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Growth by urea granules Transforming the urea process with continuous innovation Content About us Urea licensing A winning product from a winning player Innovation Safurex® stainless steel: resistant to corrosion 10 Stamicarbon’s urea processes 11 ® 6.1 Synthesis 1: Avancore urea process ™ 14 6.2 Synthesis 2: Urea 2000plus Pool Condenser Concept 16 6.3 Synthesis 3: Urea 2000plus™ Pool Reactor Concept 18 6.4 Low-pressure recirculation section 19 6.5 Evaporation section 20 6.6 Waste-water treatment section 21 6.7 Finishing technology 1: Fluid-bed granulation 22 6.8 Finishing technology 2: Prilling 24 6.9 Finishing technology 3: Rotoform urea pastillation 25 UAN Process 27 Mega Plant Concept 29 Full life cycle support 31 9.1 Plant operation 32 9.2 Plant maintenance 32 9.3 Plant improvement and debottlenecking services 33 Supplements Contact us About us Stamicarbon is the global market leader in the development and licensing of urea technology and services Our solutions are the culmination of generations of high-quality research and indepth knowledge of our customers’ processes, requirements and operating practices Around the world, over 230 urea plants have used, or are currently using, our technology Our innovation is continuous: working in close cooperation with research institutes, suppliers to the urea business, and our licensees, we are constantly developing new technologies and upgrading our existing technologies Our expertise Wherever our people are based, they can all draw on Stamicarbon’s more than 60 years of experience in the urea industry We also work with a number of reputable engineering, procurement and construction (EPC) contractors and suppliers of specific products and critical equipment Together, this network offers the expertise that enables us to create the best solution for your business What we Our services include: • Licensing and process design • Plant improvement • Plant commissioning support • Equipment procurement services • Supply of critical equipment • Engineering services • Troubleshooting, both mechanical and operational • Equipment inspections • Training Urea licensing Our market-leading urea licensing expertise includes the following elements: Providing technology licenses for new urea plants Traditionally, many urea plants are built under LSTK (Lump Sum Turn Key) conditions In these cases, Stamicarbon provides its urea license through one of its licensed contractors, who has been provided with the necessary process license and know-how All our licensed contractors are carefully selected to ensure they have the capability and experience to implement large-scale ammonia/urea projects Their names can be found in the supplement at the back of this brochure Recently, a number of different contract models have become increasingly important in mitigating project costs and risks As a result, Stamicarbon has diversified its urea licensing methods so we can tailor our services to the needs of specific projects Process design package Contractors or customers who obtain a license to conduct the Stamicarbon urea process are supplied with a comprehensive process design package This generally includes: • Process description • Material balance, steam balance and cooling water balance for different operating modes - all with accompanying flow sheets • • • • • • • Piping and instrumentation diagrams (P & ID) Process data sheets for equipment Instrument index, setting list and data sheets Data sheets for safety valves Logic diagrams and functional control diagrams General design and material specifications Operating manual Our comprehensive process design package enables an experienced engineering contractor (who is ultimately appointed by the customer) to: • Carry out the basic & detailed engineering (E) • Procure equipment and materials (P) • Construct the plant (C) Thanks to the expertise and capabilities of our licensed contractors, customers’ projects will be executed both professionally and competitively Project execution services Stamicarbon can provide the following services at any point during project implementation - either directly to the customer or indirectly through a contractor: • Contractor guidance and control • Assistance in selection of equipment manufacturers • Procurement and inspection services • Training of the customer’s technical staff in plant commissioning and operation, using state-of-the-art plant simulation and other training aids • Commissioning services, up to and including completion of the performance test run • Supply of critical equipment • Plant simulation and optimization Technology exchange In some cases, customers may require information additional to that supplied in the process design package To meet this need, we provide customers with any additional information or expertise they require, through training, know-how exchanges and symposia, or other methods agreed with our customers In cases where our customers need something completely new, we will work jointly with them to develop the required adjustment Revamping existing urea plants In a dynamic business environment, customers’ needs will shift due to changing market conditions and