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In Urea plant passivation air is used in reactor, stripper and downstream of the all equipments. The reactor liner material used Titanium, Zirconium, SS 316L (urea grade), 2RE-69 and duplex material .except Titanium and Zirconium all stainless steel required more passivation air. In CO2 some quantity of Hydrogen is present about 0.14% to 0.2% . The passivation oxygen and Hydrogen makes explosive mixture. To avoid a fire or explosion in a process vessel is to introduce inert (noncombustible) gases in such a way that there is never a mixture with a combustible concentration in exit of MP vent. Mixtures of fuel, oxygen, and inert gases are not combustible over the entire range of composition. In CO2 stripping process the HP scrubber is the risky vessel and this vessel consisting blanketing sphere, Heat exchanger part and a scrubbing part. With help of triangular diagram that shows the shape of the combustible/noncombustible regions for a typical gaseous mixture of fuel, oxygen, and inert at specified temperature and pressure. Present article how to avoid that combustible rang and how to tackle that gases in CO2 & ammonia stripping process.

The explosion hazard in urea process (1)

The explosion hazard in urea process (1)

The explosion hazard in urea process (1)

Urea process flow diagram

Urea process flow diagram

Urea process flow diagram

Materialtechnologyforfertilizersindustries

Materialtechnologyforfertilizersindustries

Materialtechnologyforfertilizersindustries

Ever since the declaration of 100% neem coated urea by India Government, the number of neem trees is increasing continuously in India Neem coated urea requires neem oil, more urea more oil and trees also required more. When it comes to oil, neem plants are rather promising. Probably no other plant yields as many exploitable by-products and benefits. Earlier, 100% Neem Coated Urea was made mandatory in 2015.

Neemcoatedureaaphilosophyforenvironment

Neemcoatedureaaphilosophyforenvironment

Neemcoatedureaaphilosophyforenvironment

Prills /granular urea are not only costly for the producer but may be harmful to humans and the environment. Furthermore, nano Urea may also be used for enhancing abiotic stress tolerance. Nano-Urea prevents environmental pollution and improves physiological traits of wheat grown under drought stress conditions. The nano urea consist of higher surface area because lesser in size of the nano particle and have high reactivity, solubility in water. Nano Urea are the important tools in agriculture to improve crop efficiency, yield and quality parameters with increase nutrient use efficiency, reduce wastage of fertilizers and cost of cultivation. Nano-urea is very effective for precise nutrient management in precision agriculture with matching the crop growth stage for nutrient and may provide nutrient throughout the crop growth period. Nano-Urea increase crop growth up to optimum concentrations further increase in concentration may inhibit the crop growth due to the toxicity of nutrient. Nano-Urea provide more surface area for different metabolic reactions in the plant which increase rate of photosynthesis and produce more dry matter and yield of the crop. It is also prevent plant from different biotic and abiotic stress.

Nano ureathephilosophyoffuture

Nano ureathephilosophyoffuture

Nano ureathephilosophyoffuture

Installation of S-50 ammonia synthesis converter along with waste heat boiler in downstream of existing S-200 ammonia synthesis converter is one of the major schemes of Energy Saving Project of Ammonia plant. The energy saving reported 0.18 G.Cal/T of Ammonia. Several ammonia plants have installed an additional ammonia synthesis converter in combination with a HP steam waste heat boiler, downstream of the existing ammonia converter. The result is increased conversion per pass, reduced compression requirements due to the smaller recycle gas stream, and improved waste heat recovery. Among the methodologies aimed at finding energy saving opportunities, pinch analysis linked to power and steam modeling has proved to be a powerful way for determining projects to improve the overall energy efficiency of industrial sites. This procedure has been applied successfully in many industrial facilities, allowing optimal energy recovery in the process and hence reduction of fuel consumption.

Installation of s 50 in ammonia plants

Installation of s 50 in ammonia plants

Installation of s 50 in ammonia plants

In Urea Conversion gas/liquid mixing in urea reactor with application of high efficiency trays homogeneous and heterogeneous phases’ iquilibria and kinetics is very important. The efficiency of Urea Reactors can be improved by the application of the latest generation of internals .Generally Fluid dynamics phenomenon are created by the concurrent gas liquid flow through the simple perforated trays which generates irregular bubbles now this problem has been solved by new generation high efficiency device super cup patented by M/S. Saipem. Present article intended how conversion increases by super cup with geometry of the shape of super cup etc. The increase in the efficiency has permitted direct benefits to the overall production and energy of the units, thus allowing lower energy consumption and a reduced environmental impact emission of greenhouse gases. The Super Cups can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a revamp design.

Super conversion in urea reactors with super cup high efficiency trays

Super conversion in urea reactors with super cup high efficiency trays

Super conversion in urea reactors with super cup high efficiency trays

In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H2 is demineralized water and the hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section.

Ammonia plant material balance

Ammonia plant material balance

Ammonia plant material balance

Sswi april may-2021_lowres

Sswi april may-2021_lowres

Sswi april may-2021_lowres

The paper describes a successful of plant start-up despite the pandemic difficulties and introduces a set of first considerations about the possible future application of available digital technologies for remote and distributed control system from central control room commissioning of complex Dangote Fertilizer Plants. The numbers of problem were faced during commissioning stage ultimately the 17th march 2021 was the historical date for achieved plant production of line-1 plant .The major problem was pandemic due to which scarcity of staff availability. However numbers of problems faced in Ammonia and urea plants. About 4 time’s unsuccessful attempt were done and finally we got historical success. In this paper we described the failure attempt and types of problems faced in ammonia and urea plants and each time problems were differ from previous.

