| Stamicarbon has realized more than 70 revamp projects
in different kind of urea plants. Of course doing a revamp
in an original Stamicarbon plant derives a considerable benefit
from the fact that all plant information including design
limits are available at Stamicarbon.
However, also non-Stamicarbon
conventional plants, such as Mitsui-Toatsu Total Recylce C-improved Process,
Montedison Urea Process and Chemico Processes can be succesfully
revamped when incorporating the Urea 2000plus™ technology,
using a pool condensor.
A revamp can cover elements like increase of plant capacity, reduction of the NH3 consumption and
emissions to the environment, product quality improvement and energy optimization.
Stamicarbon has carried out all of these elements combined in one revamp project or, as the case
may be, in separate projects.
When the present operation of the urea plant should be integrated into the revamp,
Stamicarbon performs a revamp study, in order to examine the present performance of the
plant and to investigate the optimum solution for the revamp and integration with the
original plant design. Together with the introduction of innovative state of the art
technologies the plant performance can be improved considerably.
Many times it is useful to consider a debottlenecking project as it is very attractive
to take full advantage of all the design margins available in order to produce more urea.
This will lead to a maximum production level in a rather costly process installation.
A higher production level will be achieved with the same number of people, the same
infrastructure and the same buildings. The total fixed costs can be divided by more tons
of urea leading to a lower cost price of urea. This is also a reason that the sizes of
grass root plants are nowadays growing significantly.
Revamping is improving your competitive
advantage
The figure above shows that quite a number of plants with rather small capacities
can be debottlenecked (e.g. double or triple the existing capacity) and consequently reduce
the cost price of the urea produced.
Debottlenecking urea plants depends on the availability of
feed stocks and utilities. Because this availability of feed
stocks and utilities are different at every site, Stamicarbon
developed several debottlenecking concepts. From these concepts
the following expectations about capacity increase are given
as a ballpark figure in the following table:
|
| Concept type |
Expected capacity increase
% |
|
More in more out |
10 - 25 |
|
In-line medium-pressure recirculation |
15 - 30 |
|
The carbon dioxide carbamate stripper |
20 - 35 |
|
The medium-pressure recirculation add-on |
30 - 45 |
|
The double stripper |
35 - 45 |
|
The pool condenser/ combi-reactor |
40 -> 100 |
| |
Note:
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 used design margins of the
large capital equipment.
|
Stamicarbon
realized more than 70 revamp projects.
Some examples of debottlenecking projects are: |
|
|
PIC Kuwait: |
original 550 mtpd 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, Geleen |
original 1100 mtpd Pool reactor CO2
stripping plant debottlenecking to 1500 mtpd with MP
Add On technology |
|
Ningxia, China |
original 1740 mtpd NH3 stripping
plant debottlenecking to 2610 mtpd with Pool condenser
and CO2 stripper technology |
| |
These are just a few examples of revamp projects, the complete listing of all revamp
projects can be found in our Reference list Urea Debottlenecking & Improvements.
For more details about possible improvements please check our brochure
Full Life Cycle Support [ 1.253 kb], which contains:
Increase safety
- H2 removal unit
- Leak detection in lined HP urea equipment
- Blow off to safe location
Reduce emissions
- High performance absorbers
- Process water treatment section for re-use of waste water
Reduce energy consumption
- High Efficiency Trays
- Advanced Process Control, N/C ratio and carbamate density meter
Improve product quality
- Prilling bucket
- Seeding system
- Granulation
Maximize production
- CO2 chiller
- Debottlenecking concepts
 |
UREA 
