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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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Shiphon Jet Pumps

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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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Urea Synthesis gas lines suffering from leakages

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In the 2014 turnaround all original AISI316L-UG high-pressure gas lines were replaced in the urea synthesis section, in accordance with advice from Stamicarbon. The material utilized for the replaced

gas lines was again AISI316L-UG, because there were still some such tubes in stock, dating from the time the plant was constructed.The affected areas showed evidence of stress corrosion cracking (SCC), but reduction in the wall thickness was also observed. This was attributable to condensation corrosion, which is normally observed in the gas lines. It was most severe in the heat-affected zones (HAZ) near the welds. The affected elbows were subjected to metallographic examination in Brazil as well as in Stamicarbon laboratory. This paper presents the investigations carried out on the elbows and piping removed from the urea synthesis gas lines in order to find the root cause of the leakages. 

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THE VALUE OF A RELIABLE LEAK DETECTION MONITORING SYSTEM IN HP SYNTHESIS SECTION

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• A urea plant contains large amount of toxic ammoniaat elevated temperature and pressure. • For instance:the synthesis section of a1000MTD urea plant contains > 35ton of NH3 • Keeping this ammon

ia inside the process equipment is essential from a safety,environmental andeconomica lpoint of view

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Sustainable plant operation without stripper level indication

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Stripper level indication is critical in CO2 Stripping plant as loss of level can cause CO2 Slippage towards the LP Section whilst too high level causes unequal distribution of CO2 resulting in poor s

tripper performance.  The stripper level indication (Radioactive type) LT-1043 got erratic at our plant and we sustained plant operation without this indication by: 1. Keep the plant load constant and avoid any changes in plant load.  2. Observe the stripper outlet temperature as this temperature will change with increase or decrease of the stripper bottom level.  3. Observe the steam consumption of the stripper as the steam flow will change with a change in the liquid level. 4. Observe the N/C Ratio and keep it constant. 5. Observe the downstream section pressure at constant plant load.

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Round table Operations, topic RADAR

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New Overpressure Protection System for the Urea Synthesis

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The motivation for the development of the New Overpressure Protection System for the Urea Synthesis results from the following safety-related and process-related facts: Urea plants in Germany be

long to the so-called accident plants. For these plants it is required that the security is improved constantly. The management wants to constantly improve the environmental-protection and upgrading the technological conditions to increase the production and to save energy.

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Blockage of leak detection system

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A leak detection system is installed at the High Pressure equipment items of a Urea Plant in order to detect any leakage in these HP Equipment. Normally vacuum is maintained in this system, blockage i

n the system is checked by opening atmospheric valves and breaking the vacuum on a defined frequency of one month. We could not check the blockage on this defined frequency, we performed a blockage test after a period of 10 months; blockage was found in valves V-16 & V-17 in the leak detection system of the HP Stripper. After further investigation it revealed that the blockage in the leak detection system was inside the stripper top dome. We tried to de-block the system with instrument air having a pressure of 7 bar and with low pressure steam but this failed. Then on the running plant we tried to de-block using an argon cylinder having a pressure of 100 bar and de-blocked the lines at 30 bar. The root cause of the blockage was corrosion inside the leak detection tube due to moisture ingress through the atmospheric valves. The equipment condition was found healthy on inspection during a turnaround.

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Leak Detection Safeguarding Stamicarbon's High Pressure Urea Vessels

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Urea solutions are not very corrosive, but ammonium carbamate, an intermediate in urea synthesis is highly corrosive. To protect the carbon steel high pressure synthesis equipment from corrosion, stai

nless steel loose liners are commonly applied. With a loose liner a hazardous situation may arise if a leak occurs and carbamate containing fluids enters the space between liner and carbon steel. For this reason Stamicarbon designed a system which continuously monitors for leaks to allow safe operation of said equipment.

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ADVANCE MONITOR™ Leak Detection Monitoring System

Public

Stamicarbon’s ADVANCE MONITOR™ Leak Detection Monitoring System for both new and existing High Pressure equipment. Existing Leak Detection Monitoring System can be inspected to ensure proper operation

.

