STAMICARBON

LAUNCH MELTTM
FLASH DESIGN

Stamicarbon – Urea
Revamp Concepts

Leon Postma
Process Engineer R&D Department

March, 2017

The innovation & license

company of Maire Tecnimont
STAMICARBON - UREA REVAMP CONCEPTS

• Pool condenser / Pool reactor 140-200%

• Medium Pressure recirculation add-on 130-145%

• Double stripper 135-145%

• Adiabatic flash technology 115-130%

• More In More Out 110-125%

• Design plant capacity 100%

TYPICAL CO2 STRIPPING PROCESS

CW

CW

LP STEAM
LP STEAM

NH3

HP STEAM

CO2
 1. MORE IN MORE OUT

Use design margins

Bottlenecks to be considered:
• CO2 compression
• NH3 compression
• HP carbamate recycle
• Synthesis
• Urea finishing capacity
DECREASING INERT PRESSURE

• Purification of ammonia
• Purification of carbon dioxide
• Maximizing the high-pressure scrubber load
UREA CONVERSION UPGRADING

Siphon jet pump principle:

Reaction conversion improvement

Siphon jet pumps

7
Double stripper technology Saskferco
Double stripper technology Saskferco Canada

1992: Original 2000 mtpd

1997: After revamp design 2850 mtpd
Actual >3000 mtpd and > 1 mln tons yearly !

First application and a Success !

STAMICARBON MEGA UREA CONCEPT

Purpose:
• Revamping urea plant up to 145 %
• Decreasing the steam consumption by 50 to 100 kg per
ton of produced product
• Increased operational flexibility (turn-down ratio)
Synthesis condensation and stripping capacity

MEGA concept
Condensation

PRE-EVAPORATOR
ABSORBER
TCW REACTOR
Urea

TCW HPCC

SCRUBBER
CARBAMATE CARBAMATE
PUMP CONDENSER

CO2 EJECTOR
DISSOCIATER
MP COMPRESSOR CO2
NH3 STRIPPER STRIPPER
1+2

CO2 NH3 PUMP

RECIRCULATION
SECTION
Urea solution
CO2 COMPRESSOR
Concentration

February 27, 2017 Presentation no. 11

LAY OUT

OCI Urea plant at Geleen

LAY OUT

SKW Piesteritz Germany

MEGA CONCEPT APPLICATION

References:

• Urea plant at OCI Geleen in operation 2004

• SKW Piesteritz Germany in operation 2003
• PetroChina Daqing in operation 2005
• Yara Belle Plain Canada in operation 2009
• EFC1 and EFC2 Egypt in operation May 2012
 POOL CONDENSER POOL REACTOR

Replacing falling film type HPCC with

Pool Condenser / Pool Reactor

Synthesis:
• Increase condensation capacity
• Increase residence time

Revamp References:
• Qafco 2 Qatar
• Petrobras Brazil
2. ADIABATIC FLASH

CW

CW

LP STEAM
LP STEAM

NH3

HP STEAM

CO2

The innovation & license

company of Maire Tecnimont
LAUNCH MELTTM FLASH CONCEPT

CW
• Adiabatic Flash Vessel
• Pre-evaporator
• MP carbamate condenser

LP STEAM
LP STEAM

NH3

HP STEAM

CO2

The innovation & license

company of Maire Tecnimont
LAUNCH MELTTM FLASH CONCEPT

CW

Plop

LP STEAM
LP STEAM

Plop
NH3

HP STEAM

CO2

The innovation & license

company of Maire Tecnimont
 LAUNCH MELTTM FLASH CONCEPT: EQUIPMENT

+ ADIABATIC FLASH SEPARATOR

+ PRE-EVAPORATOR

+ MP CARBAMATE PUMP

- HP SCRUBBER

NH3
- HP EJECTOR

CO2

The innovation & license

company of Maire Tecnimont
 BENEFITS OF THE LAUNCH MELTTM FLASH CONCEPT

ADVANTAGES
• HP Steam consumption
reduced with some 150 kg/ton Urea
• No LP Steam export
• Stable operation
• Reduction of HP equipment
• Proven technology NH3

CO2

The innovation & license

company of Maire Tecnimont
LINGGU PROJECT

THE LINGGU PROJECT

• Capacity: 2700 MTPD
• Finishing: GGT-Granulation
• In operation since: summer 2015

Achieved results:
Capacity: > 100%
Steam Consumption: < 740 kg/ton

The innovation & license

company of Maire Tecnimont
XLX PROJECT

XinLianXin, PRC
NPC: 1300 MTPD
Running at: ~1500 MTPD

• CO2 Stripping plant

• Falling Film HPCC
• Prilling

• Adiabatic Flash introduced to

reduce steam consumption

• From plant assessment to

commissioning < 1 year

• Shut down < 2 wks

• Steam saving: ~ 150 kg/ton

The innovation & license

company of Maire Tecnimont
XLX PROJECT

The innovation & license

company of Maire Tecnimont
 Flash Tank
XLX PROJECT
Condenser

Pre-evap / MPCC

Pump vessel

The innovation & license

company of Maire Tecnimont
XLX PROJECT

Adiabatic Flash
Vessel

The innovation & license

company of Maire Tecnimont
THE FLASH TECHNOLOGY AS REVAMP TOOL

EXISTING PLANT
• HP scrubber end-of-life
• Reduction of OPEX

NH3

CO2

The innovation & license

company of Maire Tecnimont
EXPANDING FINISHING CAPACITY

Expanding melt capacity only makes sense when finishing

capacity is available

Limitation:
• Max capacity of the finishing section reached
• No capacity increase possible as per emission legislation

The innovation & license

company of Maire Tecnimont
 DRY FINISHING TECHNOLOGY

DRY FINISHING TECHNOLOGY

EXISTING EVAPORATION
PRILLING/GRANULATION

UREA
SOLUTION
TANK

CW

BAROMETRIC
CONDENSER
DRY
CW
FLASH
LP steam
VESSEL

Condensate

FINAL PRODUCT
COMPACTING SUPER
GRANULES
OR
BASIS FOR
ADBLUE

The innovation & license

company of Maire Tecnimont
PROCESS SIMULATOR
PROCESS SIMULATOR

User Interface DCS Screens

Process Studio Plant model

Stamicarbon Thermodynamics
PROCESS SIMULATOR EXAMPLE: ADIABATIC FLASH MODEL
PROCESS SIMULATOR EXAMPLE: ADIABATIC FLASH MODEL
PROCESS SIMULATOR EXAMPLE: ADIABATIC FLASH MODEL

Complimentary Urea Simulator Workshop:

• Thursday, 9:00 – 12:00

Program:
• Short introduction
• Plenty of room to experience the simulator by DIY
• Including a model with an Adiabatic Flash
AND FINALLY

THANK YOU FOR

YOUR
ATTENTION

The innovation & license

company of Maire Tecnimont