Risk analysis tools such as hazard identification (HAZID), is often a first step in broader risk management and is especially valuable for green ammonia, where new technologies and processes introduce novel risks. This article explores various aspects of HAZID, from the basics of hazard identification to unique considerations specific to green ammonia facilities.
A European ammonia plant, has successfully restarted following a revamp of the process gas cooling section, executed by Casale. Casale replaced the outdated boilers located downstream of the secondary reformer with three new double-tube type boilers supplied by Arvos. The new boilers were installed in the same location as the previous ones, minimising investment costs and plant modifications. The more robust and reliable design of the Casale-Arvos boilers has resulted in enhanced overall performance and reliability of the ammonia plant.
Paralloy has developed Omega technology, an advanced reformer tube design that enhances heat transfer, gas turbulence, and process efficiency. Dr Dominique Flahaut of Paralloy explores the real-world implications of Omega reformer tubes.
Maire Group says that its nitrogen fertilizer technology licensor Stamicarbon has been awarded new contracts related to its NX STAMI UreaTM technology in Canada. The first award is a process design package and the licensing of an integrated urea and diesel exhaust fluid (DEF) production plant currently being developed by Genesis Fertilizers, a farmer-owned consortium, at Belle Plaine, Saskatchewan. The plant will have a urea melt capacity of 2,500 t/d, with operations expected to begin by 2029. Also thanks to a carbon capture and sequestration unit, it will be the first proposed low-carbon nitrogen fertilizer plant in Canada. Stamicarbon will apply its proprietary flash urea melt technology to enhance operational efficiency and reliability while minimising process steam consumption. The plant will also include a DEF facility with a production capacity of 1,500 t/d.
In part 5 of this series on stripper efficiency issues we conclude the discussion with a focus on fouling inside stripper tubes.
Apart from having a good plant design, good maintenance practices and good operational discipline are key to optimise the performance of an acid plant and to protect it from corrosion and achieve a long life. B. Mumba, T. Mwanza and P. Ng’ambi of Kansanshi Mining PLC explore the Kansanshi sulphuric acid plant operations and the key parameters monitored and practices adopted that have helped to extend the catalyst campaigns from two years to four years.
Preventing regenerator amine carryover to the sulphur recovery unit can have catastrophic consequences and must be avoided at all costs. B. Spooner and M. Sheilan of SGS Amine Experts detail how by correctly interpreting operating data, having proper instrumentation and good chemical analysis, amine carryover can be prevented.
Fertilizer International interviews Graeme Cousland, Managing Director, and Martyn Dean, Sales Director, Begg Cousland Envirotec Limited.
Rotary coolers remain a popular choice with fertilizer producers, explains Shane Le Capitaine of FEECO International, thanks to their ability to meet the industry’s rigorous demands.
Igor Makarenko of Solex Thermal Science reviews the main equipment options for fertilizer cooling and their relative merits.