governmental regulations Stamicarbon has developed several safe, cost-effective and environmentally friendly revamp schemes to enable urea producers to cope with these changes Depending on customer requirements, Stamicarbon can develop a tailor-made solution based on proven technology and the best engineering practices We offer detailed plant-performance studies to our customers to determine revamp needs, plus a variety of revamp technologies and services to ensure that those needs are met In these sorts of revamp projects, Stamicarbon can license the technology and supply its services and expertise directly to the producer In turn, the producer can appoint the engineering contractor to perform any required engineering, procurement and construction Replacement of high-pressure urea equipment When the high-pressure equipment comes to the end of its life, there is a real opportunity to improve the efficiency and capacity of a plant Stamicarbon can provide solutions that not only improve your high-pressure equipment, but also require only minimum changes and minimum downtime in your plant Experience us for yourself Stamicarbon is the global market leader in the development and licensing of urea products and technology We invite potential licensees to visit one of our plants so they can see for themselves how we boost operational flexibility, reduce maintenance requirements and increase on-stream times After the visit, we will work closely with you to assess your needs and develop a customized proposal for your urea plant A winning product from a winning player With a market share of over 50%, Stamicarbon is the world’s leading player in the field of urea licensing This position is the result of our: As a result, we have been able to revolutionize the urea production process several times Low costs Extensive experience Stamicarbon has over 60 years’ experience in licensing its urea technology In fact, we have licensed over 230 new urea plants and have completed over 85 revamp projects in Stamicarbon and non-Stamicarbon plants A complete list of references is available in our Reference List brochure Leading innovations Stamicarbon has been at the forefront of urea research and innovation for over half a century Our latest urea plants were designed by our task force of experienced engineers, contractors and material and equipment suppliers In creating a new plant design, the task force used the Urea 2000plus™ technology, Safurex® material, fluid-bed granulation technology, as well as their extensive experience, gained from completing many successful plant revamps As a result, plant investment costs were cut by a massive 17% compared to plants using the old CO2 stripping process Our competitive advantages include: • Low elevation • Low investment, operating and maintenance costs, resulting in lower cost price of urea • Competitive energy consumption figures* • Stochiometric raw-material consumption figures* • Low emissions and effluents *The typical consumption figures can be found in the supplement at the back of this brochure State-of-the-art urea production processes Stamicarbon technologies offer customers a variety of benefits, including: Excellent performance • Unbeaten synthesis efficiency with high conversion of ammonia and carbon dioxide • Lower temperatures and pressures required in the urea production process • High on-stream times (for both urea melt production and urea granulation) • All product quality standards met • High utilization rates • Long turnaround intervals (3-4 years) • Compliant with the most stringent environmental requirements Simplicity and reliability Sustainable technology • Minimum number of high-pressure equipment items and piping • The only process that requires only one single recirculation stage • Superior corrosion resistance of materials used in plants • Stable process and easy to operate • Unbeaten lifetime of critical equipment • Option to have an intrinsically safe (zero oxygen) urea process For Stamicarbon, sustainability is a precondition of innovation and Safety, Health, and Environment (SHE) awareness is a key condition for sustainable licensing This focus ensures our technology is efficient, environmentally friendly, reliable and above all, safe Flexibility • Single-train capacity allowing for up to 5000 mtpd Multiple synthesis choices: Avancoređ or Urea 2000plus™ Pool Process both are available with a pool condenser or a pool reactor • Multiple finishing choices: Granulation, Prilling and Rotoform pastillation • Urea Ammonium Nitrate (UAN) and Ad-Blue/ SCR/automotive grade urea solution technologies available as an integrated, cost-efficient design Collaboration In order to create and to improve innovative urea plants, Stamicarbon also collaborates with a number of suppliers of critical equipment to ensure product quality, and we co-develop new technologies with strategic partners The names of these companies can be found in the supplement at the back of this brochure Global reach With the experience of licensing urea plants in more than 80 countries, we have the tools to meet your requirements - wherever in the world you need us Innovation At Stamicarbon, we recognize the power of innovation That’s