In Fertilizers industries the material plays a very important role. Right material can save energy as well as plant life and 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 urea plant very corrosive chemicals are used for urea production. The raw material of urea plant is Ammonia and Carbon Dioxide gas which makes very corrosive chemical ammonium Carbamate. For reduced corrosion passivation air is used in reactor as well as stripper according to material of selection different quaintly of air is used. Controlled and less quantity of passivation air is required for Titanium and Zirconium material and hence saving of energy because the huge amount of ammonia is waste with venting of inerts, i.e. saving of energy and environments also. Passivation oxygen given in CO2 is directly proportional to ammonia losses in MP section. This paper intended how to increase life of urea reactor liner and energy saving with low passivation air and high N/C ratio, Ammonia is the noncorrosive and ammonia to CO2 Ratio is an important parameter for process optimization occurring less losses and less 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.
Experience of material in fertilizers industriesPrem Baboo
This document discusses materials used in urea fertilizer plants, focusing on materials used for reactor liners. It describes the history of different materials used such as titanium, zirconium, stainless steel, and duplex stainless steel. Zirconium has proven highly resistant to corrosion in urea plants without needing additional oxygen. Newer materials like 2RE-69 and duplex stainless steels provide good resistance with weldability. The design of urea reactors is also covered, noting key parameters like diameter, height, and residence time depending on production size. Passivation air levels vary between process licensors but help control corrosion.
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.
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.
Urea reactor liner leakage(a case study)Prem Baboo
The document discusses liner leakage issues in the urea reactor of a fertilizer plant in India. It describes two instances of leakage detected through the weep hole monitoring system, in 2006 and 2017. Both times, the plant underwent shutdowns to locate and repair the leak. Detection methods like soap solution, ammonia testing, and differential pressure checks were used. The 2017 leak took longer to locate and required welding repairs between trays. The shutdown lasted 72 hours before feed was restored. Proper monitoring and maintenance of weep holes and liners is important for preventing corrosion and leaks.
In this article includes many studies and investigation reporting on the effect of various parameters to the prills quality like crushing strength, size distribution, abrasion and impact resistance, humidity factors urea moisture absorption, vacuum studies etc. The Nitrogen, moisture, Prill strength &Biuret contents and the size distribution of prilled urea are important factors of determining urea quality. High temperature of prilled product is a common in most of urea plant in India. In some plants in India the temperature of prills as high 80oC in hot summer days at high load. Our plant temperature of prills is also 65-700C.This result in poor strength dust formation, increase in caking tendency. Granulated urea has definite advantage over prilled urea but expensive to produce till recently. We have installed BFC for line-1 & 2.A modification also done in Urea line –I plant in month of March 2018 to solve foaming problem in waste water section (distillation tower) and this modification proven and beneficial.
Ureap lant energy improved with operation philosophyand reactor internalsPrem Baboo
The energy of H.P. loop directly proportional to the pressure of h.p loop. The H.P loop is the heart of urea plants. Conversion of urea depends upon N/C & H/C ratio, reactor internal construction, i.e. configuration of trays, reactants mixing phenomenon, flow pattern etc. other than pressure. In conventional plants there was too much pressure of the reactors for higher urea conversion. Now philosophy has been changed our mind concentrated on flow pattern of the fluid dynamics and internals of the reactors. The performances of Urea Reactors can be improved by the application of the latest generation of internals like HET, Vortex mixture and conversion booster. As a consequence, the HET & Vortex mixture can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a retrofit design. The increase in the efficiency has permitted direct benefits to the overall day-by-day performances of the units, thus allowing lower energy consumption and a reduced environmental impact. The present paper based on these facts and how to improve energy by changing internals, operational parameters like molar ratio, recycling of water in the system, pressure & temperature of the system to improve energy and equipment’s life. The most important of these consists of a sharp reduction in specific steam consumption. The fluid-dynamics of a urea reactor can be significantly improved by the introduction of the latest generation of internals. e.g. Super cup trays, Vortex mixture, NIIK internals, siphon jet trays etc. No pressure drop observed because the gas phase directly converted to liquid phase the driving force compensates the pressure drop and No load limitation.
2018 06 baboo caking of urea in summer seasonPrem Baboo
The document summarizes a case study on urea caking in the summer season in India. High ambient temperatures cause urea prill temperatures to rise significantly during production. Several factors influence urea caking, including moisture content, free ammonia levels, temperature, and relative humidity. The main causes of caking are the formation of crystal bonds between prills and the transfer of moisture through piled urea. Methods to reduce caking discussed include controlling moisture and temperature during production, installing bulk flow coolers to lower prill temperatures, and reducing free ammonia levels in prills.
The document discusses EDTA cleaning of boilers. It explains that EDTA is a strong chelating agent that forms complexes with metal ions like iron and copper to remove deposits from boiler surfaces. The document outlines BHEL's experience using EDTA cleaning for 43 projects since 2003. It describes the full EDTA cleaning process used by BHEL, which includes alkali flushing, EDTA pickling and passivation, rinsing, and inspection stages. The process aims to improve boiler efficiency and minimize corrosion and failures.
Experience of material in fertilizers industriesPrem Baboo
This document discusses materials used in urea fertilizer plants, focusing on materials used for reactor liners. It describes the history of different materials used such as titanium, zirconium, stainless steel, and duplex stainless steel. Zirconium has proven highly resistant to corrosion in urea plants without needing additional oxygen. Newer materials like 2RE-69 and duplex stainless steels provide good resistance with weldability. The design of urea reactors is also covered, noting key parameters like diameter, height, and residence time depending on production size. Passivation air levels vary between process licensors but help control corrosion.
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.
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.
Urea reactor liner leakage(a case study)Prem Baboo
The document discusses liner leakage issues in the urea reactor of a fertilizer plant in India. It describes two instances of leakage detected through the weep hole monitoring system, in 2006 and 2017. Both times, the plant underwent shutdowns to locate and repair the leak. Detection methods like soap solution, ammonia testing, and differential pressure checks were used. The 2017 leak took longer to locate and required welding repairs between trays. The shutdown lasted 72 hours before feed was restored. Proper monitoring and maintenance of weep holes and liners is important for preventing corrosion and leaks.
In this article includes many studies and investigation reporting on the effect of various parameters to the prills quality like crushing strength, size distribution, abrasion and impact resistance, humidity factors urea moisture absorption, vacuum studies etc. The Nitrogen, moisture, Prill strength &Biuret contents and the size distribution of prilled urea are important factors of determining urea quality. High temperature of prilled product is a common in most of urea plant in India. In some plants in India the temperature of prills as high 80oC in hot summer days at high load. Our plant temperature of prills is also 65-700C.This result in poor strength dust formation, increase in caking tendency. Granulated urea has definite advantage over prilled urea but expensive to produce till recently. We have installed BFC for line-1 & 2.A modification also done in Urea line –I plant in month of March 2018 to solve foaming problem in waste water section (distillation tower) and this modification proven and beneficial.
Ureap lant energy improved with operation philosophyand reactor internalsPrem Baboo
The energy of H.P. loop directly proportional to the pressure of h.p loop. The H.P loop is the heart of urea plants. Conversion of urea depends upon N/C & H/C ratio, reactor internal construction, i.e. configuration of trays, reactants mixing phenomenon, flow pattern etc. other than pressure. In conventional plants there was too much pressure of the reactors for higher urea conversion. Now philosophy has been changed our mind concentrated on flow pattern of the fluid dynamics and internals of the reactors. The performances of Urea Reactors can be improved by the application of the latest generation of internals like HET, Vortex mixture and conversion booster. As a consequence, the HET & Vortex mixture can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a retrofit design. The increase in the efficiency has permitted direct benefits to the overall day-by-day performances of the units, thus allowing lower energy consumption and a reduced environmental impact. The present paper based on these facts and how to improve energy by changing internals, operational parameters like molar ratio, recycling of water in the system, pressure & temperature of the system to improve energy and equipment’s life. The most important of these consists of a sharp reduction in specific steam consumption. The fluid-dynamics of a urea reactor can be significantly improved by the introduction of the latest generation of internals. e.g. Super cup trays, Vortex mixture, NIIK internals, siphon jet trays etc. No pressure drop observed because the gas phase directly converted to liquid phase the driving force compensates the pressure drop and No load limitation.
