Abstract:
First commissioned back in 1966 as a 550 mtpd conventional-type Stamicarbon plant, the capacity of this plant was already doubled by a revamp in 1977. In the 1990s, PIC and Stamicarbon took the unprecedented step of a further revamp to 1750 mtpd, while changing from conventional technology into CO2-stripping technology. The plant capacity has now reached triple its original design capacity while featuring the successful Pool Condenser. One of the oldest urea-plants still running, this plant now compares favorably to much newer plants by utilizing state-of-the-art urea technology.
Ambitious as this revamp was, the start-up revealed some obstacles. The initial process instability emerged in a fluctuating load on both stripper and high pressure in the MP recirculation section downstream; and consequently to the emission of ammonia. This upset was quickly recognized, researched and solved with joint effort by PIC and Stamicarbon, with minimum hardware modifications needed. When the plant load reached 95% of design capacity, the reused MP condenser lagged behind expectation. A synthesis stripping gas ejector will now be introduced which will allow for improved performance.
This paper briefly touches the history of the plant, the concept of changing it into a CO2-stripping plant and the decisions taken to overcome the above-mentioned setbacks. The paper intends to highlight the revamp capabilities of Stamicarbon as much in terms of developing the optimum process scheme as in terms of troubleshooting and elegantly solving capacity limitations.
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