Process Performance

ACES21UREA
PROCESSby TOYO®

Product Quality (Typical)
Nitrogen (N) Content
Biuret Content
Water

46.4 wt%
0.8 wt%
0.2 wt%Consumption Figure (Typical, Granulation Case)
Raw Material
NH3 (100%)
CO2 (100%)

0.563 ton
0.731 tonNote: (1) The loss from Ammonia Pump and CO2 Compressor is included.
(2) Unit is per metric ton of granular urea.

Utilities (per metric ton of granular urea product )Unit
Steam Import
22 bar, 300℃
42 bar, 380℃
110 bar, 510℃
Steam Export
5 bar, Saturated
Cooling Water (Δt=10℃)
Electricity
Process
Granulation
Note:

All Motor Driven Case
Steam Self Balance
Steam Export

Steam Turbine Driven Case
42 bar
110 bar

ton
ton
ton

0.67

ton
m3

0.24
52

52

81

75

kWh
kWh

105
24

105
24

21
24

21
24

(1) All figures above include:- CO2 Compression- Ammonia and Carbamate Pumping- Urea Synthesis- Purification and Recovery- Urea Concentration- Urea Granulation- Process Condensate Treatment

0.58
0.80
0.69

(2) The figures above exclude:- air conditioning, ventilation, air heater,
steam trace, etc.
- urea storage and bagging facility(3) Ammonia Pump and Carbamate Pump are driven
by motor.
(4) Local conditions may change the figures above.
(5) Unit is per metric ton of granular urea.

Advanced
processfor Cost andEnergy Saving

Toyo Engineering Corporation
2-8-1 Akanehama, Narashino-shi, Chiba 275-0024, Japan
Tel: 81-47-451-1111
Fax: 81-47-454-1800
http://www.toyo-eng.co.jp

ACES21® is a registered trademark of Toyo Engineering Corporation in Japan (Registered Number 4309123).

©2006-2012 Toyo Engineering Corporation
H24.10.20 2 SAN

Synthesis

TOYO:
Leader in Urea Process
Technology
Since its establishment in 1961, Toyo Engineering Corporation (TOYO) has been a leader inthe urea industry. TOYO has designed, engineered, constructed and commissioned over
100 urea plants based on the TOYO Urea Process including its urea synthesis technologies
and urea granulation technologies.
Using its own expertise, advanced technology and new thinking, TOYO has established the
ACES21® Process, which achieves energy saving and plant cost reduction without
sacrificing high performance and high efficiency of the urea plant.

ACES21® process synthesis section
consists of a reactor, a stripper and acarbamate condenser. Liquidammonia is fed to the reactor via the
HP Carbamate Ejector which provides
the driving force for circulation in thesynthesis loop instead of the gravity
system of the original ACES. The
reactor is operated at an N/C ratio of
3.7, 182 °C and 152 bar. The CO2
conversion to urea is as high as 63% at
the exit of the reactor. Urea synthesis

solution leaving the reactor is fed tothe stripper where unconverted
carbamate is thermally decomposedand excess ammonia and CO2 areefficiently separated by CO2 stripping.
The stripped off gas from the stripper
is fed to the Vertical Submerged
Carbamate Condenser (VSCC),
operated at an N/C ratio of 3.0,
180°C and 152 bar. Ammonia andCO2 gas condense to form
ammonium carbamate andsubsequently urea is formed bydehydration of the carbamate in theshell side. Reaction heat of carbamate
formation is recovered to generate 5
bar steam in the tube side. A packed
bed is provided at the top of the
VSCC to absorb uncondensed
ammonia and CO2 gas into a recycle
carbamate solution from the MP
absorption stage. Inert gas from the
top of the packed bed is sent to the
MP absorption stage.

