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TM
Prem Baboo
National Fertilizers Ltd. India
Introduction
Back in the late sixties, the development of the Stamicarbon CO2 stripping process
revolutionized urea process technology. The introduction of Stamicarbon's Urea
2000plusTM in 1996, was yet another milestone. By combining equipment, our engineers
have been able to reduce the number of high pressure vessels in the process, thereby also
simplifying the overall design, piping and construction.
The result: a considerable lowering of investments and operating costs.The Pool
Condenser concept was the first step in the development of this technology. A second
step was the introduction of the Urea 2000plus TM Pool Reactor concept, which has been
built at DSM in Geleen, The Netherlands, with a capacity of 1150 mt/d.
Stamicarbon can offer this process in its pool condenser alternative in single train
capacities up to 3,250 mt/d. This capacity range again signifies an improvement over
today's plants, which have typically been designed for around 2000 mt/d.
Strip-gases are condensed in a pool of liquid on the shell side, with low
pressure steam being generated on the tube side.
Adequate residence time allows the reaction of ammonium carbamate to
urea and water to proceed to up to 60 % of equilibrium.
The condensation temperature on the shell side is high as a result of the
formation of high boiling components (urea and water), resulting in a
higher delta T for the exchanger part. The formation of gas bubbles
ensures a high degree of turbulence and provides a large area for mass
and heat transfer. Both phenomena contribute to a higher heat transfer.
Tube supports
Advantages
The pool condenser configuration offers the following technological
advantages:
The urea reactor volume is reduced by some 40 %.
The pool condenser requires some 45 % less heat exchange area.
The height of the steel structure is reduced by some 10 meter.
No stress corrosion can take place, because of the absence of crevices
between tube and tube sheet.
The operational flexibility has improved immensely.
The start-up of the synthesis section is very easy.
Operational Experience
The pool condenser is used in the urea plant of
Karnaphulli Fertilizers Company in Chittagong,
Bangladesh. The plant has a design capacity of
1725 mtpd and was constructed by Chiyoda of
Japan. It came on stream in December 1994. The
pool condenser concept was selected for this
plant because of its location in the vicinity of
Chittagong Airport. A low skyline of the plant
was a restricting requirement. The pool
condenser allowed the reactor to be made The 1725 mtpd KAFCO urea
considerably shorter because the compensating plant with the Pool Condenser,
reactor volume is available in the shell side of the in operation since December
1994.
horizontal
carbamate
condenser.
In the 4 years of operation this pool condenser
plant is performing on a higher than design load
in a very reliable way.
Introduction
Back in the late sixties, the development of the Stamicarbon CO2 stripping
process revolutionized urea process technology. The introduction of
Stamicarbon's Urea 2000plusTM in 1996, was yet another milestone. By
combining equipment, our engineers have been able to reduce the number of
high pressure vessels in the process, thereby also simplifying the overall
design, piping and construction. The result: a considerable lowering of
investments
and
operating
costs.
Stamicarbon can offer this process in single train capacities up to 3,500 mt/d.
This capacity range again signifies an improvement over today's plants, which
have
typically
been
designed
for
around
2000
mt/d.
The Pool Condenser concept was the first step in the development of this
technology.The second step was the introduction of the Urea 2000plus TM Pool
Reactor concept.
The innovative Pool Reactor at the DSM urea plant in The Netherlands
The stripper off-gases, the recycle carbamate solution and the ammonia
feedstock are introduced into the pool reactor. The liquid phase is thoroughly
agitated by the gases from the stripper. The heat of condensation is utilised for
aiding the dehydration reaction and for generating steam in the tube bundle.
The rate of condensation is controlled by the pressure of the generated steam.
The part of the pool reactor that is equipped with the tube bundle is the
condensing part of the reactor while the other section can be called the reaction
part.
Advantages
The pool reactor configuration offers the following technological advantages:
The amount of heat transferred through the condenser bundle in the
reactor is far better than in falling film condensers.
The baffles in the reactor prevent back-mixing, thus affording the nearest
approach to equilibrium in the urea reaction and, consequently the
highest conversion and most economical downstream equipment sizing.
The operational flexibility has improved immensely because the inverse
response of the synthesis loop has been eliminated and the synthesis is
far less sensitive to deviations in the N/C ratio.
The start-up of the synthesis section is very easy and progresses
smoothly.
Operational Experience
The first operational experiences with the pool
reactor at DSM have been magnificent. Right
from the initial start-up of the section it became
clear that the fundamental design aspects of the
reactor were correct. The plant produced its first
urea on March 18th, 1998 and apart from a few
teething troubles during the first week and a
leaking flange after two weeks of operation it
has been trouble-free since. After three months
of operation the plant was shut down for an
inspection. This inspection showed a perfect
vessel and no signs of any corrosion were
reported.
The new 1150 mt/d DSM urea
plant with the Pool Reactor,
started up in March 1998.
Unique features
The Stamicarbon Urea 2000plusTM technology
boasts several distinctive features:
low cost
low investment
low operating and maintenance costs
lowest raw material consumption
figures
very competitive energy consumption
figures
flexible
excellent performance
safe
meets the most stringent environmental
requirements
meets all quality standards
proven life times far over 20 years.