The document discusses operation and troubleshooting in the low pressure (LP) and vacuum sections of a urea plant. It describes the key equipment in these sections, including the LP decomposer, LP condenser, carbonate solution accumulator, and LP inerts washing tower. It explains their functions, operating parameters, and how water balance must be carefully controlled. The document also discusses sources of corrosion in the LP and vacuum sections, particularly in the second stage of vacuum, and outlines some root causes and mitigation strategies. Maintaining proper pressures, temperatures, and concentrations throughout the process is important to minimize corrosion and ensure stable operations.
OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdfPremBaboo4
In M/S. Saipem process the HP loop operation is very typical including HP stripper and Reactor N/C ratio, H/C ratio and conversion of the reactor. The MP loop also very typical in operation point of view in which the level of Medium pressure absorber is fluctuating frequently when plant starts up /shut down or any process disturbances/upset. This article intended how to tackle theses type of problem and the MP absorber level and why the level is so important? Why density variation in startup/shut down or any upset of the process by any reason. Why the level transmitter of MP absorber is showing erratic level? How to prevent CO2 Carryover to ammonia receiver through ammonia condenser. Can we replace the DP type transmitter with radar type in stripper as well as MP absorber?
OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdfPremBaboo4
In M/S. Saipem process the HP loop operation is very typical including HP stripper and Reactor N/C ratio, H/C ratio and conversion of the reactor. The MP loop also very typical in operation point of view in which the level of Medium pressure absorber is fluctuating frequently when plant starts up /shut down or any process disturbances/upset. This article intended how to tackle theses type of problem and the MP absorber level and why the level is so important? Why density variation in startup/shut down or any upset of the process by any reason. Why the level transmitter of MP absorber is showing erratic level? How to prevent CO2 Carryover to ammonia receiver through ammonia condenser. Can we replace the DP type transmitter with radar type in stripper as well as MP absorber?
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.
Some Facts about Urea Stripper By Prem Baboo.pdfPremBaboo4
If we talk about the costly and biggest heat exchanger in urea plants, then the name of the stripper comes first. Nowadays the competition of stripper is running for more and more capacity. In this regards some urea plant licensers have gone ahead some are left behind some are very much behind and some are dragging. Urea stripper is a vertical in tube falling film decomposer in which the liquid, distributed on the heating surface as a film, flows by gravity to the bottom. The Urea stripper is the heart of urea plants.
A case study on Process Condensate Stripper in Ammonia Plant by Prem Baboo.pdfPremBaboo4
A trouble shooting case study in Fertilizers unit, India.Solving the problem of Feed/Effluent Exchanger E-3321A/B in Process Condensate stripping section of Ammonia plant by Analytical approach. The problem solved by in house experts without changing the heat exchangers while others plant change the heat exchangers. Number of modification done and huge amount of energy saved. The paper intended how to save energy by changing heat exchanger and pressure of PC Stripper. The treated process condensate was earlier cooled by CW in final cooler from about 90ºC to 40ºC. This available heat of PC is being recovered by exchanging heat with DM water in a plate heat exchanger. The pressure of PC stripper has been raised to about 1.5 kg/cm²g to make the extra heat recovery possible. Now pressure is 41.5 kg/cm2. A new Plate heat exchanger was procured & installed for the heat recovery.
Super conversion in urea reactors with super cup high efficiency traysPrem Baboo
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.
WASTEWATER TREATMENT TECHNOLOGIES FOR THE REMOVAL OF NITROGEN & PHOSPHORUS Rabia Aziz
more chemistry contents are available
1. pdf file on Termmate: https://www.termmate.com/rabia.aziz
2. YouTube: https://www.youtube.com/channel/UCKxWnNdskGHnZFS0h1QRTEA
3. Facebook: https://web.facebook.com/Chemist.Rabia.Aziz/
4. Blogger: https://chemistry-academy.blogspot.com/
environmental chemistry
OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdfPremBaboo4
In M/S. Saipem process the HP loop operation is very typical including HP stripper and Reactor N/C ratio, H/C ratio and conversion of the reactor. The MP loop also very typical in operation point of view in which the level of Medium pressure absorber is fluctuating frequently when plant starts up /shut down or any process disturbances/upset. This article intended how to tackle theses type of problem and the MP absorber level and why the level is so important? Why density variation in startup/shut down or any upset of the process by any reason. Why the level transmitter of MP absorber is showing erratic level? How to prevent CO2 Carryover to ammonia receiver through ammonia condenser. Can we replace the DP type transmitter with radar type in stripper as well as MP absorber?
OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdfPremBaboo4
In M/S. Saipem process the HP loop operation is very typical including HP stripper and Reactor N/C ratio, H/C ratio and conversion of the reactor. The MP loop also very typical in operation point of view in which the level of Medium pressure absorber is fluctuating frequently when plant starts up /shut down or any process disturbances/upset. This article intended how to tackle theses type of problem and the MP absorber level and why the level is so important? Why density variation in startup/shut down or any upset of the process by any reason. Why the level transmitter of MP absorber is showing erratic level? How to prevent CO2 Carryover to ammonia receiver through ammonia condenser. Can we replace the DP type transmitter with radar type in stripper as well as MP absorber?
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.
Some Facts about Urea Stripper By Prem Baboo.pdfPremBaboo4
If we talk about the costly and biggest heat exchanger in urea plants, then the name of the stripper comes first. Nowadays the competition of stripper is running for more and more capacity. In this regards some urea plant licensers have gone ahead some are left behind some are very much behind and some are dragging. Urea stripper is a vertical in tube falling film decomposer in which the liquid, distributed on the heating surface as a film, flows by gravity to the bottom. The Urea stripper is the heart of urea plants.
A case study on Process Condensate Stripper in Ammonia Plant by Prem Baboo.pdfPremBaboo4
A trouble shooting case study in Fertilizers unit, India.Solving the problem of Feed/Effluent Exchanger E-3321A/B in Process Condensate stripping section of Ammonia plant by Analytical approach. The problem solved by in house experts without changing the heat exchangers while others plant change the heat exchangers. Number of modification done and huge amount of energy saved. The paper intended how to save energy by changing heat exchanger and pressure of PC Stripper. The treated process condensate was earlier cooled by CW in final cooler from about 90ºC to 40ºC. This available heat of PC is being recovered by exchanging heat with DM water in a plate heat exchanger. The pressure of PC stripper has been raised to about 1.5 kg/cm²g to make the extra heat recovery possible. Now pressure is 41.5 kg/cm2. A new Plate heat exchanger was procured & installed for the heat recovery.
Super conversion in urea reactors with super cup high efficiency traysPrem Baboo
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.
