Experience of material in fertilizers industries

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EXPERIENCE OF MATERIAL IN FERTILIZERS INDUSTRIES
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GSJ: Volume 9, Issue 1, January 2021, Online: ISSN 2320-9186
www.globalscientificjournal.com
EXPERIENCE OF MATERIAL IN FERTILIZERS INDUSTRIES
Prem Baboo,
DGM (Production & Process), Dangote Fertilizer Limited) Ex. Sr. Manager, National Fertilizers Ltd, India
Abstract
Materials plays very important role in any industry.
Selection of material is vital at design stage itself
,Wrong selection of material may lead to
catastrophic failures and outage of plants & even
loss of Human lives, Right selection of material
leads to long life of plant. In the latest plants
specialty 2 RE-69 materials are used for liner. The
actual reactor has been constructed using a variety
of materials, e.g. Zirconium, Vessel inside a
protective liner. This paper intended study Material
in urea plant in different vessels and equipment
design. In Primary reformer numbers of materials
are modified such as micro alloy are also used in
tubes.
Keyword- Corrosion, Duplex, Stainless steel, 2-
RE-69, SCC, Titanium, Zirconium
Introduction
National Fertilizers Ltd, (NFL) operates a fertilizer
complex at Vijaipur, Distt. Guna (Madhya Pradesh)
consisting of two units Vijaipur-I and Vijaipur-II,
plants were commissioned in December 1987 and
March 1997 respectively. Ammonia Plants are
based on M/s. HTAS’s Steam Reforming of
Natural Gas and Urea plants are based on M/S.
Saipem’s Ammonia Stripping technology. The
Vijaipur unit, which is an ISO 9001:2000 & 14001
certified, comprises of two streams. The Vijaipur
have two ammonia plant M/S. Haldor Topsoe
Technology, Denmark capacity 1750 & 1864 TPD
for Line-I & line-II respectively and urea plant
capacity 3030 and 3231 TPD for line-1& Line-II
respectively. In urea line-1 & line-2 plant many
time shut down taken due to leakage of stripper,
Reactor and carbamate condenser. Maximum
leakage occurred due to stripper tube leakage. Both
unit have bimetallic stripper. Initially line -1 have
Titanium stripper and changed by bi-metallic
stripper.
History of Urea Reactor Liner
The all four reactors(R-1) of Urea line 1 & 2 plants
are 40 meters Height (Tan to tan). The liner of all
reactors has SS 316 L (mod) while shell of line 1 &
line 2 are differing. The line -1 both reactors are
coil layered vessel while 31 unit has multi layered
and that of 41 is mono block reactor. Detail as
following table N0-1. The all four Urea reactor
have 15 number of sieve trays. These have been
provided to prevent the escape of gaseous CO2,
which must react with NH3 in the lower portion of
the reactor. These trays also help in preventing the
internal recycling of the reaction products with
higher specific gravity products formed in the
upper part of the reactor. Reactor shell is made of
CS with a 7 mm liner of SS316L (mod) on the liner
surface. In the sixties the convention or non
stripping process are used having high pressure, the
process based on the 1st
principal of decrease in
pressure and increase in temperature” and then
have a series of decomposition stage where the
Reactor discharge is treated in successively at
lower pressure. In the CPI allied process having
400 kg/cm2 pressure, the reactor liner used
Zirconium;
Sr.
No.
Material of
Construction
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
3 Stainless Steel Immune to Erosion
Good Weld ability
Large amount of passivation
require.
4 316L(urea grade) Excellent Weld ability Large amount of passivation
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Fair corrosion
Relatively less cost
require
5 2RE-69 (Sandvik) Excellent weld ability
Better Corrosion resistance than
316L(urea grade)
Susceptible to SCC by chloride
Costly
6 Duplex Stainless Steel
(SAFUREX)
Good Weld ability Excellent for
stress corrosion cracking Corrosion
Resistance Passivation air is not
required
Costly
Table-1(Material detail)
This is the first and unique process having
Zirconium liner in the reactor. 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. 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. Numerous in-plant coupon tests
have helped to confirm the operating plants’
experience. 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 general are
greatly magnified in their significance regarding
process reliability and operation profitability.
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
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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 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,
Snamprogetti 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 .
Sr.
No.
