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ADVANCE HSE Products and Services

ADVANCE HSE™ Products and Services

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Stamicarbon’s selection of HSE products and services that can make your plant safer and more environmentally friendly.

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Accurate Eddy current wall thickness measurements of SAFUREX™ heat exchanger tubes

Registered users

Triggered by the reported higher passive corrosion rate of Safurex® heat exchanger (HEX) tubes compared with BC.05 (X2CrNiMo25-22-2) HEX tubes in HP strippers, an extensive study was undertaken to ana

lyse the accuracy and reliability of the applied inspection method. Together with the introduction of Safurex®, a modified eddy current inspection technology was developed to assess the wall thickness of HP stripper HEX-tubes. After utilizing this inspection technology for a couple a years, the reported higher passive corrosion rates of Safurex® HEX-tubes were doubted, since Safurex® outperforms BC.05 material in all laboratory corrosion tests. Proper understanding of the modified eddy current inspection technology resulted in a more reliable and accurate inspection technique. By using this optimized procedure, the corrosion rate of Safurex® HEX-tubes is currently reported in the same order of magnitude as the BC.05 ones. Still a distinct advantage of Safurex® over BC.05 HEX tubes in HP strippers is the absence of active corrosion, which makes the use of the former far more favorable .

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EXPERIENCES AND NEW DEVELOPMENTS IN SAFUREX™ STEEL

Registered users

Forms of corrosion in Urea Syntheses in fully austenitic stainless steels: 1) Overall attack (passive or active) All vessels 2) Crevice corrosion All vessels 3) Condensation corrosion All vessels

4) Stress corrosion cracking Typically vertical HPCC 5) Strain induced intergranular cracking Typically Urea Reactor 6) Stern face attack Typically HPCC & Scrubber 7) Under deposit corrosion Typically HP Stripper

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A new production route for SAFUREX™ HIP-2

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An all Safurex® urea synthesis loop comprises a number of diverse Safurex® components, which are fabricated by a variety of production methods/routes. These include among others hot extrusion (for HP

piping), cold pilgering (for heat exchanger tubes), hot and cold rolling (for plates) and forging (for bars).During the development of the HIP-ing method for Safurex®, it also became clear that its corrosion resistance was superior to that of non HIP-ed Safurex®. This opens opportunities to use the HIP-ed material in specific applications where higher corrosion resistance is needed. In this paper the development and achievements of this production route are presented as well as the first operational experiences. HIP-ed Safurex® is patented by Sandvik and Stamicarbon.

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GMA welding process for SAFUREX™ liners

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Based on the results of the program, Stamicarbon considers the special semi-automatic GMA welding process validated and has approved it as an alternative welding process for liner welding. It will be

included in the Stamicarbon Specification A4-71111 for welding of Safurex® liners. 

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SAFUREX™ experiences and developments

Registered users

1. More flexibility in plant operations • Oxygen passivation not needed • Turndown ratio not critical • Blocking in time not critical 2. Less inspections, longer inspection intervals (6 years) 3. Less

maintenance and repairs; lower OPEX costs 4. Lower APEX

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Fifteen years SAFUREX™ in Stamicarbon Urea Plants

Registered users

Since 1998 Safurex® equipment are in operation and Stamicarbon has gained extensive in-service experiences with the corrosion behavior of Safurex®. In this paper the behavior of Safurex® will be compa

red with the corrosion behavior of the traditionally used fully austenitic stainless steels (316L UG [BC.01] and X2CrNiMoN 25-22-2 [BC.05]). 

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How rigorously plant modeling can advance your urea business

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This paper gives an overview on Stamicarbon’s capabilities and products related to urea plant modeling. These models are typically implemented in the ADVANCE and EVOLVE life-cycle of a urea plant. In

the LAUNCH phase, grass root plants can apply the models to optimize consumption and emission figures.  It allows urea producers to stay competitive with production improvements, monitoring and detection, staff training and full lifecycle support. Further, feedback will be given on the EVOLVE OPTIMIZER™ project at OCI in the Netherlands. This has been in operation since 2012.

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Benefits of optimizing basic control loops

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It is axiomatic that a stable process consumes less energy and needs less maintenance, thus lowering operating costs and improving profitability.  The optimization should be carried out by people

who have a thorough knowledge of the dynamic behavior of the process and the spectrum of algorithms which can be implemented in the process control system. The optimization process itself consists of several steps, like setting up a controller performance monitoring system, determining the root cause of poorly performing control loops, fixing potential hardware problems, and tuning the controllers with the proper algorithm and parameters. These well-tuned basic control loops can also act as a solid backbone for model-based advanced process control software like the Stamicarbon EVOLVE OPTIMIZER™, which offers extensive possibilities for stable plant operation and further enhanced economic benefits.

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Would Urea enhanced fertilizers be a profitable and viable innovation for Urea producers

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Bulk blending of fertilizer is an alternative compounded NPK fertilizer. Granular urea has proven to be a good feedstock for bulk blending. Bulk blending of fertilizer has been widely applied in

the Americas due to mechanization of agriculture. In order to blend a high quality of granular fertilizer it is very important to produce a stable blend where no segregation of mixture occurs. For good bulk blending quality granules containing nutrients like P, K and/ or S are required. For such granules a premium is paid in the market. In some Asian countries like India bulk blending of fertilizers is not an alternative to compound fertilizer because bulk blending fertilizers is forbidden due to quality control issues in these countries.

