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Keywords

Y4

system or software

Z3/2

natural gas/oilL

Technical Service
Toyo Engineering Corporation

Energy-saving Urea Synthesis ProcessFeatures
ACES21® (Advanced process for Cost and Energy Saving 21) is a simplified urea synthesis processthat allows reducing the plant construction cost. The operating cost is also reduced because theoptimized process condition in ACES21® realizes low synthesis pressure and significantly reduces theenergy consumption.
Basic Concept or Summary
ACES21® has the advantages as follows:
1. Reduction of the construction cost by lowering the equipment elevation and making the layout more compact:- Reactor on ground level by applying a high-pressure ejector;- Vertical submerged carbamate condenser (VSCC);- Simple synthesis loop.
2. Reduction of the equipment cost by making the design more compact:- Small reactor by two stage reaction;- Less number of equipment in the synthesis loop.
3. Energy saving by adopting the optimum process condition:- Realization of low synthesis pressure and energy saving by adopting the optimum process condition.
4. Easy and stable plant operation:- Easy and stable plant operation realized by forced circulation in the high-pressure loop using a high-pressure
ejector (no gravity flow).
5. Reduction of the maintenance cost:- Reduction of risks of corrosion problems by adopting lower synthesis system temperatures and more reliablematerials.
ACES21® synthesis loop

ACES21® process overall flow diagramEffects or Remarks
As a result of energy saving, utility consumption was reduced to the levels as follows (per ton of large
granular urea).
TOYO established a large granular urea
production technology named Spout Fluid Bed
Granulation Process by combining the spouted
bed and fluidized bed. This technology cansignificantly reduce the power consumption andequipment cost, and has been introduced to urea
plants in many countries around the world.
In 2022, TOYO announced the innovative next-generation urea process, "ACES21-LP®". ACES21-LP®
is the most advanced urea process which realizes the lowest synthesis pressure together with thehighest CO2 conversion among any modern urea processes, maintaining salient features of current
ACES21®. ACES21-LP®, thanks to the sophisticated combination of the excellent process concept ofACES21® and the state-of-the-art low-pressure urea synthesis technology, further reduces energy
consumption by reducing power requirements in pressurizing raw materials and reduces plant cost bytrimming weight of synthesis equipment, and contributes to low-cost production of urea and global
environmental protection.
Installation in Practice or Schedule
Overseas

The ACES21® process was adopted by urea plants in China, Indonesia, Trinidad and Tobago,
Venezuela, Iran, Bolivia, Nigeria and India. The original ACES process before it was improved
as ACES21® was adopted in Indonesia, India, Bangladesh, Pakistan, Korea, Spain, etc.
Urea plant with ACES21® process in Nigeria (4,000 t/d)

Further, TOYO's energy-saving large granular urea production technology was introduced toNew Zealand, Germany, China, Indonesia, Iran, Brazil, Venezuela, Ukraine, Bolivia, Nigeria,etc.

Contact:

Toyo Engineering Corporation, Urea Technology Business Development OfficeE-mail: urea@toyo-eng.com
Toyo Engineering Corporation: https://www.toyo-eng.com/jp/en/
Urea Technology: https://www.toyo-eng.com/jp/en/solution/energy/

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