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Middle East 300000 Tons/Year Fertilizer Project Customized Urea and Ammonia Production Lines1
Chemical Equipment MachineryProduction LineCustomizable Production Lines
Yangzhou Tongyang Chemical Equipment Co., Ltd.
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Product Description 300,000 tons/year fertilizer project of Middle East Zambia United CapitalProject backgroundIn order to improve the regional fertilizer self-sufficiency capacity, Middle East Zambia United Capital invested in the construction of a 300,000 tons/year urea and synthetic ammonia integrated project. The project is located in a desert industrial area and needs to adapt to high temperature, high dust environment and harsh process conditions. With ASME U/U2 certification and global project experience, Tongyang Chemical designed and manufactured 12 types of core pressure vessels and separation equipment for it, covering the entire process of synthetic ammonia gasification, urea synthesis and steam system.---Technical challenges-Extreme working conditions: High-pressure flash tanks (design pressure 12MPa) need to withstand high temperature (400oC+) of syngas and H2S corrosion;-Sealing reliability: Liquid ammonia buffer tanks, liquid seal tanks and other equipment require zero leakage, in accordance with API 620/ASME Section VIII standards;-System integration: The steam drum and flash tank need to seamlessly match the DCS control system to achieve precise pressure-liquid level joint adjustment.---Core equipment and solutionsTongyang adopts modular design and special material technology to deliver the following key equipment in a customized manner:1. High-pressure flash separation tank- Material: SA-387 Gr.11 CL2+Inconel 625 lining, the life of hydrogen sulfide stress corrosion resistance is increased to 15 years;- Structure: Integrated cyclone separator and multi-stage demister, gas phase entrained droplets ≤0.01%.2. Low-pressure nitrogen buffer tank/liquid ammonia buffer tank- Intelligent monitoring: Equipped with wireless pressure sensor and AI prediction system, real-time warning of leakage risk;- Energy-saving design: The cold insulation layer uses nano aerogel, and the cold loss is reduced by 30%.3. Steam system equipment group (high-pressure steam saturator, medium/low-pressure flash tank)- Efficient heat transfer: Threaded pipe strengthens the heat exchange structure, and the steam dryness is stable ≥99%;- Anti-erosion: Tungsten carbide wear-resistant bushing is installed at the pipe mouth, and the life of the flow rate sensitive area is extended by 3 times.4. Environmental compliance equipment (slag lock bucket flushing water tank, discontinuous discharge cylinder)- Zero emission: closed-loop circulating water system + activated carbon adsorption unit, 100% wastewater reuse rate;- Automation: PLC controls emission frequency, reduces manual intervention and VOCs emission.---Project results- Production capacity meets the standard: put into production in the first quarter of 2024, the daily output of urea exceeds 900 tons, and the purity reaches 46.3% (agricultural grade one standard);- Safe operation: The equipment has passed TüV SIL3 certification and has been running continuously without trouble for more than 6,000 hours;- Green benefits: The waste heat recovery of the steam system reduces carbon emissions by 28,000 tons per year, helping customers obtain ISO 14064 certification.---Customer evaluation"Tongyang's equipment far exceeds expectations in terms of high-pressure sealing and corrosion resistance, and its intelligent monitoring system provides a solid guarantee for stable production in desert environments." - Project Chief Engineer---Case Technical Highlights-Material Innovation: Jointly developed SA-533 Gr.B hydrogen-resistant steel with Baosteel, and passed NACE TM0177 certification;-Digital delivery: Apply BIM technology to pre-install pipeline interfaces, shortening the on-site installation cycle by 45%;-Global service: The local technical center in the Middle East provides spare parts and remote diagnosis, and the fault response is ≤12 hours.We can provide equipment and engineering design services for some small and medium-sized production lines.Full-Project MasteryFrom process design to commissioning, we control all stages with ls0 9001/14001/45001,PEDASME U/U2, and GOST-certified precision.Supply Chain Service IntegrationIntegrated E+P Solutions, 50 engineers +80000 m2 workshops deliver turnkey production lineswith optimized supply chain for SMEs.Value-added ServicesO2O online-offline integration, website synchronizes offline information, provides negotiationentry