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Category: Outlook & Reviews

Problem No. 60: Urea process passivation and heating rate

A Stamicarbon urea plant attempts to start up after a scheduled turnaround. Due to maintenance issues, it is necessary to shut down and block in the synthesis section several times. Although licensor’s procedures have been followed, several signs of active corrosion are noticed in the liner of the reactor. What could the cause be for this unexpected behaviour? Can sharing experiences from colleagues from other urea plants provide valuable support to find the root cause or even provide new insights into possible new causes? One observation is that the typical heating up rate of a liner in a reactor is much higher than recommended (refer to diagram). The condensation heat of steam heats up the liner much faster than the carbon steel pressure bearing wall. This creates stress on the liner and affects the lifetime of the liner. Another observation is a temperature rise in the reactor during a blocking in situation. This can be a cause for loss of oxygen required for passivation, resulting in higher corrosion rates.

The new normal

The devastating effects of the Covid-19 pandemic continue to be felt around the world. At time of writing, nearly 4 million cases have been recorded, and at least a quarter of a million people have died, with the suspicion of many more, either from accidental or deliberate undercounting. Figures for excess deaths above a normal seasonal baseline show that places such as Turkey, Ecuador and Indonesia have probably been far worse affected than the official statistics show. There are nevertheless finally hopeful signs that Europe, so far the worst affected region, is beginning to follow the pattern of East Asia and Oceania and that cases are falling. The infection also seems to have peaked in North America, though in the US there is a long tail of infections. Elsewhere, cases are still rising in countries such as Brazil and Mexico.