WASTEWATER TREATMENT TECHNOLOGIES FOR THE REMOVAL OF NITROGEN & PHOSPHORUS Rabia Aziz
more chemistry contents are available
1. pdf file on Termmate: https://www.termmate.com/rabia.aziz
2. YouTube: https://www.youtube.com/channel/UCKxWnNdskGHnZFS0h1QRTEA
3. Facebook: https://web.facebook.com/Chemist.Rabia.Aziz/
4. Blogger: https://chemistry-academy.blogspot.com/
environmental chemistry
High pressure vessel leakage in urea plantsPrem Baboo
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)Prem Baboo
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.
The explosion hazard in urea process (1)Prem Baboo
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.
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.
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.
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.
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
Some fact about Ammonia Production by Prem Baboo.pdfPremBaboo4
Operation of the plant is mainly supervised by the operators in the control room, who monitor the various instruments and adjust operating conditions in order to obtain satisfactory operation. They should also react when an alarm is activated. In some cases they can re-establish normal conditions by adjusting the controls in the control room; in other cases they give instructions to a field operator to make the necessary adjustments at various locations in the plant. Field operators work in regular shifts in the plant, especially in the reforming section, in order to supervise the firing of the reformer and the temperature of the tubes in the reformer, to record local instrument readings, and to notice any irregularities such as leaks. Every change of temperature of the reformer a little change can bring big change resulting energy losses, e.g. temperature of the primary reformer and CO slip losses in methanation etc.
Question Answer on Fertilizers Industries.pdfPremBaboo4
There are numbers of Fertilizers are used for improve productivity of grain, N; P &K are important fertilizers among them. Commercially Urea is more produced because the Nitrogen percentage is higher than all fertilizers. These three NPK are primary nutrient. There are some question arises about these industries, present paper intended to attempt the answer those questions. These question are very useful in interview point of view and also for new comers joining in Fertilizers Industries.
How to control prilling tower dust emissionPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
HOW TO CONTROL PRILLING TOWER DUST EMISSION.pdfPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling
routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission
control system in prilling tower is a considerable burden. It not only presents a substantial investment
but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of
strong demand for environment friendliness and effective use of power it is then an issue of utmost
importance to pick the legally emission control solution, the one that can guarantee, if not a full
return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea
dust and ammonia, wet processes are generally applied. The available technologies vary with regard to
the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is
directly proportional to temperature. Dust emission can control by internal and external process. In
India generally followed internal routs. The pollution control Board sample should be ok just thinking
so. Either reduction of plant load or bypassing the recovery system at the time of sampling or
manipulating data. It is the bitter truth. In reality dust emission control system should be installed in
prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all
urea plants. Number of Revamp Companies are available in market.
NPK Bio-fertilizer Production from Banana Peel.pdfPremBaboo4
The possibility of formulating nitrogen, phosphorus and potassium (NPK) biofertilizer from ashes of waste organic
materials such as chicken feathers, bone and banana peels is investigated in this study by first subjecting the agricultural
waste to 80-250℃ heat in a muffle furnace to produce ash. Kjeldatherm block digestion unit, UV spectrophotometer,
and flame photometers, respectively helped in measuring the concentrations of N, P and K inherent in the fertilizer
precursors as well as in 5 formulated blends (i.e., A, B, C, D & E). It was discovered that NPK in the single substrate
and blends favorably compared with standard NPK 20:10:10 chemical fertilizer to some extent. Among single material
fertilizer sources, feather ash with 0.179:1:0.134 NPK and bone ash with 0.009:1:0.021 NPK had the closest nutrient
content with the standard, showing potential promise. On the other hand, Blend E is the same as the standard, followed
by Blend A, B, D and C, which are hierarchically close in elemental composition to the standard. The choice of these
biofertilizers is dependent on their nutrient compositions, the type of crops to be grown, and the soil mineral
requirements. Most importantly, different NPK ratio organic fertilizers produced in this study can competitively be
produced in a large scale to address huge costs associated with the NPK 20:10:10 standard commercial fertilizer. Blend
E (NPK 20:10:10) can be formulated locally by farmers in rural areas easily using this particular agricultural residue or
a host of other confirmed farm wastes.
Biological Waste water Treatment Fundamentals and Recent developmentin Nutrie...PremBaboo4
A type of treatment that uses substances made from living organisms to treat waste and waste water. These substances may occur naturally in the body or may be made in the laboratory. Biological treatment is the sustainable treatment of waste. Biological treatment is an attractive and useful technology that results in the complete conversion of organic compounds into less harmful end products such as CO2 and H2O. It is considered low-cost and environmentally friendly compared to physical or chemical methods for removing contaminants without any harmful chemicals. The biological waste management technologies include composting, incineration, landfill, anaerobic digestion, and bioconversion to produce biofuels, i.e., bioethanol, biodiesel, biogas, methane production etc.
More Related Content
Similar to OPERATION AND TROUBLE SHOOTING IN LP AND VACUUM SECTION FOR MS SAIPEM PROCESS (1).pdf
High pressure vessel leakage in urea plantsPrem Baboo
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)Prem Baboo
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.
The explosion hazard in urea process (1)Prem Baboo
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.
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.
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.
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.
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
Some fact about Ammonia Production by Prem Baboo.pdfPremBaboo4
Operation of the plant is mainly supervised by the operators in the control room, who monitor the various instruments and adjust operating conditions in order to obtain satisfactory operation. They should also react when an alarm is activated. In some cases they can re-establish normal conditions by adjusting the controls in the control room; in other cases they give instructions to a field operator to make the necessary adjustments at various locations in the plant. Field operators work in regular shifts in the plant, especially in the reforming section, in order to supervise the firing of the reformer and the temperature of the tubes in the reformer, to record local instrument readings, and to notice any irregularities such as leaks. Every change of temperature of the reformer a little change can bring big change resulting energy losses, e.g. temperature of the primary reformer and CO slip losses in methanation etc.
Question Answer on Fertilizers Industries.pdfPremBaboo4
There are numbers of Fertilizers are used for improve productivity of grain, N; P &K are important fertilizers among them. Commercially Urea is more produced because the Nitrogen percentage is higher than all fertilizers. These three NPK are primary nutrient. There are some question arises about these industries, present paper intended to attempt the answer those questions. These question are very useful in interview point of view and also for new comers joining in Fertilizers Industries.
