TOAZ completed the second stage of ammonia unit 2 overhaul project. After repairs, the unit was ramped to the design capacity.

At this overhaul stage, work was carried out at the synthesis area. The tasks included inspections of heat exchangers and internals of the vessels at the gas CO2 removal area, change of catalysts in the desulfurization unit, installation of a new feedwater pump and replacement of boiler water heaters weighing 80 tonnes each. An industrial safety appraisal of equipment was carried out.

Also, as part of the overhaul project the ammonia converter was revamped based on a project by Ammonia Casale, all the internals and the catalyst were replaced with the same of improved design, the flare unit was overhauled. The final stage of the scheduled activities involved fitting new insulation to process vessels and piping.

Commenting on the competed overhaul project, Viktor Kazachkov, Deputy CEO and Operations Director, CJSC Corporation Togliattiazot, said: “This overhaul is remarkable in that absolutely all the tasks were accomplished by Togliattiazot’s internal personnel, without outsourcing. The activities performed increased the ammonia unit capacity, while cutting consumption and enhancing operational reliability and stability of equipment.”

The first stage of ammonia unit 2 overhaul was completed in 2013, with a major revamp of the reformer. In 2019 the company plans to pass on to the third stage, which will involve an upgrade of the synthesis gas compressor turbines.

The ammonia unit 2 was overhauled as part of TOAZ’s major production capacity upgrade program. In 2015 to 2017, completed were repairs and revamp of ammonia units 3, 4, 5 and 6, two cryogenic ammonia storage tanks, and carbamide units. Since 2012, the company has spent over RUB 26bn in total to invest in revamps.

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