Material Grade C Cr Ni Mo N2 Others
1 SS 316L 0.03 16-18 10-15 2.0-3.0 . P-≤0.045
S-≤0.03
2 SS 316L UG 0.02 16-18 13.0 2.0-3.0 <0.1 P-≤0.015
S-≤0.01
3 2 RE 69(Saipem) 0.02 24-26 21-23.5 2.0-2.6 0.10-1.5 P ≤ 0.02;
S ≤ 0.01;
B ≤ 0.0015
4 Safurex(Stamicar
bon)
0.03 28-30 5.8-7.5 1.5-2.6 0.3-0.4 Cu ≤ 0.8
5 DP28W(Toyo) 0.03 27-28 7.0-8.2 0.8-1.2 0.3-0.4 W: 2.1-2.5
Table-2 (MOC)
The carbon dioxide in the solution is reduced by
stripping action of ammonia which in fact boils out
of the solution. Overhead gases from the high
pressure stripper and the recovered solution from
the medium pressure absorber all flow to high
pressure carbamate condenser. The drawback of
Titanium When the material is heated
during welding, oxygen like that found in ambient
air can infiltrate and corrupt the weld. 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. As compared to stainless
steel, zirconium does not require any additional
oxygen to be added to the process stream to remain
resistant to corrosion. Additionally, zirconium has a
much higher temperature capability in the urea
process solution compared to other materials. This
makes the metal brittle and prone to cracking or
premature fracture in service, which is clearly
unacceptable in critical-use applications.2RE69 are
also used in conventional process. After
development since sixties the Stripping or non
conventional process became very popular, e.g.
Ammonia stripping process and CO2 stripping
Process, To reduce the partial pressure of product
by swamping the system by one of the reactant
which reduce the partial pressure of other reactant
considerable without changing the total pressure
either CO2 or NH3 or both can be used as a
stripping agent.”
Design of Urea Reactor
The reactor is a simple vessel with adequate
volume to let the reaction progress, but the
pressure, the large dimensions and the huge surface
to be lined make it a critical construction, where
each detail must be designed according to specific
features to guarantee the expected reliability. The
reactor has been layered with titanium, zirconium,
austenitic stainless steels (316L-UG and 25Cr-
22Ni-2Mo) and duplex stainless steel. The choice
depends on the type of process and the specific
experience of the licensor. 25Cr22Ni-2Mo has been
the typical choice for modern plant, giving
excellent results in terms of reliability and
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endurance.
Urea reactor is the plug flow type reactor and
diameter of the vessel is designed such a way that
the solution cannot be come down. A reactor for
the synthesis of urea from ammonia and carbon
dioxide at elevated temperature and pressure is
provided with perforated reactor high efficiency
trays in which at least a pair of spaced part
perforated reactor trays each have at least one
opening at least a distance closer towards the
periphery than the center, such as on or near the
edge of a perforated reactor tray, and each of such
pair perforated reactor trays is provided with a tube
with a height of 50-500 mm located on and
depending from an underside, e.g. bottom side in a
column reactor, of each of such pair perforated
reactor tray. The tubes extend to no more than 1/3
of the distance between two adjacent reactor trays.
The designed of the vessel according to following
table.3.
Fig-1
Corrosion is the function of Temperature as well as
Corrosiveness of process fluid is not constant
owing to effect of start-up/shut-down, fluctuation
of temperature and dissolved oxygen content and
geometrical flow distribution. For stripper.
Passivation air role is principal in this issue The
Passivation given in CO2 depends upon the process
to process in M/Saipem it is 0.25% and in M/S
Stamicarbon it is 0.4-0.6%.This passivation
depends upon N/C ratio in Reactors.
Design of Urea Reactor
Sr. No.
Urea
Production,TPD
Reactor
ID,Meters
Radius,
Meters
Reactor
Height, Meter
Reactor
Volume.M3
Residenc
e Time,
Min
1 1000-1500 2.04 1.02 40.0 135.2
35
2 1600-2000 2.65 1.33 26.2 154.3
34
3 2100-2500 2.15 1.08 42 157.7
33
4 2600-3000 2.25 1.13 43 177.0
32
5 3100-3500 2.45 1.23 44 215.2
31
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6 3600-4000 2.55 1.28 47.0 248.8
30
7 4100-4500 2.6 1.30 48 264.2
29
8 4600-5000 2.7 1.35 49 291.0
28
9 5100-5500 2.8 1.40 50 319.5
27
Table-3
Fig-2
HP stripper
The stripper is possibly the most critical equipment
in the urea process. Different process designs have
different requirements; that is why so many
materials have been used in the past. The
equipment itself is generally a falling evaporator,
and different details generally related to the
different material requirements. Tube material is
the most important choice. Reliability is mainly
connected to the specific choice that each basic
material selection involves. Notwithstanding the
general basic material selection, from stainless steel
to duplex to titanium imply a specific detailed
design, where specific knowledge and experience is
the key for a trouble free life of the equipment.