points, and extends business scenarios.Industry InnovationHelping enterprises reduce risks in high-risk industries and meet regulatory.CUSTOMIZATIONMax Dia 1000mm, Max Lifting Weight 100TThe preparation of materialsAustenitic stainless steel: 304/304L/316/316L/317/310/310S/323 - Renowned for its superb corrosion resistance, making it an ideal choice for demanding applications.Duplex stainless steel: S31803/S32205/S32304/S32507/SUS329J4L - Offers enhanced strength combined with excellent corrosion resistance, perfect for tough conditions.Super austenitic stainless steel:S3254/N08904/N08367 - Known for exceptional resistance to corrosion and durability, making it suitable for extreme environments.Chrome molybdenum steel:1CR-0.5Mo/1.25CR-0.5Mo/2.25Cr-0.5Mo - Provides robust performance in high-temperature applications, delivering strength and reliability.Manganese molybdenum nickel:SA302Gr.C/D / SA533Gr.B/C/D - Combines the attributes of strength and toughness, ideal for pressure vessel applications.Titanium/Aluminium/Copper/Zirconium etc... - Offers unique properties for special applications where high resistance to specific conditions is required.ANNUAL OUTPUTYEAR2017201820192020202120222023Reactor129133177180220303339Heat Exchanger119132153210260375452Column112128177147180285317Storage Tank95150162142203300556Special Equipment19010698119138350378Annual Output645649707798100116132042TYPICAL APPLICATION AREA Chemical Industry Food Engineering Bioengineering Field Pharmaceutical FieldCOMPANY PROFILEABOUT USYangzhou TongYang Chemical Equipment Co., Ltd., established in 2000, is conveniently situated in Yangzhou City, Jiangsu Province, just a four-hour drive from Shanghai Airport. Our expansive facility spans over 80,000 square meters and is staffed by nearly 300 dedicated professionals. We specialize in the development and manufacturing of sophisticated chemical machinery and equipment, catering to diverse industries such as pharmaceuticals, chemicals, and petrochemical engineering. Our commitment to excellence is reflected in our diverse product range.For over three decades, TongYang has steadfastly adhered to our guiding principles: 'Serve customers with professional work; improve ourselves with continuous innovation; contribute to society in good faith.' Our product portfolio encompasses columns, continuous evaporative crystallizers, BM series thin film evaporators, hydrogenation reactors, tube exchangers, spiral plate heat exchangers, vacuum reduced pressure thickeners, inorganic pervaporation membrane devices, and three-in-one filter washing machines, among others.Simultaneously, TongYang is committed to rigorous internal quality control and high-volume production standards. We proudly hold certifications including ISO 9001/14001/45001, ASME U1 U2, GOST, TRCU, EAC, as well as special equipment production licenses and radiation safety licenses. Moreover, we are equipped with cutting-edge labs for comprehensive testing such as Radiographic Tests, Hydrostatic Tests, and Magnetic Particle Tests, ensuring our products meet the highest standards of safety and reliability.At Yangzhou Tongyang Chemical Equipment Co., Ltd., we are dedicated to excelling in the art of manufacturing products. Our commitment doesn't end there; we also strive to offer innovative solutions and unparalleled service, ensuring both industrial and societal advancements. We warmly anticipate building a fruitful collaboration with you, leading us all toward a brighter future.TRANSPORTATIONGiven the substantial dimensions of our pressure vessels, which often exceed 20,000mm (787") x 3500mm (137") x 3500mm (137") or weigh more than 40T, transportation by truck is impractical. To overcome this, we partner with a nearby port. Initially, we transport the segmented devices via truck to the port. There, we expertly weld the pieces together, forming a complete unit. This full equipment is then shipped to the Shanghai port, ready for export across the seas.CERTIFICATEFAQ 1. Q:Are you a manufacturer or trading company? A:We are a manufacturer with over thirty years of experience in China.2.Q:Can we visit your factory before placing orders? A: Sure, warmly welcome to our factory! 3.Q:What's the information needed if I send one inquiry ? A : Please tell us the working conditions, mediums,temperature ,pressure, equipment ' s material,size,quantity, and other special requests. 4.Q:How does your factory do quality control? A: Quality is priority ,we make relevant strict testing before delivery. Our factory has already obtained ASME, GOST, ISO9001 quality and ISO 14001 Environmental management system certificate.
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