why the professionals in our Technology Department are always on the lookout for innovative ways to renew, improve and add to the portfolio of products that we offer our customers Every year, we spend about 6% of our turnover on developing breakthrough innovations Working together with R&D groups, universities, customers and suppliers, our Technology Department creates technologies that optimize the urea production process In the past 60 years, this has resulted in a number of developments that have improved the urea production process These include: • • • • • • • • • • • • • • • • • • • Passivation of urea synthesis by air CO2 stripping process 25-22-2 material N/C measurement system Non-destructive testing techniques Online Leak Detection System Waste-water treatment section UAN Process Urea 2000plus™ Pool Condenser Concept Safurex® stainless-steel material (together with Sandvik) Urea granulation technology (fluidized bed type) Siphon jet pumps Urea 2000plus™ Pool Reactor Concept Integrally geared CO2 compressors Mega Plant Concept Rotoform pastillation technology (together with Sandvik) Zero-emission technology RADAR level measurement (together with Vega) Avancore® urea process (introduced in 2008) 10 Safurex® stainless steel: resistant to corrosion Stamicarbon has a long and distinguished track record in developing superior, cutting-edge urea plant materials X2CrNiMoN 25-22-2 With the introduction of the high-pressure stripper, a new stainless steel was needed Together with Sandvik, a Swedish stainless-steel supplier, we developed the X2CrNiMoN 25-22-2 material This widely used austenitic stainless steel allows higher operating temperatures and is also more resistant to condensation corrosion However, it remains vulnerable to active corrosion when used in an HP stripper and chloride stress corrosion cracking when used in a high-pressure carbamate condenser Safurex® Despite the success of the 25-22-2 material, Stamicarbon continued the search for ways of developing even better materials The ultimate breakthrough came in 1996 with the creation of a special duplex steel called Safurex®, also developed together with Sandvik Materials Technology As this innovative material is highly resistant to corrosion, it does not require the addition of oxygen - enabling an intrinsically safe plant design Safurex® offers numerous significant benefits, including: • Zero oxygen, making the plant intrinsically safe • Lower corrosion rates, leading to longer lifetimes • No active corrosion • No stress corrosion cracking • No condensation corrosion • No crevice corrosion • Better mechanical properties • Lower fatigue properties • Improved weldabilities What’s more, Safurex® requires a lower investment than traditional materials and offers you a nearly maintenance-free urea plant with a significant longer lifetime than any other commercially available urea process 22 Film spraying: The design of the melt film sprayers in the granulator is at the heart of our fluid-bed granulation technology These sprayers not only require a minimum amount of formaldehyde, but they also reduce the amount of dust formed compared to other fluid-bed granulation technologies 6.7 Finishing technology 1: Fluid-bed granulation Today, the most commonly used finishing technology is fluid-bed granulation, which was commercialized by Stamicarbon in response to changing market needs Our patented fluid-bed urea technology is in use in several urea plants Stamicarbon’s fluid-bed granulation technology offers: • Large reductions in formaldehyde content compared to other fluid-bed granulation technologies • Unprecedented uninterrupted run times, which can exceed 100 days before washing is required • Excellent product quality (round and uniform, with a smooth surface) • More stable operation conditions • Low urea dust formation, resulting in a lower recycle of urea solution to the urea synthesis plant • Low opacity at outlet granulation vent stack • Substantial savings on operational costs when compared to other fluid-bed granulation technologies • Excellent properties for downstream coating (for specialty fertilizers) In just five years, Stamicarbon’s fluid-bed granulation technology has been licensed over 10 times for commercial scale plants, including capacities exceeding 3500 mtpd The plants using this technology are operating at or above their original design capacity, producing superior-quality products that meet all required product quality standards Stamicarbon’s fluid-bed granulation process works as follows: A urea melt stream with a urea concentration of 98.5wt% is introduced into the fluid-bed granulator through the injection headers, which are connected to the urea melt line and the secondary air system Each injection header comprises vertically placed risers fitted with spray nozzles that spray the urea melt onto the seed particles The secondary air, required to transport the granules through the urea melt film, is provided by a secondary air blower Urea formaldehyde is added to the urea melt as a granulation additive and anti-caking agent This also improves the granule crushing strength 23 The granulator is divided into a granulation section and a cooling/conditioning section In