2018 06 baboo caking of urea in summer seasonPrem Baboo
The document summarizes a case study on urea caking in the summer season in India. High ambient temperatures cause urea prill temperatures to rise significantly during production. Several factors influence urea caking, including moisture content, free ammonia levels, temperature, and relative humidity. The main causes of caking are the formation of crystal bonds between prills and the transfer of moisture through piled urea. Methods to reduce caking discussed include controlling moisture and temperature during production, installing bulk flow coolers to lower prill temperatures, and reducing free ammonia levels in prills.
The document discusses EDTA cleaning of boilers. It explains that EDTA is a strong chelating agent that forms complexes with metal ions like iron and copper to remove deposits from boiler surfaces. The document outlines BHEL's experience using EDTA cleaning for 43 projects since 2003. It describes the full EDTA cleaning process used by BHEL, which includes alkali flushing, EDTA pickling and passivation, rinsing, and inspection stages. The process aims to improve boiler efficiency and minimize corrosion and failures.
The document discusses a weep hole monitoring system installed in a urea plant reactor and stripper vessels to detect any leakage from the vessels. The system works by connecting each weep hole internally through grooves to another weep hole, with nitrogen passed through one hole of each pair and the other hole connected to bubblers for continuous monitoring to ensure nitrogen flow through all pairs. The Microgenie-Scan scanner monitors the resistance of each weep hole pair to detect leaks below 3k ohms and openings above 20k ohms. Safety risks of high pressure equipment in urea plants are also discussed.
Nano urea is a more efficient form of urea fertilizer that can be produced through various nanotechnology methods like using spinning cone reactors or nano-channel reactors. It has particles sized 20-50 nm that provide higher surface area and reactivity than conventional urea. Field trials showed nano urea can increase crop yields by 8% on average and reduce urea requirements by 50% while being more environmentally friendly through lower pollution. Its small size allows for more effective absorption by plant leaves and controlled release of nutrients within the plant.
Energy saving and pollution control in urea plant though prilling tower and o...Prem Baboo
In Prilling Tower the ambient air is used as the cooling air stream for this process. In hot days, the temperature of the product at the bottom of the tower are hot that cannot be packed directly.Prilling tower have variable opening louvers system, this helps to control air intake flow to prilling tower at bottom, which is very useful in rainy seasons as CRH (critical relative humidity) of urea becomes less than atmospheric humidity and prills tends to absorb moisture from air. Humidity of air along the height of tower increases due to evaporation of moisture from prills. Rate of change of humidity at the top is more than that at the bottom indicates most of the moisture is removed at the top when the prills is in the liquid stage. In addition, in hot/ humid days, the prills form lamps and cakes with each other. To overcome this problem the bulk flow cooler (BFC) or cooling fluidized dryer (CFD) are used.
A mathematical hydrodynamics, heat, and mass transfer between the urea and the cooling air is developed. The prilling tower is the source of pollution in form of dust and ammonia and that can be control by simple technic also energy saving in terms of ammonia saving, ammonia is the harmful pollutant if you vent and useful product if you recovers.
On-line Heater & Boiler Chemical Cleaning TechnologyGTC Technology
GTC's advanced fired heater cleaning technology uses chemical measures to remove deposits from heater tubes, improving heater efficiency without shutdowns. The chemical cleaning process increases heater throughput and lowers fuel costs while reducing emissions. GTC's proprietary liquid chemicals are sprayed onto heater tubes, vaporizing to clean surfaces. This quick online process increases heater efficiency by 3-4% and provides substantial financial benefits through reduced fuel consumption and increased processing capacity.
This document provides information about feed water treatment methods used in power plants. It discusses the necessity of feed water treatment due to impurities in raw water and the effects of those impurities like scale formation, corrosion, priming and foaming. It then summarizes various treatment methods including zeolite treatment, demineralization, and reverse osmosis. It provides details on how each process works to purify water and remove dissolved solids and minerals. The document is a student presentation covering key aspects of feed water treatment technologies.
The document discusses pollution from coal-based direct reduced iron (DRI) plants in India. It provides background on the DRI process and explains that DRI production has increased in India due to access to iron ore and lack of coking coal. It then discusses various sources of air, water, and solid waste pollution from DRI plants. Specific pollutants include PM, SO2, NOx, CO, and contaminated water discharged into rivers. The document recommends pollution control mechanisms like improved dust collection systems and utilizing waste materials to reduce environmental impacts from India's DRI industry.
This document summarizes a gasoline vapor recovery system designed to capture gasoline vapors during storage and distribution to prevent their release into the atmosphere. The system uses a positive displacement pump to transfer vapors from a storage tank to an indirect condenser. The condenser contains copper tubes packed with ice to cool and condense the vapors back into liquid gasoline. A simple heater is also included to generate sufficient vapors for demonstration purposes by heating air pumped into the storage tank. The entire system is assembled on a basic frame and uses low-cost materials like PVC pipes and a soldering iron for heating. Measurement devices like a stopwatch and flask are used to test the system performance.
Thermal power plants require ultra pure water known as boiler feedwater that is pretreated to remove impurities which can cause scaling, corrosion, and other problems. Common pretreatment methods include filtration, coagulation, ion exchange, chemical precipitation, and deaeration to remove suspended solids, dissolved gases, and minerals. Emerging technologies like membrane contactors and reverse osmosis are also being used to further purify boiler feedwater from wastewater and other sources. Proper pretreatment is crucial to minimize damage to high pressure boilers in thermal power plants.
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
The document summarizes recent developments in sulphuric acid technology presented by Outotec. It describes the OTOVent venturi quench system, which separates hot/dry and cold/wet areas to prevent particle deposits. It also details the HEROSTM energy recovery process, which generates steam while recovering waste heat. Additionally, it discusses drying and absorption towers, focusing on new materials like SX stainless steel and designs like the FiDiTM distribution system.
This document discusses alternative iron making processes that are more relevant for India given concerns over resource depletion, rising energy demands, and environmental regulations. It describes several emerging smelting reduction technologies including COREX, FINEX, and Hismelt that allow for more flexible use of raw materials like iron ore fines and non-coking coal. These processes aim to eliminate sintering and coke-making while producing high quality iron. COREX and FINEX have been implemented commercially while Hismelt offers potential cost savings over blast furnaces and lower environmental impact. Overall, alternative technologies are needed to sustainably meet India's growing steel demand given restrictions on raw material quality and availability.
This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas. Factors affecting productivity and emissions from each process are presented. Opportunities for cleaner technologies like using beneficiated coal or synthesis gas from coal gasification in rotary kilns or shaft furnaces are discussed along with challenges. The MIDREX and HYL gas-based shaft furnace processes and use of synthesis gas in these furnaces are also summarized.
The document discusses various technologies for producing hydrogen and synthesis gas, including steam reforming, partial oxidation, coal gasification, and water electrolysis. It provides an overview of the main industrial processes used for ammonia synthesis gas production, noting that about 85% is based on steam reforming of natural gas or other light hydrocarbons. Various hydrogen and syngas production processes are also compared in terms of energy consumption, investment cost, and production cost.
Mono ethylene glycol is a chemical often used for plant and pipeline integrity management - but if used incorrectly it can have an adverse effect on a facility. Advisian’s Steve Cooper discusses what needs to be considered when working with MEG at the IChemE Hazards Australiasia Conference in Melbourne
The document discusses the production of multilayer printed circuit boards using tin plating protection technology. It describes the tin plating process in detail, including bath composition, operating conditions, and quality control measures. Potential quality issues in the tin plating process like poor coating distribution and exposed copper are analyzed along with recommended solutions. The document concludes that multilayer PCB production is complex but tin plating provides effective protection as long as the process is properly controlled and monitored.
