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Urea Synthesis and HP Recovery Section (Abnormal Operations and Operational Emergency Handling)

Introduction

Urea Synthesis and HP Recovery Section (Abnormal Operations and Operational Emergency Handling)

Objectives

Upon successful completion of this course, the delegates will be able to:

• • Describe the synthesis reaction and physical properties of urea.
  • Know the process steps of urea production and urea synthesis
  • Identify the complete urea production plants, steam reforming ammonia plants and ammonia plants based on partial oxidation
  • Know the modernization of Urea older plants (revamping), and also their objectives and revamping options
  • Classify the integration of another process into urea plant
  • Outline the material considerations for equipment fabrication
  • Recognize the storage, shipping, and transportation of urea
  • Become aware of the various quality specifications and analysis of urea
  • Learn the environmental, safety, and health aspects of production and handling urea, including its safety, health features and toxicity of biuret.
  • Why maximum Biuret 1.5% permissible in Urea?
  • Determine the urea chemical reactions
  • Recognize the different troubleshooting regarding; Urea synthesis and HP recovery section.
  • Recognize the different troubleshooting regarding; Urea Abnormal Operations &Operational Emergency Handling

Who Should Attend?

• This course is intended for engineers, technicians, and operators working in the urea industry, particularly those who have recently assumed new responsibilities, to increase their technical knowledge in urea production and for experienced engineers to become better acquainted with new technologies in the industry.
• The course will help to improve the participants’ skills and understanding of the entire industry, including technology, economics, energy, use, safety, and environmental stewardship.

Course Outline

Day 1: Introduction Urea Process Technologies

• Urea product
• General urea market information
• History of process technologies
• Various Synthesis Methods (Licenses)
  1. Snamprogetti
  2. Stamicarbon
  3. Toyo
  4. Casal
• Various Solidification Methods
  1. Prilling
  2. Granulation
  3. Pastillation

Day 2: Operational aspects of urea plants

• Control philosophy of various sections
• Basic Chemistry
  1. Side Reactions: Biuret Formation
  2. Side Reactions: Isocyanic Acid
  3. Carbamate Chemistry
  4. NH3/CO2 Ratio
• Historical Perspective of Urea Processes
  • Conventional (Total-Recycle) Processes
  • Stripping Processes
    • Stamicarbon Stripping Processes
    • Combating Corrosion in the Stamicarbon Processes
    • Snamprogetti Stripping Processes
    • TEC Stripping Processes
• Key analysis for process control (Biuret % control)

Day 3: Corrosion in carbamate solutions

• Theory of corrosion in ammonium carbamate solutions
• Overview of various corrosion phenomena in urea plants
• Cases of various types of corrosion such as;
• Passive, Active, crevice, condensation corrosion, stress corrosion, cracking, and erosion.
• Effect of oxygen, temperature, carbamate, N/C ratio, pressure, the temperature on corrosion rates
• How to detect active corrosion?

Day 4: Materials of construction in urea plants

• Historical overview of applied materials
• The typical properties of materials applied in urea plants;

1. (Austenitic stainless steels in high pressure and
2. low-pressure sections, Duplex stainless steels
3. (DP12, DP28W®, Safurex®) as well as Titanium, Zirconium, Tantalum.

• Which materials to apply in specific process conditions?

High-Pressure Synthesis equipment

• Process aspects
• Mechanical aspects
• Multi-layer or solid wall, Low or high strength steels
• Leak Detection Systems for vessels and heat exchangers
• Tube failures
• Gaskets and Bolting
• How to assure high reliability of critical equipment
• Corrosion cases caused by failing leak detection systems

Day 5: Troubleshooting Urea Plants

1. General troubleshooting techniques
2. Corrosion and failure cases
3. Process upset cases
4. Fouling cases

Safety, Health & Environmental aspects

1. Reliability aspects
2. Safety and Health concerns
3. Emission sources (continuous and discontinuous)
4. Flare systems, containment systems
5. Safety valves

Revamp Technologies

1. Capacity increase
2. Energy conservation
3. Emission reduction
4. New developments
5. Solid heat exchanger revamp opportunities
6. Energy reduction management

Failure modes High-Pressure Equipment

1. Reactor, condenser and stripper failure modes
2. Heating up / cooling down, stop-starts and blocking in
3. Baffle hammering problems and effects of different loads
4. Effect of temperature and partial oxygen pressure
5. Effect of liquid distribution