Urea- A Cost Effective Way to Feed the World Elizabeth Moscoso Oleg Yazvin Sule Alabi Jonathan Arana Mentor: Daniel Rusinak - Middough

Table of Contents Williston Basin Fertilizer Plant Design Basis Block Flow Diagram Process Flow Diagram Plant Layout Environmental Concerns Economics Summary Stage Gate 2 Considerations Questions

Williston Basin Fertilizer Plant Purpose: Convert shale gas into a nitrogen-based fertilizer Plant Location: Williston Basin Reason for Location: Bakken Shale Gas Formation Agricultural Activities

Design Basis Producing: Require: 2,180 TPD of 72% Urea Solution 1155 TPD to the UAN plant 1025 TPD to Prill Block 740 TPD of 99.8wt% Urea Prill 89 TPD water to the CHP plant Require: 892 TPD NH3 from Back-End Ammonia Plant 1,153 TPD CO2 from Front-End Ammonia Plant

Reaction ΔH = -159 kJ/mole ΔH = +31.4 kJ/mole

Block Flow Diagram Cleaned Water Water from CHP Plant Condensate Water Urea Solution (72wt%) to UAN Plant Air Out Inlet CO2 & NH3 from NH3 Plant Urea Solution (72wt%) Prilled Urea (99.8wt%) Product Reactor Block Evaporator Block Prilling Block Urea Melt (99.8wt%) Water from CHP Plant Recycled Gas Condensate Water Air In Wastewater Treatment Block Cleaned Water to CHP Plant Reactor Block Cleaned Water to CHP Plant Water from CHP Plant Condensate Water Recycled Gas Prilled Urea (99.8wt%) Product Air Out Urea Solution (72wt%) Urea Melt (99.8wt%) Waste Water Treatment Block Evaporator Block Prilling Block Air In to UAN Plant Inlet CO2 & NH3 from NH3 Plant

Process Flow Diagram This is a snapshot of our entire plant. P Steam Manual Valve LIC FIC FY AIC T V PT PIC FO High Pressure Steam P - 305 F 330 SIC M E 19 C Controller TIC Master Controller HIC DT AE TT CO 2 in NH 3 O in To CHP Legend Solid Connector – Pipeline Dashed Connector Signal 4 8 9 11 Urea Prill Product To UAN L Steam PRILLING BLOCK REACTOR BLOCK EVAPORATOR BLOCK This is a snapshot of our entire plant. We have fully automated the process to account for any fluctuations in production. There are various points of energy efficiency and optimization. AE AIC TIC LIC PIC AY FTC FIC LP Steam To CHP HP Steam Vapor To Urea Plant Wild Screening WASTEWATER TREATMENT BLOCK

Reactor Block Cleaned Water Water from CHP Plant Condensate Water Urea Solution (72wt%) to UAN Plant Air Out Inlet CO2 & NH3 from NH3 Plant Urea Solution (72wt%) Prilled Urea (99.8wt%) Product Reactor Block Evaporator Block Prilling Block Urea Melt (99.8wt%) Water from CHP Plant Recycled Gas Condensate Water Air In Wastewater Treatment Block Cleaned Water to CHP Plant 8 Reactor Block Cleaned Water to CHP Plant Water from CHP Plant Condensate Water Recycled Gas Prilled Urea (99.8wt%) Product Air Out Urea Solution (72wt%) Urea Melt (99.8wt%) Waste Water Treatment Block Evaporator Block Prilling Block Air In to UAN Plant Inlet CO2 & NH3 from NH3 Plant

Reactor Block

Evaporator Block Cleaned Water Water from CHP Plant Condensate Water Urea Solution (72wt%) to UAN Plant Air Out Inlet CO2 & NH3 from NH3 Plant Urea Solution (72wt%) Prilled Urea (99.8wt%) Product Reactor Block Evaporator Block Prilling Block Urea Melt (99.8wt%) Water from CHP Plant Recycled Gas Condensate Water Air In Wastewater Treatment Block Cleaned Water to CHP Plant 10 Reactor Block Cleaned Water to CHP Plant Water from CHP Plant Condensate Water Recycled Gas Prilled Urea (99.8wt%) Product Air Out Urea Solution (72wt%) Urea Melt (99.8wt%) Waste Water Treatment Block Evaporator Block Prilling Block Air In to UAN Plant Inlet CO2 & NH3 from NH3 Plant

Evaporator Block

Prilling Block Cleaned Water Water from CHP Plant Condensate Water Urea Solution (72wt%) to UAN Plant Air Out Inlet CO2 & NH3 from NH3 Plant Urea Solution (72wt%) Prilled Urea (99.8wt%) Product Reactor Block Evaporator Block Prilling Block Urea Melt (99.8wt%) Water from CHP Plant Recycled Gas Condensate Water Air In Wastewater Treatment Block Cleaned Water to CHP Plant 12 Reactor Block Cleaned Water to CHP Plant Water from CHP Plant Condensate Water Recycled Gas Prilled Urea (99.8wt%) Product Air Out Urea Solution (72wt%) Urea Melt (99.8wt%) Waste Water Treatment Block Evaporator Block Prilling Block Air In to UAN Plant Inlet CO2 & NH3 from NH3 Plant

Prilling Block

Wastewater Treatment Plant Urea Solution (72wt%) to UAN Plant Air Out Inlet CO2 & NH3 from NH3 Plant Urea Solution (72wt%) Prilled Urea (99.8wt%) Product Reactor Block Evaporator Block Prilling Block Urea Melt (99.8wt%) Water from CHP Plant Recycled Gas Condensate Water Air In Wastewater Treatment Block Cleaned Water to CHP Plant 14 Reactor Block Cleaned Water to CHP Plant Water from CHP Plant Condensate Water Recycled Gas Prilled Urea (99.8wt%) Product Air Out Urea Solution (72wt%) Urea Melt (99.8wt%) Waste Water Treatment Block Evaporator Block Prilling Block Air In to UAN Plant Inlet CO2 & NH3 from NH3 Plant

Wastewater Treatment Block

Plant Layout

Environmental Concerns & Mitigation Total Recycle – 99.8% Conversion For every ton of Urea produced 0.3 tons of wastewater formed Simple discharge is harmful EPA Standards: WWTP < 1 ppm Ammonia Prill Tower < 1.8 ppt of Urea Dust No Solid Waste Prill Dust recycled Use of Scrubbers before venting

Raw Material Analysis $175 Million Annually in NH3 & CO2 $250 Million Annually in Prilled Product and solution sold to UAN $75 Million Annually in revenue

Material & Energy Balance Total Capital Cost Competing Processes Process Chosen Material & Energy Balance Simulations/Excel Equipment Sizing Equipment Cost Total Capital Cost $400 Million Installed Cost

Bottom Line $31 MM Annually Simple Payback 12.9 Years [economic potential] = [gross profit]-[raw material per yr] – [utility per yr] –[total capital cost per yr] = $250 MM – $175 MM - $15MM -$29MM $31 MM Annually Simple Payback 12.9 Years

Summary Energy Efficient Total Recycle – Conversion 99.8% No Solid Waste Well below limits required by EPA Profitable Projected increase in demand (2030)

Considerations for Stage Gate 2 Ammonium Carbamate & Urea Solution Prill with Formaldehyde Prill Tower redesign Rigorous Safety Analysis

Questions