Effect of LVOF Sprayed Coating in Oxidation & Hot Corrosion Performance of Bo...IJRES Journal
Oxidation and hot corrosion is the major degradation mechanism of failure of boiler and gas turbine components. These failures occur because of the usage of wide range of fuels such as coal, oil at increased temperatures. To obviate these problems, in current investigation Al2O3+40%TiO2 powder has been deposited on Boiler Steel SA-192by LVOF (Low velocity oxy fuel process). The oxidation and hot corrosion performances of Al2O3+40%TiO2 coated as well as bare Boiler Steel SA-192 has been evaluated in air and with aggressive environment Na2SO4+60%V2O5 under cyclic conditions at an elevated temperatures of 8500C & 9500C. The kinetics of the corrosion is approximated by weight change measurements made after each cycle for total duration of 50 cycles. Each cycle consists of keeping the samples for 1 hour duration in Kanthol wire tube furnace at 8500C and 9500C followed by 20 minute cooling in ambient air. Weight change data has been taken after each cycle by digital electronic balance machine with an accuracy of 1 milligram. Graphs have been plotted between weight gains per surface area to number of cycles. Boiler Steel SA-192 has shown poor performance in oxidising and in hot corrosion environment it suffered intensive spallation in the form of removal of scales. To improve oxidation and hot corrosion resistance Al2O3+40%TiO2 coating has been successfully deposited on Boiler Steel SA-192 by Low velocity oxy fuel process using CERAJET spray nozzle (A proprietary item of MECPL, Jodhpur). Coating has shown approximately 90% & 92% improvement respectively in the oxidation and hot corrosion resistance of Boiler Steel SA-192have been observed .
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
The document describes the specifications and processes involved in annealing and pickling a stainless steel coil. The line can process AISI 200, 300, and 400 grade stainless steel coils that are 0.3-3 mm thick and 600-1300 mm wide. The processes include welding, degreasing, annealing in a furnace, pickling using electrolytic sulfuric acid and mixed acid tanks, skin passing using a two-high mill, tension leveling, and recoiling. The goal is to improve machinability, refine grain size, and remove stresses and surface oxides.
Urea is a nitrogen-rich fertilizer produced from ammonia and carbon dioxide. It exists as white crystalline prills or granules and contains 46% nitrogen. Urea is synthesized through a two-stage reaction where ammonium carbamate is first formed and then dehydrated to melt urea. The process occurs in a tower reactor at high pressure and temperature. The molten urea is then prilled or granulated and dried. Urea fertilizer is widely used due to its high nitrogen content and low production cost, though it can decompose rapidly if not packaged properly.
The Role of Material in Fertilizers IndustrieswithEnergy saving.pdfPremBaboo4
In Fertilizers industries the material plays a
very important role. Right material can save
energy as well as plant life and 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 urea
plant very corrosive chemicals are used for
urea production. The raw material of urea
plant is Ammonia and Carbon Dioxide gas
which makes very corrosive chemical
ammonium Carbamate. For reduced
corrosion passivation air is used in reactor as
well as stripper according to material of
selection different quaintly of air is used.
Controlled and less quantity of passivation
air is required for Titanium and Zirconium
material and hence saving of energy because
the huge amount of ammonia is waste with
venting of inerts, i.e. saving of energy and
environments also. Passivation oxygen
given in CO2 is directly proportional to
ammonia losses in MP section. This paper
intended how to increase life of urea reactor
liner and energy saving with low passivation
air and high N/C ratio, Ammonia is the
noncorrosive and ammonia to CO2 Ratio is
an important parameter for process optimization occurring less losses and less
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.
The explosion hazard in urea process (1)Prem Baboo
The document discusses explosion hazards in the urea production process. Passivation air used in the reactor, stripper, and downstream equipment can form an explosive mixture with the small amount of hydrogen (0.14-0.2%) present in CO2. The HP scrubber is identified as a risky vessel where an explosive mixture could form. Triangular diagrams are used to show combustible and non-combustible gas mixtures. Test results from a fertilizer plant show that optimal oxygen levels are needed to avoid explosions while minimizing ammonia losses. Higher chromium stainless steel grades require less oxygen for passivation than lower grades.
The document discusses a weep hole monitoring system installed in a urea plant reactor and stripper vessels to detect any leakage from the vessels. The system works by connecting each weep hole internally through grooves to another weep hole, with nitrogen passed through one hole of each pair and the other hole connected to bubblers for continuous monitoring to ensure nitrogen flow through all pairs. The Microgenie-Scan scanner monitors the resistance of each weep hole pair to detect leaks below 3k ohms and openings above 20k ohms. Safety risks of high pressure equipment in urea plants are also discussed.
Nano urea is a more efficient form of urea fertilizer that can be produced through various nanotechnology methods like using spinning cone reactors or nano-channel reactors. It has particles sized 20-50 nm that provide higher surface area and reactivity than conventional urea. Field trials showed nano urea can increase crop yields by 8% on average and reduce urea requirements by 50% while being more environmentally friendly through lower pollution. Its small size allows for more effective absorption by plant leaves and controlled release of nutrients within the plant.
Energy saving and pollution control in urea plant though prilling tower and o...Prem Baboo
In Prilling Tower the ambient air is used as the cooling air stream for this process. In hot days, the temperature of the product at the bottom of the tower are hot that cannot be packed directly.Prilling tower have variable opening louvers system, this helps to control air intake flow to prilling tower at bottom, which is very useful in rainy seasons as CRH (critical relative humidity) of urea becomes less than atmospheric humidity and prills tends to absorb moisture from air. Humidity of air along the height of tower increases due to evaporation of moisture from prills. Rate of change of humidity at the top is more than that at the bottom indicates most of the moisture is removed at the top when the prills is in the liquid stage. In addition, in hot/ humid days, the prills form lamps and cakes with each other. To overcome this problem the bulk flow cooler (BFC) or cooling fluidized dryer (CFD) are used.
A mathematical hydrodynamics, heat, and mass transfer between the urea and the cooling air is developed. The prilling tower is the source of pollution in form of dust and ammonia and that can be control by simple technic also energy saving in terms of ammonia saving, ammonia is the harmful pollutant if you vent and useful product if you recovers.
On-line Heater & Boiler Chemical Cleaning TechnologyGTC Technology
GTC's advanced fired heater cleaning technology uses chemical measures to remove deposits from heater tubes, improving heater efficiency without shutdowns. The chemical cleaning process increases heater throughput and lowers fuel costs while reducing emissions. GTC's proprietary liquid chemicals are sprayed onto heater tubes, vaporizing to clean surfaces. This quick online process increases heater efficiency by 3-4% and provides substantial financial benefits through reduced fuel consumption and increased processing capacity.
This document provides information about feed water treatment methods used in power plants. It discusses the necessity of feed water treatment due to impurities in raw water and the effects of those impurities like scale formation, corrosion, priming and foaming. It then summarizes various treatment methods including zeolite treatment, demineralization, and reverse osmosis. It provides details on how each process works to purify water and remove dissolved solids and minerals. The document is a student presentation covering key aspects of feed water treatment technologies.
The document discusses pollution from coal-based direct reduced iron (DRI) plants in India. It provides background on the DRI process and explains that DRI production has increased in India due to access to iron ore and lack of coking coal. It then discusses various sources of air, water, and solid waste pollution from DRI plants. Specific pollutants include PM, SO2, NOx, CO, and contaminated water discharged into rivers. The document recommends pollution control mechanisms like improved dust collection systems and utilizing waste materials to reduce environmental impacts from India's DRI industry.
This document summarizes a gasoline vapor recovery system designed to capture gasoline vapors during storage and distribution to prevent their release into the atmosphere. The system uses a positive displacement pump to transfer vapors from a storage tank to an indirect condenser. The condenser contains copper tubes packed with ice to cool and condense the vapors back into liquid gasoline. A simple heater is also included to generate sufficient vapors for demonstration purposes by heating air pumped into the storage tank. The entire system is assembled on a basic frame and uses low-cost materials like PVC pipes and a soldering iron for heating. Measurement devices like a stopwatch and flask are used to test the system performance.
Thermal power plants require ultra pure water known as boiler feedwater that is pretreated to remove impurities which can cause scaling, corrosion, and other problems. Common pretreatment methods include filtration, coagulation, ion exchange, chemical precipitation, and deaeration to remove suspended solids, dissolved gases, and minerals. Emerging technologies like membrane contactors and reverse osmosis are also being used to further purify boiler feedwater from wastewater and other sources. Proper pretreatment is crucial to minimize damage to high pressure boilers in thermal power plants.