How to control prilling tower dust emissionPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
HOW TO CONTROL PRILLING TOWER DUST EMISSION.pdfPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling
routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission
control system in prilling tower is a considerable burden. It not only presents a substantial investment
but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of
strong demand for environment friendliness and effective use of power it is then an issue of utmost
importance to pick the legally emission control solution, the one that can guarantee, if not a full
return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea
dust and ammonia, wet processes are generally applied. The available technologies vary with regard to
the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is
directly proportional to temperature. Dust emission can control by internal and external process. In
India generally followed internal routs. The pollution control Board sample should be ok just thinking
so. Either reduction of plant load or bypassing the recovery system at the time of sampling or
manipulating data. It is the bitter truth. In reality dust emission control system should be installed in
prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all
urea plants. Number of Revamp Companies are available in market.
Similar to OPERATION AND TROUBLE SHOOTING IN LP AND VACUUM SECTION FOR MS SAIPEM PROCESS (1).pdf (20)
NPK Bio-fertilizer Production from Banana Peel.pdfPremBaboo4
The possibility of formulating nitrogen, phosphorus and potassium (NPK) biofertilizer from ashes of waste organic
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and flame photometers, respectively helped in measuring the concentrations of N, P and K inherent in the fertilizer
precursors as well as in 5 formulated blends (i.e., A, B, C, D & E). It was discovered that NPK in the single substrate
and blends favorably compared with standard NPK 20:10:10 chemical fertilizer to some extent. Among single material
fertilizer sources, feather ash with 0.179:1:0.134 NPK and bone ash with 0.009:1:0.021 NPK had the closest nutrient
content with the standard, showing potential promise. On the other hand, Blend E is the same as the standard, followed
by Blend A, B, D and C, which are hierarchically close in elemental composition to the standard. The choice of these
biofertilizers is dependent on their nutrient compositions, the type of crops to be grown, and the soil mineral
requirements. Most importantly, different NPK ratio organic fertilizers produced in this study can competitively be
produced in a large scale to address huge costs associated with the NPK 20:10:10 standard commercial fertilizer. Blend
E (NPK 20:10:10) can be formulated locally by farmers in rural areas easily using this particular agricultural residue or
a host of other confirmed farm wastes.
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A type of treatment that uses substances made from living organisms to treat waste and waste water. These substances may occur naturally in the body or may be made in the laboratory. Biological treatment is the sustainable treatment of waste. Biological treatment is an attractive and useful technology that results in the complete conversion of organic compounds into less harmful end products such as CO2 and H2O. It is considered low-cost and environmentally friendly compared to physical or chemical methods for removing contaminants without any harmful chemicals. The biological waste management technologies include composting, incineration, landfill, anaerobic digestion, and bioconversion to produce biofuels, i.e., bioethanol, biodiesel, biogas, methane production etc.
NOx SOx CO2 and Urea Dust Control inFertilizers Plants.pdfPremBaboo4
NOx, SOx & CO2 emission are the serious problem in any fertilizers plant. The urea production and use of nitrogen fertilizers lead to the release of SOx, CO2, N2O and CH4, which are among the most important global GHGs. The synthesis of ammonia, from which all synthetic fertilizers are produced, accounts alone for about 0.8% of the global GHG emissions and 2% of global energy. CO2 emission factor from urea is 0.2 kg Carbon per kg urea, which is equivalent to the mass percent of Carbon in urea. Urea dust control system should be there in every plant. The pollution point of view urea dust is very harmful to buildings and humans. If you install CO2 recovery system, then you can also control SOx and NOx. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
Environmental protection is the practice of protecting the individuals, organizations and governments. Wastewaters from chemical fertilizer industry mainly contain organics, alcohols, ammonia, nitrates, phosphorous, heavy metals such as cadmium and suspended solids. The nature of effluent streams varies in terms of its constituents and complexity. This paper intends to elaborate the standpoint views of the production technology and environment management of harmful emissions. Typical nitrogen based fertilizer plants producing ammonia and urea using the advanced available technologies as in the Dangote fertilizer plant. The study centers on the development of a multi-treatment advanced biological system which comprises enzymatic hydrolysis and biological nitrification to produce effluent suitable for discharge to the Atlantic Ocean. A wide variety of methods and online analysers are installed for monitoring emission, assure advanced and high level of protection & method adopted to reduce the emission and control pollution
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In any centrifugal compressor the Antisurge protection in action interlock is given for compressor safety. This logic is very typical and related to much input. Each input is very important for compressor life and internals. This paper intended how to work this logic. This paper explains surge protection in action phenomena and explains why the anti-surge protection system is a very important part of a compressor? The multi stage compressor has many stages for developing pressure and high rpm which is generated with steam turbine. Numbers of companies are available for controlling surging of compressor like CCC (Compressor Controls Corporation), USA. Woodward and Yokogawa, Turbo machinery control system etc. are provider solutions for compressor flow control device with software and hardware.
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Catalyst is the heart of ammonia plants. A catalyst accelerates reaction by providing alternate paths to products, the activation energy of each catalytic step being less than that of no catalytic reaction, in the reaction cycle, active centers of catalysis first combine with at least one reactant and then is reproduced with the appearance of product. Equilibrium conversion not altered by catalysts. The catalyst can radically alter selectivity. In chemical industry, catalysts are used in order to bring some chosen reaction as close as possible to a selected equilibrium point in the shortest possible time. The rate of reaction is influenced by a substance that remains chemically unaffected.
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Question Answer on Energy Conservation Vol 2 by Prem Baboo.pdfPremBaboo4
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Dear friends today we will discuss on urea product quality. What are the factors on which urea product quality depends? How to improve urea product quality. Urea produced by prilling and granulation rout. In India Prilling is very popular and other countries Granulation rout is adopted. There are some merits and demerits are prilling and granulation routs. Different types of question with their answers
Question & Answer on Fertilizers Industries Vol 2.pdfPremBaboo4
After the success of Vol-1, now here is Vol-2, Vol-1 is very much liked by people. There was a time when people did not share their knowledge in public and his knowledge used to be buried with him but he did not tell anything throughout his life. But I want to share my rich experience with people before dying. The practical knowledge is an important part of life, which is not found in books, this volume contains unprecedented experience of my chemical & fertilizers industries experience. This volume contains Urea HP/MP/LP/Vacuum and waste water questions & answer with trouble shooting.
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In Urea Process corrosion/Erosion also observed in LP and vacuum section. The paper indeed how to tackle this type of problem? Root cause of corrosion in LP & vacuum section. Construction of material used in these sections. Operation of LP section with trouble shooting How to balance water in the process, Distillation Tower Versus LP carbonate solution tank with operation of LP decomposer. Water balance in whole plant prilling rout as well as granulation rout. How a small variation of Pressure & temperature makes a drastic change in the process including waste water section? How Distillation tower feed related to LP decomposer pressure & temperature? The detail described in this article. The intensity of corrosion is greatest in the reaction section and the first recycle, where pressures, temperatures and concentrations are higher than downstream. The reactor liner, pumps, decomposers, strippers and condensers are more vulnerable to attack by ammonium carbamate. But the corrosion is also important in LP and vacuum sections. The typical corrosion is observed in 2nd stage of vacuum in some plants of urea.
