Urea Capacity Increase

This client’s chemical plant has undergone a number of expansions since its startup in 1971. The plant sought to increase its urea capacity from 1,300 TPD to approximately 1,650 TPD. Demand for urea has increased, due primarily to its ability to reduce NOX emissions in diesel engines while achieving a 4% to 7% increase in gas mileage as well. Because of the economic opportunities realized by increasing production capacity, C&I was commissioned to conduct an FEL-1 conceptual phase estimate to achieve the new throughput.

The initial basis for the FEL-1 conceptual phase estimate was the existing equipment datasheets, PFD’s, P&ID’s, and equipment arrangements. C&I developed equipment sizing for FEL-1 conceptual phase without a simulation of the high pressure synthesis section (the part with ammonium carbamate) by making assumptions about ideality and using velocity rules-of-thumb, then applying appropriate safety margins. The equipment was re-checked in subsequent phases once the simulation was developed to confirm sizing and process conditions. The new equipment was designed for 1,650 TPD.

The engineering scope included the following activities:

• Collect data historian data, equipment data from files, and conduct field walk down to prepare sketches and markups
• Prepared process specifications/equipment datasheets for new equipment
• Prepared modification PFD’s with heat and material data
• Prepared hand marked up P&ID’s for proposed modifications
• Solicit equipment quotes (RFQ’s)
• Review vendor bids and submit pricing for the estimate
• Prepare simplified equipment arrangement plan drawing showing approximate locations of eleven (11) new pieces of equipment relative to the existing equipment that is pertinent to the project
• Prepared a +/- 40% factored estimate based on new equipment values
• Prepared a milestone schedule

This project was a major success for the client and C&I.