Tag: Troubleshooting

A discussion about CO2 coolers in the inter stages of CO2 compressors and the problems that can occur after the third stage when cooling water is on the shell side and the CO2 is on the tubes side.

A discussion about the high-pressure CO2 stripper and how to solve the problem of a high temperature in the bottom of the stripper.

Dust formation in the granulator can adversely affect stream time. There are several reasons for increased dust in the fluid bed granulator. No formaldehyde or less formaldehyde injection, lower bed level in the granulator, lower concentration of urea melt to the granulator, a higher pressure in atomisation (sprayer) air and a higher pressure in the urea melt header are all factors which can play a role. This article discusses increased dust level and its causes.

Control of the process conditions of the MP absorber is one of the key control parameters in a Saipem urea plant. CO2 carryover to the ammonia receiver is not permitted in the process as it will create corrosion problems and upset conditions in the ammonia recovery and pumping system. This round table discussion considers the problems and solutions in this process section.

Pressure transmitters have become essential parts of virtually all urea plants. This discussion looks at a case where a plant is experiencing frequent faults with a reactor pressure transmitter. The urea industry shares its experiences and solutions.

A discussion about the causes for a change in urea product colour. Stainless steels exposed to carbamate containing solutions in the urea synthesis section can be kept in a passive state by adding a minimum amount of oxygen. If the oxygen content drops below this minimum, active corrosion starts, which can be identified by a shiny silver colour on the surface.

The waste water treatment section in a urea plant processes the water containing NH3-CO2 and urea from the vacuum system in the evaporation section. This discussion looks into the possible root cause of problems with the concentration in the waste water section feed tank of a urea plant and the off-grade condensate produced.

In a urea plant, too much carbamate solution recycle back to the synthesis section will increase the amount of water in the synthesis and will negatively influence the reactor conversion figures. Fouling in the recirculation section can sometimes cause these operational problems, but how can fouling be identified as the root cause of a problem?

A discussion into the possible causes of a temperature drop of the HP stripper outlet of a Saipem urea plant after start-up.

The protective loose liners in high pressure urea synthesis equipment require an accurate and reliable leak detection system in order identify in time when there is a leak in the liner, but locating a small leak is not always easy to find. Several methods are available but which works best for small leaks?