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In Fertilizers industries the material plays a
very important role. Right material can save
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selection of material may lead to
catastrophic failures and outage of plants &
even loss of Human lives, Right selection of
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plant very corrosive chemicals are used for
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which makes very corrosive chemical
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well as stripper according to material of
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explosion probability in urea reactor because
it affects the amount of produced urea and
corrosion to the material in the reactor.
Generally we are using urea reactor liner
316L (urea grade), now adopted 2RE69 for
large capacity plant (world largest) and
Duplex stainless steel.
RISK MANAGEMENT IN AMMONIA UREA PLANTS.pdfPremBaboo4
Risk Management is the Identification, Analysis
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Earning Capacity of an Enterprise” Risk
management is the process of identifying,
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organization's capital and earnings. These risks
stem from a variety of sources including
financial uncertainties, legal liabilities,
technology issues, strategic management errors,
accidents and natural disasters. The article
intended The Fertilizer Plant pose fire, explosion
and toxic hazards due to unwanted and
accidental release of natural gas as well as
process gas containing CO, H2, Methane and
toxic gases like Ammonia and Chlorine. The
effect zones of the fire and explosion hazard are
generally restricted within the plant boundary
limits and near the source of generation itself.
However, effect of accidental release of
Ammonia and other toxic gases may go outside
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In Ammonia plant numbers unwanted products are formed such as CO2 & methanol, Methanol is the by-product and it is very dangerous for environment and cations and anion resin also, which is used treated waste water through urea plant. Methanol is also dangerous for Ozone layers.CO2 is also by-product in ammonia process but it is used for production of urea. The paper intended how it is generate in ammonia plant as a by-product.how to control and minimized. How does this damage the environment? It is desirable to minimize methanol by-product formention for several reasons: Methanol emissions are being regulated to protect the environment. Several ammonia plants are already facing regulations that limit methanol emissions to the atmosphere. These regulations affect plants that vent the CO2 stream as well as plants that are not designed to recover methanol from the various vents. The methanol recovers from CO2 compressor separators are using in anaerobic water treatment plant as bacteria feed.
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DESIGN AND ANALYSIS OF A CAR SHOWROOM USING E TABS
OPERATION AND TROUBLE SHOOTING IN LP AND VACUUM SECTION FOR MS SAIPEM PROCESS (1).pdf
1. See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/362034614
Operation and Trouble shooting in LP & Vacuum Section for M/S. Saipem Process
Presentation · July 2022
DOI: 10.13140/RG.2.2.33716.32641
CITATIONS
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1 author:
Some of the authors of this publication are also working on these related projects:
Silo (UREA) level measurement View project
Comparison Stamicarbon Saipem View project
Prem Baboo
The Institution of Engineers (India)
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2. www.researchgate.net
16th
July. 2022
Research Gate is an academic social networking site
This is an open access article, Research Gate is a European commercial social networking site for scientists and researchers
Operation and Trouble shooting in LP & Vacuum Section
for M/S. Saipem Process
By
Prem Baboo
Retired from National fertilizers Ltd. India
&
Dangote Fertilizers Ltd. Nigeria
Abstract
In Urea Process corrosion/Erosion also
observed in LP and vacuum section. The
paper indeed how to tackle this type of
problem? Root cause of corrosion in LP &
vacuum section. Construction of material
used in these sections. Operation of LP
section with trouble shooting How to
balance water in the process, Distillation
Tower Versus LP carbonate solution tank
with operation of LP decomposer. Water
balance in whole plant prilling rout as well
as granulation rout. How a small variation of
Pressure & temperature makes a drastic
change in the process including waste water
section? How Distillation tower feed related
to LP decomposer pressure & temperature?
The detail described in this article. The
intensity of corrosion is greatest in the
reaction section and the first recycle, where
pressures, temperatures and concentrations
are higher than downstream. The reactor
liner, pumps, decomposers, strippers and
condensers are more vulnerable to attack by
ammonium carbamate. But the corrosion is
also important in LP and vacuum sections.
The typical corrosion is observed in 2nd
stage of vacuum in some plants of urea.
Key words
Corrosion, erosion, water balance, trouble
shooting, vacuum section, Saipem,
Equilibrium. waste water.
Introduction
In M/S. Saipem Urea process the LP
decomposer is very important because the
water balances is related to either LP
carbonate solution or Distillation Tower
feed. In startup/shut down or any upset
condition of the process the 2nd
stage
vacuum section observed corrosion and
reduction of the vessel thickness. The sight
glasses are also given in the vessel for
seeing actual level in the field. The M/S.
Saipem process is the popular world famous
process and known as ammonia stripping
process. In capacity wise then there is no
comparison from other process. The HP loop
also very important for reactor and stripper
any variation in N/C & H/C ratio can cause
disturbances in downstream especially
vacuum section. Now 5000TPD plant is
ready and number of plants more than
4000TPD. Saipem is an advanced
technological and engineering platform for
the design, construction and operation of
safe and sustainable complex infrastructure
and plants. Saipem has always been oriented
towards technological innovation and is
currently committed, alongside its clients, on
3. www.researchgate.net
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July. 2022
Research Gate is an academic social networking site
This is an open access article, Research Gate is a European commercial social networking site for scientists and researchers
the frontline of energy transition with
increasingly digitalized tools, technologies
and processes that were devised from the
outset with environmental sustainability in
mind.
Description of the process
Snamprogetti ammonia stripping process is
characterized by a urea synthesis loop
operating at about 160 kg/cm2 (g) with
ammonia to carbon dioxide molar ratio at
urea reactor inlet of 3.3 - 3.6. This allows a
CO2 conversion into urea of 62 - 65% in the
reactor itself, also thanks to the perforated
trays which prevent back-flow and favor gas
absorption by the liquid. There are two kinds
of chemical reactions at the same time in the
urea reactor. Urea is produced by synthesis
from liquid ammonia and gaseous carbon
dioxide. Ammonia and carbon dioxide react
to form ammonium carbamate, a portion of
which dehydrates to form urea and water.
The reaction of ammonium carbamate
dehydration is influenced by the ratio of
various reactants, operating pressure,
temperature and residence time in reactor.
The reaction of ammonia and carbon dioxide
takes place in two stages to produce urea.