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
The document summarizes recent developments in sulphuric acid technology presented by Outotec. It describes the OTOVent venturi quench system, which separates hot/dry and cold/wet areas to prevent particle deposits. It also details the HEROSTM energy recovery process, which generates steam while recovering waste heat. Additionally, it discusses drying and absorption towers, focusing on new materials like SX stainless steel and designs like the FiDiTM distribution system.
This document discusses alternative iron making processes that are more relevant for India given concerns over resource depletion, rising energy demands, and environmental regulations. It describes several emerging smelting reduction technologies including COREX, FINEX, and Hismelt that allow for more flexible use of raw materials like iron ore fines and non-coking coal. These processes aim to eliminate sintering and coke-making while producing high quality iron. COREX and FINEX have been implemented commercially while Hismelt offers potential cost savings over blast furnaces and lower environmental impact. Overall, alternative technologies are needed to sustainably meet India's growing steel demand given restrictions on raw material quality and availability.
This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas. Factors affecting productivity and emissions from each process are presented. Opportunities for cleaner technologies like using beneficiated coal or synthesis gas from coal gasification in rotary kilns or shaft furnaces are discussed along with challenges. The MIDREX and HYL gas-based shaft furnace processes and use of synthesis gas in these furnaces are also summarized.
The document discusses various technologies for producing hydrogen and synthesis gas, including steam reforming, partial oxidation, coal gasification, and water electrolysis. It provides an overview of the main industrial processes used for ammonia synthesis gas production, noting that about 85% is based on steam reforming of natural gas or other light hydrocarbons. Various hydrogen and syngas production processes are also compared in terms of energy consumption, investment cost, and production cost.
Mono ethylene glycol is a chemical often used for plant and pipeline integrity management - but if used incorrectly it can have an adverse effect on a facility. Advisian’s Steve Cooper discusses what needs to be considered when working with MEG at the IChemE Hazards Australiasia Conference in Melbourne
The document discusses the production of multilayer printed circuit boards using tin plating protection technology. It describes the tin plating process in detail, including bath composition, operating conditions, and quality control measures. Potential quality issues in the tin plating process like poor coating distribution and exposed copper are analyzed along with recommended solutions. The document concludes that multilayer PCB production is complex but tin plating provides effective protection as long as the process is properly controlled and monitored.
Effect of LVOF Sprayed Coating in Oxidation & Hot Corrosion Performance of Bo...IJRES Journal
Oxidation and hot corrosion is the major degradation mechanism of failure of boiler and gas turbine components. These failures occur because of the usage of wide range of fuels such as coal, oil at increased temperatures. To obviate these problems, in current investigation Al2O3+40%TiO2 powder has been deposited on Boiler Steel SA-192by LVOF (Low velocity oxy fuel process). The oxidation and hot corrosion performances of Al2O3+40%TiO2 coated as well as bare Boiler Steel SA-192 has been evaluated in air and with aggressive environment Na2SO4+60%V2O5 under cyclic conditions at an elevated temperatures of 8500C & 9500C. The kinetics of the corrosion is approximated by weight change measurements made after each cycle for total duration of 50 cycles. Each cycle consists of keeping the samples for 1 hour duration in Kanthol wire tube furnace at 8500C and 9500C followed by 20 minute cooling in ambient air. Weight change data has been taken after each cycle by digital electronic balance machine with an accuracy of 1 milligram. Graphs have been plotted between weight gains per surface area to number of cycles. Boiler Steel SA-192 has shown poor performance in oxidising and in hot corrosion environment it suffered intensive spallation in the form of removal of scales. To improve oxidation and hot corrosion resistance Al2O3+40%TiO2 coating has been successfully deposited on Boiler Steel SA-192 by Low velocity oxy fuel process using CERAJET spray nozzle (A proprietary item of MECPL, Jodhpur). Coating has shown approximately 90% & 92% improvement respectively in the oxidation and hot corrosion resistance of Boiler Steel SA-192have been observed .
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
The document describes the specifications and processes involved in annealing and pickling a stainless steel coil. The line can process AISI 200, 300, and 400 grade stainless steel coils that are 0.3-3 mm thick and 600-1300 mm wide. The processes include welding, degreasing, annealing in a furnace, pickling using electrolytic sulfuric acid and mixed acid tanks, skin passing using a two-high mill, tension leveling, and recoiling. The goal is to improve machinability, refine grain size, and remove stresses and surface oxides.
Urea is a nitrogen-rich fertilizer produced from ammonia and carbon dioxide. It exists as white crystalline prills or granules and contains 46% nitrogen. Urea is synthesized through a two-stage reaction where ammonium carbamate is first formed and then dehydrated to melt urea. The process occurs in a tower reactor at high pressure and temperature. The molten urea is then prilled or granulated and dried. Urea fertilizer is widely used due to its high nitrogen content and low production cost, though it can decompose rapidly if not packaged properly.
The Role of Material in Fertilizers IndustrieswithEnergy saving.pdfPremBaboo4
In Fertilizers industries the material plays a
very important role. Right material can save
energy as well as plant life and 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 urea
plant very corrosive chemicals are used for
urea production. The raw material of urea
plant is Ammonia and Carbon Dioxide gas
which makes very corrosive chemical
ammonium Carbamate. For reduced
corrosion passivation air is used in reactor as
well as stripper according to material of
selection different quaintly of air is used.
Controlled and less quantity of passivation
air is required for Titanium and Zirconium
material and hence saving of energy because
the huge amount of ammonia is waste with
venting of inerts, i.e. saving of energy and
environments also. Passivation oxygen
given in CO2 is directly proportional to
ammonia losses in MP section. This paper
intended how to increase life of urea reactor
liner and energy saving with low passivation
air and high N/C ratio, Ammonia is the
noncorrosive and ammonia to CO2 Ratio is
an important parameter for process optimization occurring less losses and less
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.
The explosion hazard in urea process (1)Prem Baboo
The document discusses explosion hazards in the urea production process. Passivation air used in the reactor, stripper, and downstream equipment can form an explosive mixture with the small amount of hydrogen (0.14-0.2%) present in CO2. The HP scrubber is identified as a risky vessel where an explosive mixture could form. Triangular diagrams are used to show combustible and non-combustible gas mixtures. Test results from a fertilizer plant show that optimal oxygen levels are needed to avoid explosions while minimizing ammonia losses. Higher chromium stainless steel grades require less oxygen for passivation than lower grades.
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.
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.
IRJET- Process Simulation of High Pressure Urea Production from Carbon Dioxid...IRJET Journal
This document describes a process simulation of high pressure urea production from carbon dioxide and ammonia. The simulation was conducted using Aspen Plus software and the SRK thermodynamic model. Two stoichiometric reactors were used - the first at low temperature and high pressure for ammonium carbamate formation, and the second at elevated temperature for carbamate dehydration to urea. The simulation examined varying conversion levels of carbon dioxide and ammonium carbamate. Higher conversions led to increased urea yield, as did adding more separation stages. The study provides an improved base case process for urea synthesis that is thermodynamically feasible.
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.
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.
EXPERIMENTAL STUDIES ON DURABILITY ASPECTS OF SELF- COMPACTING CONCRETE USING...IRJET Journal
The document discusses experimental studies on the durability of self-compacting concrete that uses Alccofine and biochar as partial replacements for cement. Alccofine is an ultrafine material with particles smaller than cement that can replace up to 70% of cement. Biochar is a solid product created from pyrolyzing biomass. The study aims to examine the durability properties such as sulphate attack resistance, water absorption, and carbonation of self-compacting concrete with 10% Alccofine and 2% biochar replacements, compared to conventional self-compacting concrete. The results indicate the compressive strength of concrete improved with Alccofine, and the durability properties were superior to conventional self
IRJET- Study of Sugarcane Bagasse and Orange Peel as Adsorbent for Treatment ...IRJET Journal
This document studies the use of orange peel and sugarcane bagasse as low-cost adsorbents for removing nickel from electroplating wastewater. Batch adsorption experiments were conducted to determine the optimum conditions for nickel removal. Orange peel was found to be most effective at removing nickel (95.21% removal) with conditions of 60 minutes, 10g dosage, and pH 8-10. Sugarcane bagasse achieved lower removal (not specified) with conditions of 75 minutes, 8g dosage, and pH 8-10. The study aims to develop affordable, environmentally-friendly methods for treating heavy metal pollution using agricultural waste materials.
