Statistical Process Control is a good way to check, but more-over control your product quality, and reduce the amount of complaints and overdosing of formaldehyde, and avoid caking and dust in the warehouse. 

Typically one wants to do quality control on the Size Guide Number (SGN) and Uniformity Index (UI), because these parameters determine how ones fluid bed granulation or prilling plant is running. One can also opt to apply Statistical Process Control on the load-out product, to enable a product certification and happy customers...More information

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What is reason #3 to choose for a vacuum system ?

What is reason #3 to choose for a vacuum system ?

We recommend a vacuum based leak detection system for several reasons:

Reason #3: A vacuum system is less prone to clogging.

In case of a liner leak and operating a vacuum system, the vacuum pump of the leak detection system will pull the leaking ammonia to the ammonia analyser. After the leak detection circuit in which the leak occurs has been determined, one is able to dilute the leak in this line with air via the vacuum pump by opening the atmospheric ball valve and in that way one dilutes the leaking fluid and reduces (eliminates) the risk for clogging!

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AmmoniaKnowHow.com - Online Roundtable - Corrosion Issues in Ammonia and Urea Plants: Causes, Consequences and Safeguard Solutions

AmmoniaKnowHow.com - Online Roundtable - Corrosion Issues in Ammonia and Urea Plants: Causes, Consequences and Safeguard Solutions

On the 25th of March, AmmoniaKnowHow.com will hold a webinar to discuss corrosion issues in ammonia and urea plants. Industry experts and specialists will share their experience. Incidents and case studies will be presented together with the latest technologies for corrosion prevention and mitigation. AmmoniaKnowHow.com webinars are an opportunity for participants to get together in an interactive setting to examine issues related to operation and maintenance of ammonia and urea plants.

Amine_Experts
E2G
IGS
NTT Consultancy
UreaKnowHow.com

Register Now via this link

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We are at 2000 Round Table Discussions!

We are at 2000 Round Table Discussions!

UreaKnowHow.com has reached the impressive milestone of 2000 Round Table discussions. 2000 active Round Table discussion with totally more than 9500 posts or an average of 5 posts per discussion and 2-3 new posts per day. This means everybody who posts a question, for sure will get a reply making the UreaKnowHow.com Round Tables a very valuable information source and place to share experiences.
We thank all participants for their valuable contributions and support and like to highlight and thank very much the 10 most active participants:...Click here to read more

 

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How a vacuum LDS system is able to distinguish a false indication from an ammonia cloud in the atmosphere from a real liner leak ?

How a vacuum LDS system is able to distinguish a false indication from an ammonia cloud in the atmosphere from a real liner leak ?

High pressure urea equipment consists of a carbon steel pressure bearing wall, which is protected against corrosion by a protective stainless, titanium or duplex steel layer. This protective layer can be an overlay welding, an explosive cladded layer or a loose liner. Any leak in a loose liner will lead to a dangerous situation in that a large surface of the carbon steel pressure bearing wall underneath the leaking loose liner compartment will be exposed to the extremely corrosive ammonium carbamate. Experience has shown that ammonium carbamate can corrode carbon steels with very high corrosion rates up to 1,000 mm (40 inch) per year.

When talking about active leak detection systems, one can distinguish a pressurized system, in which an inert carrier gas stream flows through the leak detection circuits and a vacuum based system, where one pulls vacuum pressure behind the liner. We recommend a vacuum based leak detection system for several reasons.

But how can a vacuum system distinguish a false indication from for instance an ammonia cloud in the atmosphere from a liner leak ?

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What is reason #2 to choose for a vacuum system?

What is reason #2 to choose for a vacuum system?

This question 7 is in continuation of question 6 in which we started explaining why an active vacuum leak detection system is superior over an active pressurized system. Active leak detection systems can be either a pressurized system, in which an inert carrier gas stream flows through the leak detection circuits most probably only via the machined leak detection grooves present in the carbon steel and a vacuum system, where one pulls vacuum pressure underneath the liner.