Process Description
TO MP ABSORPTIONACES21® has been developed together with P.T. Pupuk Sriwidjaja (PUSRI) of Indonesia as a
Cost and Energy Saving version of the ACES(*) Process.
ACES21® is advanced technology to realize low investment cost and low energy
consumption for urea production. A major feature of this technology is that it reduces thenumber of components in the urea synthesis loop to simplify the system. This lessens
construction costs with the installation of the reactor on the ground in the CO2 stripping
process (resultantly existing urea reactor can be re-utilized for conventional solution
recycle process or ammonia stripping process). In addition, the operation conditions of thesynthesis section have been optimized under lower operation pressure than in the previous
process. As a result, a remarkable reduction in energy consumption has been achieved.

FROM CARB. PUMPCONDENSER(VSCC)STRIPPER
REACTORBFW LPSTEAM

MP STEAMCOND

EJECTORFROM NH3 PUMPTO MP
DECOMPOSITIONFROM CO2 COMP

( )* ACES: Advanced process for Cost and Energy Saving urea production
REACTORCARBAMATE
STRIPPER CONDENSERMPDECOMPOSERLPDECOMPOSERVACUUM
CONCENTRATOR

EVAPORATOR

NH3

CO2

RECYCLE CARBAMATE SOLUTION
HP
STEAM

SYNTHESISLSMS

LP STEAM
GENERATIONUREA, EXCESS NH3
CARBAMATE, H2O
LP
STEAM

PURIFICATIONLSTOPRILLING TOWER
OR
GRANULATOR

Methanol Holdings (Trinidad) Limited (Trinidad and Tobago)
CO2
NH3, CO2 & H2O

RECOVERYCOOLING
WATER

SC
STM

UREA
H2O
LP
STEAM

CONCENTRATIONHPCARBAMATE
EJECTORRECOVERED NH3, & CO2 VAPOR
H2O
H2O & SMALL QUANTITIESOF NH3, & UREA

PROCESS CONDENSATETREATMENT

LP
STEAM

MP
ABSORBERLS
NH3PREHEATERPROCESS COND.
STRIPPER

SURFACECONDENSERS LS
LP
ABSORBER

UREA
SOLUTIONHYDROLYZER

TO LPD
C.W.

C.W.

C.W.

UREA

GRANULATIONORPRILLINGLS

CLEAN PROCESS CONDENSATE

2NH3 + CO2 = NH4CO2NH2 – 38,000 cal/mol
NH4CO2NH2 = NH2CONH2 + H2O + 5,000 cal/mol
Hence,
2NH3 + CO2 = NH2CONH2 + H2O – 33,000 cal/mol

NH3 PUMP

CO2 COMPRESSORCARBAMATE PUMP

NH3

CO2

UREA PRODUCT

2

3

Synthesis

TOYO:
Leader in Urea Process
Technology
Since its establishment in 1961, Toyo Engineering Corporation (TOYO) has been a leader inthe urea industry. TOYO has designed, engineered, constructed and commissioned over
100 urea plants based on the TOYO Urea Process including its urea synthesis technologies
and urea granulation technologies.
Using its own expertise, advanced technology and new thinking, TOYO has established the
ACES21® Process, which achieves energy saving and plant cost reduction without
sacrificing high performance and high efficiency of the urea plant.

ACES21® process synthesis section
consists of a reactor, a stripper and acarbamate condenser. Liquidammonia is fed to the reactor via the
HP Carbamate Ejector which provides
the driving force for circulation in thesynthesis loop instead of the gravity
system of the original ACES. The
reactor is operated at an N/C ratio of
3.7, 182 °C and 152 bar. The CO2
conversion to urea is as high as 63% at
the exit of the reactor. Urea synthesis

solution leaving the reactor is fed tothe stripper where unconverted
carbamate is thermally decomposedand excess ammonia and CO2 areefficiently separated by CO2 stripping.
The stripped off gas from the stripper
is fed to the Vertical Submerged
Carbamate Condenser (VSCC),
operated at an N/C ratio of 3.0,
180°C and 152 bar. Ammonia andCO2 gas condense to form
ammonium carbamate andsubsequently urea is formed bydehydration of the carbamate in theshell side. Reaction heat of carbamate
formation is recovered to generate 5
bar steam in the tube side. A packed
bed is provided at the top of the
VSCC to absorb uncondensed
ammonia and CO2 gas into a recycle
carbamate solution from the MP
absorption stage. Inert gas from the
top of the packed bed is sent to the
MP absorption stage.

