Technologies

Most robust and efficient adiabatic ammonia converter layout available on the market. Suitable for capacity up to 5000 MTD on single train configuration. Suitable for new and revamped converter.

The Advanced Urea On-Line Raman Analyzer (AURORA) is a new powerful tool for on-line process analysis and control of urea plants developed by Casale in cooperation with Kaiser Optical Systems Inc. – a company of Endress+Hauser group, worldwide leader in the spectrographic instrumentation.

Ammonia Absorption Refrigeration Plants (AARP) are refrigerators that use low value heat sources (like low pressure steam or even hot water) to power the refrigeration process instead of using compressors, which, on the other hands, require high grade thermal energy (like MP steam) or electrical power.

Casale has been the first licensor to pioneer the concept of ammonia converter revamping when, in 1986, four axial converters were converted to axial-radial flow by just modifying the internals, without replacing the HP parts of the converter.

Simple and efficient removal of the water and CO2 from synthesis gas.
Energy saving up to 0.1÷0.15 Gcal/MT.

Optimized synthesis catalyst for ammonia converter.
Up to 30% more activity than the standard Magnetite, Cobalt or standard Wustite catalyst.
Additional energy saving (compared to standard AmoMax®) up to 0.05 Gcal/MT.

The AN based fertilizer granulation process allows, in the same unit, the easy granulation of ammonium nitrate (AN), calcium ammonium nitrate (CAN) with possible elemets addition like Mg, S, etc., ammonium sulphate nitrate (ASN) and also 34.5% ammonium nitrate for technical uses.

The AN fattening process was developed as way to obtain larger granules than those produced in prilling towers while avoiding the high investment cost of a new grass route granulation plant.

The Burner is the key element in the autothermal reforming technology; a good ATR design begins (essentially) from a good burner design.

The ATR process design is suitable for production in a single line up to 700'000 Nm3/h of CO+H2 (equivalent to a production of 24'000 bpd of distillates in a FT unit).
It is referenced up to 100'000 Nm3/h of CO+H2.

Casale's axial-radial catalyst bed technology is used in both HT and LT shift converters.

Casale burner hood is made of perforated deflectors, placed at different heights to ensure uniform distribution of the air-ammonia mixture over the platinum gauzes.

Casale Absorption Column has been designed to cope with the most enviromental limitations and to minimize plant specific ammonia consumption.

Reduction of CW consumption in existing AARP (russian AXY).
Cooling water saving in existing AARP (russian AXYs).
Energy saving.

Casale can offers a combined tail gas treatment system with both DeNOx and DeN2O catalysts to treat tail gas and achieve requested environmental regulatory limits.

Casale Purifier is a special designed exchanger that re-evaporates part of process condensate shell side through process steam condensation.

Package to provide liquid ammonia to the ammonia plant.
Energy sources LP steam or hot water.
Plant summer stabilization and energy saving up to 0.2 Gcal/MT.

Steam reformer is one of the most critical unit in the hydrogen, ammonia and methanol plants. It is complex, energy intensive, very expensive and by nature its design is often aggressive, due to the need for harsh operating conditions and specialty materials.

Modern vertical secondary reformer WHB.
Natural circulation.
Solution to replace existing bayonet tube WHB. Robust design and long lasting RG boiler.
Higher reliability and availability to the ammonia plant.

Most efficient and relliable urea reactor trays in the market.
Increase of plant capacity.
Decrease of steam consumption.

Clean CO2 produced with up to 100 ppm vol of H2 residual content.
Simple solution.
Low Capex.

New tower design to provide reliability and better performances to the Ammonia plant CO2 removal section.

Leveraging on Casale’s specific know-how and experience with all commercially available CO2 removal section technologies, either amine-based or hot potassium carbonated based, Casale can assess the performance of existing units with the goal to identify bottlenecks, suggest improvements and propose revamp solutions.

Applicable to Amine-based, Hot carbonate-based and CO2 removal section based on other system
Energy saving up to 0.3 Gcal/MT
Capacity increase up to +100% of plant capacity
CO2 quality improvemnet.

MP condensate stripper, LP condensate stripper and Saturator specifically designed.
Process condensate quality improvement.
Energy recovery up to 0.2 Gcal/MT.

To obtain AA grade methanol, the final purification of the crude is performed with a two-step distillation: the first column, named topping, separates the lighter compounds, while in second column (refining) water and higher ends are separated from the pure product.

Casale Dual Pipe reactor technoly can be advantageously used in granular Complex Fertilizer plants, namely in the granulator (GPR) and/or in the dryer (DPR).

Installed inside the pressure vessel.
Compact design to minimizes the synloop plot area.

Casale has developed a new concept of Radar Level specifically designed for the High Pressure Urea Service.

It is the most widespread process to produce ammonium nitrate with an average size up to 2.5mm.