both sections, fluidization air is evenly distributed to fluidize and cool the granules Seed (recycled) material is introduced into the first chamber of the granulation section The urea melt is then sprayed onto this seed material As the granules move through the granulation section, their size is steadily increased by layering until they reach the required granule diameter At this point, the product finally flows out of the granulator The granules flow from the granulation section to the cooling section (without spray nozzles), where they cool down and harden Fluidization air and secondary air are exhausted from the top of the granulator by means of an off-gas fan in the off-gas line of the granulator scrubbers In the scrubbers, the air is cleaned using a scrubbing solution, and the cleaned air is exhausted into the atmosphere The scrubbing solution (a dilute urea solution) is partly recycled to the scrubber as a scrubbing solution A purge stream is also pumped to the urea-dissolving vessel and recycled to the urea melt plant The product from the granulator flows through a screen to prevent any lumps from reaching the granulate cooler The fluidization/cooling air, which contains some dust, is exhausted from the top of the granulate cooler and is combined with the air from the product cooler and the de-dusting air This combined stream is cleaned in the cooler scrubber system A bucket elevator lifts the cooled urea granules onto screens, where they are sorted according to size Fine product is recycled to the granulator Coarse product is crushed to a smaller size and then recycled to the granulator On-size product is transported to the product cooler, where it is aircooled in a fluidized bed cooler or a bulk-flow heat exchanger 24 6.8 Finishing technology 2: Prilling The prilling process works as follows: The urea solution is concentrated to 99.7% urea in two steps under vacuum The resultant molten stream is prilled with the aid of a rotating prilling bucket, designed by Stamicarbon Using an optional technique of seeding when prilling, impact-resistant prills are obtained These prills are very resistant to degradation during product handling 25 6.9 Finishing technology 3: Rotoform urea pastillation Stamicarbon continuously endeavors to improve the urea process and has now introduced the Rotoform process designed by Sandvik Process Systems as a very useful alternative or addition to the traditional finishing techniques of prilling and granulation The Rotoform process has been successfully employed in the petrochemical, chemical, food and fertilizer industries since the early 1980s and there are currently more than 1400 Rotoform units in operation worldwide The Rotoformer principle The Rotoformer principle brings together the specially designed drop-former with the outstanding features of the Sandvik steel belt cooler This technology is ideal for removing bottlenecks, for upgrading the prill tower or granulation section, or for the production of specialty urea products (UAS S-urea, micro nutrients) Premium-quality pastilles can be produced at low investment costs, low operating costs and with minimum emissions The Rotoform process offers the following advantages: • Very low dust emissions • Simple solution to realize very low ammonia emissions • Very low power consumption figure • More uniform product • Good crushing strength even without adding formaldehyde • Flexible production by switching on/off rotoformer lines • Lower investment costs • Possibility of producing controlled-release urea and mixed fertilizer The Rotoform-based urea pastillation process Mechanically, a single Rotoform unit for urea pastillation consists of a continuously moving steel belt, typically 1.5m wide and 15-20m long (for a 125 ton/day unit), with a drop-former feeding device at one end of the moving belt and a scraper at the discharge end The feed to the Rotoform is urea melt with a concentration of 99.6wt% and typically branched off from the urea evaporation section downstream from the urea melt pumps Urea is introduced under pressure (3 bar) in molten form to the drop former The Sandvik Rotoform High Speed Drop Former consists of a heated stator and a perforated rotating shell, which turns concentrically around the stator to deposit drops of urea across the full width of the belt The circumferential speed of the Rotoformer is synchronized with the speed of the steel belt cooler ensuring that the drops are deposited on the belt without deformation and, after solidification, result in regular pastilles with an optimum shape The rotating shell contains 26 rows of small holes which are sized to deliver the required product size The heat released during crystallization and cooling is transferred by the stainless-steel belt to the cooling water The cooling water is sprayed against the belt underside, absorbs the heat and is collected in pans, cooled in a cooling system (cooling tower) and returned to the Rotoform units Under no circumstances can the cooling water come into contact with the urea product After solidification, the pastilles are smoothly released from the steel belt via an oscillating scraper The product then falls directly onto a conveyor belt for transfer to