Tetronics is an environmental company that has 50 years of experience using plasma technology for resource recovery and hazardous material destruction. Their vision is to enable a sustainable planet through responsible environmental solutions. Their plasma technology has over 100 patents and can treat waste streams from electronics, mining, steel plants, and more. It recovers resources and transforms hazardous materials into an inert rock product while emitting low levels of emissions. Tetronics has numerous customer references and installations globally across industries like mining, steel, and electronics waste processing.
This document discusses mercury removal from natural gas streams. It notes that mercury is naturally present in gas reservoirs and must be removed to protect health, the environment, and equipment. Non-regenerative adsorbents using sulfur are commonly used, but activated carbons can have issues with wet gas streams. Newer mercury removal solutions use engineered alumina-based adsorbents with metal sulfide active phases, which have higher mechanical strength and can handle high pressures and water-saturated gas. The document provides examples of using these solutions and compares their performance to other technologies at upstream locations.
IRJET- Analysis of strength Characteristic of Concrete using Vernacular MaterialIRJET Journal
This document analyzes the strength characteristics of concrete using vernacular materials like fly ash and potassium hydroxide as replacements for Portland cement. The study compares the compressive and tensile strengths of normal geopolymer concrete made using sodium hydroxide and sodium silicate to a concrete made using potassium hydroxide and sodium silicate. Test results showed the average compressive strength of the sodium hydroxide concrete was 50.5% higher while the average tensile strength was 34.85% higher compared to the potassium hydroxide concrete. The document concludes that sodium hydroxide produces a more economical and suitable concrete than potassium hydroxide.
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.
The document discusses slotted anodes used in aluminum production. It describes how Vedanta Aluminium Ltd implemented slotted anodes in their smelter in Jharsuguda, India. Key points include:
- Slots were designed into the anodes to reduce bubble resistance and lower pot voltage/energy consumption.
- Trials showed reduced pot voltage, emissions, and energy usage of 35.2 kWh/MT. Full implementation further reduced pot voltage and energy usage by 67.3 kWh/MT, increasing annual savings.
- Slotted anodes provide environmental benefits like conserving resources and reducing greenhouse gas emissions by 30-50%. They also improve productivity and working conditions.
Activated carbon sorbents are important tools for water purification and air pollution control. They work by adsorbing impurities from liquids and gases through physical and chemical adsorption within their highly porous structure. This article discusses the fundamentals of activated carbon, including raw materials, activation processes, post-processing, and factors affecting performance. It also provides an overview of emerging applications for activated carbon in biogas purification and sediment remediation.
Effect of steel fiber and poly propylene fiber on the strength properties of ...IRJET Journal
This document summarizes a study on the effect of adding steel fibers and polypropylene fibers to fly ash-based geopolymer concrete. The study used low-calcium fly ash as the source material and an alkaline activator solution made from sodium hydroxide and sodium silicate. Steel fibers with an aspect ratio of 60 and polypropylene fibers with an aspect ratio of 240 were added in varying volume fractions to geopolymer concrete mixes. The compressive strength, split tensile strength, and flexural strength of the fiber-reinforced geopolymer concrete beams were then tested and compared to non-fiber mixes.
IRJET- Treatment of Tannery Effluent using Groundnut ShellsIRJET Journal
The document describes a study on treating tannery effluent using groundnut shells. Tannery effluent contains high levels of pollutants like chromium, copper and nickel that contaminate water sources. The researchers prepared activated carbon from groundnut shells and used it to adsorb pollutants from tannery effluent. They characterized the activated carbon and analyzed pollutant levels in the raw and treated effluent. The treatment significantly reduced pollutant concentrations like chromium, chemical oxygen demand and biological oxygen demand. Using an agricultural byproduct like groundnut shells for treatment provides an inexpensive and effective alternative to existing costly treatment methods.
ABRAFATI 2015 OVERVIEW OF LOW ENERGY EB FOR INDUSTRIAL COATINGS 100915Carignano
The document provides an overview of low energy electron beam (EB) technology for curing industrial coatings. It discusses:
1) How EB equipment advancements have enabled safe and consistent curing of coatings.
2) A case study of a company that implemented a hybrid UV/EB coil coating line, increasing line speed 6x and reducing energy costs.
3) Remaining challenges for UV/EB coatings in replacing conventional coil coatings, including matching weathering performance and end user awareness.
Similar to The role of material in fertilizers industries with energy saving (20)
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.
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
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.
“Antisurge Protection in action” for Compressors By Prem Baboo.pdfPremBaboo4
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.
Ammonia Plant and Catalyst By Prem Baboo.pdfPremBaboo4
Research Gate is an academic social networking site for scientists and researchers. This document discusses catalysts used in ammonia plants. It describes how catalysts work by providing alternate reaction paths with lower activation energies than non-catalytic reactions. It also discusses factors that influence catalyst performance like size, shape, promoters, and poisons. Specific catalysts used in different sections of an ammonia plant are described.
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.
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.
General Knowledge on Ammonia Production By Prem Baboo.pdfPremBaboo4
The present paper description of Ammonia Plant, Production of Green Hydrogen, Different types of revamp option of Ammonia & urea plant different types of ammonia process, calculation. This paper is very useful for Engineering students, new comers in fertilizers Industries .Practical data detail of vessel, Electric heating primary reformer and what is the difference of Gas fired primary reformer and Electric heating, calculation, efficiency etc.
How to Calculate Separation Efficiency of compressor separators By Prem Babo...PremBaboo4
The centrifugal Compressor is designed for gas and vapour if the separation efficiency goes down then the water carryover in next stage and this is very dangerous for compressor internals because the gas & vapours are compressible fluid while the liquid is incompressible fluids. As a result a rapid and exponential rise in hydraulic pressure will be occurred and also Vibration. So, overall, vanes and impellers are the main victims of liquid droplets in a centrifugal compressor, or any compressor. Two phase flow in a compressor always damage its internal and it may damage the casing and deposition takes place on internals
Question Answer on Energy Conservation Vol 2 by Prem Baboo.pdfPremBaboo4
78-80 % energy of Urea process depends upon ammonia process and rest on power & steam. If the energy of ammonia plants is improved then the urea plant energy automatically improves. The specific consumption of urea stoichiometrically is 0.566 but due to losses it generally found 0.569-0.574 depends upon loses of urea/ammonia in the process etc. steam consumption if you are using 40 ata steam turbine then you will have to change into 100 ata steam turbine. The energy will be improved about 0.097 G.Cal/ton of urea. In this quiz how to improve energy in urea plants. Indian urea manufacturers are on a par with the best of the world in terms of low energy consumption and greenhouse gas (GHG) emissions, Besides becoming a global concern for pollution of groundwater and surface water bodies, the production and use of urea has also significantly contributed to GHG emissions. “Energy conserved is energy produced “Energy conserved is energy produced “
Question Answer on Energy Conservation Vol 1 By Prem Baboo.pdfPremBaboo4
G.Cal/ton of Ammonia, G.Cal/ton of urea is the most important data in fertilizers industries for performance evaluation. The energy of the fertilizers is depends upon Reformer feed & fuel. Earlier thinking Fertilizers should be produced at any cost we have nothing to do with energy & pollution and what environment we don’t know? But today time has changed. We have to meet the energy & environment conditions otherwise penalty will be imposed and your factory will be closed. In this quiz we will discuss about energy. How to reduced energy and how to reduced pollution how to save environment? Etc. Hydrogen and could be a boon for renewable energy demand. But greening ammonia, the chemical primarily used to make fertilizer, will take a lot of heavy lifting. Green ammonia is two to three times more expensive than gray ammonia. Depends upon power source means where we are getting power from, i.e. Hydro power or non renewable source.
Discussion on Urea Product Quality by Prem Baboo.pdfPremBaboo4
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
This document discusses questions and answers related to fertilizer industries. It addresses questions about urea reactor design and operation, including why the reactor is heated to a certain temperature before ammoniation and how reactor volume is determined based on plant capacity. It also discusses different types of pressure vessels and layered wall reactor designs. Additional questions cover topics like leak detection systems, stripping processes, and common problems that occur after plant shutdowns.
