SẢN XUẤT URÊ THEO CÔNG NGHỆ STRIPPING CO2

State-of-the-art urea production processes Stamicarbon technologies offer customers a variety of benefi ts, including: Excellent performance Unbeaten synthesis effi ciency with high conv

Transforming the urea process with continuous innovation

6.2 Synthesis 2: Urea 2000plus™ Pool Condenser Concept 16

1 About us

Stamicarbon is the global market leader in the

development and licensing of urea technology

and services Our solutions are the culmination

of generations of high-quality research and

in-depth knowledge of our customers’ processes,

requirements and operating practices Around

the world, over 230 urea plants have used, or are

currently using, our technology Our innovation

is continuous: working in close cooperation with

research institutes, suppliers to the urea business,

and our licensees, we are constantly developing

new technologies and upgrading our existing

technologies

Our expertise

Wherever our people are based, they can all

draw on Stamicarbon’s more than 60 years of

experience in the urea industry We also work with

a number of reputable engineering, procurement

and construction (EPC) contractors and suppliers

of specifi c products and critical equipment Together, this network offers the expertise that enables us to create the best solution for your business

What we do

Our services include:

Licensing and process design Plant improvement

Plant commissioning supportEquipment procurement servicesSupply of critical equipmentEngineering services Troubleshooting, both mechanical and operational

Equipment inspectionsTraining

Our market-leading urea licensing expertise

includes the following elements:

Providing technology licenses

for new urea plants

Traditionally, many urea plants are built under

LSTK (Lump Sum Turn Key) conditions In these

cases, Stamicarbon provides its urea license

through one of its licensed contractors, who has

been provided with the necessary process license

and know-how All our licensed contractors

are carefully selected to ensure they have the

capability and experience to implement large-scale

ammonia/urea projects Their names can be found

in the supplement at the back of this brochure

Recently, a number of different contract models

have become increasingly important in mitigating

project costs and risks As a result, Stamicarbon

has diversifi ed its urea licensing methods so we

can tailor our services to the needs of specifi c

projects

Process design package

Contractors or customers who obtain a license

to conduct the Stamicarbon urea process are

supplied with a comprehensive process design

package This generally includes:

Process description

Material balance, steam balance and cooling

water balance for different operating modes

- all with accompanying fl ow sheets

Our comprehensive process design package enables an experienced engineering contractor (who is ultimately appointed by the customer) to:Carry out the basic & detailed engineering (E)Procure equipment and materials (P)Construct the plant (C)

Thanks to the expertise and capabilities of our licensed contractors, customers’ projects will be executed both professionally and competitively

Project execution services

Stamicarbon can provide the following services at any point during project implementation - either directly to the customer or indirectly through a contractor:

Contractor guidance and controlAssistance in selection of equipment manu-facturers

Procurement and inspection servicesTraining of the customer’s technical staff in plant commissioning and operation, using state-of-the-art plant simulation and other training aids

to enable urea producers to cope with these changes Depending on customer requirements, Stamicarbon can develop a tailor-made solution based on proven technology and the best engineering practices We offer detailed plant-performance studies to our customers to determine revamp needs, plus a variety of revamp technologies and services to ensure that those needs are met In these sorts of revamp projects, Stamicarbon can license the technology and supply its services and expertise directly to the producer In turn, the producer can appoint the engineering contractor to perform any required engineering, procurement and construction

Replacement of high-pressure urea equipment

When the high-pressure equipment comes to the end of its life, there is a real opportunity to improve the effi ciency and capacity of a plant Stamicarbon can provide solutions that not only improve your high-pressure equipment, but also require only minimum changes and minimum downtime in your plant

Experience us for yourself

Stamicarbon is the global market leader in the development and licensing of urea products and technology We invite potential licensees to visit one of our plants so they can see for themselves how we boost operational fl exibility, reduce maintenance requirements and increase on-stream times After the visit, we will work closely with you

to assess your needs and develop a customized proposal for your urea plant

Commissioning services, up to and including completion of the performance test runSupply of critical equipment

Plant simulation and optimization

Technology exchange

In some cases, customers may require information

additional to that supplied in the process design

package To meet this need, we provide customers

with any additional information or expertise they

require, through training, know-how exchanges

and symposia, or other methods agreed with our

customers In cases where our customers need

something completely new, we will work jointly

with them to develop the required adjustment

Revamping existing urea plants

In a dynamic business environment, customers’

needs will shift due to changing market conditions

and governmental regulations Stamicarbon

has developed several safe, cost-effective

and environmentally friendly revamp schemes

•

•

•

3 A winning product from a winning player

With a market share of over 50%, Stamicarbon

is the world’s leading player in the fi eld of urea

licensing This position is the result of our:

Extensive experience

Stamicarbon has over 60 years’ experience

in licensing its urea technology In fact, we

have licensed over 230 new urea plants and

have completed over 85 revamp projects in

Stamicarbon and non-Stamicarbon plants

A complete list of references is available in our

Reference List brochure

Leading innovations

Stamicarbon has been at the forefront of urea

research and innovation for over half a century

As a result, we have been able to revolutionize the urea production process several times

Low costs

Our latest urea plants were designed by our task force of experienced engineers, contractors and material and equipment suppliers In creating a new plant design, the task force used the Urea 2000plus™ technology, Safurex® material,

fl uid-bed granulation technology, as well as their extensive experience, gained from completing many successful plant revamps As a result, plant investment costs were cut by a massive 17%

compared to plants using the old CO2 stripping process

Our competitive advantages include:

Low elevationLow investment, operating and maintenance costs, resulting in lower cost price of urea Competitive energy consumption fi gures*

Stochiometric raw-material consumption

fi gures*

Low emissions and effl uents

*The typical consumption fi gures can be found

in the supplement at the back of this brochure

State-of-the-art urea production processes

Stamicarbon technologies offer customers a variety of benefi ts, including:

Excellent performance

Unbeaten synthesis effi ciency with high conversion of ammonia and carbon dioxideLower temperatures and pressures required

in the urea production processHigh on-stream times (for both urea melt production and urea granulation)

All product quality standards metHigh utilization rates

Long turnaround intervals (3-4 years)Compliant with the most stringent environmental requirements

Simplicity and reliability

Minimum number of high-pressure equipment items and piping

The only process that requires only one single recirculation stage

Superior corrosion resistance of materials used

in plantsStable process and easy to operateUnbeaten lifetime of critical equipmentOption to have an intrinsically safe (zero oxygen) urea process

Flexibility

Single-train capacity allowing for up to

5000 mtpdMultiple synthesis choices: Avancore® or Urea 2000plus™ Pool Process both are available with

a pool condenser or a pool reactorMultiple fi nishing choices: Granulation, Prilling and Rotoform pastillation

Urea Ammonium Nitrate (UAN) and Ad-Blue/

SCR/automotive grade urea solution logies available as an integrated, cost-effi cient design

For Stamicarbon, sustainability is a precondition

of innovation and Safety, Health, and Environment (SHE) awareness is a key condition for sustainable licensing This focus ensures our technology is effi cient, environmentally friendly, reliable and above all, safe

at the back of this brochure

Global reach

With the experience of licensing urea plants in more than 80 countries, we have the tools to meet your requirements - wherever in the world you need us

At Stamicarbon, we recognize the power of

innovation That’s why the professionals in our

Technology Department are always on the

look-out for innovative ways to renew, improve and

add to the portfolio of products that we offer our

customers Every year, we spend about 6% of our

turnover on developing breakthrough innovations

Working together with R&D groups, universities,

customers and suppliers, our Technology

Department creates technologies that optimize

the urea production process

In the past 60 years, this has resulted in a number

of developments that have improved the urea

production process

These include:

Passivation of urea synthesis by air

CO2 stripping process25-22-2 materialN/C measurement systemNon-destructive testing techniquesOnline Leak Detection SystemWaste-water treatment sectionUAN Process

Urea 2000plus™ Pool Condenser ConceptSafurex® stainless-steel material (together with Sandvik)

Urea granulation technology (fl uidized bed type)Siphon jet pumps

Urea 2000plus™ Pool Reactor ConceptIntegrally geared CO2 compressorsMega Plant Concept

Rotoform pastillation technology (together with Sandvik)

Zero-emission technologyRADAR level measurement (together with Vega)Avancore® urea process (introduced in 2008)

