UREA PLANT REVAMPING:

CASALE TECHNOLOGY PORTFOLIO

M. Fumagalli
REVAMPING TECHNOLOGIES

• Revamping of the main process schemes

• CO2 stripping process
• NH3 stripping process
• Total recycle
• Revamping of Finishing Section
• Melamine off gas integration
• Melamine plant revamping
CO2 STRIPPING PROCESS

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
CO2 STRIPPING - SPLIT FLOW™ & FULL CONDENSER™

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
CO2 STRIPPING - SPLIT FLOW™ & FULL CONDENSER™

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
SPLIT FLOW™ & FULL CONDENSER™… boosting capacity

SPLIT OF STRIPPER VAPORS

-66% INERTS TO REACTOR

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
 SPLIT FLOW™ & FULL CONDENSER™… boosting capacity

FULL CONDENSER
+50% EFFICIENCY

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MP SPLIT FLOW SECTION…massive capacity increase

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MP SPLIT FLOW SECTION…massive capacity increase

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MATURE TECHNOLOGY

Country Capacity [MTD]

India 1780
Ukraine 1600
Russian Federation 1350
P.R. China 2610
Russian Federation 1500
Ukraine 1600
UAE 2500
United States 1350
Ukraine 1500

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
NH3 STRIPPING PROCESS

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
NH3 STRIPPING PROCESS

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
IMPROVED LOOP…improving reliability

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
IMPROVED MP ABSORBER…no more CO2 carry over

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
REFERENCES

Improved Loop Improved MP Absorber

Country Capacity [MTD] Country Capacity [MTD]

India 1800 Russia 2400
Canada 1100 North America 825
Russia 1400 Eastern Europe 2000
Russia 1400 Central America 2100
Eastern Europe 2000
Russia 2200

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MHP SECTION…massive capacity increase

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MHP SECTION…massive capacity increase

MAIN FEATURES:

MHP Pressure 70 bar

Steam production 3 barg
Capacity increase +50-70%

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
TOTAL RECYCLE PROCESS

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
TOTAL RECYCLE PROCESS

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
HIGH EFFICIENCY COMBINED (HEC) TECHNOLOGY

Energy saving 0.3 Gcal/MT

Capacity up to +70%

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
REFERENCES

Country Capacity [MTD]

United States 1080
Qatar 1610
Iran 1250
India 1650
Brazil 1500
Canada 625
Oceania 750
Canada 750

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
 from TOTAL RECYCLE to STRIPPING PROCESS

…the latest approach Energy saving 0.6 Gcal/MT

Capacity up to +100%

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
FINISHING SECTION

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
VORTEX® GRANULATION TECHNOLOGY

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MELAMINE OFF-GAS INTEGRATION

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MELAMINE OFF-GAS INTEGRATION

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
REFERENCES

Melamine Capacity Capacity Urea

Country
Technology Melamine [MTY] [MTD]
Middle East HP (MP Off-Gas) 20000 1650
Middle East HP (MP Off-Gas) 60000 1610
Middle East HP (HP Off-Gas) 80000 2700
Eastern Europe HP (MP Off-Gas) 60000 2000
Russian Fed. Low Pressure 50000 1500
India (*) HP (Casale) 40000 520
Russian Fed. (**) HP (Casale) 40000 1600

(*) Start-up 2018.

(**) Start-up 2019.

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MELAMINE PLANT REVAMPING

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
MELAMINE PLANT REVAMPING

Revamping of the Synthesis

section of High Pressure Sinlge-
Reactor Melamine Plants:

• Dry HP Off-Gases

• Conversion increase

• Lower side-products (OAT,

Melam, Melem)

• Heat recovery: Low Pressure

Steam generation

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK
CONCLUSIONS

•Wide portfolio of technologies developed for revamping

of urea plants

•Tailored approach: different plants, different technologies

•Focus on customer’s requirements: solutions for energy

saving, capacity increase, emission control, melamine
integration

Nitrogen + Syngas 2017

27 Feb – 02 Mar 2017 – London, UK