Carbamate The design of this eq substantially
according to the technology selected. Horizontal or
vertical installation with process fluid tube side or
shell side are commonly used. Since the reaction
heat is usually utilized to generate steam stress
corrosion can be a problem. In this case the use of a
duplex material for tubes may be advantageous.
The stripping of unconverted carbamate from the
autoclave effluent is accomplished in the HP
stripper by CO2 feed stock from CO2 compressor.
The 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. In practice, it is a vertical shell-and-tube
exchanger with the heating medium on the shell
side, and an upper head on tube side sheet specially
designed to permit the uniform distribution of urea
and carbamate solution. In fact, each tube has an
insert-type distributor (ferrule or male type)
designed to put the feed uniformly around the tube
wall in film form. The holes of the ferrule act as
orifices and their diameter and liquid head control
the flow rate. As the liquid film flows, it is heated
and decomposition of carbamate and surface
evaporation occur. The carbon dioxide content of
the solution is reduced by the stripping action of
the ammonia as it boils out of the solution.
Generated vapors (essentially ammonia and carbon
dioxide) are removed by flowing to the top of the
tube. The carbamate decomposition heat is supplied
by means of condensing saturated steam at 219 °C.
Decomposition in stripper based on Henry Law of
partial pressure.Heat transfer area depends upon
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plant load and depends upon what types of
stripping, i.e. ammonia stripping or CO2 stripping.
The exchanger consists of a stainless steel tube
bundle with fixed tube sheet and a carbon steel
shell with expansion bellow to take up the
differential expansion. The top channel houses the
liquid distribution ferrules which are extensions of
the heat exchanger tubes. Ferrules fixed in each of
the tubes have 3-4 liquid holes, each of 2.0-3.0 mm
diameters according to plant load . Liquid flows
into the tubes wetting the walls. The liquid level
above the ferrule in top channel, provides the static
head for the liquid flow. Liquid distribution in the
tubes is a very important factor as any of the tube
starved of liquid flow may tend to overheat and
may result in heavy
corrosion of tubes. The CO2 enters the bottom
channel from a gas distributor above the liquid
level in the bottom channel to prevent CO2 flowing
to the recirculation section. accurate control of the
level is necessary to maintain a liquid seal. The
flow of CO2 to stripper is measured by FR. A low
flow of CO2 will also be indicated by a high
temperature of the liquid from the stripper. The
radioactive level recorder is provided at HP stripper
bottom. The Radar type level transmitters are also
provided to maintain the kevel. LRC controls the
level in the HP stripper bottom. A high level alarm
is also provided for the HP stripper bottom level. A
drain and a vent line (each 1”) are provided for the
shell side of the heat exchanger. A bursting disc
BD-1202 on the shell relieves CO2, NH3 and H2O
mixture to the atmosphere in case of tube failure. A
high temperature alarm is installed in the solution
outlet line of HP stripper. Saturated steam from 23
ata steam saturator at a pressure of 21.0 kg/cm2 g
and temperature of 215.90 C is used in the shell
side of the HP stripper for the decomposition of
carbamate.
According to plant load the stripper heat transfer
area is increases i.e. number of tubes increases as
per following table-40. The CO2 stripping process
the stripper size is more than Ammonia stripping
process
.
Titanium & Bimetallic Stripper
Urea Stripper used in Saipem presses is a falling
film shell and tube type heat exchanger. The urea
solution from reactor outlet carrying unconverted
Carbamate, urea, water and excess ammonia enters
the vertical tube through ferrules(inserts) mounted
on the top of tubes. Ferrules are provided with three
(or four) tangential holes at 1200
(or 900
) angle
which allow inside the tubes. The film adheres to
the tube surface while flowing down to the bottom
of each tube. The film is heated by means of
saturated steam at 25 ata. The excess ammonia
present in the urea solution evaporates thus
reducing the partial pressure of the CO2 in the
vapour phase hence causing stripping of the CO2
from the Carbamate present in the solution phase.
Advantages of falling film heat Exchanger
1. Higher rate of heat transfer due to high velocity of
film and less convective resistance.
2. Reduced biuret formation due to less residence
time.
3. Minimum internal pressure drops.
4. Less tube skin Temperature for same solution
outlet temperature.
