stamicarbon’s real time urea process simulator training ... · pdf filevertical reactor....
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Stamicarbon B.V.Mercator 3 - 6135 KW Sittard,The Netherlands.P.O. Box 53 - 6160 AB Geleen,The Netherlands.
Tel. +31 46 4237000 Fax. +31 46 4237001
Stamicarbon’s real time urea process simulator training for melt plants.
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Stamicarbon’s real time urea process simulator training for melt plants.
STAMI_Advance_Inspect_leaflet_Concept_designs_WEB.indd 1-3 11-04-17 13:29
STAMI_Advance_Instruct_leaflet_WEB - FEB 2017 PAGE 1/3
What is it?Stamicarbon, off ers a dynamic, high fi delity
process simulator for the urea process. The process
simulator provides the user with a plant simulation
that behaves like the real plant including the look
and feel of a DCS system. This is made possible
by Stamicarbon’s know-how of the urea process in
the form of kinetic and thermodynamic models.
Stamicarbon provides complete training that off ers guided use of the simulator, covering:• Normal operation (for the full capacity range:
turn-down to full capacity)
• Cold start-up
• Recovery mode
• Blocking-in and restarting
• Blocking-in and draining
• Switching pumps
• Recovering from pre-defi ned upset scenarios
The model is equiped with all relevant items including:• Control valves
• Interlocking system
• Clearly marked (fi eld) manual valves
• Sample points
• Trending system
What will you get out of this training?• Experience in the urea process and its fully
real-time dynamic behaviour
• Knowledge in how to deal with standard
operating procedures
• How to handle upset conditions
• Learning how to run the plant at maximum
capacity whilst dealing with boundary
conditions e.g.:
• Minimizing specifi c steam consumption
• Minimizing ammonia losses
• Stamicarbon Academy certifi cate
Who should a� end?*• Urea melt plant operators
• Urea melt plant engineers
• Urea production managers
* This training is relevant for personnel
of all levels of experience
Upcoming regional training:• Abu Dhabi, UAE: 8-11 May 2017
• Colorado, USA: 12-15 June 2017
On-site training:Stamicarbon’s urea melt simulator training is
also available as tailor-made, on-site training.
For more information about the training please contact John Oostveen at [email protected]
Program outline for a 4-day training:
Day 1:• Introduction to Stamicarbon’s urea melt process• Urea Simulator User Interface• General start up procedure• Starting simulator on 60% capacity and familiarization of the interface by increasing plant load to 100%
Day 2:• Performing a cold start-up • Stabilizing the plant
Day 3:• Blocking-in the plant• Draining• Restarting the blocked-in plant
Day 4:• Troubleshooting based on scripts and/or instructor interventions • Case discussions
Based on the experience of the attendees the intensity and content can be tailor-made to fit the needs and requirements of the group.
A E 2 1 0 3
0 . 0 %
6 3 . 8 %
T I 2 1 1 01 8 6 . 6 OC
T I 2 1 1 11 8 6 . 8 OC
T I 2 1 1 21 8 6 . 0 OC
T I 2 1 1 31 8 4 . 9 OC
T I 2 1 1 41 8 3 . 3 OC
T I 2 1 1 51 8 1 . 3 OC
T I 2 1 1 61 7 7 . 8 OC
T I 2 1 1 71 7 5 . 5 OC
T I 2 1 1 81 7 5 . 0 OC
T I 2 1 1 91 7 3 . 2 OC
T I 2 1 2 11 7 9 . 1 OC
L I C 2 1 0 1
R 2 0 2
1 0 0 %
0 . 0 %
0 . 0 %
X P V 2 1 0 1
0 . 0 %
A5 2 . 1 5 0 . 0 %
F I 1 1 0 15 4 . 0 0 t / h
F I 1 1 0 5K 1 0 2
P 1 0 2
P 9 0 2
5 3 . 9 9 t / h
P I 2 1 0 70 . 0 b a rg
A I 2 3 0 1
A E 2 1 0 1
L P V 2 1 0 1
H P V 2 1 0 3
X P V 2 1 0 5
E 2 0 1
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R E S E T
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1 4 7 . 4 b a rgP I 2 1 0 5 _ 1P I 2 1 0 1 _ 1
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1 4 7 . 4b a rg b a rg b a rg
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R E S E T H I C 2 1 0 30 . 0 0
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H I C 2 1 0 5
H P V 2 1 0 5
8 2 . 0 0T I 2 1 0 5
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PAGE 2/3
This means:• Easy and stable plant operation due to pool condensation principle pool reactor• Well established technology with an extensive proven track record• Compact and low elevation plant design results in lower construction costs • Easier maintenance and longer time between turn arounds with significant reduction on corrosion issues with Safurex®
• Suitable for any type of plant capacity (suitable for low and highest single line capacities)
The challengeTo reduce investment, increase plant efficiency,
reduce operating and maintenance costs and
minimize plant emissions.