Process Description
TO MP ABSORPTIONACES21® has been developed together with P.T. Pupuk Sriwidjaja (PUSRI) of Indonesia as a
Cost and Energy Saving version of the ACES(*) Process.
ACES21® is advanced technology to realize low investment cost and low energy
consumption for urea production. A major feature of this technology is that it reduces thenumber of components in the urea synthesis loop to simplify the system. This lessens
construction costs with the installation of the reactor on the ground in the CO2 stripping
process (resultantly existing urea reactor can be re-utilized for conventional solution
recycle process or ammonia stripping process). In addition, the operation conditions of thesynthesis section have been optimized under lower operation pressure than in the previous
process. As a result, a remarkable reduction in energy consumption has been achieved.

FROM CARB. PUMPCONDENSER(VSCC)STRIPPER
REACTORBFW LPSTEAM

MP STEAMCOND

EJECTORFROM NH3 PUMPTO MP
DECOMPOSITIONFROM CO2 COMP

( )* ACES: Advanced process for Cost and Energy Saving urea production
REACTORCARBAMATE
STRIPPER CONDENSERMPDECOMPOSERLPDECOMPOSERVACUUM
CONCENTRATOR

EVAPORATOR

NH3

CO2

RECYCLE CARBAMATE SOLUTION
HP
STEAM

SYNTHESISLSMS

LP STEAM
GENERATIONUREA, EXCESS NH3
CARBAMATE, H2O
LP
STEAM

PURIFICATIONLSTOPRILLING TOWER
OR
GRANULATOR

Methanol Holdings (Trinidad) Limited (Trinidad and Tobago)
CO2
NH3, CO2 & H2O

RECOVERYCOOLING
WATER

SC
STM

UREA
H2O
LP
STEAM

CONCENTRATIONHPCARBAMATE
EJECTORRECOVERED NH3, & CO2 VAPOR
H2O
H2O & SMALL QUANTITIESOF NH3, & UREA

PROCESS CONDENSATETREATMENT

LP
STEAM

MP
ABSORBERLS
NH3PREHEATERPROCESS COND.
STRIPPER

SURFACECONDENSERS LS
LP
ABSORBER

UREA
SOLUTIONHYDROLYZER

TO LPD
C.W.

C.W.

C.W.

UREA

GRANULATIONORPRILLINGLS

CLEAN PROCESS CONDENSATE

2NH3 + CO2 = NH4CO2NH2 – 38,000 cal/mol
NH4CO2NH2 = NH2CONH2 + H2O + 5,000 cal/mol
Hence,
2NH3 + CO2 = NH2CONH2 + H2O – 33,000 cal/mol

NH3 PUMP

CO2 COMPRESSORCARBAMATE PUMP

NH3

CO2

UREA PRODUCT

2

3

GAS OUT

LIQ. IN
Packed Bed

200
EQUILIBRIUM
PRESSURE

70180

EQUILIBRIUM
CONVERSION

160
OPERATING PRESSURE

60

EXCESS PRESSURE

140

50
120
CONDENSER
N/C

REACTOR
N/C

40

EQUILIBRIUM PRESSURE (Bar)EQUILIBRIUM CONVERSION (%)

80

100
2

2.5

3

3.5

4

N/C

Baffle Plates

Down Pipes

Mechanical properties of DP28W™
Grade

Tensile Strength(MPa)

0.2% Proof Stress(MPa)

Elongation(%)

Hardness(Hv)

DP28W™

934

647

42

281

DP12

822

610

42

251

25-22-2(S31050)

676

352

50

173

316L

518

234

52

144

U-tube Bundle

LIQ. OUT

BFW + STEAM OUTGAS INBFW IN

Process Features

Ground Level Reactor
The sophisticated two-stage synthesis
concept employing a VSCC and an
HP ejector enables the HP equipmentin the synthesis section to be laid-out
very compactly in low elevation. The
highest level (the VSCC top) is about
30 to 35 m(*), which is significantly
lower than even the traditional
solution recycle process in which thereactor is installed on the ground.
(*) Depending on the plant’s capacity andconfiguration

