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SEPARATOR
FLASH
PRILLING
BASKET
SEPARATOR
SEPARATOR
SEPARATOR
UPPER
FINAL
LOWER
CARB CARB
COND NO 1 COND NO 2
LPD
STM
REACTOR
STM SC
HPD
UREA SOLUTION
STM PUMP SC
PRILLING
SC TOWER
VV UREA SOLUTION
CW FEED PUMP MOLTEN UREA
PUMP
PC
STRIPPER STRIPPER
HP
CW CW HYDROLYSER
ABSORBER
MP
STEAM
COND LP
ABSORBER
UREA CW
SLURRY /
HOT WATER / UPC
CW SCRAPPER
PRODUCT
UREA
CO2
NH3 COMP CARB FEED HP ABSORBENT HYDROLYSER
FEED PUMP PUMP FEED PUMP
PC FEED
NH3 PUMP CO2 PUMP
Process Aspect
Cost-effective reuse of resources readily available in the urea
production lines is critical to productivity and profitability.
Urea strippers effectively remove carbamate and recyle
unconverted ammonia and carbon dioxide for process reuse
thereby reducing operating costs.
Following reaction occurs inside the stripper.
NH2COONH4 + heat ↔ 2NH3 + CO2 ΔH = +84 kJ/mol
NH3(l) → NH3(g)
These strippers are vertical shell-and-tube heat exchangers,
with fixed tubesheets, where the urea solution flows on the
tube side and the steam on the shell side.
Mechanical Design
Urea stripper stands up to high temperatures, high
pressures and the strong corrosive action of the urea
solution.
Urea strippers are made of high quality urea-grade
materials. These materials have excellent mechanical
properties and withstand highly corrosive
environments.
Advanced welding and production technology,
fabrication techniques that meet international
standards and special non-destructive examination
(NDE) technology ensure equipment durability and
long service life.
Mechanical Tubeside is highly corrosive
environment so following
Design 1. Shell and D’end are
lined with DP-28W
TUBE
2. Tubesheet is weld
Side
overlayed with DP-28W
3. Tubes are of material
DP-28W
4. Internals are of material
25Cr.
Multilayer
Construction
SHELL
material.
SIDE
2. Internals are of CS
material.
Multilayer
Construction
TUBE
Side
Tube to Tubesheet Joint
Tubesheet thickness is around 410 mm with about 10-
15 mm overlay of corrosion resistant material when
the pressure difference across the tubesheet is
around 135 kg/cm^2.
Tubes in stripper are closely located, and there is no
welding between tube and CS part of tubesheet. The
only part of the tubesheet that is welded with the
tube is the overlaid portion of the tubesheet which is
normally 10-15 mm thick.
Tube to Tubesheet Joint
This is the tube-to-tubesheet joint which has the
maximum potential of getting corroded during
service due to the HAZ area formation during
welding. Welding of tube to tubesheet in strippers
requires very high quality work. An air bubble
trapped in weld or any other defect would ultimately
lead to stripper leakage.
Tube to Tubesheet Joint
Because of the high quality level required, following
NDE procedures are performed
1) Visual examination of the bead and the tube
internal wall.
2) Liquid penetrant inspection
3) Ultrasonic inspection
4) Control of the quantity of ferrite
5) Leak test with Helium at 0.5 bar(g)
Leak Detection Holes
A leak detection system in general is designed to
detect leaks in the liner. A liner consists of plates,
which are welded together and it are these welds
which are to be considered the most critical areas.
These liner connections can be divided in
(i) loose liner welds (two liner plates welded
together without any fixation to the carbon steel)
and
(ii) fixed liner welds (two liner plates
welded together while at the
same time fixed to the carbon steel.
Leak Detection Holes
The loose liner welds can be inspected by Non
Destructive Testing (NDT) and when done correctly,
these welds can be considered as sound as the liner
plates itself.
However the fixed liner welds cannot be inspected by
radiography and are thus a potential risk for leaks.
This means that basically leak detection systems are
designed in such a way that leakages in these welds
will be detected earliest
Leak Detection Holes