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JSC Acron is to de-bottleneck urea solidification processes at its facility in Russia with the installation of a Rotoform HS pastillation line delivering a throughput capacity of up to 40,000 MTPY.

The order, scheduled for delivery in March 2009, is for the high-speed version of the Rotoform pastillation process from Sandvik Process Systems, plus the facilities necessary to support an additional two Rotoform HS lines in the future and increase total capacity to 120,000 MTPY.

This includes a common cooling water and exhaust air system, together with the electrical instrumentation and controls necessary to provide fully automatic operation.

Sandvik is also providing supervision of erection, start-up and training.

The Rotoform HS system was initially developed to provide high-capacity sulphur pastillation at oil and gas refineries.

The system, which can be used to produce either fertiliser urea or technical urea without any modification, enables pastilles to be produced in 2mm, 3mm or 4mm diameters.

Multiple lines can be run in parallel to deliver high-throughput capacities and the flexibility to switch to partial operation without halting production.

‘It’s possible to handle anything from 100 to more than 2,500 tonnes a day using multiple Rotoform lines,’ said Sandvik sales manager Albert Baeder.

‘This makes it ideal for de-bottlenecking or completely revamping urea processing facilities.’ The Rotoform process has more than 1,400 installations worldwide, with products handled ranging from sulphur and agrochemicals to resins, waxes and rubber chemicals.

The basic principle consists of a continuously running steel belt, which is cooled from the underside by spraying water through nozzles.

A specially-developed feeding system – the Rotoformer – deposits the melt uniformly onto the continuously-running steel belt in form of droplets.

These are cooled as they run with the steel belt and are discharged in the form of solid pastilles (semispherical granules) at the end of the system.

This delivers free-flowing pastilles of uniform size and quality.

A high crushing strength ensures an almost complete lack of dust – ideal for subsequent handling, storage, transportation and application as a fertiliser.

The company said it is also an environmentally-friendly process with low energy consumption, low dust and ammonia emissions, and a closed cooling water system that ensures no contamination and therefore no need for waste water treatment.

Sandvik Process Systems

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