1. Formation of ammonium carbamate, at 25 0
C
2 NH3 (g) + CO2 (g) → NH4COONH2 (s) -38 086 cal/gmol
2. Dehydration of ammonium carbamate to urea, at 25 0
NH4COONH2 (s) → NH2CONH2 (l) + H2O (l) +10 330 cal/gmol
3. Overall reaction, at 25 0
C
2 NH3 (g) + CO2 (g) → NH2CONH2 (l) +H2O (l) -27 756 cal/gmol
The first reaction is highly exothermic and
heat is liberated as the reaction occurs. With
excess NH3, the CO2 conversion to
carbamate is almost 100%, provided
solution pressure is greater than
decomposition pressure. The decomposition
pressure is the pressure at which carbamate
will decompose back into CO2 and NH3 i.e.
,NH2 COO NH4 (s) → 2 NH3 (g) +
CO2 (g)
Decomposition pressure is a function of NH3
concentration in the feed and the solution
temperature and increases if either
temperature or NH3 recycle is increased. It is
desirable to operate at higher pressure and
high mole ratio of NH3 to CO2 provided
reactor operating pressure is quite high
enough to prevent carbamate from
decomposition into NH3 and CO2. This will
maximize CO2 conversion to urea towards
the reaction (ii). The second reaction is
endothermic; therefore heat is required for
this reaction to start. The heat for this
reaction comes from the heat of formation of
carbamate. This reaction is a function of
temperature and ammonia concentration in
the feed. The solution effluent from the
reactor being mixture of urea solution,
ammonium carbamate, un- reacted
ammonia, water and CO2 is extremely
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corrosive in nature. The subsequent stages of
process consist of decomposition
unconverted carbamate, recovery of
The decomposition of urea at temperatures
above 132 ◦C, some undesired parallel and
equilibrium intermediates and by
in liquid, solid and gaseous form are
produced , More than 23 possible reactions,
including urea and its numerous by
products, biuret, Triuret, cyanuric acid,
Fig-1
Description of LP & Vacuum section
Low pressure decomposer
Its function is to decompose residual
carbamate from M.P. decomposer, 10
02A/B, and separate it from the urea
solution. The final operating temperature is
determined by the concentration of urea
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corrosive in nature. The subsequent stages of
process consist of decomposition of
unconverted carbamate, recovery of
resulting ammonia and carbon dioxide for
recycle, concentration and prilling of urea
solution.
The decomposition of urea at temperatures
◦C, some undesired parallel and
equilibrium intermediates and by-products
in liquid, solid and gaseous form are
produced , More than 23 possible reactions,
including urea and its numerous by-
cyanuric acid,
ammelide, ammeline, melamine and others,
exist . In the whole reaction scheme,
isocyanic acid has been found to play a
major role. Nonetheless, it evaporates at
23.5 ◦C; reactions occurring at temperatures
exceeding 133 ◦C were formulated in the
condensed phase.As shown in the figure
& Vacuum section
Its function is to decompose residual
carbamate from M.P. decomposer, 10-E-
02A/B, and separate it from the urea
solution. The final operating temperature is
determined by the concentration of urea
solution needed at the outlet. NH3 content at
the outlet is between 1-3 % wt, CO2 is
between 0.3 -1.1 % wt and urea is around 70
% wt. These concentrations are obtained
with a temperature of approx. 144 °C and an
operating pressure of 3.7 kg/cm2 g.
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resulting ammonia and carbon dioxide for
recycle, concentration and prilling of urea
ammelide, ammeline, melamine and others,
exist . In the whole reaction scheme,
cid has been found to play a
major role. Nonetheless, it evaporates at
◦C; reactions occurring at temperatures
◦C were formulated in the
As shown in the figure-1.
at the outlet. NH3 content at
3 % wt, CO2 is
1.1 % wt and urea is around 70
% wt. These concentrations are obtained
with a temperature of approx. 144 °C and an
operating pressure of 3.7 kg/cm2 g.
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L.P. condenser 10-E-08
Its function is to condense mixture of gas
and liquid coming from L.P Decomposer
separator 10-V-03 and from Reflux
accumulator 27-V-17 . The L.P. condenser
10-E-08 receives the mixture of gas and
liquid from L.P Decomposer Separator 10
Carbonate solution accumulator 10
Fig-2
Normally it collects the diluted carbonate
solution coming from L.P. condenser, 10
08 and occasionally solution discharged
from M.P. absorber, 10-C-01 It is also used
for the recovery of NH3 and CO2 in case of
shut-down followed by emptying of the high
pressure equipment. By means of M.P.
carbonate pumps 10-P-03 A/B part of the
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Its function is to condense mixture of gas
and liquid coming from L.P Decomposer
03 and from Reflux
17 . The L.P. condenser
08 receives the mixture of gas and
liquid from L.P Decomposer Separator 10-
V-03 and from Reflux accumulator 27
through Reflux pumps 27
condensed solution flowing out of 10
is sent into carbonate solution accumulator,
10-V-06, at a temperature of 39 °C.
Carbonate solution accumulator 10-V-06
Normally it collects the diluted carbonate
solution coming from L.P. condenser, 10-E-
08 and occasionally solution discharged
01 It is also used
for the recovery of NH3 and CO2 in case of
emptying of the high
pressure equipment. By means of M.P.
03 A/B part of the
carbonate solution collected in 10
recycled into the M.P. absorber fed upstream
10-E-06. The operating temperature of 10
V-06 is about 39 °C and the
kept low in normal operation (20
max.) in order to recover all carbonate in
case of plant shutdown.
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03 and from Reflux accumulator 27-V-17
through Reflux pumps 27-P-17A/B. The
condensed solution flowing out of 10-E-08
is sent into carbonate solution accumulator,
06, at a temperature of 39 °C.
carbonate solution collected in 10-V-06 is
recycled into the M.P. absorber fed upstream
06. The operating temperature of 10-
06 is about 39 °C and the level must be
kept low in normal operation (20-30 %
max.) in order to recover all carbonate in
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Fig-3
L.P. inerts washing tower 10-C-04
Its function is to absorb with cold steam
condensate the NH3 vapors coming from
10-V-06. Non condensed vapours from L.P.
condenser, 10-E-08 are routed into 10-V-06,
and then absorbed with cold steam
condensate in L.P. inerts washing tower, 10-
C-04, where an ammonia solution is formed.
The ammonia solution is collected in
carbonate solution accumulator, 10-V06.
The released inert gases from 10-C-04 are
sent to the vent stack under pressure
controller that provides to maintain 10-V-06
at about 3.4 kg/cm2 g. Medium pressure
carbonate pumps 10-P-03 A/B Duty - Its
function is to pump carbonate solution from
carbonate solution accumulator, 10-V-06 to
medium pressure absorber, 10-C-01, through
M.P. condenser, 10-E-06. Operation - The
liquid is sucked from bottom of 10-V-06 at a
temperature of about 39 °C. The electrical
motor driven pumps have been designed to
recycle the dilute carbonate solution from
L.P. to M.P. Water is one of the products of
reaction during transformation reaction of
carbamate to urea. Its presence has a
depressing effect on the conversion. Any
addition of water with the feed reduces the
conversion. One mole of water is formed
when one mole of urea is produced.