Our solutionStamicarbon’s answer is its LAUNCH MELT™
series. Depending on your capacity requirements,
Stamicarbon’s LAUNCH MELT™ series offers
two designs:
1) A horizontal high-pressure Pool Condenser combined with a vertical reactor2) A horizontal high-pressure Pool Reactor Design (for smaller plant capacities)
Capital investment is reduced due to its compact
design which requires less equipment. This makes
the process simpler and more stable and your plant
much less maintenance intensive.
HP scrubber
LP absorber
Reactor
NH3
Ejector
Stripper
Poolcondenser
To atmospheric absorber
LP carbamate recycle
MP steamcondensate
LP steamBFW
CO2
To LPrecirculationMP steam
GasLiquidUrea solution/melt/slurrySteam/water
Stripper
To recirculationScrubber
Carbarnate recycle
Pool Reactor
CO₂
NH₃
Absorber
GasLiquidUrea solution/melt/slurrySteam/water
Stripper
To recirculationScrubber
Carbarnate recycle
Pool Reactor
CO₂
NH₃
Absorber
GasLiquidUrea solution/melt/slurrySteam/water
The LAUNCH MELT™ Pool Condenser at work Ammonia and carbon dioxide are introduced to
the high-pressure synthesis using a high-pressure
ammonia pump and a carbon dioxide compressor.
The ammonia then drives an ejector, which conveys
the carbamate solution from the high-pressure
scrubber to the pool condenser. In the high-
pressure stripper, the carbon dioxide, entering the
synthesis as a feed, flows countercurrent to the urea
solution leaving the reactor.
On the shell side, the high-pressure stripper is
heated with steam. The off-gas of the high-pressure
stripper, containing the carbon dioxide, together
with the dissociated carbamate, is then fed into
the pool condenser, where ammonia and carbon
dioxide are condensed to form carbamate. The heat
released by condensation and subsequent formation
of carbamate is used to produce re-usable low-
pressure steam.
After the pool condenser, the remaining gases and
a liquid containing urea and carbamate enter the
vertical reactor. Here, the final part of the urea
conversion takes place. The urea solution then
leaves the top of the reactor (via an overflow funnel)
before flowing back into the high-pressure stripper.
Ammonia and carbon dioxide conversions in the
synthesis section of a Stamicarbon carbon dioxide
stripping plant, are particularly high. As a result
of that, the Stamicarbon CO2 stripping process is
the only commercial available process that does
not require a medium-pressure recirculation stage
downstream from the high-pressure stripper.
Gases leaving the reactor are fed into the high-
pressure scrubber. Here, the gases are washed with
the carbamate solution from the low-pressure
recirculation stage. The enriched carbamate
solution is then fed to the high-pressure ejector and,
subsequently, to the pool condenser. Inert gases,
containing some ammonia and carbon dioxide, are
then released into the 4-bar absorber.
The LAUNCH MELT™ Pool Reactor at work Unlike the Pool Condenser concept, the Pool Reactor concept combines the
condenser and reactor in a single pool reactor. This is achieved by enlarging
the horizontal condenser so as to incorporate additional reactor volume.