High Pressure Corporation and Passivation
method
For the Titanium Stripper the dissolve O2 in the
bottom Stripper solution should be 2.0 ppm even
less, whereas for bimetallic stripper, the dissolve
O2 in the bottom stripper solution should be 5.0-
6.0 ppm .By increasing the temperature in the
stripper bottom (if air is not injected directly), the
dissolve O2 in the bottom solution should decrease
as per following data:-
Design feature of the stripper
During initial plant construction, Saipem, used
special grade of stainless steel i.e.2-RE69 (25-22-2)
as material of construction for tubes, ferrules and
tube sheet / channel side lining in plants in the
world. It was found that these strippers generally
suffered from severe corrosion attack particularly
during lower turn down plant operation due to less
availability of O2 for passivation layer.
Bimetallic Tubes
1. Tubes consist of two tubes an external tube of 2
RE-69 and an internal tube of Zirconium.
2. These tubes are fabricated separately according to
specification of Saipem.
3. Then they are assembled and drawn together.
4. During drawing operation a proper mechanical
bonding is obtained.
Temperature Vs. O2
Sr. No. Stripper bottom temperature, 0
C Oxygen in Bottom solution, ppm
1 204 6
2 205 5
3 206 4
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4 207 3
5 208 2.5
6 209 2
7 210 2
Table-4
Zirconium in ammonium Carbamate solution is
highly corrosive resistance; furthermore it does not
show the erosion problems typical of Titanium.
When it is in contact with air, the Zirconium is
covered by film formed by ZrO2 that are able to
protect the metal up to 3000
C. Only few agent are
attack the Zirconium: Floridic acid, copper and iron
chloride. The main limitation of the Zirconium use
is the high cost of it. To circumvent the above
problem, stainless steel as above was replaced by
Titanium which was extremely good corrosion
resistance and not requires O2 for passivation. For
all plants in India and also around the world,
similar construction was followed till recently by
Saipem. However, the above change in material of
construction unfortunately could not solve all the
operation and maintenance problem and the
stripper continued to attract greater attention by the
plant operators and also of the designer
1. Titanium inherently offers excellent corrosion
resistance but being soft as metal has little
resistance to corrosion. Due to process/operational
reasons the exchanger is subjected to both
corrosion and erosion. Therefore, major causes of
failures in stripper are attributable to erosion of
tubes leading to thickness reduction.
2. Process requirement calls for effective liquid film
inside the tube and also stripping of CO2 by heating
along the tube length. To fulfill the above
requirements it is desire to have:
3. Good coupling between tube and ferrules to
prevent bypassing of liquid through the mating
surface.
4. Effective positive pressure on the on the top of the
ferrules to secure a leakage free joint (external
ferrules).
5. Provision of anti-erosion (Teflon bush) in between
ferrule and tube end.
6. To have least erosion damage to tube due to high
velocity of fluid leaving at the end (tip) of internal
ferrule.
7. Titanium inherently offers excellent corrosion
resistance but being soft as metal has little
resistance to corrosion. Due to process/operational
reasons the exchanger is subjected to both
corrosion and erosion. Therefore, major causes of
failures in stripper are attributable to erosion of
tubes leading to thickness reduction.
8. Process requirement calls for effective liquid film
inside the tube and also stripping of CO2 by heating
along the tube length. To fulfill the above
requirements it is desire to have:
9. Good coupling between tube and ferrules to
prevent bypassing of liquid through the mating
surface.
10. Effective positive pressure on the on the top of the
ferrules to secure a leakage free joint (external
ferrules).
11. Provision of anti-erosion (Teflon bush) in between
ferrule and tube end.
12. To have least erosion damage to tube due to high
velocity of fluid leaving at the end (tip) of internal
ferrule.
13. It consists of a vertical tube bundle exchanger, with
hemispherical head cylindrical channels at top and
bottom
14. The heat needed for decomposition of Carbamate,
for the separation of vapour and for increasing the
temperature is supplied by steam condensing in
shell side of stripper.
15. The solution inside the tube falls down along the
internal walls of tube to ensure high residence time
(to prevent burette formation). and high heat
transfer.
16. Passivation air is injected at bottom channel by K-3
compressor along with electric heater for
preheating.
Material of Constructions
Sr. No Part Material
1 Hemispherical head(Top bottom) 516-GR-60+2-RE-69(LINER)
2 Channel(Top & Bottom) A266-C12+2-RE-69 A266-C12+2
RE 69 Overlay
Table-5
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About 2-Re 69 Materials
1. It is a tailor made grade of Austenitic Stainless
Steel ordered according to Licensor's .
