Started as 2 burners in parallel-Dual pressure plant; 3-9 barg; initial capacity was 700 tpd at 100%

REVAMPS

-1982: Revamped with Uhde engineering

• addition of second absorption tower
• modification of machinery to increase speed
• capacity now 840 tpd at 100%

-2002: MDR increased at 980 tpd at 100%

-2003: Installation of a basket inside both burners to test N20 catalyst developed by owner

-2005: Increase N20 catalyst quantity in both burners

-2007-08: MDR increased to 100 td at 100% (steam turbine speed increased to 5920 rm)

• NH3 flow to burner limited at 15200 nm3/hr following oxydation boiler limitations

-2012: Replacement of burner basket with new design

-2017: Replacement of burner basket with new design

190 Acre API Manufacturing Plant Complex Grimsby, England, UK

This world-class, fully integrated API manufacturing site, formerly operated by Novartis, includes over 1,200m3 of total reactor vessel capacity across three distinct production buildings, available for sale or lease as a whole site or individual buildings for operation in-place. The facility could be utilized for pharmaceutical and animal health API manufacturing or repurposed for specialty/fine chemical manufacturing, flavors and fragrances, or agrochemicals.

VIDEO: https://www.youtube.com/watch?v=AUWUHnAyWos&list=PLRlhdb05DXKR4eyHsLOkB6NzTyh2R4YCE

The site is located adjacent to the river Humber and between the Immingham and Grimsby port facilities, less than 5 minutes from downtown Grimsby, 25 minutes from Humberside Airport, 2.5 hours from Manchester Airport, 3.5 hours from London Heathrow.

Inside the fenceline is approximately 100 acres, with significant development land and infrastructure available inside the fence. There is an additional approximately 90 acres of agricultural land outside the fenceline.

Facility has the capabilities to perform various chemical synthesis, including hydrogenation, Grignard/Friedel-Crafts Reactions, Azide, and Tin Chemistries.

Building 110: Multi-product, Multi-purpose facility (ca. 1993)

• Total Reactor Capacity: 140m3
• Hydrogenation, Crystallization, Centrifugation, Nutsche Filters, Short-Path Distillation, Milling/Blending, Solvent Recovery
• Overhead manifolds and flex piping for production flexibility
• Glass Lined, Hastelloy, and Stainless Steel Equipment

Building 120: Mixed High Volume, Multi-Purpose Facility (ca. 1994/2007)

• Total Reactor Capacity: ~450m3
• 3 dedicated, 3 multi-purpose lines -Hydrogenation, Crystallization, Sublimation, Nutsche Filters, Paddle Dryers, Milling/Blending, Solvent Recovery
• Glass Lined, Hastelloy, and Stainless Steel Equipment

Building 150: High Volume, Multi-Product Facility (ca. 2004/2007)

• 4 Dedicated Process Trains
• Total Reactor Capacity: ~550m3
• Hydrogenation, Crystallization, Centrifugation, Drying, Milling/Blending, Solvent Recovery
• Glass Lined, Hastelloy, and Stainless Steel Equipment

Each building has its own dedicated solvent storage and recovery, in-process lab spaces, workshops, and offices.

Site Utilities:

• 2400m3/day Wastewater (Effluent) Treatment Facility
• 2x4.2MVA grid electricity
• 8000m3/h compressed air
• 3000m3/h nitrogen (by pipeline)
• 4x8MW cooling water capacity
• Towns Water potable supply & 400m3/day borehole (well) water for process cooling
• Previously, there was a CHP plant which has been removed and steam boilers will need to be added to support operations.

The production buildings are supported by the following non-production infrastructure:

• Security Facility
• Administrative Office Building
• 4600m2 (50,000ft2) Engineering Workshop and Offices to support major projects, MRO stores, fabrication, equipment and instrument maintenance, etc.
• 3700m2 (40,000ft2) Lab/R&D Space with sample retain storage facility
• Restaurant/Canteen Building
• Medical Facility/Employee Welfare
• Sports Club and Fields
• Capital Good Stores
• Changeover Warehouses

Warehousing:

• Raw Materials & Intermediate Storage: 3000 pallets
• Solvent (flammable & hazardous) Warehouse: 1930 pallets
• Packaging Storage: 500 pallets
• Finished Goods Storage: 750 pallets
• Cold Storage (-8 deg. C): 320 pallets
• Classified area for sampling / repacking of raw materials: 40 pallets
• Waste Storage: 1200 pallets

The facility was not used in production of of plant/animal extracts, fermentation, penicilin, beta-lactams, steroids, hormonals, or cytoxic compounds.

maximum proven capacity = 1.16 kt ammonia per day

feedstock: natural gas 50bar,

specific consumption 0.62-0.64 Tm³/t

energy/utilities: natural gas 5bar 0.35-0.37 Tm³/t;

