Are rising energy costs, tightening emission regulations, and the need for higher output putting pressure on your urea plant's profitability? These are common challenges for established facilities.

At Stamicarbon, we specialize in revamping urea plants to address these issues directly, turning operational challenges into opportunities for significant improvements in energy consumption, capacity, and environmental performance.

Through continuous innovations in urea melt production technology and urea granulation technology, we can revamp your urea plant to lower energy consumption, reduce construction costs and raise the efficiency of your production.

Energy Consumption Decrease

To help decrease the energy (high-pressure steam) consumption of a traditional CO2 stripping plant we apply adiabatic flash technology. That way we minimize the excess of low-pressure steam by utilizing a process-to-process heat exchanger.

In this heat exchanger, the heat of condensation of condensing carbamate vapors is used to concentrate urea solution, resulting in steam savings in the evaporation section.

By increasing the efficiency of the HP stripper (and thus decreasing steam consumption) more carbamate vapors can be produced in the adiabatic flash section, leading to more process-to-process heat exchange and a further reduction of steam consumption.

Capacity Increase

Capacity increase of a urea plant can be achieved by introducing a bypass line directly from the reactor in the synthesis section to the newly build adiabtic flash section.

Bypassing the HP stripper nd bringing reactor liquid directly to the adiabatic flash section produces more carbamate vapors in that section, resulting in further decrease of the energy consumption.

Emission Reduction

Further reducing the emission of your plant can be realized by introducing an atmospheric flash section in the existing process line. This way more unconverted reactants are recycled back to the synthesis section before reaching the evaporation section and (over)loading the wastewater section, leading to a reduction of the plant emissions.

Tailored Solutions for Your Plant

Every urea plant has a unique operational fingerprint, with its own specific opportunities for improvement. That's why a one-size-fits-all solution is never the answer.

Our approach to any plant revamp begins with a deep, collaborative analysis of your facility. By understanding your specific goals and technical realities, we design and implement a tailor-made solution that delivers measurable results.

We start every revamp process with a plant assessment and study, giving you an overview of your plant status quo and debottleneck opportunities. The outcome of this study is discussed with you first to ensure a tailor-made solution.

The solution aims for a significant energy consumption decrease, while increasing your plant capacity and reducing emissions. This is how we do it! 

Take the first step towards modernizing your plant by contacting us.