Research and Development

Modelling: digital model as technology draft

Every investment shall be justified and predictable. Customers try to minimize the risks — so, that they are manageable and understandable, and the payback time of project investments is minimal. In this context, digital tools are becoming the key element of confidence in decisions – they allow to significantly supplement and expand the capabilities of traditional empirical approaches by increasing the accuracy of engineering calculations.

We combine years of production experience, our own experimental data, and a deep understanding of the fundamental principles of processes in terms of physical chemistry. All of this is complemented by modern digital methods—from thermodynamic and kinetic modeling to CFD and machine learning. This approach ensures the high accuracy of predictions and controlled efficiency, both during upgrade of the existing units and during design of the new ones.

For customers it means decrease of uncertainty, refusal of excess stock, predictable economics and flexibility in scaling.

Prototyping: model building, reverse engineering capabilities

Creation of prototype model allows to visualize the idea and test its efficiency at the first stages. The available 3D printing and 3D scanning tools make it possible to perform reverse engineering of inaccessible or lost technologies and use them as the basis for creating products with even better properties and characteristics.

Pilot units: final check before start-up

We minimize process risks by testing each solution on prototypes and pilot units. JSC NIIK has its own research and development and experimental and pilot base that allows to perform both fundamental and applied research.

Own park of stand units for hydrodynamic research ensures continuous efficiency improvement of the internals of the urea synthesis reactor — conversion boosters, mixers, trays, and other key components.

JSC NIIK’s pilot and demonstration park also includes highly efficient urea granulation units: a high-speed drum granulator and a fluidized bed granulation unit. These units are used to refine the process for producing commercial products, as well as to modify commercial-grade urea and optimize these processes.

Laboratory pilot experiments provide reference data for verification of engineering calculations and validation of technological solutions effectiveness. The availability of mini-units and research stands allows to promptly test the new engineering ideas, materials, and design solutions, accelerating the transition from model to industrial implementation.

The obtained data allows to provide customers with reliable process solutions and equipment ready for industrial implementation.