• power 0.06-0.08 MWh/t;
• steam consumption needed only during startup
• 4bar steam generation (export) 1 – 1.27 t/t;
• 16bar steam generation 0.1-0.2 t/t

CO2 emission 2.0-2.1 t/t

last major TARs: 2021 (reformer tubes exchange, syngas line renovation, catalyst change, turbines & compression overhaul, incl. 2.5-yearly DLRG (pressure equipment directive) inspections), 2019 (DCS migration user interface, SLPC, CUI measures, incl. 10-yearly DLRG inspections), 2017, 2014, 2011

MAJOR UNITS

The plant consists of:

• Natural gas desulphurization
• Primary reformer (operates at 790°C and 30bar with the secondary reformer at 950°C)
• Secondary reformer with air compressors
• Natural gas desulphurization
• Primary reformer
• Secondary reformer with air compressors
• High and low temperature shift.
• CO2 removal
• Mechanization
• Syn gas compressor and air compressor
• Ammonia synthesis (reaction is 270 bar)
• Ammonia evaporation

• Chemico Design – Conventional 1000 STPD Nameplate
• CO2 Compression – Centrifugal followed by reciprocating
• Urea Reactor – Unocal/Stamicarbon conventional design (1992)
• Urea Concentration – Crystallization, Crystal dryer
• Product Solidification – Prill tower with prill seeding
• Environmental – Process flare (1997)

1,250 TPD Ammonia Plant Equipment Available

Compressors

212808 - Clark-Model #4M9-7-P, rotary air compressor

• Capacity: 24,979 ACFM
• Direct driven by steam turbine through gear reducer
• HP=8920/RPM 538
• 7 stages, 2670 critical speed
• 14.07 PSIA / PD-86.0 PSIA (1st Stage: Air)

212809 - Clark Model #2M8-6, CS rotary air compressor

• Capacity: 4,079 ACFM
• Driven by a steam turbine through a gear reducer
• 8920 hp / 10211 rpm
• 6stages 6500 rpm critical 10211 rpm
• PS-8.5 PSIA / PD-490 PSIA (2nd Stage: Air)

212812 - Clark Model #2BF-7(5), CS Centrifugal

• Capacity:611  ACFM, rated for 16930 hp/10585 rpm
• Driven by Turbine/Gear
• PS-1,796 PSIA / PD-2,530 PSIA (1st Stage: SynGas)

212813 - Clark Model #2BF-7, CS Centrifugal

• Capacity: 1,326ACFM, rated for 16930 hp
• Driven by Turbine/Gear
• PS-904 PSIA / PD-1,816 PSIA (2nd Stage: SynGas)

212814 - Clark Model #2BC-8, CS Centrifugal

• Capacity: 3,528 ACFM , rated for 16930 hp
• Driven by turbine/gear
• PS-358 PSIA / PD-914 PSIA (3rd Stage: SynGas)

212815 - Clark Model #2M8-5, CS Centrifugal

• Capacity: 4,284 ACFM, rated for 9185 hp
• Driven by turbine/gear
• 5 stages - 10,438 rpm speed/1,000 rpm max/6650 critical
• PS-140 PSIA / PD-230 PSIA (1st Stage: Refrigeration)

212816-Clark Model #4M8-7, CS Centrifugal

• Capacity 11,763 ACFM  rated for 918 5hp
• Driven by turbine/gear
• 7 stages, 5875 rpm speed/6220 rpm max/3000 critical
• PS-29 PSIA / PD-143 PSIA (2nd Stage: Refrigeration)

Ammonia Converter

212801- Struthers Wells

• Capacity: 19,135 Gallons
• 7’ d x 75’l (overall)
• 2,600 PSI (Haldor Topsoe: S-200)
• Shell thickness 4.125"/ Head thickness 3.125"

Gears

212811 - General Electric Model #S-234-BG

• Input RPM-5,380 / Output RPM-10,211
• HP-4,862

212818 - General Electric Model #S-234-BH

• Input RPM-5,875 / Output RPM-10,413
• rated for 1.78 ratio
• HP-3,267
• Clockwise rotation
• Gear and pinion

212819 - Lufkin Model #D290C

• Input RPM 1,749/ Output RPM-74
• Rated for 23.33:1 ration
• HP 155

95078 - General Electric Model #SI-458-A

• Input RPM-4,860 / Output RPM-10,585
• HP-20,000

Turbines

212810 - Model #3TDFOV2

• CS, horizontal multi stage condensing turbine
• Manufactured by Worthington
• RPM-5,650
• HP-9,800
• Inlet-540 PSIG
• Rotation clock wise
• 5 stage rateau (double 4th & 5th stage)