4

Vertical Submerged
Carbamate Condenser
The Vertical Submerged Carbamate
Condenser (VSCC) functions tocondense NH3 and CO2 gas from thestripper to form ammonium
carbamate and synthesize urea by
dehydration of ammonium carbamatein the shell side, and to remove thereaction heat of ammonium carbamate
formation by generating 5 bar steam
in boiler tubes.
The advantages of the verticalsubmerged configuration of thecarbamate condenser are summarized
as follows:- High gas velocity, appropriate gas
hold up and sufficient liquid depth
in the bubble column promote massand heater transfer.
- An appropriate number of baffle
plates distribute gas bubbles in thecolumn effectively without pressureloss.
- A vertical design allows a smaller
plot area.

Optimum Selection of
Synthesis Condition
In the ACES21® Process, the VSCC isoperated at an N/C ratio of 3.0 whichallows relatively high temperature

operation of the VSCC, rendering
efficient heat transfer between theshell and the tube and higher reaction
rate of ammonium carbamate
dehydration to form urea.
The reactor N/C ratio is selected ataround 3.7 to maximize CO2
conversion with appropriate excesspressure. Resultantly, a high CO2
conversion of 63% is achieved in thereactor at relatively low temperatureand pressure, i.e. 182 °C and 152 bar.

Less Corrosion
TOYO and Sumitomo Metal Ind.,
Ltd. (SMI) have jointly developed

new duplex stainless steel DP28W™
for urea plant.
The biggest advantage of duplex
stainless steel is the excellent corrosion
resistance and passivation property inurea-carbamate solution, which
enhances reliability of equipment andenables a reduction of the passivation
air. In addition, DP28W™ has highmechanical strength which drasticallyreduces the thickness of the highpressure section components.
DP28W™ is the optimal material for
urea plants benefiting from the vast
flow of feedback stemming from theextensive amassed experience of

TOYO and SMI.

Clean EffluentsThe liquid effluents from the urea
plant contaminated with NH3, CO2
and urea are processed in the processcondensate stripper-urea hydrolyzer
system.
The process condensate leaving thesystem is purified to 1 ppm of urea
and 1 ppm of NH3.
The exhaust air from the prilling
tower (or granulator) is scrubbed
through a packed bed scrubber toreduce the urea dust content to 30
mg/Nm3-air.
5

GAS OUT

LIQ. IN
Packed Bed

200
EQUILIBRIUM
PRESSURE

70180

EQUILIBRIUM
CONVERSION

160
OPERATING PRESSURE

60

EXCESS PRESSURE

140

50
120
CONDENSER
N/C

REACTOR
N/C

40

EQUILIBRIUM PRESSURE (Bar)EQUILIBRIUM CONVERSION (%)

80

100
2

2.5

3

3.5

4

N/C

Baffle Plates

Down Pipes

Mechanical properties of DP28W™
Grade

Tensile Strength(MPa)

0.2% Proof Stress(MPa)

Elongation(%)

Hardness(Hv)

DP28W™

934

647

42

281

DP12

822

610

42

251

25-22-2(S31050)

676

352

50

173

316L

518

234

52

144

U-tube Bundle

LIQ. OUT

BFW + STEAM OUTGAS INBFW IN

Process Features

Ground Level Reactor
The sophisticated two-stage synthesis
concept employing a VSCC and an
HP ejector enables the HP equipmentin the synthesis section to be laid-out
very compactly in low elevation. The
highest level (the VSCC top) is about
30 to 35 m(*), which is significantly
lower than even the traditional
solution recycle process in which thereactor is installed on the ground.
(*) Depending on the plant’s capacity andconfiguration

4

Vertical Submerged
Carbamate Condenser
The Vertical Submerged Carbamate
Condenser (VSCC) functions tocondense NH3 and CO2 gas from thestripper to form ammonium
carbamate and synthesize urea by
dehydration of ammonium carbamatein the shell side, and to remove thereaction heat of ammonium carbamate
formation by generating 5 bar steam
in boiler tubes.
The advantages of the verticalsubmerged configuration of thecarbamate condenser are summarized
as follows:- High gas velocity, appropriate gas
hold up and sufficient liquid depth
in the bubble column promote massand heater transfer.
- An appropriate number of baffle
plates distribute gas bubbles in thecolumn effectively without pressureloss.
- A vertical design allows a smaller
plot area.