Specification and also known as 25-22-2.
2. According to Saipem specification CR.UR.G510
1995 material shall meet to following
requirement.
Chemical Composition:-
Cr-24-26%,Ni-21-23.5%,Mo-2-2.6%,C-.02,Mn-
1.5-2.0,Si-0.4,S-0.015,P-.02,N-.1-.15%
2-RE-69 Vs Titanium
Advantages:-
1. Excellent erosion and corrosion resistance
especially in tube due to Zr. Lining.
2. Cost effective.
3. Easy maintenance.
Limitations.-
Stripper bottom temperature is limited to 2070
C
means less decomposition. High pressure air
compressor is required for passivation of bottom
part. Plant cannot be run at lower capacity than
normal.
1. As per M/S. Saipem, the maximum operating
temperature of the Bimetallic Stripper with bottom
passivation air is 2050
C.
2. It was reported that in Mexico, against the
recommendation of M/S Saipem, Bimetallic
Stripper was run at 2100
C.After 3 years of
operation, on inspection, the bottom liner was
found totally worn-out.
3. On this experience, M/S Saipem have been
recommending the maximum bottom temperature
of bimetallic stripper as 2050
C.
4. It was reported that minor problem has been faced
at Oswal Chemicals (Presently Kribhco Shyam)
with Bi-Metallic Stripper.
5. It has been in operation without passivation air at
the bottom (on account of non-availability of the air
compressor) against the recommendation of M/S
Saipem. Now the bottom temperature remains at
206-2070
C at 115% plant load.
Metallographic Properties
1. Material in contact with process fluid shall have
Austenitic structure.
2. Ferrite content shall not exceed 0.6%except for
manual welds for which 1.0% is allowed.
3. Sigma phase shall be absent.
4. Chromium carbide may be present in amount only.
5. Material shall pass Huey Test
6. Mechanical Properties
The mechanical properties of the material shall
conform to the values indicated in the following
tables. The values indicated below should be
obtained on each specimen and no averaging shall
be permitted.
At room temperature (Specimen in solution
annealed condition)
Yield strength E 0.2%, Min. - 220 MPa
Ultimate tensile strength, Min.-525 MPa
% elongation L=5.65 - √A, Min. -45 ,% reduction
of area shall be noted for information.
Charpy U-notch impact strength -14 da J/cm2
(min.
individual value), Hardness (maximum) Brinell -
200 , Rockwell-B - 94
At elevated temperature
(Specimen in solution annealed condition)
Minimum strength for 0.2% Permanent off set with
110 MPa at 823 K (550o
C)
5 minutes holding time - 110 MPa at 823
K (550o
C)
Ultimate Tensile Strength, % elongation & %
reduction of area shall be noted for information.
Sr.No. Urea Production
No. of
Tube
Tube
Length, M
Tube
ID,m
Surface Area
one tube, m
Total Heat
transfer
Area,m2
1 1200-1600 1677 6 0.0200 0.377 631.9
2 1600-2000 1800 6 0.0200 0.377 678.2
3 2000-2500 1900 6 0.0200 0.377 715.9
4 2500-3000 2670 5.5 0.0200 0.345 922.2
5 3000-3500 3350 5.5 0.0200 0.345 1157.1
6 3500-4000 4370 5.5 0.0200 0.345 1509.4
7 4000-4500 4500 5.5 0.0200 0.345 1554.3
8 4500-5000 4500 5.5 0.0220 0.380 1709.7
Table-6
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Fig-3
Omega Bond Stripper
Omega bond stripper is the development of M/S.
Saipem, it is the best stripper in the Fertilizers
industries. First Omega bond stripper installed
GPIC complex and second in FFC Pakistan. The
omega bond stripper can be operated at higher
temperature no passivation is required and boosting
plant capacity. Expected life is about 25 years. The
return investment projected at the rime of project
initiation estimated a payback with 2 years.
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Fig-4
For Stamicarbon Design stripper
Sr.No. Urea Production
No. of
Tube
Tube
Length, M
Tube OD,
m
Surface Area
one tube,m2
Total Heat
transfer
Area,m2
1 1200-1600 2600 6 0.031 0.584 1510
2 2000-2500 3000 6 0.031 0.584 1752
Table-7
Comparison of Stripper for Ammonia & CO2 Stripping Process
Sr.
No.