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Stamicarbon Stripper Performance in Non-Stamicarbon Plants

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This paper describes the successful experience of a Stamicarbon designed Safurex® HP Stripper in a world scale Snamprogetti urea plant commissioned in early 2001. The Stamicarbon designed Safurex® HP

Stripper replaced a bi-metallic designed Snamprogetti stripper in 2003 which suffered extreme corrosion issues within a short period after startup in the bottom channel section of the vessel that caused persistent operational outages and huge financial losses. The problems encountered with the original HP bi-metallic stripper and results of the decision to replace the bi-metallic tube stripper with a HP Safurex® stripper are addressed. The subject Safurex® stripper was in service for 850 operational days from March 2003 up until November 2006, after which the subject stripper was returned to Canada and installed in another Snamprogetti urea plant in 2007. The subject stripper has been in operation in Canada since 3Q 2007 and has had no issues in its new location as of this writing.

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Stamicarbon Critical Proprietary Equipment

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Quality & Safurex • Proprietary Equipment • PEQ procurement

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Report of the steps description

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A specialty SAFUREX™ for HP stripper tubes

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This paper presents a historical overview of the corrosion behavior of the Safurex® HEx tubes in HP strippers and gives an account of the development of the new specialty grade. 

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WORLD UREA MARKET DYNAMICS

Registered users

Stamicarbon: leader in urea technology • Global supply-demand outlook • Urea price outlook • North American’s unique nitrogen industry, supply-demand and trade • Cost competiveness of North Americ

an producers • Investments drivers for North American projects • Key take-aways

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World & Russian Market Dynamics

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Stamicarbon: leader in urea technology Global supply-demand outlook Urea price outlook Cost competiveness of Russian producers Trade flows Investments drivers for Russian projects Key take

-aways

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Urea Producers & Project Development

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1. Historical review presents in the region 2. Stamicarbon philosophy aplication: Full Life-Cycle 3. Successful cooperation practices 4. Project Development 5. New business development: O&M an

d Training 6. Conclusions

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Unlocking the potentials of innovative fertilizers

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The required global food production increase by 70 percent must be achieved mostly from land currently under cultivation. Balanced fertilizers containing micronutrients are increasingly found importan

t to boost yield, enhance the nutrients.

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The impact of low energy prices and increasing capacity

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Over the past decade we have seen many new urea projects being awarded, with the vast majority in China and US. Industry analysts foresee an increasing overcapacity, but how much capacity will effecti

vely hit the market?

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Presentation Gral+AN

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• Stamicarbon licensed nitric acid technologies • Between 50's-80's licensed >40 plants worlwide • 20 Stamicarbon HNO3 plants still in operation

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How rigorously plant modeling can advance your urea business

Registered users

The use of first-principles models to support process operations has been practiced in the chemical and petroleum industry for over 40 years; however their appearance in urea plants is very limited. A

ttempts making such urea models have been limited in scope and usage, due to the rapid rise in complexity, execution time, and difficulties encountered as model size increases to encompass sufficient fidelity and scope to address overall economic impact to  the business. Urea plant models however can encapsulate a large amount of process knowledge and companies start realizing significant value from the use of these models in offline and online model based applications. Such applications include real-time optimization, model predictive control, data reconciliation, virtual sensors, process performance monitoring and total plant monitoring systems to name a few. 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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How Industry 4.0 will Transform Urea Production and Engineering

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Driving the Digital Enterprise Industry 4.0 –The next Level of Manufacturing

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Changing farmer needs for fertilizer

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In several parts of the world the focus of farmers shifts from maximizing yield for example through increasing the application rate of fertilisers, to optimizing inputs. This shift requires adaptation

of the fertiliser product and/or the fertiliser application technology.

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An historic perspective on Stamicarbon

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Problem statement Solution directions Requirements for an OTS Stamicarbon's 40 year history and experience with OTS Cooperation OTS offerings.