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19th

AFA Intl Fertilizer Technical

Conference & Exhibition18- 20 April 2006Four Seasons Hotel

Doha- Qatar

High Pressure stripper replacement in urea plant

Mr. Basheer Al-AWAMI Process Review Team Leader

Mr. Praveen GARG Cost Contral TeamAlbayroni

S. Arabia

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INTRODUCTION

BACKGROUND

HISTORY OF HP STRIPPER

DESIGN & SIZING HIGHLIGHTS

PROJECT MILESTONES

PROJECT ACHIEVEMENTS & CHALLENGES

OPERATION BENEFITS

PROJECT COST

CONCLUSION

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Al-Jubail Fertilizer Co. ALBAYRONI was established in 1979 in Al-Jubail Industrial City; K.S.A.

A joint venture between SABIC and TFC.

It produces four major products namely Ammonia, Urea, 2-EthylHexanol 2-EH & Di-Octyl Phthalate DOP.

Commercial production of Ammonia and Urea Plants was started in1983 and for 2-EH & DOP was in 1995 & 1996 respectively.

Urea Plant is a Stamicarbon based technology with a design capacityof 1600 MTPD. Actual production is +1900 MTPD.

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HP Stripper material of construction in Urea plant was BC.05 with acorrosion rate of 0.06 mm/y

In operation from 1983 to 2005

Due to tube thinning, about 3.1% of total area was plugged

In 2003, it was decided to replace it with a new modified one.

In July 2005, HP Stripper failed due to tube rupture.

The new one was installed during T/A 2005.

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HP Stripper failed during operation. This happened 8 days before the scheduled T/A in July

2005. Plant was S/D and new one was installed.2005

The wall thickness remains 2.35-mm max. and 1.30-mm min. 58 tubes were plugged due to

low thickness.2003

The wall thickness remained at 2.35-mm max. & 1.35-mm min. 23 tubes were plugged due

low thickness.2002

Inlet box found severely corroded. Liquid dividers were changed due to mal-distribution of

liquid. The corrosion rate was 0.06 mm/year.1997

Wall thickness remained 2.44-mm max. and 1.95-mm min.1995

First inspection by Stamicarbon B.V. Eddy current inspection carried out for all the tubes &

used as the base line data. Wall thickness was 2.52-mm max. & 1.2-mm min.1993

Manhole liner showed 1-2 mm pitting due to lack of passivation.1991

EventYear

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Three options were considered, namely:

Replacement in kind.Similar capacity replacement with upgraded metallurgyHigher capacity replacement with upgraded metallurgy.

SAFUREX Material Selected:

First use in Urea plants was in 1997.Lowest corrosion rate when compared to BC.05.Lower tube thickness due to high mechanical strength.Passivation air can be reduced and hence more CO2 feed ispossible.Low susceptibility to stress corrosion cracking

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14 August 05Commissioning

18 MonthsTotal Project Period

July - August 05Installation13 May 05Delivery to site

15 Feb 05Final inspection and release for dispatch

25-27 Jan 05Hydro test - Shell side (51 barg) & Tube side (265 barg)

July 04 to Jan 05Fabrication

Jun - Sep 04Sourcing of major components

15 June 04Approval of design and fabrication drawings

22-24 Mar 04KOM at SBN shop. ALBAYRONI, Stamicarbon and TUV participated

15 Feb 04Issue of Letter of intent by SABIC

DURATIONDESCRIPTION

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2.54.5CO2

3.56.5Ammonia

Desorber & Hydrolyser Inlet, wt%

1.41.9Re-circulation Pressure, Bar

26.526.25H2O

57.255.55Urea

9.369.90CO2

6.608.00Ammonia

Outlet Composition, wt %

0.8530.871Steam Consumption, MT/MT Urea

161165Bottom Temperature, C

82 ~ 8378 ~ 80Stripping Efficiency, %

27802650Number of Tubes

1880 19401850 - 1900Actual Production, MT/D

21501600Design Capacity, MT/D

New StripperOld StripperEquipment Performance

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Achievements:Engineering, Procurement, and Construction was completed within the timeframe of the project.Performance Test Run was successful and met all the guarantee figures.Equipment was installed without any change in the existing piping orstructure.Plant production could be increased by 30 MT/D.Specific consumption of NH3/ Urea dropped from 0.591 to 0.580.

Challenges:Higher weight of the new stripper.Changing the material of construction to SAFUREX.Installation of equipment in limited time and space.

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1002,800,000Total Project Cost

11300,000Installation at site

9270,000Transportation ex-works to job site

722,000,000Material & Fabrication

8230,000Design & Engineering

% of TOTALCOST

COSTUS $

DESCRIPTION

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Regular inspection may minimize the chances of sudden equipment failures.

SAFUREX is a proven material for Urea HP equipment.

Prior to any equipment replacement, future plant upgrades and expansionrequirements should be considered, if possible.

Installation of the new HP Stripper in Al-Bayroni was successful as severaloperational benefits were realized:

Higher Production.

Lower Ammonia & steam consumption.

Recycle of NH3 & CO2 reduced.

Venting of NH3 & CO2 reduced.

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