For example, over the years we have brought plant height down from some 80 metres to just 20 metres - vastly improving efficiency, carbon footprint, safety, longevity of equipment, and most importantly profitability.
Pivotal to this particular innovation have been breakthrough technologies like urea2000plusTM and lately, Avancore® all featuring the acclaimed pool condenser/reactor as the centrepiece equipment, and Safurex® as the best stainless steel available for the entire high pressure urea synthesis section.
Urea2000plus™ Pool condenser: Stamicarbon’s pool condenser is able to condense more efficiently by reversing the former high-pressure carbamate condenser’s process and steam side, and submerging the entire heat exchanging part in condensed carbamate. It does so through higher heat transfer, while staging two thirds of the entire synthesis section’s urea conversion in its liquid hold-up. This in turn enables the urea reactor to be much smaller and plant height to be lower, thus saving a great deal of time and money.
More Urea2000plus™ Pool reactor: Taking this a stage further, we invented the pool reactor – which effectively combines the pool condenser and downstream reactor into a single piece of high-pressure equipment at ground level, saving yet more plant height, piping and of course money.
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Safurex® duplex steel: This unique metal enables vessels and pipes to be designed smaller, lighter – yet extremely resistant to corrosion. Some working parts can be omitted entirely – all of which can realise more than a 10% saving in investment costs. Safurex® is also safer, enabling the oxygen content in the carbon dioxide feed to the urea synthesis to be reduced to virtually zero – greatly increasing plant safety. Our customer, SAFCO of Saudi Arabia was the first plant to build its entire synthesis section from Safurex®, in 2003. Now there are fifteen plants licensed with a full Safurex® synthesis section – and counting.
Avancore®: Our very latest urea development brings together our family of unique and proven innovations to provide the most efficient urea synthesis ever:
- Urea2000Plus® featuring pool condenser / reactor.
- Safurex®.
- Low elevation layout.
- Reduced pressure inert scrubbing system.
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Mega Urea Plant™: How do you meet growing demand for urea when existing technologies have not yet reached 4000 mtpd production capacity? Answer: reinvent the process. That’s what Stamicarbon did with its Mega Urea Plant™ concept. The introduction of the pool condenser, coupled with our Medium Pressure Add-on Debottlenecking technology, has enabled plants to produce more with less – allowing for capacities up to 5,000 mtpd.
Our Mega Urea Plant™ concept doesn’t need the ammonia recycle section or the ammonia hold-up steps that are commonly seen in competitors’ total recycle urea plants. The result is greater capacity without the need for up-scaled, high-pressure equipment. More