We recommend a vacuum based leak detection system for several reasons:

Reason #2: Direct detection of the complete carbon steel surface

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The State-Of-The-Art Ammonia Terminal

The State-Of-The-Art Ammonia Terminal

Since 100 years ago the industrial production of ammonia began for the widespread agricultural and industrial application. Safety hazards and risks have been identified and for a large extend resolved.

Nowadays ammonia is used more and more as a very efficient hydrogen energy storage, carrier and carbon free fuel. This means that more and more people will get involved with this potentially toxic substance. How will the public and the authorities react?

Are the previously known safety regulations sufficient for the storage / bunkering of ammonia?

We say no, it can be better, more safe and reliable.

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What is reason #1 to choose for a vacuum system?

What is reason #1 to choose for a vacuum system?

We recommend a vacuum based leak detection system for several reasons:

Reason #1: No risk of liner bulging

A first reason is that when using a vacuum system there will be no risk for liner bulging and damage due a to too high pressure in the leak detection system behind the liner. Be aware that the relatively large liner compartments are welded to the carbon steel pressure bearing wall. These large areas allow only a very limited pressure difference between each side of the liner.

Some vendors try to avoid this risk of bulging by switching off the leak detection system when the pressure in the synthesis section is below a certain value. In our view this is not a good solution because...

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Which kind of active leak detection systems exist ?

Which kind of active leak detection systems exist ?

High pressure urea equipment consist of a heavy carbon steel pressure bearing wall, which is protected against corrosion by a thin corrosion resistant layer; this layer is in the most cases made out of stainless steel or a duplex. This protective layer can be an overlay welding, an explosive cladded layer but is in most cases a loose liner.

Any leak in a loose liner will lead to a dangerous situation because a potentially corrosive fluid can be spread and trapped in the gap between the carbon steel pressure bearing wall and the loose liner. This area will then be exposed to the extremely corrosive ammonium-carbamate.

Real situations have proven that ammonium-carbamate can corrode carbon steels with very high corrosion rates up to 1,000 mm (40 inch) per year. But also stainless steels will show accelerated corrosion because of lack of oxygen. That means that it is an absolute must to have a detection system present that already warns for al leak in an early stage. Then one can only conclude that an active leak detection system is required...

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Why flushing with steam or condensate is NOT a good practice ?

Why flushing with steam or condensate is NOT a good practice ?

To check if a leak detection system is not facing any clogging or to unclog a leak detection system, some plants practice a flushing procedure with steam or water.
This is not recommended and even dangerous! Introducing water can lead to corrosion. Corrosion, as known, is an electrochemical reaction so corrosion can only take place when water is present.

Without water no corrosion.

The corrosion product will block the passage ways and can also block the leak detection holes.
A more threatening form of corrosion that can occur is  stress corrosion  cracking  of the carbon steel pressure vessel wall.

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UreaKnowHow.com will present at CRU's Nitrogen+Syngas 2021 Virtual Conference

UreaKnowHow.com will present at CRU's Nitrogen+Syngas 2021 Virtual Conference

For 33 years, CRU's Nitrogen + Syngas conference has provided an annual platform for the global industry to meet, network, and learn. Every year, 740+ producers, licensors, and materials and equipment providers attend to ensure they have knowledge, understanding and professional connections required to improve their production, maximise profitability, and maintain safe, reliable, and environmentally responsible operations.
In 2021, due to the pandemic, Nitrogen + Syngas will go ahead - as a virtual event. The tried and tested virtual platform allow CRU to deliver an interactive environment for all participants to meet, learn and network. The only virtual element of the conference is the venue - the conference still offers real insight, real networking, and real business opportunities.
UreaKnowHow.com will present a paper with the title: How to Improve Safety and Reliability of the High Pressure Synthesis Section of Urea Plants. The paper draws conclusions from a detailed analysis of the more than 130 serious incidents of the UreaKnowHow.com Urea Incident Database.
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In Memoriam Jan van der Werf

In Memoriam Jan van der Werf

Jan van der Werf died peacefully Monday morning November 30, 2020 at an age of 76 in his hometown Sittard-Geleen.