Fire Safety Network for Fertilizers Industries.pdfPremBaboo4
Fire network & Fire prevention device with fire station is essential for all industries. The fire Industries have very dangerous substances and gases that can catch fire at any time. Most of the accidents/injuries are caused by human errors. Industry says, human error accounts for 96% of accidents. The rest takes place due to external conditions and failure factory equipment. In which fertilizers industries account for most of such fatal accidents. Safety is a condition or state of being resulting from the modification of human behavior, and/or designing of the physical environment to reduce the possibility of hazards, thereby reducing accidents. Safety is an ever changing condition in which one attempts to minimize the risk of injury, illness or property damage from the hazards to which one may be exposed. Perfect fire network is must for fertilizers Industries. Life is god's special gift to mankind. It is therefore important to treasure & protect it from all kinds of potential threats. Regardless of the precautions that we take in our day-to-day life, fire accidents are seldom averted. Risky jobs with a potential to put your life at risk can be a cause for concern especially to your family & friends. Moreover,constant exposure to dangerous surroundings increases the chances of enduring major/minor injuries with a likelihood of developing a permanent handicap.
OPERATION AND TROUBLE SHOOTING IN LP AND VACUUM SECTION FOR MS SAIPEM PROCESS...PremBaboo4
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 LP AND VACUUM SECTION FOR MS SAIPEM PROCESS...PremBaboo4
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.
RISK MANAGEMENT IN AMMONIA UREA PLANTS.pdfPremBaboo4
This document discusses risk management in ammonia and urea plants. It begins by introducing ammonia production and describing the hazards posed by accidental releases of gases like ammonia. It then analyzes the hazards using indices to assess the fire, explosion, and toxicity risks of different units. Several potential hazards are identified with severity ranging from light to severe. The document provides an overview of the ammonia production process and describes some of the key units involved like desulfurization and reforming. It analyzes failure modes and risks to help evaluate consequences and determine risk reduction measures.
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.
HOW TO CONTROL PRILLING TOWER DUST EMISSION.pdfPremBaboo4
This document discusses how to control dust emissions from urea prilling towers. It begins with background on urea production and the prilling process. There are two main types of prilling towers: natural draft and forced draft. Dust emission is directly proportional to temperature and can be controlled internally through process changes or externally by installing dust control systems in the prilling tower. Wet scrubbers are commonly used and can reduce dust and ammonia emissions to around 25 mg/Nm3 while also recovering product. Manual cleaning of scrapers in prilling towers presents safety risks, so movable structures or remote methods are preferable.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
Discover the latest insights on Data Driven Maintenance with our comprehensive webinar presentation. Learn about traditional maintenance challenges, the right approach to utilizing data, and the benefits of adopting a Data Driven Maintenance strategy. Explore real-world examples, industry best practices, and innovative solutions like FMECA and the D3M model. This presentation, led by expert Jules Oudmans, is essential for asset owners looking to optimize their maintenance processes and leverage digital technologies for improved efficiency and performance. Download now to stay ahead in the evolving maintenance landscape.
An improved modulation technique suitable for a three level flying capacitor ...IJECEIAES
This research paper introduces an innovative modulation technique for controlling a 3-level flying capacitor multilevel inverter (FCMLI), aiming to streamline the modulation process in contrast to conventional methods. The proposed
simplified modulation technique paves the way for more straightforward and
efficient control of multilevel inverters, enabling their widespread adoption and
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Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Introduction- e - waste – definition - sources of e-waste– hazardous substances in e-waste - effects of e-waste on environment and human health- need for e-waste management– e-waste handling rules - waste minimization techniques for managing e-waste – recycling of e-waste - disposal treatment methods of e- waste – mechanism of extraction of precious metal from leaching solution-global Scenario of E-waste – E-waste in India- case studies.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
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The role of material in fertilizers industries with energy saving
1. See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/355734341
The Role of Material in Fertilizers Industries with Energy Saving
Presentation · October 2021
DOI: 10.13140/RG.2.2.21615.36002
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
Industrial Process View project
Prem Baboo
Dangote Fertilizer Ltd
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The Role of Material in Fertilizers Industries
with
Energy Saving
By
Prem Baboo
Former Sr. Manager (Production)
National Fertilizers Ltd., Vijaipur, Guna (M.P.), India
Abstract
In Fertilizers industries the material plays a
very important role. Right material can save
energy as well as plant life and 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 urea
plant very corrosive chemicals are used for
urea production. The raw material of urea
plant is Ammonia and Carbon Dioxide gas
which makes very corrosive chemical
ammonium Carbamate. For reduced
corrosion passivation air is used in reactor as
well as stripper according to material of
selection different quaintly of air is used.
Controlled and less quantity of passivation
air is required for Titanium and Zirconium
material and hence saving of energy because
the huge amount of ammonia is waste with
venting of inerts, i.e. saving of energy and
environments also. Passivation oxygen
given in CO2 is directly proportional to
ammonia losses in MP section. This paper
intended how to increase life of urea reactor
liner and energy saving with low passivation
air and high N/C ratio, Ammonia is the
noncorrosive and ammonia to CO2 Ratio is
an important parameter for process
optimization occurring less losses and less
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.
Keywords
Corrosion, Duplex stainless steel, energy,
2RE-69, Zirconium, Liner
Introduction
For Urea production number of Process are
used there are two types of Process
Conventional and nonconventional process
or stripping process. Stripping process first
introduced by M/S. Saipem and called
ammonia stripping process and then by M/S
Stamicarbon Process called CO2 stripping
Process. Urea is formed according to the
following reactions: -
2NH3 + CO2 = NH2 COO
NH4 + 37.64 K Cal/Mole ....... (1)
Ammonium Carbamate.
NH2 COO NH4 = NH2 CO NH2
+ H2O - 6.32 K.Cal/Mole. (2)
Urea
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Reaction No. (1) Given
instantaneous and completes very fast. It is
exothermic in nature and 37.64 K.Cal of
heat is produced in the formation
Ammonium Carbamate. Reaction No.2,
however, is very slow and controls the Urea
formation. It is endothermic and 6.32
K.Cal/Mole is consumed in the dehydration
of Ammonium Carbamate. Actual available
heat in an ideal Urea Synthesis reaction will,
however, is only approx. 5.74 Kcal/mole
because of the heat lost in evaporation of
liquid NH3, evaporation of water
melting of Urea. 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 as shown in the table
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above is
instantaneous and completes very fast. It is
exothermic in nature and 37.64 K.Cal of
heat is produced in the formation
Ammonium Carbamate. Reaction No.2,
however, is very slow and controls the Urea
ic and 6.32
K.Cal/Mole is consumed in the dehydration
of Ammonium Carbamate. Actual available
heat in an ideal Urea Synthesis reaction will,
however, is only approx. 5.74 Kcal/mole
because of the heat lost in evaporation of
, evaporation of water formed and
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
on as shown in the table-2.
Material Used for Urea Process
In Urea reactor following material are used
for liner
1. Titanium
2. Zirconium
3. 2RE-69
4. SS-316L(Urea grade)
5. Duplex stainless steel
For stripper following material are
used
1. Titanium
2. 2RE-69
3. Duplex stainless
4. Bimetallic stripper( the two metal
are used inside Zirconium and
outside 2RE-69.
In MP section SS
LP/Vacuum and section SS304
are used.
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Material Used for Urea Process
In Urea reactor following material are used
316L(Urea grade)
Duplex stainless steel
For stripper following material are
steel
Bimetallic stripper( the two metal
are used inside Zirconium and
In MP section SS-316 L and for
LP/Vacuum and section SS304
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Fig-1(Urea Plant Process flow diagram with
material)
In Conventional process Titanium liner is
used in reactor, very small quantity of air is
required for Titanium material , CPI allied
process Zirconium liner is used .In
conventional process high pressure and high
temperature are required but in stripping
process less pressure and temperature.
Zirconium has a very tenacious, naturally
occurring, passive oxide layer that is
virtually impervious to conditions inside a
urea process plant. As compared to stainless
steel, zirconium does not require any
additional oxygen to be added to the process
stream to remain resistant to corrosion. In
ammonia stripping process 158 bar pressure
and 190 0C in Urea reactor while CO2
stripping 140, 150 & 175 bar pressure are
used in Stamicarbon, ACES-21 and ACES
Process respectively. Following material
detail.