Sweet and sour experience of commissioning 1

Sweet and sour experience of commissioning 1

Sweet and sour experience of commissioning 1

This paper elaborates the most critical safety hazards: Ruptures and toxic ammonia leaks. The paper also provides the Top 10 prevention and mitigation measures. To minimize / avoid that incidents do repeat, we recommend to make use of the Center for Chemical Process Safety: Risk Based Process Safety Management approach. Pay proper attention to avoid ruptures, to handle leaks and to apply the right and state-of-the-art leak detection systems.

How to improve safety and reliability of the high pressure section of urea pl...

How to improve safety and reliability of the high pressure section of urea pl...

How to improve safety and reliability of the high pressure section of urea pl...

Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty 2 RE-69 materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study Material in urea plant in different vessels and equipment design. In Primary reformer numbers of materials are modified such as micro alloy are also used in tubes.

Experience of material in fertilizers industries

Experience of material in fertilizers industries

Experience of material in fertilizers industries

This book covers design of high Pressure equipment and developments, Process flow diagram of different section of Ammonia, Urea and others fertilizers .Fundamentals of ammonia urea plant trouble shooting risk assessment corrosion in different vessels and remedies. This book is useful for Engineers and Sr. Managers for plant commissioning and trouble shooting and Engineering Students. This book contains about 51 tables and 144 useful diagram and chart graphics etc. Detail description of ammonia/CO2 stripping process and new developments. Design Parameters of High pressure vessel and comparison. Study of corrosion for various equipments and control. How to control corrosion by changing of equipments material.

Fertilizers technology book

Fertilizers technology book

Fertilizers technology book

In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.

High pressure vessel_leakage_in_urea_plants (1)

High pressure vessel_leakage_in_urea_plants (1)

High pressure vessel_leakage_in_urea_plants (1)

In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.

High pressure vessel leakage in urea plants

High pressure vessel leakage in urea plants

High pressure vessel leakage in urea plants

Gas turbine

P & i diagram and tagging philosphy for

P & i diagram and tagging philosphy for

P & i diagram and tagging philosphy for

If the material of liner changed with 2RE 69 or Duplex material instead of SS316(urea grade), then passivation air can be reduced, resulting the energy saving because the inerts vented from M.P section and loss of ammonia and problem of pollution. To enhance capacity and energy of the existing plant the internals like vortex mixture and HET may be changed the capacity may increase up to 10-15%.HET, you can changed with super cup.The CO2 and feed top of the vortex mixture nozzle and Ammonia plus carbamate feed from side of the vortex mixture. In the mixing area the initial dispersion of gas and formation of liquid – gas mixture are performed.

Ureaplantenergysavingbyselectionoflinermaterialandinernals

Ureaplantenergysavingbyselectionoflinermaterialandinernals

Ureaplantenergysavingbyselectionoflinermaterialandinernals

5000 tpd urea mega plants design

5000 tpd urea mega plants design

5000 tpd urea mega plants design

Inst maint practices

Inst maint practices

Inst maint practices

More from Prem Baboo (20)

The explosion hazard in urea process (1)

The explosion hazard in urea process (1)

The explosion hazard in urea process (1)

Urea process flow diagram

Urea process flow diagram

Urea process flow diagram

Materialtechnologyforfertilizersindustries

Materialtechnologyforfertilizersindustries

Materialtechnologyforfertilizersindustries

Neemcoatedureaaphilosophyforenvironment

Neemcoatedureaaphilosophyforenvironment

Neemcoatedureaaphilosophyforenvironment

Nano ureathephilosophyoffuture

Nano ureathephilosophyoffuture

Nano ureathephilosophyoffuture

Installation of s 50 in ammonia plants

Installation of s 50 in ammonia plants

Installation of s 50 in ammonia plants

Super conversion in urea reactors with super cup high efficiency trays

Super conversion in urea reactors with super cup high efficiency trays

Super conversion in urea reactors with super cup high efficiency trays

Ammonia plant material balance

Ammonia plant material balance

Ammonia plant material balance

Sswi april may-2021_lowres

Sswi april may-2021_lowres

Sswi april may-2021_lowres

Sweet and sour experience of commissioning 1

Sweet and sour experience of commissioning 1

Sweet and sour experience of commissioning 1

How to improve safety and reliability of the high pressure section of urea pl...

How to improve safety and reliability of the high pressure section of urea pl...

How to improve safety and reliability of the high pressure section of urea pl...

Experience of material in fertilizers industries

Experience of material in fertilizers industries

Experience of material in fertilizers industries

Fertilizers technology book

Fertilizers technology book

Fertilizers technology book

High pressure vessel_leakage_in_urea_plants (1)

High pressure vessel_leakage_in_urea_plants (1)

High pressure vessel_leakage_in_urea_plants (1)

High pressure vessel leakage in urea plants

High pressure vessel leakage in urea plants

High pressure vessel leakage in urea plants

Gas turbine

P & i diagram and tagging philosphy for

P & i diagram and tagging philosphy for

P & i diagram and tagging philosphy for

Ureaplantenergysavingbyselectionoflinermaterialandinernals

Ureaplantenergysavingbyselectionoflinermaterialandinernals

Ureaplantenergysavingbyselectionoflinermaterialandinernals

5000 tpd urea mega plants design

5000 tpd urea mega plants design

5000 tpd urea mega plants design

Inst maint practices

Inst maint practices

Inst maint practices

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