2025 Fumagalli Self-stripping plant revamping with HYPER-U

HYPER-U is a novel urea synthesis process recently developed by Casale to address the ever- growing demand of sustainable fertilizer production. Based on the conventional self-stripping technology, it features innovative concepts which allows a drastic reduction of the consumption of MP steam and cooling water. Namely, a thorough heat recovery strategy is implemented in order to maximize the re-use of the thermal energy supplied via MP steam to the HP Stripper which in fact is used five times. In the following paper it will be presented how HYPER-U can be conveniently applied for the revamping of conventional self-stripping plants. Since the back-bone of HYPER-U resides in the original self-stripping process, by adding few new items it is possible to upgrade a vintage plant into a modern efficient plant achieving a significant improvement of the energy efficiency. Due to the intrinsic characteristics of the new items required by HYPER-U, the High-Pressure synthesis loop and the Medium-Pressure purification section are consequently debottlenecked which opens the possibility for increasing the plant capacity even by a relevant figure. Applying HYPER-U to an existing self-stripping plant allows the simultaneous saving of energy and capacity increase which yields attractive project payback.

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