Sr. No. MOC Advantages Disadvantages
1 Titanium Good passivation properties with
less air
Susceptible to Erosion Difficult
to Weld Costly.
2 Zirconium Zirconium is extremely well suited
to the urea processing environment.
No passivation required
Costly
4 Stainless steel Immune to Erosion Good Weld
ability
Large amount of passivation
required hence more losses
5 SS-316-L(urea
grade)
Excellent weld ability Large amount of passivation
6 2-RE-
69(Sandvik)
Excellent weld ability Better
Corrosion resistance than
316L(urea grade)
susceptible to SCC by chloride
7 Duplex Stainless
Steel (SAFUREX)
Good Weld ability Excellent for
stress corrosion cracking Corrosion
Resistance Passivation air is not
required
Costly
Table-1 (Material detail)
Additionally, Zirconium has a much higher
temperature capability in the urea process
solution compared to other materials.
Zirconium is extremely well suited to the
urea processing environment; it has a very
high tolerance for variable plant conditions
and compositions. Very little formal
corrosion data has been generated for
Zirconium in this application beyond the
numerous successful applications in
operating plants. The material of liner in
urea reactor essentially affects the reliability,
operability and maintainability of urea plant.
Zirconium is highly resistant to corrosion in
typical urea processing conditions. Sandvik
2 RE 69 is a fully austenitic stainless steel
with extra low carbon and impurity contents.
Excellent resistance to corrosion in
ammonium Carbamate excellent resistance
to inter granular corrosion, high resistance to
pitting and crevice corrosion and good weld
ability. Zirconium has a long successful
track record in solving very difficult
corrosion problems in the urea industry. In
an era where urea plants are expanding and
“mega” plants with capacities approaching
5000 TPD in Saipem plants are designed and
built, plant downtime and corrosion issues in
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general are greatly magnified in their
significance regarding process reliability and
operation profitability. The excellent
corrosion resistant properties of the Safurex
material eliminate the need of using
passivation air in the urea processes.
Because of the absence of oxygen in the
synthesis section, hydrogen or any other
combustibles present in the feed no longer
poses any risk of explosion for the urea
plant. The ammonia emissions are also kept
to an absolute minimum. Increasing, process
designers and operators are looking to
Zirconium to provide the materials
performance necessary for these mega-
plants. By using Zirconium, existing urea
processes can perform at a higher level.
Increasingly capacity, energy savings,
reduction of corrosion products in the
process stream, and elimination of the
requirement for additional passivation air,
and other environmental benefits in addition
to longer equipment life may be possible
with the proper application of Zirconium.
The Zirconium also used in Omega Bond
Tubing in urea applications developed by
Saipem Technology. However, certain
impurities are known to be deleterious to
Zirconium even in relatively low
concentrations. Fluoride, in particular can
cause rapid general attack on zirconium,
especially in an acidic environment.
Additionally, some metal ions (i.e., Cu or
Fe3+) may promote the initiation of pitting
in certain conditions. In MTC process the
reactor liner is used Titanium. Titanium is
used frequently in urea processing
applications due to its passivity in the urea
processing environment. However the oxide
layer of titanium is not nearly as hard and
tenacious as that of Zirconium, and it
therefore suffers from localized erosion /
corrosion on the inside of heat exchanger
and stripper tubes, specifically where the
fluid velocity is high. Titanium is used in the
relatively pure state .It has excellent
corrosion resistance but is one of the more
costly and difficult alloy to weld. Titanium
corrosion resistance is due to the impervious
oxide film i.e.100% TiO2 film on surface.
Titanium is resistant to stress corrosion
cracking and erosion corrosion, but it is
susceptible to crevice corrosion in stagnant
chloride solutions. Titanium is not
maintenance friendly the difficult in welding
Titanium is due to high affinity for
Hydrogen, Nitrogen and oxygen in the
molten state. Therefore, it must be welded
by such inert-gas welding method as the TIG
or MIG process. After a weld has been
made, the inert-gas protection must be
maintained until the welding joint cool
below 6500
C, otherwise the Titanium will
react with the oxygen, Nitrogen and
moisture in the air, resulting in weld
embrittlement. The conventional process is
generally not economical to maximize the
percentage conversion in the reactor since
this would require an excessive retention
time. The aim therefore is to attain
maximum quantity of urea production per
unit of time with due regard to the cost of
recycling un reacted CO2 and NH3 as well as
the cost of increased reactor size and
corrosion difficulties which increase with
temperature and reduction of N/C ratio.
Typical operating conditions are:
temperature, 180°-210°C; pressure, 140-250
kg/cm2
; NH3 CO2 mole ratio, 3:1 4:1; and
retention time, 20-30 minutes. The MTC
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Process having pressure 240-250 kg/cm2
pressure, Liquid NH3 and gaseous CO2 are
pumped to the urea reactor at 200 atm. The
temperature of the reactor is maintained at
about 185°C by proper balance of excess
NH3 and Carbamate solution recycles feed.
About 100%-110% excess ~NH3 is used;
about 70% of the NH3 and 87% of the C02
are converted to urea. The remaining 30% of
the NH3 will be recycled back to reactor.
Shortly after Stamicarbon introduction of the
C02 stripping process, Saipem launched its
ammonia stripping technology. In this
process stripping gas is ammonia and carbon
dioxide is introduced directly into the
synthesis reactor. The route is also
distinguished by the use of two stage
Carbamate decomposition, the first
operating pressure~ at 17 kg/cm2 g and the
second at 3.5 kg/cm2 g. The synthesis
conditions are maintained at 185-190°C and
155-166 kg/cm2 . Ammonia corning from
M.P section is raised to 230 kg/cm2 g and is
used as driving fluid in Carbamate ejector
where the recycled Carbamate is compressed
up to synthesis pressure. The reaction
products leaving the reactor flow to the
steam heated falling film stripper which
operates at 150kg/cm2 g.
Role of oxygen and stainless steel
The practical was done in November 2018 in
National Fertilizers Ltd, Vijaipur Oxygen Vs
ammonia losses in Urea Plant line- and
tabulated in table number-2 and it is found
the supplied passivation air is the function of
ammonia losses. In every urea plant where
no special precautions have been taken to
avoid the presence of hydrogen & Oxygen
explosive gas mixtures will show up if the
non condensable gases are purified
thoroughly to prevent ammonia losses or to
minimize emission of ammonia into the
atmosphere. The optimum passivation is
required if more than optimum the chances
of explosive mixture and also ammonia
losses, i.e. danger for environment also.
Flammable gas mixtures and the consequences
there of on urea plant safety have been important
issues in the entire history of the urea process
industry. High chromium stainless steel owe
their high resistance to corrosion under
oxidizing condition due to the formation of a
surface-oxide film which is very adherent
and highly impervious; thus the metal is
protected from attack or we say it is passive.
However, if the oxidizing conditions are
lost, the metal is rapidly attacked. The
protective film once formed is not damaged
in normal course. The presence of sulphur
compounds damages this protective film. It
is essential that the protective film is not
damaged during operation and as such
continuous feeding of air has been
incorporated in our process. It was found
from experiments that SS 316L stainless
steel requires 5 ppm of 02 for passivation
and 2RE-69 stainless steel requires 3 ppm.
Although this value is low and in actual
practice as high as 6000 ppm of 02 is being
maintained. Material of higher chromium
content requires less oxygen to remain
passive than low chromium steels. This fact
also points to the suitability of using
stainless steel with a chromium content of
24.5% in HP stripper. Chromium slows
down and nickel accelerates the corrosion of
materials in the active state .This is best
illustrated by corrosion rates of a number of
materials in relation to their Ni contents. At
higher temperature and pressure and where
aggressive condition of urea Carbamate
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mixture exists, stainless steel of higher
chromium and nickel contents are found to
be more effective against corrosion. At this
condition, the influence of Nickel
apparent. However, the corrosion rate of
2RE-69 stainless steel is about 5
low as that of SS-316L which indicates that
the favorable influence of Chromium
much larger than the unfavorable
of Nickel.