As a result, it becomes possible to achieve sufficiently high residence times,
eliminating the need for a separate vertical reactor, while creating the
conditions that will allow the reaction to reach its optimum condition with
the advantage of having a plant height of about 30 meters.
The high pressure scrubbing operation can also be simplified in the Pool
Reactor concept by placing the scrubber sphere above the pool reactor and
adding the ammonia to the synthesis via this scrubber. This ensures that no
separate heat exchanging section in this scrubbing operation is required.
In the Pool Reactor concept, carbamate from the low pressure recirculation
section flows together with the absorbed gases and the ammonia into the
pool reactor. As the static liquid height ensures gravity flow, no high-
pressure ejector is needed.
STAMI_Launch_Melt_leaflet_WEB.indd 6 05-12-16 13:45
What is it?Stamicarbon, off ers a dynamic, high fi delity
process simulator for the urea process. The process
simulator provides the user with a plant simulation
that behaves like the real plant including the look
and feel of a DCS system. This is made possible
by Stamicarbon’s know-how of the urea process in
the form of kinetic and thermodynamic models.
Stamicarbon provides complete training that off ers guided use of the simulator, covering:• Normal operation (for the full capacity range:
turn-down to full capacity)
• Cold start-up
• Recovery mode
• Blocking-in and restarting
• Blocking-in and draining
• Switching pumps
• Recovering from pre-defi ned upset scenarios
The model is equiped with all relevant items including:• Control valves
• Interlocking system
• Clearly marked (fi eld) manual valves
• Sample points
• Trending system
What will you get out of this training?• Experience in the urea process and its fully
real-time dynamic behaviour
• Knowledge in how to deal with standard
operating procedures
• How to handle upset conditions
• Learning how to run the plant at maximum
capacity whilst dealing with boundary
conditions e.g.:
• Minimizing specifi c steam consumption
• Minimizing ammonia losses
• Stamicarbon Academy certifi cate
Who should a� end?*• Urea melt plant operators
• Urea melt plant engineers
• Urea production managers
* This training is relevant for personnel
of all levels of experience
Upcoming regional training:• Abu Dhabi, UAE: 8-11 May 2017
• Colorado, USA: 12-15 June 2017
On-site training:Stamicarbon’s urea melt simulator training is
also available as tailor-made, on-site training.
For more information about the training please contact John Oostveen at [email protected]
Program outline for a 4-day training:
Day 1:• Introduction to Stamicarbon’s urea melt process• Urea Simulator User Interface• General start up procedure• Starting simulator on 60% capacity and familiarization of the interface by increasing plant load to 100%
Day 2:• Performing a cold start-up • Stabilizing the plant
Day 3:• Blocking-in the plant• Draining• Restarting the blocked-in plant
Day 4:• Troubleshooting based on scripts and/or instructor interventions • Case discussions
Based on the experience of the attendees the intensity and content can be tailor-made to fit the needs and requirements of the group.
