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Autonomous manufacturing of a AdBlue by modular container process
For this project, our client handles the supply of fluids to a power barge or power ship in New Caledonia.
This factory ship produces electricity with large diesel engines. It has a capacity of 200 MW, which can supply electricity to 90,000 homes.
Its installation is temporary - estimated at 5 years – to allow time for the construction of a power plant on land.
The treatment of the fumes (deNox) from this power ship is provided by the injection of urea solutions (AUS or AdBlue), which causes a reaction neutralizing the nitrogen oxides (NOx).
Our client had the choice of importing tanks of liquid urea, or importing bulk bags of urea in prills (powders). The choice was made to purchase bulk bags of solid urea for dissolution, which allowed the client to cut the quantity imported by a third.
Turnkey solution: AdBlue PalBlue Skid® - Production skid
For the manufacture of the AdBlue, the customer requested a pre-assembled process that was quick and easy to install. Our client therefore turned to the Palamatic Process solution - Pal’Blue Skid – assembled in a shipping container.
With daily needs of more than 120m³ of urea, a solution stored in three containers, like Pal’Blue 30, with each rotating on 2 shifts can produce up to 180m³ per day of the NOx neutralizing solution.
Each skid is integrated into a 40-foot shipping container with all the necessary equipment for its operation, containing:
- A water treatment station, which demineralizes the water to the level required by the ISO 22241 standard.
- Dosing system and water heater, which makes it possible to produce the desired types of AUS (AUS32, AUS36, AUS40). Recipes with their parameters are included in this standard skid.
- Urea dissolution system with dosing and automatic concentration control with traceability to satisfy the requirements required by this type of system.
Furthermore, Palamatic was able to adapt to the customer's requests and design a custom storage system with an integrated retention tarp, as well as a magnetic drive pump skid for the urea which can supply the ship-power plant in AdBlue.
Production supervision is provided via our Pal’Touch PLC technology. The program contains many features:
- the possibility of changing concentration very easily via the recipe menu
- the traceability menu, which records the productions with their technical characteristics
- the supervised maintenance menu which guides technical teams in the predictive maintenance of equipment
- the alerts and alarms menu which makes it easy to program alarms remotely by SMS or email.
The standardization of these autonomous AdBlue production skids allows commissioning in less than a week after delivery to site. This compared to commissioning a comparable non-containerized process which can take up to two months.
The key words of this process are: Reliability, Speed and Robustness.