Since the liquid phase in urea synthesis
behaves as an electrolyte, the corrosion is of
an electrochemical nature. Stainless steel in
a corrosive medium owes its corrosion
resistance to the presence of a protective
oxide layer on the metal. As long as this
layer is intact, the metal corrodes at a very
low rate. Passive corrosion rates of
austenitic urea grade stainless steels are
Fig-2(Oxygen Vs Corrosion rate in Duplex
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mixture exists, stainless steel of higher
chromium and nickel contents are found to
be more effective against corrosion. At this
ckel is also
the corrosion rate of
stainless steel is about 5 times as
which indicates that
influence of Chromium is
unfavorable influence
Since the liquid phase in urea synthesis
n electrolyte, the corrosion is of
an electrochemical nature. Stainless steel in
a corrosive medium owes its corrosion
resistance to the presence of a protective
oxide layer on the metal. As long as this
layer is intact, the metal corrodes at a very
te. Passive corrosion rates of
austenitic urea grade stainless steels are
generally between <0.01and (max.) 0.10
mm/a. Upon removal of the oxide layer,
activation and consequently, corrosion set in
unless the medium contains sufficient
oxygen or oxidation agent to build a new
layer. Active corrosion rates can reach
values of 50 mm/a. Stainless steel exposed
to Carbamate containing solutions involved
in urea synthesis can be kept in a passivating
(non corroding) state by a given quantity of
oxygen. If the oxygen content drops below
this limit, corrosion starts after some time
depending upon process conditions and the
quality of the passive layer. Hence,
introduction of oxygen and maintenance of
sufficiently high oxygen content in the
various process streams are prerequisites to
preventing corrosion of the equipment.
Material)
2(Oxygen Vs Corrosion rate in Duplex
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generally between <0.01and (max.) 0.10
mm/a. Upon removal of the oxide layer,
activation and consequently, corrosion set in
unless the medium contains sufficient
agent to build a new
layer. Active corrosion rates can reach
/a. Stainless steel exposed
arbamate containing solutions involved
in urea synthesis can be kept in a passivating
(non corroding) state by a given quantity of
ygen content drops below
this limit, corrosion starts after some time
depending upon process conditions and the
quality of the passive layer. Hence,
introduction of oxygen and maintenance of
high oxygen content in the
re prerequisites to
preventing corrosion of the equipment.
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Table-2(Oxygen Vs ammonia losses with inerts)
From the point of view of corrosion
prevention, the condensation of NH3-CO2-
H2O gas mixtures to Carbamate solutions
deserves great attention. This is necessary
because an oxygen deficient corrosive
condensate is initially formed on
condensation. In this condensate the oxygen
is absorbed only slowly. The Oxygen Vs
Material shows in the figure-2.This accounts
for the severe corrosion sometimes observed
in cold spots inside gas lines. The trouble
can be remedied by adequate isolation and
tracing of the lines. When the condensation
constitutes an essential process step - for
example, in high pressure and low pressure
Carbamate condensers-special technological
measures must be taken. These measures can
involve ensuring that an oxygen rich liquid
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phase is introduced into the condenser, while
appropriate liquid gas distribution devices
Fig-3(Passivation Oxygen Vs Corrosion
Not only condensing but also stagnant
conditions are dangerous, especially where
narrow crevices are present, into which
hardly any oxygen can penetrate and oxygen
depletion may occur. As an attractive
alternative to austenitic stainless steel the use of
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phase is introduced into the condenser, while
distribution devices
ensure that no dry spots exist on condensing
surfaces.
Corrosion rate)
Not only condensing but also stagnant
conditions are dangerous, especially where
are present, into which
hardly any oxygen can penetrate and oxygen
As an attractive
alternative to austenitic stainless steel the use of
duplex stainless steel in the chemical industry is
being experimented over the past few years.
They are now used not only in chloride
environment, where they are more resistant to
SCC than austenitic stainless steel, but also in a
wide variety of other demanding applications.
Due to the frequent tube failure, SS 304L tubes
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ensure that no dry spots exist on condensing
duplex stainless steel in the chemical industry is
being experimented over the past few years.
y are now used not only in chloride
environment, where they are more resistant to
SCC than austenitic stainless steel, but also in a
wide variety of other demanding applications.
Due to the frequent tube failure, SS 304L tubes
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were replaced with Sandvik duplex tubes (SAF-
2205) in all inter stage coolers of CO2
Centrifugal Compressor of many urea plants
because the SCC occurred in number of the
plants. Figure- 2 shows the Oxygen Vs
Corrosion rate. And figure -3 shows the Oxygen
Vs Corrosion rate in different metal. It was
experienced that the tubes were failing due to
stress corrosion cracking in the presence of high
CO2 gas temperature (tube side) and chloride
presence in cooling water (shell side).
Sandvik SAF 2205 is a duplex (austenitic-
ferrite) stainless steel material. Advantages
of Sandvik duplex material (SAF 2205) over
304L / 316L are as follows.
1. High resistance to stress corrosion
cracking in chloride-bearing
environments and in environments
containing hydrogen supplied.
2. High resistance to general corrosion,
pitting and crevice corrosion.
3. High resistance to erosion corrosion
and corrosion fatigue. In oxygen free
Carbamate solutions, duplex has
proved to be more corrosion resistant
than much more costly materials
such as Titanium and high-nickel
alloys. In the high pressure synthesis
section of urea plants, duplex is an
excellent alternative to traditional
urea grades such as type AISI 316 L
UG ,2RE-69( 25 22 2). These are
particularly prone to SCC on the
steam side of heat exchangers when
the boiler feed water is contaminated
with chlorides.
Sr.
No.
Material Fluid Services
1. Titanium Urea, Carbamate Urea Reactor liner, Stripper
2 Zirconium Urea, Carbamate Stripper, Urea Reactors Liner
3 2-RE-69 Urea, Carbamate Urea Reactor liner, Strippers
Carbamate Condenser
4 SS-316L Urea Carbamate,
Carbonate
Medium Pressure section,
decomposer, ammonia receiver
absorber. Decomposers.
5 SS-316L(Urea
Grade)
Urea Reactor, heat exchangers
6 SS-304 Urea Carbonate Urea LP section, vacuum section and
waste water section
Table-3
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Grade Cr Ni Mo N PRE Microstructure
2 Re 60(UG) 18.5 4.9 2.7 0.07 28 Duplex
SAF 2304 23 4.5 - 0.1 24 Duplex
SAF 2205 22 5.5 3.2 0.18 35 Duplex
25 4 7 0.3 43
SAF2507 Duplex
18
AISI 304L 18.5 10 Austenite
Austenite
AISI 316L 17.5 13 2.1 24
Table-4
Conclusion
Based on the observation described above it
can be concluded that the energy can be
saved by choosing right material in
equipment like reactor liner and reducing the
amount of passivation air and hence losses
can be saved. The Duplex stainless steel makes
it possible to reduce the passivation air stream to
a urea plant more than tenfold .Oxygen is
normally added in the form of air to the
carbon dioxide flowing to the synthesis
section. Since Oxygen may form explosive
mixtures with Hydrogen the composition of
the gas phases in the various process steps
must be so controlled that explosion cannot
occur. With optimum addition of oxygen
and thus to realize an intrinsically safe urea
plant is only possible to Duplex stainless
steel and Sandvik (2RE69). Many issues
arise over material selection and corrosion
abatement in modern fertilizer plants. With
developments of metallurgy, and usage of
newer corrosion-prevention techniques, it is
possible to cost-effectively and, more
important, safely operate and maintain large-
scale plants.
References
1. Book the fertilizers Technology (pure
knowledge) by Prem Baboo published in
Notion Press January 2021.
2. Material Technology for Fertilizers
Industries by Prem Baboo Published
on Research Gate, August 2021.
3. Stress corrosion cracking in CO2
Compressor Intercooler By Prem
Baboo, published in International
Journal of Engineering Research &
Technology (IJERT) Vol-8 issue 04,
April 2019
4. Can Passivation Air in Urea Plants be
minimized through the Use of Safurex
and Consequently Improve Plant Safety
by Bart Gevers, Sr. and Will Lemmen,
published in Ammonia technical manual
year 2002.
Legends
SCC-Stress corrosion cracking, MP-medium
pressure. LP-Low pressure. PRE-Pitting
Resistance equivalent corrosion (%Cr + 3.3
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%Mo + 16 %N), MTC- Mitsue-Totsue “C”
improved Process. TIG-Tungsten Inerts Gas.
MIG-Metal Inerts gas.
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