storage The section above the moving steel belt is enclosed with a hood and vented to an existing vent system There is no visible urea dust emission, only some ammonia vapors which can be easily removed from the very small air flow by means of a normal atmospheric absorber Several Rotoform units can be installed in parallel in order to achieve higher capacities 27 UAN Process The Stamicarbon partial-recycle CO2-stripping process is eminently suitable for the manufacture of Urea Ammonium Nitrate (UAN) solutions The ratio of unconverted ammonia to urea is such that the required ratio between urea and ammonium nitrate for the production of UAN solutions can be achieved directly Ammonia still present in the stripped urea solution, together with the ammonia in the reactor’s off-gases, is converted into ammonium nitrate in a neutralization reactor using nitric acid UAN solution product is obtained by mixing the urea and ammonium nitrate solutions The Avancore® and Urea 2000plus™ process can both be applied for the Stamicarbon UAN process The UAN process works as follows: In the high-pressure synthesis section, carbon dioxide and ammonia are converted into urea in very much the same way as in the previously described processes The urea formation is an equilibrium reaction, so the urea solution formed contains unconverted ammonia and carbon dioxide Stripping with carbon dioxide causes the greater part of these components to evaporate from the solution Evaporated ammonia and carbon dioxide, together with fresh ammonia and carbon dioxide, are condensed in the pool reactor, the heat from this condensation being used to produce low-pressure steam The condensed ammonia and carbon dioxide are partly converted into urea and water In the low-pressure dissociation section, the stripped urea solution is almost entirely freed from ammonia and carbon dioxide The overhead vapors of the reactor, mixed with off-gases from the dissociation section and the ammonia present in the urea solution from the urea solution tank, are all sent to the neutralization section 28 The neutralization section comprises a neutralizer, an (optional) ammonium nitrate storage tank, a mixing pipe, a UAN storage tank and off-gas purification equipment The neutralizer consists of a U-type combination of a circulation tube and a mixing tube with a separator It operates just above atmospheric pressure The ammonia-containing gases from the urea plant are fed into the bottom of the mixing tube; the nitric acid is introduced somewhat lower in the circulation tube Ammonia and nitric acid react exothermically to form ammonium nitrate according to the following reaction equation: HNO3 + NH3 NH4NO3 Nitric Acid + Ammonia Ammonium Nitrate The presence of liquid in the circulation tube and of the gas-liquid mixture in the mixing tube causes the fluid to circulate The heat from the reaction is used for the evaporation of water and to increase the temperature to about 135°C The pH of the solution is controlled by the addition of nitric acid The gas and liquid phases are separated in the separator, the liquid being sent to the (optional) ammonium nitrate storage tank In the mixing pipe, the following substances can be mixed: • Urea solution, still containing some ammonia (temperature 110°C) • Ammonium nitrate solution, containing some 0.4% HNO3 (temperature 135°C) • Ammonia • Nitric acid • Acidic condensate from off-gas purification Here again, the heat from the reaction is utilized to increase the temperature and to evaporate water The ammonium nitrate-to-urea ratio is controlled at about 4:3 The pH is controlled at 5-6pH by means of the nitric acid feed The resultant UAN solution is either stored or pumped to battery limits The off-gases from the neutralizer are treated in the off-gas purification section Nitric acid is supplied to this section to neutralize any ammonia that is contained in the off-gases from the neutralizers Part of the liquid effluent from the purifier flows down to the mixing pipe; the remainder can be sent to battery limits and is generally used in a nearby nitric acid plant 29 Mega Plant Concept Large urea plants require large high-pressure equipment that is difficult and costly to manufacture and transport To reduce urea fabrication costs, Stamicarbon has developed a Mega Plant concept for single-line urea plants that produce capacities of 5000 mtpd In the Stamicarbon Mega Plant concept, a proportion of the liquid effluent from the reactor is diverted to a medium-pressure recycling section, thereby reducing the size of the high-pressure vessels needed In fact, thanks to the Mega Plant concept, the size of the required high-pressure equipment and lines will not exceed the size of equipment needed for a 3250 mtpd pool condenser type CO2-stripping urea plant! A Mega Plant can be built with both the Avancore® or the Urea 2000plus™ technology The Mega Plant process works as follows: About 70% of the urea solution leaving the urea reactor flows to the high-pressure CO2 stripper, while the remainder is fed into a medium-pressure recirculation section This reduced liquid feed to the stripper in turn reduces not only the size of the stripper needed, but also the heat exchange area of the