Parameters Ammonia stripping Process CO2 Stripping Process
1 Surface Area Less More in same plant Load because the double
load of heating(CO2 as well as Reactor
effluents)
2 Nos of Tubes Less About 150 % tubes more
3 Cost Less Very Costly at same plant load
4 In Case of Tube
or tube sheet
Leakage
In case of Leakage the pH of
Steam condensate is more than
9.0-10.0 because the ammonia
content is higher, Hence no
problem of corrosion, you can
run the plant at minor leakage by
separate draining of condensate,
In case of minor leakage , take shut down
immediately because the pH of steam
condensate come down below 7.0 due to
CO2 contents is higher and hence corrosion
start in CS shell, otherwise equipment will
damage and cause major incident.
Table=8
HP Carbamate Condenser (CO2 Stripping)
The vapours (NH3, CO2 and steam) from the HP
stripper are condensed in HP carbamate condenser
with fresh ammonia from HP ammonia pumps and
recycle carbamate (65% of total) from the LP
carbamate condensers via HP carbamate pump An
overall NH3:CO2 mole ratio of 2.8 to 3.0 is
maintained so as to condense the gases.
The flow of ammonia is controlled by varying
speed (rpm) of ammonia pumps on the basis of N/C
ratio in the autoclave liquid outlet. The HP
condenser is a shell and tube heat exchanger with
the process fluids on the tube side and steam and
condensate on the shell side. The shell side
constitutes 4.5 ata steam boiler system connected to
the steam drum via eight steam risers and four
condensate down comers. By controlling the shell
side temperature (by controlling the steam
pressure), the rate of condensation of carbamate on
the tube side of the HP condenser is controlled
because the condensation reaction is a function of
the rate of exothermic heat removal from the
reaction zone. The steam drum is elevated above
the HP condenser to provide a natural thermo-
siphoning circulation for the steam system. The
carbamate solution from LP carbamate separator
via HP Pump, and liquid ammonia from the HP
ammonia pump enters the HP condenser at the top
of the channel and flows down a small packed bed
above the liquid distribution tray. The vapours
(NH3, CO2 and steam) from the HP stripper enter
outside the packed section. Some of the vapour
enters the packing from the bottom via gas risers.
Part of CO2 and NH3 in the vapours condenses in
the packing section increasing the partial pressure
of oxygen. The pressure of this oxygen acts as
corrosion inhibitor at the welds between the tubes
and the top tube sheet. The liquid from the packing
and most of the gas feed flow down the tubes
where they condense to form carbamate. Steam
temperature on the shell side is controlled such that
only about 90% (by vol.) of the vapours condense
in the HP condenser . The rest is condensed in the
autoclave. TR records the temperature of carbamate
outlet from HP condenser going to the autoclave. A
bursting disc on the shell side relieves CO2, NH3
and H2O mixture to the atmosphere via vent stack
in case of tube failure. One drain and one vent line
(25 mm each) are provided for the shell.
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Fig-5
Risky Section of CO2/NH3 Stripping
High Pressure Scrubber
HP Scrubber safe operational Conditions
The inerts, unconverted ammonia and CO2 from the
top of the autoclave are condensed in the HP
scrubber with carbamate solution formed in the low
pressure carbamate condensers. The HP scrubber
consists of bundle of U-tubes with circulating
condensate from condensate circulation system-II
via Pump, flowing through the tubes. The
condensate enters the exchanger tubes at a
temperature of 120°C and leaves at temperature of
140° C. NH3 and CO2 in the off gases from the
autoclave are condensed to form carbamate at a
temperature of about 152° C in the presence of
recycle carbamate from the LP carbamate
condensers . Under these conditions, the
crystallization of carbamate is not possible thus
avoiding the blockage of the HP scrubber However,
the circulating condensate temperature must be
maintained such that crystallisation of carbamate
doesn’t take place. . In case of temperature low
alarm, both the pre evaporator hot water heat
exchanger and CCS-II cooler shall be bypassed
with HIC and HICV respectively to maintain CCS-
II temperature to HP scrubber.
If for any reason the flow of carbamate to the
scrubber is suspended, the circulating condensate
inlet temperature is to be raised to 130° C so as to
avoid possibility of crystallization of carbamate. To
raise the CCS-II inlet temperature to HP scrubber,
9 ata steam jacket on CCS-II cooler condensate
outlet line is provided. The 23 ata steam injection
to CCS-II pump discharge is provided for initial
heating of the CCS-II circuit. The BFW pump
discharge is connected to CCS-II pump discharge
line for initial make-up of the circuit. The 15 NB
off sites BFW coil condensate connection is
provided for continuous make-up of the system.
