108,000 MTPYAmmonium Sulfate Plant from a Complete Caprolactum Facility (IPP Stock #600883)
The Ammonium Sulfate Plant is part of a Caprolactam Facility which includes all intermediate and byproduct plants. The facility starts with benzene and finishes with caprolactam and ammonium sulfate byproduct:
• Cyclohexane Plant – 80,000 MTPY
• Cyclohexanone Plant – 55,000 MTPY
• Oximation Plant – 62,000 MTPY
• Caprolactam Plant – 60,000 MTPY
• Ammonium Sulfate – 108,000 MTPY
• Incinerator – 5 m3/hr liquid waste
The facility had some upgrades over the years.
Documentation is complete and well-organized. Much of it is electronic and has already been shared with IPP. The facility received ISO-9001 certification in 1997 and ISO-14001 certification in 2004.
DCS is by Yokogawa (Centum CS-3000) and is used in the Oximation, Caprolactam, Ammonia Sulfate, and Incinerator units.
The plant has been well-maintained and is still being kept up with a staff of four employees. There is a nitrogen pad on the process and they are turning the rotating equipment monthly.
There are abundant spare parts available with the facility.
Transportation to and from the facility by road is excellent and it is 24 km to the nearest major port.
The Ammonium Sulfate Plant produces 110,000 MTPY of solid ammonium sulfate byproduct. The plant consists of evaporation, crystallization, centrifugation, and drying processes. The plant, which is almost entirely 304 stainless steel construction, closed in 2009.
The plant receives its feed as a 52% ammonium sulfate solution from the bottom of the ammonium sulfate extraction column in the Oximation Plant mentioned earlier in this report. The solution first enters the evaporator section of the plant. The evaporators take 30 m3/hr of solution from 52% to 60% ammonium sulfate in the first evaporator and from 60% to 65% in the second stage evaporator. This equates to about 8,750 lbs/hr of water removal capabilities.
The solution drops from the second evaporator into a large crystallizer. The crystallizer is 7.2 meters diameter by 9.3 m long. It is constructed of 304 stainless steel and is rated for atmospheric pressure at 100°C. The solution is then pumped from the crystallizer to the two Escher Wyss centrifuges for thickening. Mother liquor from the centrifuges is recycled back to the crystallizer. Thickened product is transported by screw conveyor to the dryer.
The dryer is 2.3 meters diameter by 8.4 meters long. It is constructed of 304 stainless steel and is rated for 0.1 bar at 180°C. Air for the dryer is steam-heated with a large 304 stainless steel exchanger. The heater is 1.4 m diameter by 4 m long and is rated for 1.8 bar at 103°C. The dry ammonium sulfate discharges from the dryer onto a flat conveyor belt. The conveyor takes the product to a bucket elevator which transfers the product through some sieves and onto another conveyor belt going to the warehouse. The product dumps onto the large concrete warehouse floor and is moved with front-end loaders to desired warehouse locations.
Utilities & Tank Farm
There are two incoming electrical feeders with automatic switching gear which is included in the plant sale. There are 13 transformers in the 1,000 to 2,000 kva range. The frequency for all electrical equipment in this facility is 60 Hz. There are three cooling tower cells with three Worthington cooling tower water pumps. The cooling tower is in poor condition, but the pumps are in good condition. There are four Trane chillers which appear to be about 300 tons of refrigeration capacity each.There is a 500 kW emergency generator driven with a diesel motor. There are two Centac instrument air compressors. The compressor is missing from one of the units. There are two diesel-driven fire water pumps capable of 18 bar discharge pressure. The flare is said to be 55 meters tall, but it appears to be much taller. There are about 17 major tanks in the tank farms. They are a mix of carbon steel and 304 stainless steel construction.
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