pool condenser The degree of stripping efficiency is adjusted to ensure that as much low-pressure steam is produced by the carbamate reaction in the pool condenser as is needed in the downstream sections of the urea plant About 30% of the urea solution that leaves the reactor is expanded and enters a gas/liquid separator in a recirculation stage operating at a reduced pressure After expansion, the urea solution is 30 heated by medium-pressure steam By heating the urea solution, the unconverted carbamate is dissociated into ammonia and carbon dioxide Our Mega Plant Concept does not need the ammonia recycle section or the ammonia holdup steps that are commonly seen in competitors total recycle urea plants This is because the low ammonia-to-carbon dioxide molar ratio in the separated gases allows for easy condensation as carbamate only The operating pressure in this medium-pressure recirculation stage is about 20 bars After the urea solution leaves the medium-pressure dissociation separator, it flows into an adiabatic CO2 stripper, which uses carbon dioxide to strip the solution As a result of this process, the ammonia-tocarbon dioxide molar ratio in the liquid leaving the medium-pressure recirculation section is reduced, facilitating the condensation of carbamate gases in the next step The vapors leaving the mediumpressure dissociation separator, together with the gases leaving the adiabatic CO2 stripper, are condensed on the shell side of the evaporator The carbamate formed in the low-pressure recirculation stage is also added to the shell side of this evaporator The heat released by condensation is used to concentrate the urea solution Further concentration of the urea solution is achieved using low-pressure steam produced in the pool condenser The remaining uncondensed ammonia and carbon dioxide leaving the shell side of the evaporator are sent to a medium-pressure carbamate condenser The heat released by condensation in this condenser is dissipated into a tempered cooling water system This process forms mediumpressure carbamate that contains only 20-22wt% water The carbamate is transferred via a highpressure carbamate pump to the high-pressure scrubber in the urea synthesis section The urea solution leaving the adiabatic CO2 stripper and the high-pressure stripper are expanded together in the low-pressure recirculation section 31 Full life cycle support Successful urea plants comply with all applicable rules and regulations and produce products efficiently and effectively with maximum onstream times However, as plants get older, it may become increasingly difficult to maintain efficient production and full compliance Many urea plants have been designed for a service life not greatly exceeding twenty years However, such plants can remain competitive due to the depreciated initial capital investment Well maintained and upgraded with state-of-the-art technology, these plants succeed in producing at competitive cost prices To ensure our customers’ urea plants remain competitive, we offer a range of activities and services covering the complete life cycle of a plant: • Plant operation • Plant maintenance • Plant improvement, including capacity increase Examples of Stamicarbon’s full life cycle support are: • Corrosion inspection of the critical urea equipment • Process analyses and plant optimization • Debottlenecking ideas and life study • Simplification of the urea process steps for ease of operation • Supply of critical equipment items • Schemes for sustained maximum output 32 9.1 Plant operation How you ensure your urea plant not only operates in a sustainable manner, but also produces its products at maximum capacity and maximum on-stream times? The solution is to optimize equipment and processes To help customers ensure their urea plant operates with maximum efficiency, we have developed a range of plant operation services to improve plant performance, production and energy consumption These services are usually carried out within the framework of a Plant Performance Assessment Throughout this assessment, we pay special attention to: • Minimizing ammonia consumption • Minimizing energy consumption • Minimizing effluents • Maximizing plant on-stream time 9.2 Plant maintenance Stamicarbon offers a range of services to ensure your urea plant is well maintained These include: Corrosion inspections We offer corrosion inspections to assess the general condition of urea plants and to determine the remaining lifetime of tubes, lining and equipment In addition, recommendations for inspection intervals are provided Equipment criticality assessment It is vital that producers know the criticality of their equipment (i.e., the probability that it will fail and the probable effects of any such failure) Equipment failure may have not only economic effects, such as costly plant shutdown and repairs, but also serious health, safety and environmental implications Re-lining of high-pressure urea equipment Over time, the alloy protection lining in highpressure urea equipment may become so thin that the equipment needs to be replaced But in fact, replacement is often unnecessary! We are experts in replacing the alloy protection lining in highpressure urea