The uncondensed vapour and inerts from the top
are sent to LP absorber via pressure control valve
PRC for further recovery of ammonia. PRCV
controls the HP loop pressure. The condensed
carbamate overflows back to the autoclave bottom
from an overflow nozzle in the heat exchange
section so that the U-tubes are always submerged.
The gas space over the liquid distribution weir and
the gas outlet pipe volume is designed to give a
minimum gas volume and one of the features of
this design is to prevent process gas finding its way
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to the top space outside the gas outlet line. The
process gas contains H2 (inerts in NH3) and O2
from CO2.
Hence, it is a potentially explosive mixture. In case
an explosion, the partition plate between the gas
space above liquid distribution will burst and the
shock will be taken up by the top space which is at
least 20 times the explosion volume. The outer top
space is therefore always purged with a small
amount of CO2 from the compressor in order to
avoid formation of explosive mixture of NH3 and
air. FI indicates the flow of CO2 going to the HP
scrubber.
The purpose of the HP scrubber is to condense and
absorb ammonia and CO2, present in the off gas
from the urea reactor, in a heat exchanger part and
an absorber part with help of the carbamate recycle
solution from the LP recirculation section.
The HP Scrubber consists of following parts-
1. A blanketing sphere which receives the
gases coming from reactor.
2. A Heat exchanging part which is equipped
with central down comer which through
degasified liquid flow down. A gas
distributor installed in the bottom.
3. A scrubbing part in which the remaining
gases are scrubbed with the weak
Carbamate solution and where the
ammonia and carbon dioxide are almost
totally condensed.
The carbamate recycle solution sent by the HP
carbamate pump passes through the packing section
at the absorber part of the HP scrubber and then
thrugh the heat exchanger part of the HP scrubber
where it reaches the bottom. Here it is mixed with
the off gas from the urea reactor, which first passes
through the hemisphere and the U shaped line. The
mixture thus formed flows upwards through the
heat exchanger tubes, during which ammonia and
CO2 in the gas are condensed and absorbed, while
the heat is removed by the tempered cooling water
on the shell side. Unabsorbed ammonia and CO2
then contact counter-currently with the carbamate
solution sent by the HP carbamate pump in the
packing section of the HP scrubber for heat
exchange and mass exchange. Inert gases going out
of the HP scrubber and a small quantity of
ammonia and CO2 are absorbed in the LP system
and then vented to atmosphere. The inert gases
origin from the inerts present in the feed plus the
air added to the CO2 feed for the operation of the
hydrogen converter and for the passivation of the
applied stainless steels in the urea plant. This
means oxygen is present in the off gases and like in
any other urea process proper attention need to be
paid to avoid explosion risks.
Process operation of the HP Scrubber
Most of the personnel operating a newly built urea
plant are not so experienced in the process
operation of the HP scrubber. Various abnormal
situations might occur during the startup, shutdown
and even during normal production of the plant. In
view of this, the following analyses are made on
the process operation of the HP scrubber:
Normal operation mode
Why should the carbamate solution outlet
temperature of the HP scrubber be controlled above
155 o C during normal operation? And how to
control? Assuming that the carbamate solution at
the outlet of the HP scrubber is in equilibrium with
the gas stream in the bottom section of the packed
bed, the temperature of this carbamate solution is
influenced by the percentage inerts present in the
gas phase. The higher the percentage inerts, the
higher the inert pressure, the lower the system
pressure (= partial pressure of NH3, CO2 and H2O)
and the lower its boiling temperature. In order to
maintain non-explosiveness of the off-gas of the
HP scrubber, inert gas content in the off gas should
be less than 36%. It can be found from NH3-CO2-
H2O ternary diagram in terms of temperature,
pressure and composition that this means that the
partial pressure of NH3+CO2 should not be less
than 8.29 MPa when the operating pressure is 14.4
MPa, which corresponds to a carbamate solution
temperature of 1550
C. If the H2O content in the
carbamate solution increases, the outlet fluid
temperature should be increased accordingly so as
to maintain the same partial pressure. Remark
UreaKnowHow.com: The carbamate solution
temperature can be controlled by means of the HP
inert valve. When opening this valve the
temperature will increase.
1. Temperature difference of the HP scrubber
gradually reduces with zigzag fluctuation
2. The vented quantity of off gases
increases.