5 Safurex ® stainless steel:

resistant to corrosion

Stamicarbon has a long and distinguished track

record in developing superior, cutting-edge urea

plant materials

X2CrNiMoN 25-22-2

With the introduction of the high-pressure stripper,

a new stainless steel was needed Together with

Sandvik, a Swedish stainless-steel supplier,

we developed the X2CrNiMoN 25-22-2 material

This widely used austenitic stainless steel allows

higher operating temperatures and is also more

resistant to condensation corrosion However,

it remains vulnerable to active corrosion when

used in an HP stripper and chloride stress

corrosion cracking when used in a high-pressure

carbamate condenser

Safurex ®

Despite the success of the 25-22-2 material,

Stamicarbon continued the search for ways of

developing even better materials The ultimate

breakthrough came in 1996 with the creation

of a special duplex steel called Safurex®, also

developed together with Sandvik Materials

Technology As this innovative material is highly

resistant to corrosion, it does not require the

addition of oxygen - enabling an intrinsically

safe plant design

Safurex® offers numerous signifi cant benefi ts, including:

Zero oxygen, making the plant intrinsically safe

Lower corrosion rates, leading to longer lifetimes

No active corrosion

No stress corrosion cracking

No condensation corrosion

No crevice corrosionBetter mechanical propertiesLower fatigue propertiesImproved weldabilities What’s more, Safurex® requires a lower investment than traditional materials and offers you a nearly maintenance-free urea plant with a signifi cant longer lifetime than any other commercially available urea process

At Stamicarbon, we are committed to the

continuous innovation and development of our

technologies so we can provide our customers with

the best urea production technology available

One acknowledged breakthrough was our

Urea 2000plus™ technology - a major improvement

on our well-known CO2 stripping process

Urea 2000plus™ is an innovative process that

reduces the plant height considerably and simplifi es

its overall design, piping and construction The

Urea 2000plus™ synthesis section incorporates

either a pressure pool reactor, or a

high-pressure pool condenser combined with a vertical

reactor

The following chart shows the development of the

Stamicarbon urea process over the last decades

and the consequences for the plant height

Our latest development is the Avancore® urea

process, which further enhances our proven

Urea 2000plus™ technology This process is

based on zero oxygen intake and is therefore

intrinsically safe In the plant height chart the Avancore® technology is shown in a confi guration for large capacities plants with a pool condenser and vertical high-pressure reactor

The Avancore ® urea process

It reduces the required plant height to just 25m

This obviously has brought down investment costs

considerably However the Avancore® process is

also available with a pool reactor for urea plants

up-to medium capacities

Customers can now choose among basic synthesis concepts that use either Avancore® or the Urea 2000plus™ technology

6.1 Synthesis 1: Avancore® Urea Process

section, hydrogen or any other combustibles present in the feed to the urea plant no longer pose any risk of explosion The ammonia emissions will also be kept to an absolute minimum thanks

to the absence of passivation air

Revamps

Experiences gained in revamp projects have also led to the incorporation of the following innovations into the Avancore® urea process:

Low elevation lay-out of the synthesis section

While the urea synthesis loop still relies on gravity fl ow, thus offering maximum reliability, the equipment elevation has been reduced, allowing for lower investment

Reduced-pressure inert washing system

The vapor leaving the urea synthesis section

is treated in a scrubber operating at a reduced pressure Most of the ammonia and carbon dioxide left after this scrubbing are absorbed in a carbamate solution coming from the downstream low pressure recirculation section As a result,

The Avancore® urea process is a new urea

synthesis concept that incorporates all the

benefi ts of Stamicarbon’s earlier proven

innovations The Avancore® urea process

combines the advantages of Urea 2000plus™

technology, Safurex® and innovations and

experiences gained from revamp projects

Urea 2000plus ™

The Urea 2000plus™ technology already provided

the technological advantage of improving heat

transfer in the condensing part of the urea

synthesis, achieved by the application of pool

condensation, and increasing the available

temperature difference over the condenser by

combining carbamate condensation and urea

reaction in one vessel

Safurex ®

The excellent corrosion-resistant properties

of the Safurex® material in an oxygen-free

carbamate environment, eliminates the need to

use the passivation air required in urea processes

Because of the absence of oxygen in the synthesis

no additional water needs to be recycled to the

synthesis section, meaning that the urea reaction

is therefore not affected

The Avancore® urea process works as follows:

Ammonia and carbon dioxide are introduced to

the high-pressure synthesis using a high-pressure

ammonia pump and a carbon-dioxide compressor

The ammonia, together with the carbamate

solution from the downstream recirculation section,

enters the pool condenser

The major part of the carbon dioxide enters the

synthesis through the high-pressure stripper

counter-current to the urea/carbamate solution

leaving the reactor On the shell side, the

high-pressure stripper is heated with steam The

off-gas of the high-pressure stripper, containing

the carbon dioxide, together with the ammonia

and carbon dioxide resulting from dissociated

carbamate, is fed into the pool condenser

The minor part of the carbon dioxide entering the

synthesis as a feed enters the urea reactor at the

bottom in order to produce suffi cient heat for the

endothermic urea reaction

In the pool condenser, ammonia and carbon

dioxide are condensed to form carbamate and

a substantial part of the conversion to urea is already established here The heat released

by condensation and subsequent formation

of carbamate is used to produce re-usable low-pressure steam

Downstream from the pool condenser, the urea-carbamate liquid enters the vertical reactor,

if required, located at ground level Here, the fi nal part of the urea conversion takes place The urea solution then leaves the top of the reactor, all by gravity fl ow (via an overfl ow funnel) before being introduced into the high-pressure stripper Gases leaving the urea reactor are directed to the pool condenser

Gases leaving the pool condenser are fed into the scrubber operating at a reduced pressure Here, the gases are washed with the carbamate solution from the low-pressure recirculation stage The enriched carbamate solution is then fed into the pool condenser This enriched carbamate fl ow contains no more water than in earlier generations

of Stamicarbon CO2-stripping plants, meaning that the conversions in the synthesis section are

as high as ever Inert gases leaving the scrubber

at reduced pressure containing some ammonia and carbon dioxide are then released into the atmosphere after treatment in a 4-bar absorber

6.2 Synthesis 2: Urea 2000plus™ Pool Condenser Concept

The Urea 2000plus™ Pool Condenser process

works as follows:

Ammonia and carbon dioxide are introduced

to the high-pressure synthesis using a

high-pressure ammonia pump and a carbon

dioxide compressor The ammonia then drives

an ejector, which conveys a carbamate solution

into the pool condenser The carbon dioxide feed

usually originates from an associated ammonia

plant, and therefore always contains hydrogen

This hydrogen is removed by catalytic combustion

that uses air Air also used to be supplied as a

passivating agent to minimize corrosion in the

synthesis When using Safurex® material, this is in

essence no longer necessary

In the high-pressure stripper, the carbon dioxide, entering the synthesis as a feed, fl ows counter-current to the urea solution leaving the reactor

On the shell side, the high-pressure stripper is heated with steam The off-gas of the high-pressure stripper, containing the carbon dioxide, together with the dissociated carbamate,

is then fed into the pool condenser

In the pool condenser, ammonia and carbon dioxide are condensed to form carbamate, and

a substantial part of the conversion to urea is already established here The heat released

by condensation and subsequent formation

of carbamate is used to produce re-usable low-pressure steam

6.2 Synthesis 2: Urea 2000plus™ Pool Condenser Concept

After the pool condenser, the remaining gases and

a urea-carbamate liquid enter the vertical reactor

Here, the fi nal part of the urea conversion takes

place The urea solution then leaves the top of

the reactor (via an overfl ow funnel) before being

introduced into the high-pressure stripper

Ammonia and carbon dioxide conversions in

the synthesis section of a Stamicarbon carbon

dioxide stripping plant are high, reducing the

need for a medium pressure stage to recycle

any unconverted ammonia and carbon dioxide

As a result, the Stamicarbon CO2 stripping process

is the only commercial available process that

does not require a medium-pressure recirculation

stage downstream from the HP stripper

Gases leaving the reactor are fed into the

high-pressure scrubber Here, the gases are

washed with the carbamate solution from the

low-pressure recirculation stage The enriched

carbamate solution is then fed into the

high-pressure ejector and, subsequently, to

the pool condenser Inert gases and some

ammonia and carbon dioxide are then released

into the 4-bar absorber

6.3 Synthesis 3: Urea 2000plus™ Pool Reactor Concept

The high-pressure scrubbing operation can also be simplifi ed in the Pool Reactor concept by placing the scrubber sphere above the pool reactor and adding the ammonia to the synthesis via this scrubber This ensures that no separate heat-exchanging section in this scrubbing operation

is required

In the Pool Reactor concept, carbamate from the low-pressure recirculation section fl ows together with the absorbed gases and the ammonia via a sparger into the pool reactor As the static liquid height ensures gravity fl ow, no high-pressure ejector is needed

The Urea 2000plus™ Pool Reactor process works

as follows:

Unlike the Pool Condenser concept, the Pool

Reactor concept combines the condenser

and reactor within a single pool reactor This is

achieved by enlarging the horizontal condenser so

as to incorporate additional reactor volume As a

result, it becomes possible to achieve suffi ciently

high residence times, eliminating the need for

a separate vertical reactor, while creating the

conditions that will allow the reaction to reach its

optimum condition