Technologies
Removes completely ammonia and urea from process condensate.
Boiler feed water quality is achieved.
Revamping to convert a hot wall converter to a cold wall one.
Improvement in terms of life, reliability and safety.
Suitable for existing plant.
H2 recovery from Purge.
Energy saving 0.04÷0.10 Gcal/MTNH3.
Customized process scheme accoding to the specific melamine technology.
Efficient integration to minimize the water recycled to Urea reactor.
Efficient layout.
Highest ammonia conversion.
Suitable for new and revamped converter.
Provides plant stabilization during hot season.
Energy sources LP steam or hot water.
Energy saving will be about 0.2 Gcal/MT.
Casale is a worldwide leader company in the field of methanol synthesis technologies, licensing its own technologies for grass-roots and revamping project.
Casale’s core business is the design of synthesis reactor, which takes advantage of Casale technologies to achieve benefits in terms of energy-efficiency and high capacity that are not achievable with other traditional technologies.
Patented technology with free choice of the export steam’s pressure (typically in the range 10÷70 bar g).
The conventional granulation plant is is central to the Casale NPK process.
Casale has put in place a program of services to assess the performances from the entire plant down to the single critical items as well as for auditing the plant operations, with the purpose to improve the production efficiency and/or reduce the environmental footprint and/or identify specific bottlenecks.
A well trained team is crucial for the smooth and successful operation of your plant.
The operating conditions for a pure oxygen burner for partial oxidation (POX) are extreme due to the extremely high temperature needed to achieve a high conversion of natural gas to CO and H2: the reformed gas temperature at the reactor outlet is maintained in the range of 1,200-1,400°C, with the maximum flame temperature around 2,800-2,900°C.
The pre-reformer is an adiabatic catalytic reactor placed upstream the reformer in which the higher hydrocarbons contained in the natural gas feed are converted into methane thus preventing the formation of coke in the primary reformer feed preheat coil and at the catalyst tube inlet.
Casale prilling towers are very compact and for this reason the most effective use of the prilling tower area is of paramount importance. Great attention is payed is the design and optimization of the air top and bottom plenums.
The primary reformer is a fired chemical reactor where the heat for the endothermic reforming reaction is supplied by the combustion of the fuel gas.
Exchanger reformer to perform plant capacity increase.
No primary reformer radiant box modification.
Capacity increase up to 30% per single TPR installed.
Steam system optimization.
Casale has devised efficient designs for special purpose burners, including for secondary reformer in ammonia plants.
Casale's sour CO-shift converter features our well-proven, reliable axial-radial flow internals. With this kind of arrangement, most of the gas passes through the catalyst bed in the radial direction, resulting in very low pressure drop. The balance passes down through a top layer of catalyst in an axial direction, thus eliminating the need for a complicated, gas sealed top cover on the catalyst basket.
The Casale superphosphate process allows all possible superphosphates (SSP, TSP, and USP) to be produced as ROP products in the same plant:
High performance Synloop heat exchangers to superheat steam, generate high pressure or medium pressure steam and to pre-heat BFW.
Reliable and robust design.
Uremium 29 is a super-duplex material specifically developed for Urea service by Casale and Tubacex, a global leader of S.S. and high Ni-alloys tubular solution.
It is well-known that it is not practical to produce an NP fertilizer by simply mixing superphosphate, especially SSP and urea because of quality problems with the final mixture during storage (formation of dust, caking).
Casale proprietary vibrating heads are specifically designed to reduce the area and the height of the prilling tower with great advantage on the capex cost.
When operating the synthesis section of an ammonia plant the amount of oxygenated compounds present in the fresh make-up gas is a critical parameter to keep closely watched.
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