Stamicarbon Symposium Papers & Presentations
Thank you for attending the 15th Stamicarbon Symposium. On this page, you can explore the technical insights shared during the event.
Introduction- Sustainable Technology Solutions
Presented by: Pejman Djavdan & Fabio Fritelli
Location: Jacob Pronk Room
Time: 10:30- 11:30
Sustainable Fertilizers; Feeding the World in an Age of Disruption
Presented by: Alzbeta Klein- International Fertilizer Association (IFA)
Location: Jacob Pronk Room
Time: 10:30- 11:30
Nitrogen Market Update
Presented by: Maureen Vermeule
Location: Jacob Pronk Room
Time: 11:30- 12:00
Summary:
The presentation provides an overview of the nitrogen market, the global factors shaping it, and its potential future outlook.
Nutrient Enhanced Urea Fertilizers
Presented by: Gerardo Duarte
Location: Jacob Pronk Room
Time: 13:30- 14:00
Abstract:
Enhanced nitrogen fertilizers offer a stable price alternative in the volatile commodity market, presenting opportunities for producers to diversify their portfolios. Despite evident benefits, adoption remains limited due to price sensitivity among large-scale growers and wholesaler focus on high-margin segments.
Stamicarbon's fluid bed slurry granulation technology is presented as a solution to the limitations faced in traditional agglomeration methods for urea based NPK fertilizers. To learn more about this technology read the full paper.
Integration of Ammonia, Urea and Nitrates for Sustainable Fertilizer Production
Presented by: Luca Amicucci
Location: Jacob Pronk Room
Time: 14:00- 14:30
Abstract:
This paper outlines a comprehensive integration strategy to produce ammonia, urea, diesel exhaust fluid (DEF), and calcium ammonium nitrate (CAN), aimed at driving the decarbonization of the fertilizer industry. Through an in-depth analysis of three configurations—a DEF complex that harnesses CO₂ and steam integration, a CAN complex employing low-carbon ammonia and efficient nitric acid synthesis, and a small-scale urea facility with optimized purge and steam management—the document highlights the significant advantages of interconnected plant operations.
AI‑Powered Digital Twins and Carbon Footprint Monitoring
Presented by: Martino Trabuio and Ali El Sibai
Location:
Jacob Pronk Room
Session Time:
14:30 - 15:00
Abstract:
As the fertilizer industry faces increasing pressure to innovate and decarbonize, the integration of digital twins and AI offers a compelling pathway to smarter, more agile, and resilient operations. Stamicarbon has developed several digital tools to support this transformation, including the Soft N/C Meter, AI Event Detection, and the carbon Footprint Monitor. Download the paper to read more.
Ultra Low Energy - The Road to the New Industry Standards
Presented by: Chuanbo Gao, Rahul Patil
Location: Jacob Pronk Room
Time: 15:30- 16:00
Abstract:
In response to growing demands for energy efficiency, sustainability, and production optimization in urea manufacturing, Stamicarbon has developed the Ultra Low Energy (ULE) revamp concept, a transformative solution for both Stamicarbon and non-Stamicarbon urea plants. This concept is built on the N=3 philosophy, where the heat of the High-Pressure (HP) steam is utilized three times, significantly reducing specific steam consumption and enabling capacity increases of up to 45%. Download the paper to learn more.
Ultra Low Energy - Updated Design
Presented by: Alex Scheerder, Mark Wagemans, Kader Lakhe
Location: Jacob Pronk Room
Time: 11:30- 12:00
Abstract:
The NX STAMI™ Urea Ultra-Low Energy (ULE) plant concept was launched during the Stamicarbon symposium in 2012 as 5XX design. Since 2021, six grassroot ULE plants have been designed, constructed and successfully put into operation, with four more plants under construction or in engineering phase. The first licensed ULE plants have a capacity of 2350 MTPD, while the capacity of the plants under construction reaches up to 3850 MTPD. For these bigger plant capacities, a second-generation ULE Pool Condenser Design is introduced.
The ULE Design for a melt plant with prilled product lowers steam consumption (23 bara, 330 ºC) to less than 560 kg steam/ton of product compared to the traditional NX STAMI™ Urea Pool Reactor Design (formerly known as Urea 2000plus®) with a steam consumption less than 870 kg steam/ton of product.
This paper highlights the mechanical design aspects of the first and second generations of ULE pool reactor and ULE pool condenser as well as operational experiences of the first-generation pool reactor and pool condenser with dual bundle (steam and carbamate) for the ULE plant.
Ultra Low Energy - Revamp Concept for Stripping Plants
Presented by: Ahmed Shams and Robert Rozek
Location: Jacob Pronk Room
Time: 16:30- 17:00
Abstract:
In response to growing demands for energy efficiency, sustainability, and production optimization in urea manufacturing, Stamicarbon has developed the Ultra Low Energy (ULE) revamp concept, a transformative solution for both Stamicarbon and non-Stamicarbon urea plants. This concept is built on the N=3 philosophy, where the heat of the High-Pressure (HP) steam is utilized three times, significantly reducing specific steam consumption and enabling capacity increases of up to 45%.