212817 - Model #3TDFOV2

• CS, horizontal condensing turbine
• Manufactured by Worthington
• 5 stage rateau (double flow 4th & 5th stage)
• RPM-6,175
• HP-10,100
• Inlet PSI-150 @ 450° max
• Exhaust-4” of Hg  ABS. at 128°F
• Rotation clockwise

212820 - Unused spare turbine rotor for Terry Turbine model GAF6

Heat Exchangers

282825

• 5,290 sq. ft Horizontal
• Manufactured by Struthers Wells
• CS Shell / CS Tubes / CS Heads
• 100 PSI Shell / 2,600 PSI Tubes (@600°F)
• Single pass Shell and Tube

212823

• 5,955 sq. ft Horizontal
• Manufactured by Heatran
• CS Shell / CS Tubes / CS Heads
• 2,600 PSI Shell / 2,600 PSI Tubes  (@600°F)
• Single Pass shell and tube

212821/212822

• 11,300 sq. ft., Horizontal
• Manufactured by Heatran
• CS Shell / CS Tubes / CS Heads
• 2,600 PSI Shell / 2,600 PSI Tubes (@ 600°F)
• single pass shell and tube

Tanks

212802

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by National Tank Co.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

212803

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by Nooter.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

212804

• 9,000 Gallon, CS,  vertical pressure tank.
• Manufactured by Delta Southwestern.
• Rated for 405 psi at 875 degrees F.13' diameter x 5' straight side with welded hemi heads.
• Wall thickness =2.9".  Eight lug supports.

212805

• 5,700 Gallon, CS, vertical pressure tank
• Manufactured by National Tank.
• Rated for 430 psi at 800 degrees F. 10'6" diameter x 7' straight side with welded hemi heads.
• Wall thickness is 1.6".  Support by lugs.

212806

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by National Tank.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

212807

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by National Tank.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

Furnace

212800

• 15.00 mm/btu, vertical furnace(SU heater) manufactured by Econo-Therm.
• Rated for 2750 psi at 950 degrees F.
• 6 burners, with stack.
• Overall height 111', stack section is 33'3" high, furnace section is 10'6" high.  Length is 111' long. 10'6" width with refractory lining.

This 321 stainless steel, high-pressure ammonia recovery system was designed by ICI and built by Robert Jenkins, LTD.  The column is rated for 275 psig at 220°C.  The system used a high-pressure steam-driven reboiler to strip ammonia from crude amine products.

The 321 stainless steel (10.5% Ni) column is 2.5' diameter by 54' straight side.  It has a design pressure of 275 psig/FV @ 220°C.  The column has 22 single-pass valve trays also constructed of 321 stainless steel.  The column has an internal overhead condenser mounted in the top head.  It also has an internally mounted reboiler in the bottom section of the column.  The system includes a feed interchanger, and a column overheads cooler.

Ammonia Converter

• 212801- Struthers Wells

• Capacity: 19,135 Gallons

• 7’ d x 75’l (overall)

• 2,600 PSI (Haldor Topsoe: S-200)

• Shell thickness 4.125"/ Head thickness 3.125"

  Download the Ammonia Converter Drawing

Capacity:  550 short tons per day

Pressure:  Single Medium Pressure 65-70 psig

% of Nitric:  61%

Spare Parts: spare 8000hp motor / Spare compressor rotating assembly /Blade carrier and various compressor spare parts on site.

Capacity:

• 600 tons/day (25 tons/hr)

Raw Materials:

• CO2 supplied from a Long Residue Gasification Plant
• Liquid NH3 supplied from an Ammonia Production Plant

Product:

• Pelletized urea (carbonic acid diamide)
• The product is surface-modified - using URESOFT® 150 agent  to avoid  agglomeration. The typical content of this agent is 0.4% by weight.

• The plant produces food grade CO2 at a capacity of 250Te/day. The CO2 final product spec is 99.998% purity.

• The plant mainly consists of

  • 3 off Sulzer 3 stage compressors 560psig discharge
  • Water scrubber to remove soluble impurities
  • Charcoal bed to remove traces of sulphur and oil
  • Activated alumina bed dryer (2 off for regeneration)
  • Condenser to produce liquid CO2 using ammonia as refrigerant
  • Stripping column to remove entrained inert gases using recycled CO2

Product specification:

Water 10.0 ppm w/w max

Sulphur 0.1 ppm w/w max

Gaseous inerts 100 ppm v/v

Methanne10 ppm v/v max

Argon 1.0 ppm w/w max

Boron 0.1 ppm w/w max

Halogens 1.0 ppm w/w max

Carbonyls 1.0 ppm w/w max

Oil 2.0 ppm w/w max

Arsenic 0.0 ppm w/w max