Modular UFC mini-plant new

Never resting on oars Safe Technologies Company has developed new, original solution that is targeted on urea manufacturers inside and outside Russia. Such comprehensive solution, aimed precisely at more effective urea production and protection of urea prills is a modular UFC mini-plant, designed for smaller capacity by UFC. The purpose of the plant is to provide effective and inexpensive means for the conditioning of urea prills, that otherwise tend to slump when transported for considerable distances. There are several types of additives that can control this problem but optimal solution today and for the near future is conditioning urea prills with UFC. It is known that 0,1% HCHO in urea prills is enough to ensure desired prill condition when transported to medium distances, still 0,25% and even 0,4% are often required by customer. That means that conditioning expenses in relation to production costs still remain considerable. Meeting needs of urea manufacturers, Safe Technologies Company offers design, shipment and construction of the UFC modular mini-plant with the capacity 3000 MTPY of UFC-85, adjusted for urea manufacturing of 5000 t per day of urea prills.

PROCESS

UFC manufacturing process includes following stages: 1. mixing methanol with air; 2. methanol oxidation to formaldehyde on metaloxide catalyst; 3. formaldehyde reactor cooling; 4. formaldehyde absorption by urea solution; 5. gas cooling;

LAYOUT
The single frame plant has the modular structure and 95% pre-constructed at the manufacturing shop. Final erection, connection to engineering networks and start up must not take more than 4 weeks. Area needed is 26 m2 The plant is constructed on the single concrete slab.

AUTOMATION
The plant is controlled by industrial controller; it functions in fully automatic mode, requiring no dedicated personnel. Operator of the urea plant can control it as a part of the integrated facility from the touch screen or PC monitor.

PERFORMANCE
UFC 85 capacity HCHO 37% solution capacity Methanol consumption per 1 t UFC 85 Power consumption (kWt/1 t UFC 85) Catalyst life quaranteed by full capacity Working days per year 3000 MTPY 5000 MTPY 700 kg less than 100 no less than 15 months no less than 350 (8400h)

ECOLOGY
1. Gas emissions minute. 2. Effluents absent. 3. Solid waste absent as well. (Used catalyst is sent to the manufacturer for regeneration) Sanitary protection zone for such a plant is 300 m according to Russian regulations, it is less than requirements for corresponding urea plant. That means that there is no need to expand sanitary protection zone installing new UFC facility.

OFFER
Today, Safe Technologies Company offers the UFC85 modular mini-plant turnkey just for EURO 990 000.Terms of delivery not more than 8 month from the Contract to start up. The urea manufacturing cost reduction is evident but those enterprises profit even more that have on site methanol manufacturing. In this case investment return is expected in 1-2 years.