Urea debottlenecking project: ABFS experience

L. Takip, . and Z. Kamarudin, . (1994) Urea debottlenecking project: ABFS experience. [Proceedings Paper]

In the 1980s ammonia/urea plant revamping was a widespread practice in the nitrogen fertilizer manufacturing plants all over the world the enormous stride in the process technology has enabled existing plants to be revamped for capacity increase a relatively low capital outlay compared to benefits that could be accrued from revamping.Considering the ready market for ABF ammonia and the projected growth in the ammonia market in Asia expanding the ABF Ammonia facility was justified.In addition the optimistic outlook on urea price which was projected to firm up from 1988 before stabilizing beyond 1995 and marketability of additional tonnage of urea via conversion of some surplus ammonia to high value product.For ABF the revamp project was seen as a sound solution for capitalizing on the projected market opportunities and introducing the various process optimisation features into the plant for both efficiency and environmental improvement.The urea debottlenecking has made a significant impact on the companys profitability through sales of additional tonnage of urea and increased profit margin due to reduction in overall unit production cost.The paper therefore focuses on the ABFs experience in the urea debottlenecking encompassing the various stages of implementations from conception through project planning execution commissioning and to ensure gas emission and effluent discharges were kept at a minimum.The debottlenecking projected was completed and commissioned in June 1991.Plant start-up after debottlenecking plat of this complexity was not without problems.However with careful analysis of the problems and the speed at which routes causes were identified and resolved enabled ABF to achieve the guaranteed capacity and efficiency within a short time frame.It is hoped that the ABFs experience in urea debottlenecking will be fruitfully shared with those urea plant owners intending to embark on a similar exercise.

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Abstract

In the 1980s ammonia/urea plant revamping was a widespread practice in the nitrogen fertilizer manufacturing plants all over the world the enormous stride in the process technology has enabled existing plants to be revamped for capacity increase a relatively low capital outlay compared to benefits that could be accrued from revamping.Considering the ready market for ABF ammonia and the projected growth in the ammonia market in Asia expanding the ABF Ammonia facility was justified.In addition the optimistic outlook on urea price which was projected to firm up from 1988 before stabilizing beyond 1995 and marketability of additional tonnage of urea via conversion of some surplus ammonia to high value product.For ABF the revamp project was seen as a sound solution for capitalizing on the projected market opportunities and introducing the various process optimisation features into the plant for both efficiency and environmental improvement.The urea debottlenecking has made a significant impact on the companys profitability through sales of additional tonnage of urea and increased profit margin due to reduction in overall unit production cost.The paper therefore focuses on the ABFs experience in the urea debottlenecking encompassing the various stages of implementations from conception through project planning execution commissioning and to ensure gas emission and effluent discharges were kept at a minimum.The debottlenecking projected was completed and commissioned in June 1991.Plant start-up after debottlenecking plat of this complexity was not without problems.However with careful analysis of the problems and the speed at which routes causes were identified and resolved enabled ABF to achieve the guaranteed capacity and efficiency within a short time frame.It is hoped that the ABFs experience in urea debottlenecking will be fruitfully shared with those urea plant owners intending to embark on a similar exercise.

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Item Type:	Proceedings Paper
Additional Information:	1 ill. 1 tables
AGROVOC Term:	UREA
AGROVOC Term:	NITROGEN FERTILIZERS
AGROVOC Term:	SOIL FERTILITY
AGROVOC Term:	FERTILIZER TECHNOLOGY
AGROVOC Term:	MALAYSIA
Geographical Term:	MALAYSIA
Depositing User:	Ms. Norfaezah Khomsan
Last Modified:	24 Apr 2025 05:27
URI:	http://webagris.upm.edu.my/id/eprint/16518

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