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Problem #1 :
Failures in Carbamate Condensers
E5A/B were frequent
Failure in top E5 was more compared to
the bottom one.
Contd…
Layout of E5 (Old)
Improvements in E5 contd…
Solution:
Top carbamate condenser was taken out of
service with no appreciable effect on
capacity.
Material of construction of bottom
carbamate condenser was changed from
SS316L UG to 25:22:2 Steel (2RE69)
Layout of E5 (Modified)
Improvements in E5 contd…
Problem #2 :
Higher temperature of Carbamate
solution to reactor
Shifting of vap. Load to MP section to a
large extent.
Analysis:
Bypassing of Partition plate
Contd…
Improvements in E5 contd…
Solution:
Welding of segments of partition
plate helped in avoiding bypass of
carbamate solution.
Result:
Let down of vapour from HP Loop to
MP Decomposer reduced.
Contd…
Improvements in E5 contd…
Bolted Segments
Improvements in
Titanium Strippers
Problem #1 :
Cracks were observed in nozzles of
two of the strippers necessitating repairs
Analysis:
These cracks were because of
frequent leakages in liquid inlet nozzle
of stripper
Contd…
Improvements in
Titanium Strippers contd…
Cracked
area
Improvements in
Titanium Strippers contd…
• Solution:
Extension of inlet nozzle by 1000mm.
Contd…
Improvements in
Titanium Strippers contd…
ORIGINAL MODIFIED
SPOOL PIECE
HV-3 HV-3
STRIPPER STRIPPER
REACTOR REACTOR
Improvements in
Titanium Strippers contd…
SACRIFICIAL SLEEVE
Stripper
Eroded
Sleeve
Sacrificial
Sleeve
Improvements in
Titanium Strippers contd…
Problem #2 :
Inadequate decomposition in stripper
Analysis:
Deterioration of performance due to
wearing away of top tube ends leading to
loss of falling film and consequent
shifting of decomposition load to MP
section.
Contd…
Improvements in
Titanium Strippers contd…
Solution:
Improved procedure for fixing of
ferrules during stripper overhaul.
This helped in saving 7 T/hr of
HP Steam per stripper.
Contd…
Improvements in
Titanium Strippers
MODIFIED FERRULE FIXING
FERRULE
TEFLON
TAPE ERRODED
TUBE END
17 mm
3 mm
5 mm
TUBESHEET TUBE
OTHER
IMPROVEMENTS
OTHER IMPROVEMENTS
Problem:
Cracks observed in Ammonia Receiver (V1)
Analysis:
Only local stress relieving of weld joints was
done during fabrication.
Solution:
Stress relieving of the complete tank was
carried out.
OTHER IMPROVEMENTS
Analysis:
It was observed that tubes were getting
severely fouled with rust and hard scale.
This was causing poor boil-off &
shifting of load to II Vac.Conc.(E15) Contd…
Improvement in 1st Vac
Conc (E14) contd…
Solution:
Special lance for hydro-jet cleaning was
developed for removing hard scale.
Fully blocked tubes in the centre portion
had to be drilled to remove hard scale
Procurement of spare heat exchanger
to reduce down time during
hydrojet cleaning.
OTHER IMPROVEMENTS
Contd…
Pinched Passage
Diaphragm
ORIGINAL MODIFIED
CO2 OUTLET CO2 OUTLET
OTHER IMPROVEMENTS
Contd…
Improving Efficiency of
Cooling Water Pumps
Before Corro-Coating
Improving Efficiency of
Cooling Water Pumps
After Corro-Coating
Efforts Towards
Steam Conservation
STEAM CONSERVATION
INSTALLATION OF PARALLEL
STEAM HEADER WITH CALCIUM
SILICATE INSULATION
MPD
Vac Sec
LS E-7
LPD
MV-52
E14
MS
MV-52
E1
E5
MV1
NH3 P-51
E5 P- 3
CO2
UREA OPTIMIZATION SCHEME
Advantages:
Steam saving of 120 kg/MT of Urea
Reduced load on M.P. condenser which is
the most critical exchanger.
Stable operation of plant at higher
loads upto 2000 MTPD.
Better utilisation of excess LP Steam
through MP pre-decomposer instead of
injection in turbine.
Installation of Parallel
HP Steam Header
STEAM DISTRIBUTION NETWORK
Existing Header
New Header
93 Kg/cm2 &
4890C
Installation of Parallel
HP Steam Header contd…
STEAM DISTRIBUTION NETWORK
Existing Header
New Header
New Header
98 Kg/cm2
& 4890C
Installation of Parallel
HP Steam Header contd…
Advantages:
HP steam consumption has reduced by 5 T/hr
HP steam pressure near the farthest compressor
has improved from 93 kg/cm2 to 98 kg/cm2
Thermodynamic efficiency of turbine has
improved.
IMPROVEMENTS IN
COOLING WATER
SYSTEM
Cooling Water System
Cooling water:
Recirculation rate : 28,000 M3/hr
Hold-up : 10,000 M3
Solution:
Identification of location of maximum
growth of bacteria and introduction of
chlorine at proper location
Improvement in efficiency of side-
stream filtration by using new properly
sized blower.
Contd…
Stabilisation of pH contd…
BIOLOGICAL
SLUDGE
Modified point of
MIDIFIED BLOW DOWN
CHLORINATION VALVES
Chlorination
POINTS FOR
TOTAL 10 CELL
Small Capacity Pump
Initial Scheme:
3 X 1.9 MW CW Pumps for a load of
4500 MTPD
Modified Scheme:
2 X 1.9 MW + 1 X 1.1 MW CW Pumps for
a load of 5400 MTPD
Savings: 600 KW of Power
Power Savings in CW Pumps
STEAM
HYDROLIZER
LS
Press. 23 kg/cm2
Temp. 2150C
REBOILER Resi. Time: 40 min
Hydroliser in Urea Plant
Press. 23 kg/cm2
Temp. 2150C
Vapour Outlet Resi. Time: 40 min
Liquid Outlet
Urea conc. in BFW
Amm. 2500ppm
CO2 800 ppm
Urea 8800 ppm
Temp 2150C
Residence time: 35 min
MV6 MV7
LW
P8 PT
ME 52
Crown washing of MV7
with Urea Melt
MV6 MV7
LW
P8
ME52 PT
PROCESS IMPROVEMENTS
Contd…
Performance improvement of
MP condenser contd…
Advantages:
Performance of condensation has improved
Ammonia reflux to MP absorber reduced
by 2 m3/hr.
Reduction of down time & consistent high
load operation
Contd…
Performance improvement of
MP condenser contd…
2,000,000 7.400
7.000
1,000,000 6.800
6.600
500,000
6.400
0 6.200
98-99 99-00 ^00-01 ^01-02 ^02-03 ^03-04
Year
Production
Sp. Energy Cons
RCF makes this possible
We thank SnamProgetti for giving
us an opportunity to present the
success story of RCF Urea Plant
to this august gathering.