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High-pressure Vessels for Urea Synthesis
For these critical plants SBN produces high-pressure heat exchangers and reactors that are cladded in high corrosion-resistant materials, together with the necessary built-in components such as liquid distribution systems, perforated sieve trays, etc. Materials used include heat-resistant carbon steels and austenitic chrome-nickel steels. The tube-to-tubesheet welding in the heat exchangers is carried out using computer-controlled welding machines with a special SBN-developed technology. Tubesheets are cladded by strip and manual overlay welding. With reactors and HP channels of heat exchangers the urea-resistant cladding is designed either as a core shell or as a loose lining.
For these critical plants SBN produces high-pressure heat exchangers and reactors that are cladded in high corrosion-resistant materials, together with the necessary built-in components such as liquid distribution systems, perforated sieve trays, etc. Materials used include heat-resistant carbon steels and austenitic chrome-nickel steels. The tube-to-tubesheet welding in the heat exchangers is carried out using computer-controlled welding machines with a special SBN-developed technology. Tubesheets are cladded by strip and manual overlay welding. With reactors and HP channels of heat exchangers the urea-resistant cladding is designed either as a core shell or as a loose lining.
Stripper
Carbamate is broken down into ammonia (NH3) and carbon dioxide (CO2). The urea solution is cleaner, and subsequent process sequences can run at lower pressures.
Pressure 23 bar, temperature 205 °C
Pressure in tube bundle 140 bar.
HP Stripper
Scrubber
Condenses ammonia (NH3) and carbon dioxide (CO2) to carbamate. Pressure in tube bundle 140 bar, temperature around 160 °C.
Scrubber
Scrubber
Pool-Condenser
Condensation of ammonia and CO2 into a liquid pool. The heat of reaction is used for the production of 4.5 bar low pressure steam at a temperature of some 150 °C.
The pressure at the process side is 140 bar at a temperature of 170 °C.
Karbamat-Kondensator
Pool reactor
Carbamate and urea reaction in a single high-pressure vessel. Ammonia and CO2 condense to carbamate, which is subsequently converted to urea and water. The newly-developed pool process reduces the high-pressure vessel volume to some 30 to 40% of the conventional reactor volume.
The process pressure is 140 bar at a temperature of 185°C. The pressure in the tube bundle is 4.5 bar at a temperature around 170°C (low pressure steam).
Reactor
Conventional urea reaction. Conversion of the carbamate to urea and water. The slow reaction requires large reactor volumes.
Pressure 140 bar at a temperature of 183°C.
Fallfilm-Kondensator
Ammoniak (NH3) und Kohlendioxyd (CO2) kondensieren zu Karbamat. Die dabei entstehende Abwärme wird zur Erzeugung von Niederdruck-Dampf verwendet.
Der prozessseitige Druck beträgt 140 bar bei einer Temperatur von etwa 170 °C.
Internals
Reactor bottoms, liquid distributor systems for strippers, internals for condensers and scrubbers.
Pipework
Prefabricated pipework and pipe bends, pipe fittings such as reduction couplings, T-pieces, etc.
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