Looking for more information or have a project inquiry? Fill out the form to connect with our experts. We will get back to you shortly.
Increasing urea production does not always require building a new plant. Existing facilities may still have unused design margins or specific process bottlenecks that can be addressed to achieve a considerable increase in output.
Before modifying the plant, it is therefore essential to determine which bottlenecks are limiting production and how the proposed capacity increase will affect energy consumption, ammonia use, emissions and on-stream performance.
The potential for debottlenecking also depends on the availability of feedstocks and utilities, as well as the original design margins of major equipment.
A plant-specific assessment is required to identify a technically sound and economically attractive route to higher output.
NEXTCHEM, through its subsidiary Stamicarbon, offers Evolve Capacity™, a structured debottlenecking approach for increasing the production capacity of existing urea plants.
Based on the plant configuration, available feedstocks and utilities, and the required production increase, we identify the constraints limiting output and develop a solution tailored to your facility.
Evolve Capacity™ starts with a Plant Performance Assessment to establish the current operating condition of the plant and identify its principal bottlenecks.
The assessment focuses on the areas that have the greatest influence on plant performance, including ammonia consumption, energy consumption, effluents, on-stream time and production capacity.
Based on the findings, we define the most appropriate debottlenecking concept for the plant.
Several solutions are available, depending on the required increase in output, and where appropriate, hybrid solutions combining more than one design can also be developed:
| Evolve Capacity™ designs | Expected capacity increase* |
|---|---|
| More-In-More-Out Design | 10–30% |
| Double Stripper Design | 30–40% |
| Add-On Mega Capacity Design | 40–50% |
| Pool Condenser/Reactor Design | 50–100% |
* Based on nameplate capacity. The actual capacity gain depends on the original design margins of large-capital equipment.
More-In-More-Out
The More-In-More-Out approach makes use of the available design margins in the existing plant. Where the principal equipment and utility systems can accommodate additional throughput, production capacity can typically be increased by approximately 10 to 30% compared with the original nameplate capacity.
Double Stripper
The Double Stripper solution introduces additional stripping capacity to overcome limitations in the high-pressure synthesis section. Depending on the existing plant configuration and equipment margins, this approach can provide a capacity increase of approximately 30 to 40%.
Add-On Mega Capacity
For projects requiring a larger increase in production, the Add-On Mega Capacity concept expands the capacity of the relevant process sections through additional equipment and process modifications.
This solution can increase production by approximately 40 to 50% compared with the original nameplate capacity.
Pool Condenser or Pool Reactor
Where a substantial increase in capacity is required, the synthesis section can be modified by applying Pool Condenser or Pool Reactor technology. Depending on the plant design and the available margins in major equipment, this option can provide a capacity increase of approximately 50 to 100%.
Hybrid configurations combining more than one debottlenecking approach can also be developed where this provides a better fit with the required output and the existing plant configuration. The actual achievable capacity increase depends on the original design margins of large-capital equipment and must therefore be confirmed through a detailed assessment of the plant.
Evolve Capacity™ provides a plant-specific route to higher output rather than applying the same revamp concept to every facility.
The selected solution is based on the actual bottlenecks, process conditions and design margins of the plant.
By using existing equipment and infrastructure as effectively as possible, producers can increase output without the investment required for an entirely new facility.
Higher production can also reduce the production cost per ton of urea and strengthen the competitive position of the plant.
Evolve Capacity™ helps urea producers identify and resolve the constraints that limit production, creating a technically reliable route to higher plant output.
Talk to our experts to arrange a Plant Performance Assessment and determine the capacity-increase potential of your urea plant.
Whether you're planning to get new facilities, upgrading an existing plant, or seeking low-carbon alternatives, Nextchem provides:
Download the leaflet to discover all the key feature about our NX Stami™ Urea technology.
Learn more about who we are, how we began, and why we're committed to enabling the energy transition.
Go to About Us Go to About UsDiscover the sustainable technology solutions and integrated E&C solutions our Group offers.
Go to Solutions Go to SolutionsExplore our open positions to find your perfect match and learn more about our Group culture.
Go to Careers Go to Careers See Open Positions See Open PositionsFind the latest news and media resources about our Group, companies, people.
Go to Newsroom Go to NewsroomLooking for more information or have a project inquiry? Fill out the form to connect with our experts. We will get back to you shortly.
Registered Office: Via di Vannina 88/94, 00156 Rome, Italy
P: +39 06 9356771
Company subject to direction and coordination of MAIRE SpA
Share capital € 32.938.653,00 fully paid-up
Tax Code, VAT number and Rome Company register number 16951401005
R.E.A. 1686636