Optimum Selection of
Synthesis Condition
In the ACES21® Process, the VSCC isoperated at an N/C ratio of 3.0 whichallows relatively high temperature

operation of the VSCC, rendering
efficient heat transfer between theshell and the tube and higher reaction
rate of ammonium carbamate
dehydration to form urea.
The reactor N/C ratio is selected ataround 3.7 to maximize CO2
conversion with appropriate excesspressure. Resultantly, a high CO2
conversion of 63% is achieved in thereactor at relatively low temperatureand pressure, i.e. 182 °C and 152 bar.

Less Corrosion
TOYO and Sumitomo Metal Ind.,
Ltd. (SMI) have jointly developed

new duplex stainless steel DP28W™
for urea plant.
The biggest advantage of duplex
stainless steel is the excellent corrosion
resistance and passivation property inurea-carbamate solution, which
enhances reliability of equipment andenables a reduction of the passivation
air. In addition, DP28W™ has highmechanical strength which drasticallyreduces the thickness of the highpressure section components.
DP28W™ is the optimal material for
urea plants benefiting from the vast
flow of feedback stemming from theextensive amassed experience of

TOYO and SMI.

Clean EffluentsThe liquid effluents from the urea
plant contaminated with NH3, CO2
and urea are processed in the processcondensate stripper-urea hydrolyzer
system.
The process condensate leaving thesystem is purified to 1 ppm of urea
and 1 ppm of NH3.
The exhaust air from the prilling
tower (or granulator) is scrubbed
through a packed bed scrubber toreduce the urea dust content to 30
mg/Nm3-air.
5

TOYO’s Activities and Services
Urea prills

1-3mm Urea Granules

2-4mm Urea Granules

5-8mm Urea Granules

ATM.

SCREENPRODUCT COOLERRECOVEREDUREA
SOLUTION

Granting of Licenses andProject Execution

DUST
SCRUBBER

CRUSHERAs a licensor of urea processes andrelated technologies, TOYO offers
various types of contracts from a
direct license to the client to anindirect license through engineeringfirms. As the contractor, TOYO
supplies the complete urea plant tothe client on a turnkey lump-sum
basis. Therefore TOYO can control alltechnologies to be used for thedesign, engineering, construction andoperation of the urea plant without
sublicensing agreements. This ensuressmoother and simple project
execution under single contractual
responsibility of the contractor.

GRANULATORFEED UREA
SOLUTIONAIR

PRODUCTAIR

Training of Client’s Operators
SKW Piesteritz GmbH
(Germany)

P. T. Pupuk Iskandar Muda (Indonesia)

Tarim Oilfield Petrochemical
Company (China)

Process Variation

TOYO owns or has the right tolicense various basic technologies tobe integrated with the urea plants inaddition to the new urea plant
construction as a package.

Urea Finishing Technologies
High Purified Industrial Grade Urea
Product: Urea crystal, Urea Prills,
Urea Granules by Crystal Separation
Process
Fertilizer Grade Urea Product: Urea
Solution, Urea Prills, Urea
6

Granules by Vacuum Evaporation
Process

Product Forming
Technologies
Urea Prilling Process- Acoustic Vibrating Prill Head
- Spinning Bucket (Tuttle Prilling
System)Urea Granulation Process- Spout-Fluid Bed Granulator

TOYO’s training program usually
includes training at TOYO’s
Engineering Center using aproprietary Operation Training
Simulator and Operation Guidance
System by which the trainees become
familiar with all phases of plant
operation including initial start-up andemergency shut-down prior to the inplant training.

