, in similar plants where ammonia is handled, can be enhanced by eliminating the release of ammonia fluid directly to the atmosphere while sustaining the highest responsibility towards the company staff & the surrounding community.

Thank You!www.gpca.org.ae