Renovation of the high-pressure loop for the complete cycle of urea in aqueous solution
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Our company operates a urea production process based on the full circulation of aqueous solutions, with an annual production capacity of 200,000 tons. After the modification of the high-pressure system, steam consumption dropped to 0.97 tons per ton of fertilizer produced; electricity consumption was reduced by 27%, while production increased by 34%. The load on the medium-pressure system was also reduced. What are everyone’s thoughts or experiences regarding the modification of high-pressure circuits in aqueous solutions? Can the steam consumption be reduced to 0.9?
Could the original poster briefly explain how your unit was renovated?
A single tower can produce 400 tons per day; if medium pressure is sufficient, two towers can produce 800 tons. Currently, the twin towers produce 430 tons per day. The problem is that the medium-pressure and low-pressure units were upgraded from the original 30,000-ton capacity systems, with only one of the towers being replaced. The company wants to increase its capacity to 250,000 tons by installing high-pressure rings. Have we lost our minds?
Don’t lose hope for the 3rd floor – it can definitely be upgraded. Our company has upgraded many units, with the highest capacity reaching 1,000 tons per day, while most have been upgraded to 700 tons per day. Please contact wangyq1971@163.com
In fact, after the modification, the synthesis conversion rate increased, and the medium- and low-pressure loads were reduced as well.
From an engineering economics perspective, upgrading the high-voltage circuit is completely unnecessary. If it’s just about renovation, then it’s possible to do it!
When upgrading the urea high-pressure system, it is first necessary to consider the economic aspects. Given your current situation, it is technically possible to increase the production capacity to 400 tons per day to 800 tons per day through such an upgrade, but economic factors also need to be taken into account: a large number of medium and low-pressure devices will need to be modified, it is necessary to determine whether steam consumption can be reduced to around 0.9, and the total investment required must also be considered. If you’re interested, you can send me detailed information about your situation at wangqf2422@gmail.com; I can share my experience in making modifications with you
That’s an overstatement; the value of renovation needs to be determined based on the specific conditions of each device, and I can’t simply agree to that claim. Based on successful cases, the payback period for high-pressure ring upgrades is generally 2–3 years, with a cost reduction of around 70 yuan per ton of fertilizer, which is quite significant……
Our company also wants to install high-voltage coils; we are currently evaluating this option. If you know which manufacturer has been most successful in this area, please share your insights
Are you using a full-circulation aqueous solution process or a CO2 stripping process? My email address is wangqf2422@gmail.com. I hope you can provide detailed contact information and relevant materials; I will recommend options to you, and there are definitely successful cases available.