Presence of excess water shifts the reaction
equilibrium in reverse direction and yield of
urea is reduced. However, water has to be
added for recycling unconverted ammonia
and CO2 back to the reactor. Lower the
amount of water concentration in low
pressure recovery section results in high
concentration of carbamate and this causes
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pumping and choking problem in piping
system. Excess water in reactor reduces
effective volume for urea formation and
additional energy is required in evaporation
section. Study shows that presence of one
mole of excess water per mole of carbamate
reduces the equilibrium yield of urea by
nearly one half.
Rate of transformation on CO2 to urea
with excess water
Fig. No. -4 shows the depressing effect of
water on conversion. The presence of water
limits the concentration of the product to an
aqueous solution containing not more than
76.93 % urea by weight. When the desired
product is a solid urea, all water must be
removed by either crystallization or
evaporation, which means expenditure of
energy and labour. Extra water from any
other source has an adverse effect upon the
concentration of urea. First, extra water
occupies volume in the autoclave, thereby
decreases its productive capacity. Second,
extra water dilutes the urea solution,
increases the load on the evaporation and
increases energy consumption. But most
important of all, excess water decrease the
yield of urea. The presence of one mole of
excess water per mole of carbamate cuts
down the yield of urea by nearly half. The
presence of excess ammonia over the
NH3:CO2 ratio of 2:1 counter acts to a great
extent the adverse influence of water. The
formation of urea in homogeneous solutions
is in no case dependant on the partial
pressure of carbon dioxide, but that the
conversion of carbamate into urea is directly
proportional to the partial pressure of
ammonia and inversely proportional to the
partial pressure of water.
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Fig-4
Low Pressure Section This section includes:
L.P. Decomposer, L.P. Condenser,
Carbonate Solution Accumulator and L.P.
inerts washing tower. Proceed with seal test
with condensate as follows:
1. Close all drains and vents on
lines and equipment. Open all
block valves and in
connections so that it is possible
to pressurize all lines and
equipment at the same time.
2. Isolate the loop by closing the
following valves: Discharge
valves of M.P. carbonate solution
pumps, Level control valve (10
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Section This section includes:
L.P. Decomposer, L.P. Condenser,
Carbonate Solution Accumulator and L.P.
inerts washing tower. Proceed with seal test
Close all drains and vents on
lines and equipment. Open all
block valves and instrument
connections so that it is possible
to pressurize all lines and
equipment at the same time.
Isolate the loop by closing the
following valves: Discharge
valves of M.P. carbonate solution
pumps, Level control valve (10-
LV-1014) of solution outlet fr
the Medium pressure
decomposer, Level control valve
10-LV-1022 of solution outlet
from low pressure decomposer,
10-HV-1012 from M.P. absorber
to the carbonate solution
accumulator.
3. Isolate this section from the
process condensate system by
closing the isolation valve on line
3”-10-P2722 which will be tested
separately.
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1014) of solution outlet from
the Medium pressure
decomposer, Level control valve
1022 of solution outlet
from low pressure decomposer,
1012 from M.P. absorber
to the carbonate solution
Isolate this section from the
process condensate system by
isolation valve on line
P2722 which will be tested
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4. Keep open the high point vent
on LP decomposer vapour line
and keep open 10-PV-1033,
5. If the steam headers are live,
isolate steam to all tracings, PSV
jacket and control valve jacket,
6. Admit condensate to the system
through the lowest points (10-
LV1022 upstream, 10-LV-1014
downstream,10-P-03 A/B
suction),
7. Close the vents when the
condensate is coming out,
8. Slowly increase the pressure in
the system up to the test value
(3.7 kg/cm2 g), keeping the
pressure controller 10-PIC-1033
on 10-V-06 in automatic mode.
9. Check all flanges and
connections in order to identify
leaks and eliminate them. If no
losses are found, keep the
pressure in the circuit over a
period of minimum 4 hours.
10. If pressure does not fall
appreciably the test can be
considered satisfactory,
otherwise it will be necessary to
look for the losses, to eliminate
them and then repeat the test.
Low Pressure Decomposer is Prime role
of Ammonium Carbonate Solution Tank
and (V-3) & Distillation Tower (C-2) for
Ammonia CO2 Load and water Balance
The LPD pressure and temperature are the
prime role of Ammonia and CO2 load on
Carbonate solution and distillation tower
Feed. As per attached figure No-5. If you
maintain the design pressure and
temperature according to equilibrium then
V-3 & C-2 load will be ok. If you raised the
temperature ad reduced the pressure then V-
3 level will be increased. Another case if
you increase the pressure and reduced the
temperature then C-2 feed concentration in
terms of Ammonia & CO2 will be increased.
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Fig-5
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Water Balance for 3850 TPD Urea Plants (Prilling Rout)
T/H
1 Water from 3850 Urea production 48.125
2 Steam added in Pre-Concentrator Ejectors 3.2
3 Steam added in 1st
stage Ejector of Vacuums 3.8
4 Steam added in 2nd
stage Ejector of Vacuum
with Booster Ejector
14.5
5 Condensate to Carbonate Solution Tank 0.9
6 Condensate to MP Inerts washing column 2.276
7
Condensate to HP ammonia Feed Pump
sealing
1.0
8
Condensate to HP Amm. carbamate pump
sealing
1.0
9
Condensate to Flushing of Pre Conc,
Vacuum, MP absorber Intermittently
1
10 Condensate to different types of FT 1
11 Condensate from Vent stack 1.5
12 Water recycle from waste water section 5.535
Total Water in Urea Process 85.036
Distillation Tower Feed
NH3 4.831
CO2 0.966
Urea 0.95
Water 85.036
Total Feed 91.783
Table-1
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Water Balance for 3850TPD Urea Plants(Granulation Rout)
T/H
1 Water from 3850 Urea production 48.125
2 Steam added in Pre-Concentrator Ejectors 3.2
3 Steam added in Ejector of Vacuums 3
4 Condensate to Vacuum Scrubber 5
5 Condensate to Crabonate Solution Tank 0.9
6 Condensate to MP Inerts washing column 2.276
7
Condensate to HP ammonia Feed Pump
sealing
1.5
8
Condensate to HP Amm.Carbamate pump
sealing
1.5
9
Condensate to Flushing of Pre Conc, Vacuum,
MP absorber Intermittently
1.5
10 Condensate to different types of FT 1.5
11 Condensate from Vent stack 2.1
12 Water recycle from waste water section 13.499
Granulation
1 Process water to Cooler Scrubber( C-51) 35.133
2 Process water to Granulation Scrubber( C-55) 31.8
3 LS to Ejector Urea solution Tank 2.0
4 water from waste basin 2.0
5 LS to X-53 (Ejector) 2.544
Total Water in Urea Process 157.577
Distillation Tower Feed
NH3 9.777
CO2 1.916
Urea 0.88
Water 145.004
Total Feed 157.577
Table-2
Waste Water Section Water Balance, in T/Hr(Prilling Rout)
Input water Outlet water
C-2 Feed water 85.036 Water from C-2 Bottom 105.556
Steam(LMS) to C-2 20.7 Water from C-2 Top 5.573
Steam(HS) to R-2 6.5 Water from R-2 Top 1.107
Total 112.236 Total 112.236
Table-3
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Waste Water Section Water Balance, in T/Hr (Granulation Rout)
Input water Outlet water
C-2 Feed water 145.004 Water from C-2 Bottom 176.524
Steam(LMS) to C-2 35.3 Water from C-2 Top 13.499
Steam(HS) to R-2 12.9 Water from R-2 Top 4.6
Total 193.204 Total 194.623
Table-4
After completion of seal test the section will
be depressurized and all the water will be
drained by keeping the high points open.