equipment - extending the lifetime of the equipment by many years All our re-lining services follow a carefully planned process to ensure minimum down-time and optimum results Replacement of high-pressure equipment Choosing the right replacement for your highpressure equipment can be difficult That’s why Stamicarbon cooperates with customers to make tailor-made equipment that not only incorporates the most advanced design features, but that is also free of defects and will not cause unnecessary shutdowns The Stamicarbon services can include: • Tailor-made specification in consultation with the customer • Preparation of the Invitation to Bid • Evaluation (including technical evaluation) of the bids and manufacturer selection together with the customer • Inspections during fabrication to check compliance in accordance with the Stamicarbon specifications • Expediting during fabrication Stamicarbon can also supply HP equipment and other critical items such as HP piping and its components; RADAR level measurements; an NC meter; and leak detection systems This will provide you a single point of responsibility for the critical activities of your project and will also reduce the often long delivery times of these items 33 9.3 Plant improvement and debottlenecking services Stamicarbon has carried out more than 85 revamp projects at all kinds of urea plants, including both Stamicarbon and non-Stamicarbon plants Thanks to a combination of state-of-the-art technologies and expert know-how, our revamp services can dramatically improve plant performance Our services include: • Increasing plant capacity • Reducing ammonia consumption and emissions • Optimizing energy consumption • Increasing product quality Debottlenecking One of the revamp services offered by Stamicarbon is debottlenecking Debottlenecking will enable your urea plant to: • Take full advantage of the plant’s design margins • Boost urea production with the same number of people and basic infrastructure • Reduce total fixed and operating costs, lowering the price of the urea produced • Improve the plant’s competitive advantage Debottlenecking concepts Rigorous onsite revamp study At the start of the process, Stamicarbon performs a rigorous onsite revamp study to determine the present performance of the plant and to design the optimum revamp solution Debottlenecking your urea plant effectively will depend on the availability of feed, utilities and particular plant limitations And because the availability of feed stocks and utilities varies from site to site, we have developed several debottlenecking concepts that enable us to meet your exact requirements Depending on your needs, a combination of debottlenecking concepts can be implemented This table details some of the concepts available and the expected capacity increases: Concept type Expected capacity increase % More In, More Out Mega Plant technology Double Stripper Pool condenser/combi-reactor 10 - 25 30 - 40 35 - 45 40 -100 The reference for the given capacity increase is the nameplate capacity It should be noted that the achievable plant capacity increase depends on the original design margins of the large capital equipment 34 Some examples of debottlenecking projects are: PIC, Kuwait: Original 550 mtpd total recycle conventional urea plant First debottlenecking to 1065 mtpd with conventional technology Second debottlenecking to 1750 mtpd with pool condenser and CO2 stripping technology Iffco, Kalol, India: Original 1200 mtpd CO2 stripping plant Debottlenecking to 1650 mtpd with More In More Out technology Saskferco, Canada: Original 2000 mtpd CO2 stripping plant Debottlenecking to 2850 mtpd with Double Stripper technology DSM, Netherlands: Original 1100 mtpd Pool reactor CO2 stripping plant Debottlenecking to 1500 mtpd with MEGA technology Ningxia, China: Original 1740 mtpd NH3 stripping plant Debottlenecking to 2610 mtpd with pool condenser and CO2 stripping technology Erdos, China: Original two lines of 1000 mtpd TEC TR-C urea plants Debottlenecking to 3520 mtpd with pool condenser and CO2 stripping technology As these examples show, even plants with relatively small capacities can be debottlenecked This can cut the cost price of the urea produced Contact us For more information on what Stamicarbon can for your organization, please contact us at: Tel.: +31 (0)46 423 7000 Fax: +31 (0)46 423 7001 Email: info.stamicarbon@dsm.com www.stamicarbon.com Visiting address Stamicarbon bv Mercator 6135 KW Sittard The Netherlands Mailing address Stamicarbon bv PO Box 53 6160 AB Geleen The Netherlands ... Avancore® Urea Process The Avancore® urea process is a new urea synthesis concept that incorporates all the benefits of Stamicarbon’s earlier proven innovations The Avancore® urea process combines... produced in the urea synthesis 20 6.5 Evaporation section Before the entire urea production process is complete, the urea solution present in the urea solution tank must be concentrated The urea solution... dioxide • Lower temperatures and pressures required in the urea production process • High on-stream times (for both urea melt production and urea granulation) • All product quality standards met •
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