Pollution Control
Technologies
Process Condensate Treatment
System- Urea Hydrolyser- Process Condensate Stripper
Urea Dust Scrubbing System- Packed Bed Type Wet Scrubber

Supporting Technologies
Anti-caking Treatment of Urea Prills
Melamine Off-gas Recovery System
Integration of Urea-Melamine Plants

Provision of Plant Lifecycle
Solutions
TOYO provides solutions to meetclient needs for urea plants such as

Corporate
Management
Level

ERP

Plant
Maintenance

Plant
Supervision
Level

Field
Automation
Level

Production
Management

Purchasing
Management

Cost
Management

Human
Resources

Inventory
Management

Sales
Management

Financials

MES

Advanced Control

Reporting

Lot Tracking

Equipment
Monitoring

Trend

Scheduling

RPMS

Optimizer

OAS

APC

Training/
Education
UPOTS

Control
DCS

Real Time
Database

PLC

ESD

Field
Instrument

Sub-System

Total Solutions by TOYO
operation and maintenance (O&M)
services that sustain and enhance theproductivity of the client’s plant. Afterthe plant is accepted by the client,
TOYO’s consulting services areavailable for:- Improvement of plant efficiency- Operation optimization- Trouble shooting- Pollution control- Product quality improvement- Plant maintenance- Plant retrofitting
One of TOYO’s solutions for the
maintenance aspect is a Risk Based
Inspection and Risk Based
Maintenance(RBI/RBM) systemand consulting service
for fertilizer complexes
provided by TOYO
together with ESR
Technology Ltd. (UK).
The system is expected
to enable plant owners
to optimize their assets
through risk
management.

Remote Plant Monitoring
SystemTOYO offers a Remote Plant
Monitoring System (RPMS) service,
which connects an actual operating
plant and a remote engineering officeusing DCS, a computer and theInternet to monitor plant conditions
in remote offices and provides a
feedback of suggestions or
recommendations to the plant ownerafter the evaluation of monitored datautilizing TOYO’s professional knowhow in the operation and maintenanceof urea plants.

7

TOYO’s Activities and Services
Urea prills

1-3mm Urea Granules

2-4mm Urea Granules

5-8mm Urea Granules

ATM.

SCREENPRODUCT COOLERRECOVEREDUREA
SOLUTION

Granting of Licenses andProject Execution

DUST
SCRUBBER

CRUSHERAs a licensor of urea processes andrelated technologies, TOYO offers
various types of contracts from a
direct license to the client to anindirect license through engineeringfirms. As the contractor, TOYO
supplies the complete urea plant tothe client on a turnkey lump-sum
basis. Therefore TOYO can control alltechnologies to be used for thedesign, engineering, construction andoperation of the urea plant without
sublicensing agreements. This ensuressmoother and simple project
execution under single contractual
responsibility of the contractor.

GRANULATORFEED UREA
SOLUTIONAIR

PRODUCTAIR

Training of Client’s Operators
SKW Piesteritz GmbH
(Germany)

P. T. Pupuk Iskandar Muda (Indonesia)

Tarim Oilfield Petrochemical
Company (China)

Process Variation

TOYO owns or has the right tolicense various basic technologies tobe integrated with the urea plants inaddition to the new urea plant
construction as a package.

Urea Finishing Technologies
High Purified Industrial Grade Urea
Product: Urea crystal, Urea Prills,
Urea Granules by Crystal Separation
Process
Fertilizer Grade Urea Product: Urea
Solution, Urea Prills, Urea
6

Granules by Vacuum Evaporation
Process

Product Forming
Technologies
Urea Prilling Process- Acoustic Vibrating Prill Head
- Spinning Bucket (Tuttle Prilling
System)Urea Granulation Process- Spout-Fluid Bed Granulator

TOYO’s training program usually
includes training at TOYO’s
Engineering Center using aproprietary Operation Training
Simulator and Operation Guidance
System by which the trainees become
familiar with all phases of plant
operation including initial start-up andemergency shut-down prior to the inplant training.

