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37th Nitrogen + Syngas conference & exhibition 2024 (to enlarge, please click on the picture)

LESER at the 37th Nitrogen + Syngas conference & exhibition 2024

LESER will be presenting the Safety Valve solution for the fertilizer industry in Gothenburg from 4 to 6 March 2024.
Corrosive and crystallizing media such as carbamate gas are processed in the production of fertilizers. For plant operators, this places high demands on the function and design of plant components - including safety valves. 

How Urea is produced

The industrial production of urea involves a chemical synthesis process in which ammonia and carbon dioxide are first converted into carbamate gas and then into urea. This process takes place under constant high pressure and high temperature. The resulting carbamate gas is very corrosive if it gets into liquid phase and tends to crystallize. For this reason, protecting the system components from corrosion and crystallisation is a key technical requirement for the materials used and the design of the components.

Market change to green hydrogen energy source

The strong focus on energy efficiency and low-emission technologies is changing the market for current and future projects. Worldwide about 150 projects for nitrogen fertilizer are under construction (~50) or in planning (~100) until 2028. The corresponding ammonia plants are mainly designed with green or blue ammonia with a view to hydrogen as a new energy source.
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Critical parts Full nozzle and disc after 2 years in operation (to enlarge, please click on the picture)

LESERs Urea Synthesis Safety Valve

The LESER urea synthesis Safety Valve is manufactured specifically for these challenging requirements. The choice of materials is optimized for critical urea applications and ensures high corrosion resistance. LESER has developed suitable solutions for the leading licensors over the last decades. The special corrosion-inhibiting materials for the critical components full nozzle and disc can be processed to ensure a long service life.
 
LESER Flushing System UREAEN 1920 1080 px
Left: Schematic sketch of LESER Flushing System – Safety Valve in open position. Right: Pressure plot at 168 barg relieving pressures – Safety Valve in open position (to enlarge, please click on the picture)

LESER Flushing System

Crystallization of the carbamate gas (in liquid phase) is prevented by a steam purging concept.

The optimum flow of steam through the design of the safety valve also reduces the amount of steam required and therefore the operating costs.

Safety Valve Solution
Typical LESER Safety Valve solution (to enlarge, please click on the picture)

LESER solution for the complete UREA synthesis section

Beside the design for the high pressure synthesis LESER offers all needed Safety Valves for the complete synthesis section with various needed designs and materials. In the past LESER has delivered in greenfield and brownfield plants more than 2500 Safety Valves.

Value to customers

The main benefits are longer maintenance intervals, reduced cleaning requirements for internal parts such as the seat area, and the elimination of the risk of crystallization in the outlet chamber of the safety valve. The result is increased system safety and reliability.
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