With a career of 55 years at Stamicarbon, Jan was enjoying his work with whole his heart. Jan did know where he was talking about, he knew what was urea as he was involved in numerous commissioning and start-up projects. Jan started up one of the first CO2 stripping plants under difficult circumstances in the former DDR, the first PoolCondenser plant in Bangladesh and left his footprint in many other countries like North Korea, Thailand, Romania, USSR, Japan, USA, Myanmar, China, Mexico and Alaska. Jan also worked at several high level management positions in Stamicarbon, always pushing forward innovations and breakthroughs in our industry; amongst many others Safurex® and Full Life Cycle support.

Everywhere we came, people asked how Jan was doing. Jan was open, friendly, flexible and always in a good mood, Jan was really a great manager and colleague, with both feet on the ground, one between his colleagues, his door was always open, Jan was always striving for cooperation and teambuilding. We and we believe many other colleagues owe Jan a lot. Jan was always in to discuss technical issues, strategical topics and life in general, preferably with a pint of beer.

Jan, we will miss you.

We send condolences to Wilma, Guido and Petra and the entire van der Werf family.

Jo Eijkenboom
Mark Brouwer
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Why is a passive leak detection system not acceptable anymore?

Why is a passive leak detection system not acceptable anymore?

In a passive leak detection system an indication of a leak in the liner only shows up when the leak emerges from the leak detection hole. Or, in case the leak detection hole is connected via tubing to for example a bottle with a phenolphthalein solution, when the colour of the liquid in the bottle changes. The detection occurs at a later moment then when the leak occurs in the liner. Time passes (dwell time) between the moment the leak occurred and the moment the leak emerges at the leak detector or when a field operator notifies the leak. The latter case is even worse as the dwell time can be much larger. During that dwell time the risk that the leak detection path gets clogged is realistic. That means that there will be a serious threat to the integrity of the carbon steel pressure bearing wall... Click here to Read more.

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FERTILIZER INDUSTRIAL SERVICES Owner's Engineer

FERTILIZER INDUSTRIAL SERVICES Owner's Engineer

As experienced professionals in fertilizer industry, we discovered a necessity to fill the gaps in technology knowhow required in various fertilizer industry projects. This is Fertilizer Industrial Services' foundational business strategy.
We are specialized in fertilizer production technologies covering process, mechanical, instrumentation, process safety and project management disciplines. Our services include design review, plant commissioning and startup, operation support, ammonia tank de-commissioning for inspection, plant revamp support and project management consultancy.
We have the unique ability to seamlessly link design, completions, commissioning and operations. That seamless link is provided by our people, an unrivalled group of independent experts. This team supported customers in the industry for new and existing fertilizer plants for more than 15 years.
We work with fertilizer manufacturers, operators, technology licensors, EPC companies and PMC consultants covering short term or long-term projects.
More info below:
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When does one need a proper Leak Detection System ?

When does one need a proper Leak Detection System ?

AMMO LASER Leak Detection System -
The #1 Safety Measure with a Guaranteed Pay Back
We are pleased to inform you about all the details via our Frequently Asked Questions
Question #2: When does one need a proper Leak Detection System ?
Click here for the answer

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The State-of-the-Art Urea Reactor

The State-of-the-Art Urea Reactor

“Highest Safety and Reliability Standards ; Minimum Maintenance and Repair Efforts”

The heart of every urea plant is the urea reactor. The high pressures, high temperatures and the presence of very corrosive ammonium carbamate puts high demands on its reliability and safety during its typical lifetime of 40-50 years. UreaKnowHow.com has established a Urea Incident Database containing numerous serious incidents with urea reactors and a Urea Reactor Risk Register containing fifty risks and failure modes of a traditional design urea reactor.

Based on the above information plus by applying our extensive experience and knowledge, we can offer you the complete detailed design specification of a State-of-The-Art Urea Reactor with optimum design details of the carbon steel pressure bearing wall, the protective layers and all the internals. This will realise the highest reliability and safety standards and minimize maintenance and repair efforts.