Syngas Production & Carbon Capture
Presented by: Cristina Guazzotti &Alexander Schulz
Location: Jacob Pronk Room
Time: 09:00 - 09:30
Summary:
Nextchem brings over 50 years of experience in hydrogen & syngas expertise, covering the entire value chain from technology development to project execution. With its wide portfolio of technical solutions, Nextchem can meet industrial requirements across all contexts. Nextchem provides best-in-class solutions for hydrogen production and CO2 capture across all capacities and plant configurations. Through its cutting‑edge technologies, Nextchem offers solutions and plant configurations that enable the virtually complete avoidance of CO₂ emissions.
Upgrading a Non-Stamicarbon Granulation Plant
Presented by: Barbara Cucchiella and Juan Coloma
Location: Cor Ruys Room
Time: 09:00 - 09:30
Abstract:
Stamicarbon granulation technology boasts unprecedented continuous running times, exceeding a world-wide average of 90 days before requiring a wash, in some cases exceeding 125 days and reaching even up to 215 days of uninterrupted operation. In response to the numerous client requests, Stamicarbon has developed a revamp design to transform atomization granulators into film spraying. Milestones include the development of a scaled-up film spray nozzle reaching up to atomization capacity (including design margin), successfully tested in pilot scale, and a tailor-made process concept that unlocks the full potential for non-Stamicarbon granulators.
NX STAMI™ Ammonia MP synloop, for World-Scale Green and Blue Ammonia Plants
Presented by: Reza Aran, Rolf Postma
Location: Jacob Pronk Room
Time: 09:30- 10:00
Abstract:
The NX STAMI™ Ammonia Medium Pressure process presents a scalable and efficient solution for green and blue ammonia production, addressing the growing demand for low-carbon hydrogen carriers and fertilizers. This technology integrates seamlessly with renewable hydrogen sources and advanced reforming systems, achieving near-complete hydrogen utilization and up to 99% carbon capture.
The process design emphasizes energy efficiency, operational flexibility, and integration with downstream technologies such as urea and nitrate production. Key innovations include a high-efficiency ammonia converter and the use of standard equipment to reduce capital expenditure.
The NX STAMI™ Ammonia MP synloop supports the transition to sustainable ammonia production through modular, integrated, and future-ready plant configurations.
Technical Grade Urea
Presented by: Bruno Teixeira and Mohamed Mostafa
Location:
Cor Ruys Room
Session Time:
09:30 - 10:00
Abstract:
Stamicarbon is honored to present the latest innovation on urea granulation technology which allows to produce technical grade urea (TGU) granules with Stamicarbon granulation technology without the use of formaldehyde. This technology does not require major CAPEX investments to an existing Stamicarbon granulation plant, while at the same time saves the end-user OPEX costs on formaldehyde consumption, avoids the application of a harmful chemical and provides higher revenues due to the premium quality product (around 100EUR per ton of granules).
Enabling Decentralized Ammonia Production with NX STAMI™ Ammonia HP Synloop – Beyond the Base Case
Presented by: Mahal Patel
Location: Jacob Pronk Room
Time: 10:00- 10:30
Abstract:
The NX STAMI™ Ammonia high-pressure (HP) synloop is designed for efficient and sustainable production of ammonia with capacities between 50-500 MTPD. Its base configuration delivers warm ammonia, ideal for direct use in fertilizer manufacturing, while also offering the option to produce cold ammonia for storage or shipping – especially valuable when using renewable energy sources. The process can be configured to recover and export steam, significantly reducing operational costs and external energy requirements.
Seamless integration with green hydrogen production and inclusion of a Deoxo-Drying unit helps to remove oxygen and water, further optimize energy use, equipment needs, and catalyst protection. Emission reduction strategies are built in, either by integrating purge gas with a nitric acid unit—eliminating continuous emissions and lowering costs—or by refining the process for standalone units to minimize or eliminate purge, maximizing hydrogen efficiency.
Collectively, these alternatives ensure that the NX STAMI™ Ammonia HP synloop remains competitive in terms of CAPEX-OPEX and environmentally responsible, supporting a wide range of plant configurations and future industry needs.
Vibro Prilling
Presented by: Juan Coloma, Chuanbo Gao
Location: Cor Ruys Room
Time: 10:00- 10:30
Abstract:
Stamicarbon has leveraged its more than 50 years’ experience in prilling technology to develop a higher quality prill through the introduction of vibro-prilling technology. While in conventional prilling, thin streams of liquid are created to form droplets which are solidified via convective cooling with counter-current cold air, there is no way to influence jet breakup and droplet formation, the latter being governed by random perturbations.