A E 2 1 0 3
0 . 0 %
6 3 . 8 %
T I 2 1 1 01 8 6 . 6 OC
T I 2 1 1 11 8 6 . 8 OC
T I 2 1 1 21 8 6 . 0 OC
T I 2 1 1 31 8 4 . 9 OC
T I 2 1 1 41 8 3 . 3 OC
T I 2 1 1 51 8 1 . 3 OC
T I 2 1 1 61 7 7 . 8 OC
T I 2 1 1 71 7 5 . 5 OC
T I 2 1 1 81 7 5 . 0 OC
T I 2 1 1 91 7 3 . 2 OC
T I 2 1 2 11 7 9 . 1 OC
L I C 2 1 0 1
R 2 0 2
1 0 0 %
0 . 0 %
0 . 0 %
X P V 2 1 0 1
0 . 0 %
A5 2 . 1 5 0 . 0 %
F I 1 1 0 15 4 . 0 0 t / h
F I 1 1 0 5K 1 0 2
P 1 0 2
P 9 0 2
5 3 . 9 9 t / h
P I 2 1 0 70 . 0 b a rg
A I 2 3 0 1
A E 2 1 0 1
L P V 2 1 0 1
H P V 2 1 0 3
X P V 2 1 0 5
E 2 0 1
V 9 0 5
S 5 0 1
V 9 0 5
P 5 0 1
S 5 0 1
X P V 2 1 0 2X P V 2 1 0 4
L P V 2 1 0 22 . 8 4
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0 . 0 %0 . 0 %
1 0 0 . 0 %
0 . 0 %
0 . 0 %-
T I 2 1 0 41 8 6 . 6
A E 2 1 0 2
OC
R E S E T
6 8 . 5 %
1 4 7 . 4 b a rgP I 2 1 0 5 _ 1P I 2 1 0 1 _ 1
1 4 7 . 4P I 2 1 0 5 _ 2
1 4 7 . 4P I 2 1 0 5 _ 3
1 4 7 . 4b a rg b a rg b a rg
0 . 0 %
0 . 0 %
8 2 . 0 %
R E S E T H I C 2 1 0 30 . 0 0
T I 2 1 0 72 0 6 . 8 OC
T I 2 1 0 81 7 5 . 4 OC
L I C 2 1 0 2 A4 0 . 1 4 0 . 0 %
H I C 2 1 0 5
H P V 2 1 0 5
8 2 . 0 0T I 2 1 0 5
1 8 9 . 8 OC
R E S E T
STAMI_Advance_Inspect_leaflet_Concept_designs_WEB.indd 6 11-04-17 13:29
STAMI_Advance_Instruct_leaflet_WEB - FEB 2017
A E 2 1 0 3
0 . 0 %
6 3 . 8 %
T I 2 1 1 01 8 6 . 6 OC
T I 2 1 1 11 8 6 . 8 OC
T I 2 1 1 21 8 6 . 0 OC
T I 2 1 1 31 8 4 . 9 OC
T I 2 1 1 41 8 3 . 3 OC
T I 2 1 1 51 8 1 . 3 OC
T I 2 1 1 61 7 7 . 8 OC
T I 2 1 1 71 7 5 . 5 OC
T I 2 1 1 81 7 5 . 0 OC
T I 2 1 1 91 7 3 . 2 OC
T I 2 1 2 11 7 9 . 1 OC
L I C 2 1 0 1
R 2 0 2
1 0 0 %
0 . 0 %
0 . 0 %
X P V 2 1 0 1
0 . 0 %
A5 2 . 1 5 0 . 0 %
F I 1 1 0 15 4 . 0 0 t / h
F I 1 1 0 5K 1 0 2
P 1 0 2
P 9 0 2
5 3 . 9 9 t / h
P I 2 1 0 70 . 0 b a rg
A I 2 3 0 1
A E 2 1 0 1
L P V 2 1 0 1
H P V 2 1 0 3
X P V 2 1 0 5
E 2 0 1
V 9 0 5
S 5 0 1
V 9 0 5
P 5 0 1
S 5 0 1
X P V 2 1 0 2X P V 2 1 0 4
L P V 2 1 0 22 . 8 4
1 0 0 . 0 %
0 . 0 %0 . 0 %
1 0 0 . 0 %
0 . 0 %
0 . 0 %-
T I 2 1 0 41 8 6 . 6
A E 2 1 0 2
OC
R E S E T
6 8 . 5 %
1 4 7 . 4 b a rgP I 2 1 0 5 _ 1P I 2 1 0 1 _ 1
1 4 7 . 4P I 2 1 0 5 _ 2
1 4 7 . 4P I 2 1 0 5 _ 3
1 4 7 . 4b a rg b a rg b a rg
0 . 0 %
0 . 0 %
8 2 . 0 %
R E S E T H I C 2 1 0 30 . 0 0
T I 2 1 0 72 0 6 . 8 OC
T I 2 1 0 81 7 5 . 4 OC
L I C 2 1 0 2 A4 0 . 1 4 0 . 0 %
H I C 2 1 0 5
H P V 2 1 0 5
8 2 . 0 0T I 2 1 0 5
1 8 9 . 8 OC
R E S E T
SYNTHESIS
PAGE 3/3STAMI_Advance_Instruct_leaflet_WEB - FEB 2017
Dear Visitor
Hereby we would like to invite you to our special Urea Simulator training in Abu Dhabi.