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How to protect your urea prills against deterioration

Registered users

Most fertilizers have a tendency to form lumps or agglomerates during storage and transportation, which is commonly referred to as caking. A quality fertilizer should meet not only the specified nutri

ent requirements, but also high standards in respect of its physical properties. This paper will focus on the causes of caking, like formation of crystal bridges serving as contact points between particles and formation of capillary adhesion forming adhesive contacts. Other subjects that will be discussed are: approaches to cake prevention, the action of anti-caking agents, and the methods of applying them. Finally, a new method of rendering prilled urea cake-resistant, based on coating with a novel, high-quality Stamicarbon coating agent named ADVANCE COAT™ Prill Strength, will be introduced. 

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Urea reactor dome liner replacement

Registered users

Repeated leaks in the Dome of Agrium’s reactor at Carseland were forcing unplanned shutdowns at intervals of less than 1 year. In December of 1992 there was a liner leak at a tray clip. Based on inspe

ctions of the reactor CNO (Carseland Nitrogen Operations) believed that there was only 3mm of original material protecting the carbon steel shell. At the end of 1995 Carseland ordered new liner material for the top dome and the cylindrical section approximately 1 m below the head. Carseland consulted Stamicarbon and potential suppliers of liner material and installation expertise. Carseland decided that for reasons of cost and time it was best placing a new liner overtop of the existing liner in the dome.

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ADVANCE COAT to improve dynamic strength of prills

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Advantages from client's perspective: • Logistic costs are lower • More selling product in range due to better granulometry • Environmental and Health advantages • Longer storage possibilities (le

ss caking, consolidation strength)

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Urea process simulator

Registered users

Motivation for investing in OTS • Less unplanned shutdowns • Faster recovery time if trips do occur • Less damage to equipment • SAFETY • Higher on-stream time = $$$

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Stamicarbon service - how to advance your plant performances moscow 2017

Registered users

Simple characterization of requested services o Ensure a constant and good product quality o Optimal process operation and control of the urea plant o Maintain the plant and keep hardware in optimal c

ondition o Comply with safety and (new) environmental regulations

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From urea to Uas to Multiproduct Granulation

Registered users

Because of increasing demand for granulated urea containing macro- and micro-nutrients, Stamicarbon  has developed a unique and flexible process for the production of granulated urea containing &

nbsp;ammonium sulfate. Given the flexibility of this process, it can well be used to also produce  granulated Urea containing other nutrients. This paper gives the background and highlights the  technology, the design and the current status of the process.

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Explosion risks in urea plants the stamicarbon y2k update

Registered users

The combination of growing insight on the one hand, and increasing demands on the other hand, justifies a regular update of safety guidelines and standards. Referring to the present year 2000, we name

d our present update “The Stamicarbon Y2K update on explosion risk in urea plants

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SIL Classification in Urea Plants

Registered users

The concept of Safety Integrity Levels (SIL) was introduced during the development of IEC 61508/61511 as measure of the quality or dependability of an instrumented system that has a safety function (S

IS). To comply with internationally recognized standards, Stamicarbon introduced the concept of SIL in its standard design urea plants. This paper focuses on the risk graph method, which is a means of quickly assessing and screening a large number of scenarios resulting in loss of containment (LOC). A limitation of the risk graph method however is that it leaves some subjective elements in assessing the consequences (severity) of LOC scenario, whereas these consequences are increasingly important in the ever increasing capacities of urea plants and equipment. To overcome this limitation Stamicarbon developed a quick reference chart covering all sections of the urea plant that allows quick and objective assessment of the severity and SIL parameters. Further, the paper highlights SIL-equivalents for safety relief valves in crystallizing media and risk reduction by means of Safety Instrumented Systems (SIS).  

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Tube leakage evaporation heater. The effects and root cause. An experience by Kafco, Bangladesh

Registered users

After the synthesis of urea and recovery of the non converted ammonia and carbon dioxide a urea solution remains. To condition this solution for the finishing section, being granulation, crystallizati

on or prilling, it needs to be  If the heater is mechanically damaged (leaking tube heat exchanger) also product can contaminate the steam/condensate system and cause corrosion in the carbon steel lines and equipment.

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Advance insight digital solutions to optimize your plant peformance

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CONSEQUENCES OF LOSS OF PASSIVATION AIR

Registered users

• Initial Shut-down June 2nd, 2013 for a planned maintenance outage. • The inspection of the R-101 Reactor produced a number of routine findings and small repairs. • All internal surfaces (liner and

weld overlays) are in passive state

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Result of recent she studies for urea plants

Registered users
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Disposal of emergency relief discharges

Registered users

Ammonia is a toxic substance. In a Urea plant, relative large amounts of ammonia are present under elevated temperature and pressure. Engineering guidelines, such as the well known ‘API recommended pr

actices’ give guidelines about the necessity and sizing of emergency relief systems, aiming at protection of the plant under emergency conditions. Traditionally, disposal of the ammonia containing gases from such emergency relief systems (safety valves or rupture discs) from urea plants has been done as direct discharge into the atmosphere. Recently a study was conducted by Stamicarbon to see whether this practice is acceptable from a safety point of view, taking into account progressing insight gained in the subject of emergency relief in recent years.

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Shiphon Jet Pumps

Restricted

While revamping a Stamicarbon Urea plant, in most of the cases, the specific reaction volume is decreased with the revamp. As a result the residence time of the urea solution in the reactor will decre

ase and thus the efficiency of the reactor will go down. However, by changing the internals of the reactor (using a different type of trays) the efficiency in the reactor can be improved. In the past two types of trays were used in Stamicarbon Urea plants: the conventional trays and the high efficiency trays. Now a new type of trays is introduced, which improves the efficiency of the reactor and thus results in savings of the high-pressure steam consumption. These trays are called the Siphon Jet Pumps. The first trays have successfully been installed in SKW Piesteritz. In this paper the Siphon Jet Pumps are introduced and several aspects around these trays are discussed.

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