Keep the level around 50% in Carbonate
solution accumulator 10-V-06.Vacuum
Evaporation Section This section includes:
Vacuum Concentrator and Separator,
Ejectors and Vacuum Condensers. The seal
test might be performed with air as follows
or filling the system with water. Isolate the
loop as follows:
1. Place adhesive tape on all
flanged connections making sure
that it is firmly sealed to the
flange edges, and then make a
small hole on the tape for leak
check by using soapy water.
2. Install blinds on the discharge
lines to the hydraulic seals at 10-
T02.
3. Close all drains and vents on
lines and equipment.
4. Open the block valves to
pressurize all the lines and
equipment simultaneously.
5. Close the level control valve 10-
LV-1022 on the L.P. decomposer
solution outlet line,
6. Close 10-P-08A/B suction
valves,
7. Close the Ejector steam isolation
valves,
8. Isolation valves on recovered
solution lines to vacuum
concentrator (from 10-P-09 A/B,
Granulation)
9. Close pressure control valves 10-
PV-1034 A/B and vent lines
from vacuum system packages.
10. Connect air hose at a suitable
location and admit air into the
system pressurizing up to 0.5
kg/cm2 g.
11. Check all flanges and
connections using soap solution
to identify leaks and eliminate
them.
12. If pressure does not fall
appreciably the test can be
considered satisfactory,
otherwise it will be necessary to
look for the losses, to eliminate
them and then repeat the test.
13. When the test has been carried
out successfully, depressurize by
opening the high point vents,
remove the blinds installed on the
discharge of the hydraulic seals
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and adjust the valves as described
later under start-up procedure.
14. during the leak test isolate steam
to all the steam tracings and
jacketing
1. Alternative by water filling Follow
operations of first nine points
mentioned above, then proceed as
follows.
2. Admit condensate to the system
through the lowest points and keep
the vent at highest point opened.
3. Stop the water injection when
condensate is coming out from
highest point.
4. Check all the flanges and valves for
leaks and attend them. When no
more leaks are detected the test can
be considered completed and the
system emptied.
Trouble Shooting of LP Decomposer
Variables Change Effect Corrective action
Bottom
temperature
decrease Overload of the down-
stream section
Check the M.P. decomposer
holder 10-L-02 temperature.
Check the L.P. decomposer 10-L-
03 holder level. Check the steam
flow to L.P. decomposer. Check
level in steam condensate
separator 10-V-24
Increase Level of carbonate
solution accumulator
10-V-06 increases due
to excessive off-gas
production in L.P.
decomposer.
Decrease the temperature by
reducing the steam flow at L.P.
decomposer.
Pressure
Decrease 10-P-03 A/B may begin
to cavitated.
Reduce water recovery from
process condensate treatment by
reducing, if possible, the steam
flow rate to the column 27-C-02
or to the Hydrolyzer 27-R02; an
option is to increase the reflux to
27-C-02. Last, reduce CW flow to
L.P. condenser 10-E-08; this may
cause
Increase Overload of the down-
stream section.
Check the M.P. decomposer
holder level controller and restore
the normal condition
Decrease Vapours can pass to the
downstream section and
there is the possibility
to break the vacuum
Close slightly L.P decomposer
level control valve or open
temporarily the M.P. decomposer
holder level control valve. Check
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Level conditions in vacuum
concentration section.
the correct functioning of L.P.
decomposer holder level control
valve and M.P. decomposer
holder level control valve.
Increase Flooding of L.P.
decomposer and
consequently urea carry
over to accumulator 10-
V-06.
Increase the steam flow to LP
Decomposer .Check the level and
restore the normal situation
without disturbing
Table-5
Corrosion Reported in 2nd
stage of
Vacuum in Many Plants
Number of plants reported corrosion in 2nd
stage of vacuum and part ion plate crack in
vacuum waste water tank (V-09).Some
plants reported erosion problem in 2nd
stage
of inlet nozzle. But question arise why in 1st
stage of vacuum? Following are the reason
for above problems. Urea itself is considered
as non-corrosive for stainless steel, while
some of its decomposition products at high
temperature may lead to corrosion. The urea
decomposition process plays a role in the
corrosion of stainless steel. All
corresponding decomposition products,
which exist in the solid, liquid and gaseous
state and correlate with temperature and pH
value at which they may lead to uniform
corrosion. In start up the urea concentration
is less means the ammonium
Carbamate/carbonates are there and it is
very highly corrosive to SS-304 L. The urea
solution from LPD/Pre concentrator to be
lined up to vacuum section when proper
temperature and concentration achieve
during start-up of the plant.
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Fig-6
1. In startup/ shut down, No Vacuum in
both vacuum separators, the quantity
wise 1st
vacuum inlet and 2nd
vacuum
inlet feed is about the same the first
vacuum separator area is more very
large vessel and 2nd
vacuum separator is
to small as compare to first and the
liquid/vapour load per square meter is
more so the corrosion is more in 2nd
vacuum separator.
2. The 1st
vacuum separator has large
volume and two number vacuum control
valves (PIC 140A/B) are there, one is
for sudden vacuum breaker (Large
capacity) other is less capacity for
controlling of vacuum. These valves are
air failure to open.
The 1st
stage vacuum design is 0.33 ata.
But practical point of view this vacuum
maintain about 0.4 ata for maintaining
the temperature to avoid crystallization.
Because of large volume the vacuum
breaker valve (B) is always open and air
introduces into the vessel this air act as a
passivation for SS 304 L.
