Equipment design and procurement

In the context of sanctions and departure of some companies from the Russian market, the issue of equipment import substitution has become acute in the chemical industry. The problem is aggravated by the fact that the most part of plants in the Russian Federation is based on foreign technologies, including urea and gas deep processing product plants.

Manufacturing of vessels for urea plants requires special corrosion-resistant steels and a severe quality control at each stage. In collaboration with metallurgical plants, JSC NIIK has developed the technical conditions for production of such steels and is able to combine orders of the Russian clients providing the partners with materials at competitive prices.

Referring to the existing repair plans of the clients, JSC NIIK purchases metal products to its warehouse by carrying out a careful input control in terms of chemical composition and corrosion resistance. Availability of a constant reserve of urea steels at the warehouse enables JSC NIIK not only to reduce supply dates for the products but also to quickly provide the clients with steel in case of an urgent need.

In order to maintain constantly a high quality, JSC NIIK carries out technical inspections of the Russian equipment and material vendors. Based on the inspection results, a certificated is issued on behalf of JSC NIIK confirming compliance of the plant with the specified requirements. Availability of such certificate ensures inclusion of the manufacturer in the guaranteed and accredited data base of JSC NIIK’s vendors that allows simplifying the further selection procedures and increase confidence of the clients.

JSC NIIK possesses competences and production capacities for manufacturing high-pressure equipment, instrumentation and automation systems, shut-off and control valves and centrifugal pumps. In the cases when Russian analogues are absent, supplies are made from friendly countries.

JSC NIIK ensures development, supply and assistance for the equipment of proprietary design for the plants of the chemical industry. The patented solutions of the company are used in urea synthesis units, prilling towers and other process sections, thus enhancing efficiency and reliability of the plants.

Set of internals for the synthesis reactor is one of JSC NIIK’s key engineering solutions. The design allows increasing CO2 conversion degree resulting in decreasing heat costs at the distillation and evaporation stages as well as in enhancing performance of the synthesis section by 15-20%.

JSC NIIK’s equipment is designed for operation in the most challenging conditions:

• pressure up to 320 bar;
• process temperatures up to +400°C;
• outdoor temperatures from -50°C to +50°C;
• seismicity up to IX points as per MSK-64 scale;
• toxic, acidic, corrosive, explosive and fire-hazardous fluids.

Equipment for prilling towers
JSC NIIK is the only company in the Russian Federation that possesses a proven technology and know-how in engineering and equipping the granulation towers. The design includes modern scrubbing systems and granule cooling in the fluidized bed ensuring high quality parameters and process sustainability.

Supply of equipment for units with liquid recycle
The list of supplied process equipment includes the following:

• distillation columns;
• recuperators;
• low-pressure distillers;
• second-stage distillation preheaters;
• stripping distillers.

Use of JSC NIIK’s design equipment allows increasing the quality of the final product, optimizing the production process, reducing energy consumption and minimizing environment impact.

Steel products for repair and replacement of synthesis column lining
JSC NIIK develops and supplies sets and individual elements of synthesis column linings:

• segments of bottoms and cylindrical section;
• reducing elements;
• nozzle forgings;
• cover sealing rings.

Manufacturing is carried out within short terms at machinery plants under control of JSC NIIK’s specialists.

These developments are patented in a number of world countries and have proved their reliability at the plants in the Russian Federation and India. Economic effectiveness is confirmed by mill test certificates.

All drawings and technical documentation are provided to the manufacturers only under strict confidentiality. Quality control is ensured at each stage – from order placement to commissioning at the client’s site.

JSC NIIK provides complex solutions for revamp and design of the new chemical plants. We perform both packaged and individual supplies of a wide range of equipment:

• vessels and units;
• valves;
• pipeline components;
• instrumentation and automation equipment;
• steel products;
• electrical installation materials.

The range of supplied products covers all key components of the modern chemical production: from large-size vessels and units to customized valves and pipeline elements. The packaged supply ensures sole responsibility of JSC NIIK before the Client not only for the project development but also for equipment quality as well as operation reliability of the entire plant.

JSC NIIK not only supplies the equipment but also provides comprehensive engineering services, including design, installation and commissioning. This allows the clients to receive fully ready-for-use production lines complying with the highest standards of efficiency and safety.