Although vibro prilling is not a new technology in itself, Stamicarbon and its long-lasting partner Kreber have developed an innovative and IP protected design that circumvents typical operational problems by transferring the vibrations to the urea melt rather than to the bucket, thus drastically reducing maintenance of critical parts such as electromagnets, bearings and the drive.
Reducing the N2O Footprint of Your Nitric Acid Plant
Presented by: Sayujya Shah
Location: Jacob Pronk Room
Time: 11:00- 11:30
Abstract:
This paper evaluates various technical options proposed in the market for emissions reduction in nitric acid plants, which are necessary to improve their overall environmental footprint. It shows why the tertiary abatement system is the most effective and technically feasible solution for reducing NOx and N2O emissions. The paper also presents the development of the Stamicarbon tertiary abatement system, which can incorporate both extruded catalyst and monolith catalyst beds. These solutions are tailored to different situations, with examples illustrating the primary challenges posed by various scenarios.
Ammonia Flue Gas Recovery
Presented by: Prayagraj Dhruv, Veronica Rivas, Hans van den Tillaart and Amit Gupta
Location: Cor Ruys Room
Time: 11:00 - 11:30
Abstract:
This paper presents a novel CO₂ capture concept in which CO₂ from flue gas is converted into an ammonium carbamate solution suitable for direct use in a urea melt plant. The process employs NH₃ as the reactant for CO₂ capture, eliminating the need for solvent regeneration and high‑pressure CO₂ compression. As a result, the recovered CO₂ can be efficiently integrated into urea synthesis. Application of this concept enables an increase in urea plant capacity of approximately 15–20% while utilizing existing excess NH₃.
In addition to improved plant economics, the high CO₂ capture efficiency of the process contributes to a lower overall carbon footprint for urea production. The proposed approach offers a practical and sustainable alternative for debottlenecking and revamping existing urea plants.
Micromist™ Venturi and Jet Venturi Scrubbers
Presented by: Murad Ismayilov
Location: Cor Ruys Room
Time: 11:30 - 12:00
Abstract:
The paper presents a comprehensive overview of advanced air pollution control technologies for fertilizer production facilities, focusing on the MicroMist™ Venturi (MMV) Scrubber and Jet Venturi Scrubber systems developed by Stamicarbon in collaboration with EnviroCare International. These technologies are engineered to address the stringent regulatory demands for reducing fine particulate and ammonia emissions, with MMV Scrubber optimized for urea granulation and Jet Venturi Scrubber for prilling tower applications.
The paper details their operational principles, performance benchmarks, including emission reduction below 10 mg/Nm³ for urea dust and below 5 mg/Nm³ for ammonia, and integration with Wet Electrostatic Precipitators (WESP) to achieve even lower dust levels and 0% opacity. Flexible salt reworking options and downstream crystallization technologies are also discussed, highlighting the potential for producing marketable fertilizer byproducts and supporting sustainable investment strategies. The paper further explores regulatory measurement standards, industry challenges, and the benefits of combining MMV with WESP for comprehensive emission control.
Next Generation Nitric Acid Production: Total Recycle and Alternative Concepts
Presented by: Paz Munoz
Location: Jacob Pronk Room
Time: 11:30 - 12:00
Abstract:
This paper explores innovative approaches to nitric acid production, with a primary focus on the NX Stami™ Nitrates Total Recycle concept, which simultaneously reduces capital expenditure (CAPEX), operating expenditure (OPEX), and environmental impact. It also describes additional routes to improve plant efficiency using pure oxygen. These options represent suitable alternatives for plant revamps, allowing for capacity increases and reductions in operating costs and emissions with relatively low capital investment.
Back-End Nitrates (Finishing Technology)
Presented by: Massimo Gori
Location: Jacob Pronk Room
Time: 12:00 - 12:30
Summary:
Ballestra offering complements Stamicarbon
technologies with top class AN final concentration
and granulation. With a complete portfolio, we bring all fertilizer technologies under one roof.
Revolutionizing Operator Training with E-certifier
Presented by: Math Steps
Location: Cor Ruys Room
Time: 12:00 - 12:30
Abstract:
Operator training is a cornerstone of safety and efficiency in urea production plants, where high-pressure systems and hazardous chemicals like ammonia present significant operational risks. Well-trained operators are essential for recognizing early warning signs of equipment failure, responding swiftly to abnormal conditions, and adhering to strict safety protocols.
E-Certifier leverages advanced simulation technologies and e-learning material to provide a comprehensive training experience that bridges the gap between theoretical knowledge and practical application.
By integrating automated scenarios, procedures and quizzes, e-Certifier ensures that operators are not only well-versed in the theoretical aspects of their roles but also proficient in handling real-world scenarios. This innovative approach to training and certification aims to enhance plant operations, improve safety, and ensure that operators are equipped with the skills and knowledge necessary to excel in their roles.