BOOK NOW! Limited space available.
What: Stamicarbon’s real time urea process simulator training for melt plants
When: 8 - 11 May
Where: Yas Island Rotana, Yas Plaza - Abu Dhabi - United Arab Emirates
Date 8 - 11 May , 2017. Venue Yas Island Rotana, Yas Plaza - Abu Dhabi - United Arab Emirates
Fee: EUR 2.750
Fee includes:
• Four full days of intensive, hands-on, Urea Simulator training by a Stamicarbon senior process engineer
• Lunch daily • Three coffee breaks with sweets and
snacks daily • Social event at Ferrari World
What is it exactly?
Stamicarbon, offers a dynamic, high fidelity process simulator for the urea process. The process simulator provides the user with a plant simulation that behaves like the real plant including the look and feel of a DCS system.
Stamicarbon provides complete training that offers guided use of the simulator, covering:
• Normal operation (for the full capacity range: turn-down to full capacity) • Cold start-up
• Recovery mode
• Blocking-in and restarting
• Blocking-in and draining
• Switching pumps
• Recovering from pre-defined upset scenarios
The model is equipped with all relevant items including:
• Control valves
• Interlocking system
• Clearly marked (field) manual valves
• Sample points
• Trending system
What will you get out of this training?
• Experience in the urea process and its fully real-time dynamic behaviour • Knowledge in how to deal with standard operating procedures
• How to handle upset conditions
• Learning how to run the plant at maximum capacity whilst dealing with boundary conditions e.g.:
o Minimizing specific steam consumption
o Minimizing ammonia losses
• Stamicarbon Academy Certificate
• Guaranteed individual attention from the trainer
Contact Chantal Spies ([email protected]) as limited seats are available.
Looking forward to meet you in Abu Dhabi!
Dear Visitor
Hereby we would like to invite you to our special Urea Simulator training in the USA.
BOOK NOW! Limited space available.
What: Stamicarbon’s real time urea process simulator training for melt plants
When: 12 - 15 June
Where: Cheyenne Mountain Resort, Colorado Springs, USA
Date 12 - 15 June , 2017. Venue Cheyenne Mountain Resort, Colorado Springs, USA
Fee: EUR 3.750
Fee includes:
• Four full days of intensive, hands-on, Urea Simulator training by a senior Stamicarbon engineer
• Lunch daily • Three coffee breaks with sweets and snacks daily • Social event
What is it exactly?
Stamicarbon, offers a dynamic, high fidelity process simulator for the urea process. The process simulator provides the user with a plant simulation that behaves like the real plant including the look and feel of a DCS system.
Stamicarbon provides complete training that offers guided use of the simulator, covering:
• Normal operation (for the full capacity range: turn-down to full capacity) • Cold start-up
• Recovery mode
• Blocking-in and restarting
• Blocking-in and draining
• Switching pumps
• Recovering from pre-defined upset scenarios
What will you get out of this training?
• Experience in the urea process and its fully real-time dynamic behaviour • Knowledge in how to deal with standard operating procedures
• How to handle upset conditions
• Learning how to run the plant at maximum capacity whilst dealing with boundary conditions e.g.:
- Minimizing specific steam consumption
- Minimizing ammonia losses
• Guaranteed individual attention from the trainer • Stamicarbon Academy certificate
Contact Chantal Spies ([email protected]) as limited seats are available.
Looking forward to meet you in Colorado!
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