Temperature of tempered cooling water is too
low
During the start-up of the HP scrubber, when the
temperature of the tempered cooling water is
controlled too low, the carbamate solution in the
tubes of the heat exchanger may crystallize and
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block the tubes. This again might cause a damage
to the cylinder in the hemisphere. Signals are:
1. The tempered cooling water shows no
temperature difference between in and
outlet of the heat.
2. Exchanger the temperature of the off gas
of the HP scrubber rises rapidly.
3. Temperature of the carbamate solution
outlet of the HP scrubber drops.
4. The temperature at the outlet of the HP
carbamate ejector drops rapidly.
5. CO2 conversion rate in the reactor
decreases.
6. Steam consumption of the HP CO2
stripper increases.
7. Steam consumption of the first-stage
evaporation heater increases.
Start up and shut down operation modes
Blocking U-shape gas line during a blocking in
shutdown of the HP scrubber the gas in the U-
shaped line from the hemisphere to the bottom of
the heat exchanger may crystallize and cause
plugging. For example when the power supply of
the plant is shut down and the emergency power
supply fails to start and the steam supply for the
plant is unavailable, etc.). Remark
UreaKnowHow.com: or when the tracing and
insulation is in bad condition. As a result a large
pressure difference between the inside and outside
of the cylinder in the hemisphere occurs and might
become damaged. Signals are: The pressure of the
HP synthesis system rises rapidly
Fig-6
Another problem which may occur when the
temperature of the tempered cooling water of the
HP scrubber is controlled at a too low level, is that
NH3 and CO2 are excessively condensed in the HP
ISSN 2320-9186 1680
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scrubber, causing that the off-gas may fall into the
explosion zone.
Hydrogen Content too high
When the hydrogen converter fails or due to a
problem in the ammonia plant too much hydrogen
is present in the feed, the off gases of the HP
scrubber may fall into the explosion zone. Signals
are:
1. Hydrogen content of the hydrogen
analyzer increases.
2. N/C ratio increases.
3. CO2 conversion rate decreases.
4. Steam consumption of the HP CO2
stripper increases.
5. Temperature of the liquid outlet of the HP
carbamate condenser drops.
6. Pressure of the HP synthesis system rises.
Carbamate solution temperature too low
We have observed that all HP scrubber off-gas fires
during the start up occur within 10-15 minutes after
overflow of the urea reactor. Why would the off-
gas become explosive at this moment ?
Observations from each plant show that it is caused
by a sudden drop of the temperature of overflow
liquid from the HP scrubber. We have made a
comparison between good operation and bad
operation practice. The minimum carbamate liquid
overflow temperature of the HP scrubber is above
155 o C in the good operation practice while the
minimum temperature drops to 136 oC in the bad
operation practice. When the overflow temperature
is lower than 150 o C the off-gas may enter into the
explosive zone.
Why there is a low point of the temperature of
overflow fluid at that moment: the reason why the
off gas of the HP scrubber may enter the explosive
zone when the urea reactor is at overflow condition
is that the temperature of the reactor solution is
lower during the overflow. When the temperature
of the reactor solution is lower, the NH3 and CO2
contents of the off gas of the reactor, which is in
equilibrium with the reactor solution, decreases. As
the off-gas discharge amount remains unchanged
(remark UreaKnowHow.com: as the off gas
discharge amount is determined by HP inert valve
position), the available NH3 and CO2 to be
absorbed by the HP scrubber decreases, thus the
reaction heat generated from the condensation in
the HP scrubber decreases, causing the temperature
of the overflow fluid of the HP scrubber to drop
down.
Conclusion
The proper selection of the equipments MOC can
save the production as well as human life in case of
causalities. This is because, there is a limit to how
far corrosion resistance can be improved by
alloying, therefore investigating how corrosion
resistance can be improved by strengthening the
microstructure through heat treatment is important.
Micro alloy can be used in reformer tubes. We have
seen the 2RE-69 for urea reactor liner is the right
selection instead of SS316 (urea grade).Omega
Bond stripper is the life time equipment. Maximum
shut down due to the failure of stripper.
References.
1. An advance book on Fertilizers
technology by Prem Baboo Jan, 2021,
Notion Press.
2. Urea stripper Tube leakage by Prem
Baboo, Published by International Journal
of Engineering Research & Technology
(Vol. 7 Issue 03, March – 2018
3. High pressure vessel leakage in urea
plants (A case study) by Prem Baboo,
Global Scientific Jouranal,Vol-9Issue-
1Jan02021.
ISSN 2320-9186 1681
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