Valorization of Excess LP Steam for Reduced Carbon Footprint of Urea Plants
Presented by: Usman Abdulrasaq and Damiano Visciotti
Location: Jacob Pronk Room
Time: 09:00- 09:30
Abstract:
The aim of this paper is to explore avenues to achieve carbon footprint reduction and reutilization of what is traditionally considered ‘waste steam ’. Several methods are industrially available; this paper will outline two categories for potential reutilization of excess LP steam: reuse of LP steam as motive fluid of turbine drivers (Case a) – a common practice in a urea plant – and mechanical vapor recompression (MVR) of LP steam as a heat exchange medium (Case b).
How to Get the Most of Your Equipment
Presented by: Alex Scheerder, Julio Padovani
Location: Cor Ruys Room
Time: 09:00 - 09:30
Abstract:
Stamicarbon, the nitrogen technology licensor of NEXTCHEM (Maire Group), provides the best solutions to get the most out of your critical high-pressure equipment. This paper highlights the key success factors for this achievement, summarized as follows:
- Continuous (open) innovation
- Best corrosion-resistant materials
- Full control of the supply chain of high-pressure equipment
- Partnerships with the sub-suppliers, such as steel mill and equipment manufacturers
- Know-how and experience built up over more than 60 years
-
Full life cycle support
Adiabatic Flash Design 2.0
Presented by: Solomon Wassie and Rahul Patil
Location: Jacob Pronk Room
Time: 09:30- 10:00
Abstract:
This paper outlines the key process design enhancements introduced in Adiabatic Flash Design 2.0 relative to the first-generation Adiabatic Flash Design, alongside operational insights from grassroot Adiabatic Flash Design 2.0 urea plants currently in operation. A comparative evaluation of critical performance metrics, including steam consumption and product quality, is also provided, highlighting the design’s advantages in terms of energy efficiency and operational performance.
Equipment for Thermal Stripping Plants
Presented by: Nitesh Saidane
Location:
Cor Ruys Room
Session Time:
09:30 - 10:00
Abstract:
This paper presents the development and advantages of a Stamicarbon high-pressure stripper tailored for thermal stripping urea plants. Traditional titanium and bimetallic strippers used in these plants often suffer from severe corrosion, erosion, limited operational lifetime, and high replacement or maintenance costs. Building on extensive feedback from end-users and leveraging experience from multiple replacement projects worldwide, Stamicarbon designed a high- performance stripper using its proprietary E-type duplex stainless stainless-steel grade.
It provides a robust, efficient, and economically attractive solution for upgrading or replacing equipment in thermal stripping urea plants, significantly extending operational lifetime and improving plant performance. The paper compares process schemes, temperature profiles, and corrosion mechanisms of thermal versus CO₂-stripping technologies, highlighting how material limitations in existing units lead to premature failures.
Long-Term Prevention of Second-Stage Evaporator Fouling
Presented by: Mr. Syed Munawar Zaman
Location: Jacob Pronk Room
Time: 10:00 - 10:30
Abstract:
The paper presents a comprehensive operational case study from a STAMI-design urea plant, addressing chronic fouling in the second-stage evaporator (S-402) of the vacuum section.
Following a start-up failure and significant production loss event in April 2024, a detailed investigation was carried out to understand why the incident occurred, how it was managed operationally, what corrective and preventive actions were implemented, and how recurrence was avoided. Particular emphasis is placed on the controlled application of urea melt flushing and the management of its associated operational challenges.
The effectiveness of the adopted strategy was validated through approximately 1.5 years of continuous operation, culminating in an internal inspection during November 2025 that confirmed a completely clean second-stage evaporator. The study demonstrates that disciplined adherence to design-intent flushing practices can eliminate chronic fouling, reduce turnaround cleaning effort, and significantly enhance long-term vacuum section reliability.
Operational Experience with High-Pressure Equipment
Presented by: S. Girish, Shakuna Udupa,
Nagaprasanna Bhat
Location: Cor Ruys Room
Time: 10:00- 10:30
Abstract:
This paper presents an overview of Paradeep Phosphates Limited, with a specific focus on the Mangaluru unit. It discusses the historical revamps and capacity enhancement initiatives at PPLM and shares operational experiences with critical high-pressure urea equipment. Detailed operating feedback is shared on liquid divider assemblies with welded construction and Hot Isostatic Pressed (HIP) designs, including observed performance, failure mechanisms, and corrective actions.
The paper further discusses long-term operating experience with a high-pressure stripper fabricated from Safurex® infinity, followed by the subsequent manufacture and replacement with a E-Type Material high-pressure stripper. Operational performance, reliability aspects, and observed improvements are presented.