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UreaKnowHow.com welcomes GRANDPERSPECTIVE as our new Sponsor

UreaKnowHow.com welcomes GRANDPERSPECTIVE as our new Sponsor

We make visible the invisible hazard. Stepping back is essential to overview.

Remote monitoring provides maximum coverage day and night.

Broaden your view. Get the Grandperspective.

Grandperspective is a solution provider for industrial monitoring of gas leaks and gas detection, based in Berlin, Germany. We provide Early Warning Monitoring Solutions for the fertilizer, ammonia urea, and petrochemical industry.

Our team of experts designs innovative Remote Monitoring solutions, that combine of high-tech hardware and intelligent software. Our spectroscopic monitoring technology identifies, locates, and tracks moving gas clouds at up to 4 km distance to cover large terrains, on the ground and for the airspace above. We identify and quantify from large distances hundreds of hazardous gases, including: Ammonia, Natural Gas, Methanol, CO and N2O.

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UreaKnowHow.com welcomes SDS SEPARATIONS as our Sponsor

UreaKnowHow.com welcomes SDS SEPARATIONS as our Sponsor

Revolutionizing Separation & Scrubbing Solutions

“SDSμ Separators and SDSμ Scrubbers revolutionize industrial filtration … replacing bulky, inefficient scrubbers, cyclones and separation vessels.”

“SDSμ Separators and SDSμ Scrubbers reduce Total Cost of Ownership (CAPEX and OPEX, no consumables & negligible maintenance).”

SDS Separation BV, a Dutch Process Technology Company focuses on the design, engineering and manufacturing of Dutch innovative separation and scrubbing solutions for the energy and process industries worldwide.

Our team is currently based in Europe and North-East Asia. Our expertise, know-how and IP-protected solutions deliver customers: Increased Production Rate, Higher Efficiencies, Less Fouling, Lower Emissions, Lean Designs and Short Pay Back Times.

Interested to learn more, click here

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Why does one need a proper Leak Detection System ?

Why does one need a proper Leak Detection System ?

AMMO LASER Leak Detection System - 
The #1 Safety Measure with a Guaranteed Pay Back
We are pleased to inform you about all the details via our Frequently Asked Questions
Question #1: Why does one need a proper Leak Detection System ?
Click here for the answer

Click here for all latest information

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UreaKnowHow.com prepares a Risk Register Leak Detection System for Loose Liners of High Pressure Equipment

UreaKnowHow.com prepares a Risk Register Leak Detection System for Loose Liners of High Pressure Equipment

Clogging in the leak detection system is by far the most serious risk to cause high corrosion rates of the carbon steel pressure bearing wall of high pressure urea equipment. A state of the art leak detection system should safeguard first and for all warn before clogging occurs. Key words to avoid the aforementioned situations are early detection and high reliability.
This is the reason that passive leak detection systems, where one waits for the leak to show up at the analyzer are unsafe and not acceptable anymore today. This has been proven through trial and error in numerous incidents, for example Urea Incident 18-005 (FIORDA Urea Case #5).
The next question is: What are the requirements for a state of the art active and reliable leak detection system?
Find the Risk Register of a Leak Detection System including the lessons learned from related incidents via the following link: Risk Register Leak Detection System.pdf

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UreaKnowHow.com welcomes FLUITEC as our Sponsor

UreaKnowHow.com welcomes FLUITEC as our Sponsor

Fluitec, a world leader in intelligent maintenance and lubrication

ABOUT FLUITEC
Industry Leader in Fluid Life Extension Technologies
Transform your fluids into assets: Fluitec is the innovator to Measure, Consult, and Treat industrial fluids to maximize their life.

Fertilizer industry solutions for reducing downtime, extending equipment life and maintenance intervals for large rotating equipment. Read the whitepaper.

MEASURE
Condition monitoring the health of industrial fluids to protect asset-functionality.

CONSULT
Expanding knowledge with Consultative Services, Support & Training, and leadership in the implementation of industry-wide standards & uniform protocols.

TREAT
Enhancement technologies to improve product reliability, productivity and sustainability

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