3. In case of 2nd
separator the vacuum
maintain about 0.03 ata , it is high
vacuum booster ejector is required to
pull of vacuum and control valve (PIC
141) is always closed.
4. Due to high vacuum the velocity of
solution inlet of nozzle is high the
erosion also observed.
5. The 2nd
vacuums also have Skirt inside
the deposition of polymer always there
inside and outside. However some plants
have removed the skirt. This skirt is the
reason of corrosion.
6. The temperature in 2nd
stage separator is
more 135-1400
C.more temperature more
corrosion see fig-6
7. The 1st
stage having more water and
about all the water removed by 1st
stage.
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water is not corrosive . Corrosive is
mixture of NH3/CO2 mixture.
8. The water balance as shown in the
following figure-9
Fig-7
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water is not corrosive . Corrosive is
mixture.
The water balance as shown in the
9. Corrosion is the function of
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Corrosion is the function of temperature
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Fig-8
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Fig-9
Waste Water Treatment Section
The distillation tower is divided into two parts:
the lower part consists of 38 trays and the upper
part of 17 valve trays. The feed is placed on the
51st
or 45th
tray. The wastewater containing
NH3, C02 and urea after a first stripping of the
ammonia in the upper part of the lower is sent to
the hydrolyser for the decomposition of urea.
The treated water from the hydrolyser comes
back to the lower where the top of lower part
where the remaining ammonia is stripped out by
means of 6.5 Ata saturated steam directly fed to
C-2 bottom. The vapors leaving the top of the
tower are condensed in 11-E-17 by cooling
water and the carbonate solution produced is
recovered in the reflux accumulator 11-V-5.The
process condensate containing NH3-CO2 and
urea coming out from vacuum system of both
urea units, 10 & 20 is treated in this section to
make free of contaminants before sent to utility
unit. The contaminated water of each urea unit is
collected in the process condensate tank 10-T-
02. From this tank the process condensate is
pumped, by means of 10-P-14 A/B, to a
common buffer off spec tank, 27-T-05, then the
mixed solution is sent to the upper part of
distillation tower 27-C-02. The Tank 10-T-02
also receives the drain solutions accumulated
into underground carbonate close drain tank 10-
T-04, and fed to process condensate tank by
means of pump 10-P-16 A/B. Before entering
the distillation column, the process condensate
picks up heat from the purified condensate
leaving the bottom of the column itself, by
means of pre heater 27-E-16. The column 27-C-
02 is provided with trays and is divided in two
main sections by a chimney tray. Column
process conditions are: - Pressure (top): 2.5
kg/cm2 (g) - Temperature (top): 118 °C The
condensate from the chimney tray is drawn and
pumped, by centrifugal pump 27-P-15 A/B/C, to
urea hydrolyzer 27-R-02, where process
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conditions are suitable to decompose urea into
CO2 and NH3.The necessary decomposition heat
is provided by adding steam at 44 kg/cm2 (g)
and 380 °C. Hydrolyzer
process conditions are: - Pressure: 34 kg/cm2 (g)
- Temperature: 235 °C The out coming vapours
from the hydrolyzer as well as the vapours from
the top of the distillation tower are mixed and
condensed in the overhead condenser, 27-E-17,
then collected in the reflux accumulator, 27-V-
17 and split to LP section of urea unit 10 & 20
by reflux pumps, 27-P-17A/B. The recycle
stream is mixed upstream of 10-E-08 with the
LP Decomposer overhead vapors. The
hydrolyzed condensate leaving the bottom of the
27-R-02, after having decreased its temperature
passing through hydrolyser preheated, 27-E-18,
enters the distillation tower immediately under
the chimney tray where the final NH3 and CO2
stripping takes place. Saturated steam at 5.3
kg/cm2 (g), injected directly at the column
bottom, and provides the necessary stripping
force. The purified process condensate leaves
the column bottom at 143°C and it is cooled at
45°C by means of : - Distillation tower feed
preheating by means of 27-E-16 - Process
condensate cooler 27-E-23
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Fig-10
Impotence of Reflux and Steam to
Distillation Tower
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Impotence of Reflux and Steam to The reflux to distillation column decide
concentration of reflux accumulator section
.How much steam is required? Increasing
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The reflux to distillation column decide
concentration of reflux accumulator section
.How much steam is required? Increasing
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/decreasing of steam can cause the
distillation column disturbed. Inside the
column, the down flowing reflux
liquid provides cooling and condensation of
the up flowing vapors thereby increasing the
efficiency of the distillation column. The
purpose of reflux is to provide down-
flowing liquid throughout the rectification
section to contact with the up-flowing vapor
in order to achieve stage-by-stage
equilibrium heat and mass transfer and,
hence, purification of the top product. The
utility cost includes Steam to distillation in
bottom and cooling water cost in overhead
condenser. As reflux ratio increases more of
the steam heat is consumed to vaporize the
incoming liquid which results in energy loss.
Also more of the steam for heating purpose
will be wasted. Because of the higher steam
duty as the more volatile component reaches
the condenser with higher rate thus more of
the cooling water will be required which
again results in a loss of energy. If you give
more steam in bottom then concentration of
reflux accumulator will be decrease because
at certain point that steam will condense in
accumulator. A practical curve for 4000
TPD Plant as figure No-11
Fig-11
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Conclusion
It has been observed the water balance of the
plant is main key factor. It must be balance
and optimized otherwise conversion of urea
will be disturbed. The safe plants operation
is the technical art. A small mistake can
make big incident. The operations of this
activity implies a unit shut-down duration of
not more than 48 hours (24 hours during 1st
start-up of the unit), leaving the H.P. loop
bottled before corrosion problems can take
place. If maintenance jobs have to be
performed on the unit (excluding the
synthesis loop) it is possible to separately
depressurize and drain the required
equipment, leaving the reactor full and ready
to restart. It is suggested, before starting any
maintenance job, isolate NH3 and carbonate
solution vessels from the remaining unit,
controlling the pressure by the respective
PIC in automatic mode. It is not advisable to
carry out series of inlet contacts to interlock
system, exception Consist of push button
and selector switches on the control board
and particular cases which must be
considered one by one. The push buttons for
shut down shall be protected from accidental
operation. The analysis points and the
frequency with which they have to be
carried out, during start-up and under normal
running conditions. Number of the
instruments in the plant are equipped with
passive alarms to warn the operators in the
control room against deviating operating
conditions which may lead to dangerous
situations or which may cause damage to the
equipment. A leakage detection system
should be developed due to impurities in
steam-damaged steels. The barrier of having
an effective start-up procedure was totally
ineffective as this not apply to the specific
conditions applicable on the day. The water
balance must be checked day by day.
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