Pollution Control
Technologies
Process Condensate Treatment
System- Urea Hydrolyser- Process Condensate Stripper
Urea Dust Scrubbing System- Packed Bed Type Wet Scrubber

Supporting Technologies
Anti-caking Treatment of Urea Prills
Melamine Off-gas Recovery System
Integration of Urea-Melamine Plants

Provision of Plant Lifecycle
Solutions
TOYO provides solutions to meetclient needs for urea plants such as

Corporate
Management
Level

ERP

Plant
Maintenance

Plant
Supervision
Level

Field
Automation
Level

Production
Management

Purchasing
Management

Cost
Management

Human
Resources

Inventory
Management

Sales
Management

Financials

MES

Advanced Control

Reporting

Lot Tracking

Equipment
Monitoring

Trend

Scheduling

RPMS

Optimizer

OAS

APC

Training/
Education
UPOTS

Control
DCS

Real Time
Database

PLC

ESD

Field
Instrument

Sub-System

Total Solutions by TOYO
operation and maintenance (O&M)
services that sustain and enhance theproductivity of the client’s plant. Afterthe plant is accepted by the client,
TOYO’s consulting services areavailable for:- Improvement of plant efficiency- Operation optimization- Trouble shooting- Pollution control- Product quality improvement- Plant maintenance- Plant retrofitting
One of TOYO’s solutions for the
maintenance aspect is a Risk Based
Inspection and Risk Based
Maintenance(RBI/RBM) systemand consulting service
for fertilizer complexes
provided by TOYO
together with ESR
Technology Ltd. (UK).
The system is expected
to enable plant owners
to optimize their assets
through risk
management.

Remote Plant Monitoring
SystemTOYO offers a Remote Plant
Monitoring System (RPMS) service,
which connects an actual operating
plant and a remote engineering officeusing DCS, a computer and theInternet to monitor plant conditions
in remote offices and provides a
feedback of suggestions or
recommendations to the plant ownerafter the evaluation of monitored datautilizing TOYO’s professional knowhow in the operation and maintenanceof urea plants.

7

Process Performance

ACES21UREA
PROCESSby TOYO®

Product Quality (Typical)
Nitrogen (N) Content
Biuret Content
Water

46.4 wt%
0.8 wt%
0.2 wt%Consumption Figure (Typical, Granulation Case)
Raw Material
NH3 (100%)
CO2 (100%)

0.563 ton
0.731 tonNote: (1) The loss from Ammonia Pump and CO2 Compressor is included.
(2) Unit is per metric ton of granular urea.

Utilities (per metric ton of granular urea product )Unit
Steam Import
22 bar, 300℃
42 bar, 380℃
110 bar, 510℃
Steam Export
5 bar, Saturated
Cooling Water (Δt=10℃)
Electricity
Process
Granulation
Note:

All Motor Driven Case
Steam Self Balance
Steam Export

Steam Turbine Driven Case
42 bar
110 bar

ton
ton
ton

0.67

ton
m3

0.24
52

52

81

75

kWh
kWh

105
24

105
24

21
24

21
24

(1) All figures above include:- CO2 Compression- Ammonia and Carbamate Pumping- Urea Synthesis- Purification and Recovery- Urea Concentration- Urea Granulation- Process Condensate Treatment

0.58
0.80
0.69

(2) The figures above exclude:- air conditioning, ventilation, air heater,
steam trace, etc.
- urea storage and bagging facility(3) Ammonia Pump and Carbamate Pump are driven
by motor.
(4) Local conditions may change the figures above.
(5) Unit is per metric ton of granular urea.

Advanced
processfor Cost andEnergy Saving

Toyo Engineering Corporation
2-8-1 Akanehama, Narashino-shi, Chiba 275-0024, Japan
Tel: 81-47-451-1111
Fax: 81-47-454-1800
http://www.toyo-eng.co.jp

ACES21® is a registered trademark of Toyo Engineering Corporation in Japan (Registered Number 4309123).

©2006-2012 Toyo Engineering Corporation
H24.10.20 2 SAN