Example projects

Shell and tube heat exchangers

Acetic acid condenser – steam generator
	End user: Oil refinery Location: Poland Design code: EN 13445, 2014/68/EU	Weight: 23,060 kg Pressure: 19 bar Temperature: 175 °C Medium flammable
	Materials: Titanium (Gr. 1 – UNS R50250 – 3.7025 / Gr. 2 – UNS R50400 – 3.7035), austenitic stainless steels, carbon steels Process: Condensing reaction gas (acetic acid) and utilising the steam produced in this process by transporting it to the turbine Additional description: – Tubesheets, heads, and conical and cylindrical chambers were explosively cladded (titanium with carbon steel). Polimer developed its own butt welding technology for connecting titanium-cladded carbon steel plates to ensure hermeticity. – 2330 titanium tubes of 7000 mm length were applied, and eddy current tested after production and assembly. – A helium leak test was performed, and the maximum leakage recorded was 10-7 Pa*m³/s. – Lens expansion joint.
Process gas cooler
	End user: Zakłady Azotowe „Kędzierzyn” Location: Kędzierzyn, Poland Design code: EN 13445, 2014/68/EU	Weight: 67 950 kg Pressure: 93 bar Temperature: 460 °C Medium toxic, flammable
	Materials: chromium molybdenum boiler steel for elevated temperatures (13CrMo4-5 – UNS K11564 – EN 1.7335, SA182 F11 CL2 – UNS K11572), SA266 Gr.3 Process: cooling of process gas with the generation of process steam Additional description: – Shell ø1708×74, total length ~15620 mm; – Safety fittings to prevent pressure rise above the permissible pressure; – Disassembly of the existing equipment and assembling of new equipment, including piping; – Management of foundation repair. Connecting the apparatus to the grounding and lightning protection system with measurement protocols.
Neutralisation vapour condenser
	End user: Zakłady Azotowe “Puławy” Location: Puławy Design code: EN 13445, 2014/68/EU	Weight: 19,100 kg Pressure: 2/-1 bar Temperature: 160 °C Medium toxic, flammable, explosive
	Materials: Austenitic-ferritic stainless steels (Duplex – UNS S31803 – 1.4462 – X2CrNiMoN22-5-3), austenitic stainless steels, carbon steels
Secondary Waste Heat Boiler
	End user: Nitrogénművek Location: Pétfürdő, Hungary Design code: ASME BPVC Sec VIII Div 1, TEMA R	Weight: 43,350 kg Pressure: 120 bar Temperature: 450 °C
	Materials: Chromium-molybdenum steels (SA–387 Gr. 11/12, Cl. 2 – UNS K11789/K11757 / SA–182 Gr. F11, Cl. 2 – UNS K11572 / SA–213 Gr. T11 – UNS K11597 – EN 1.7335 – 13CrMo4-5), carbon steels Additional description: We modernised the equipment by designing an insulation system for the hot tubesheet to reduce its operating temperature.
Steam boiler unit: Reactor sulphur condenser
	End user: Oil refinery Location: Poland Plant: Claus Quantity: 3 Design code: WUDT (Conditions of the Office of Technical Inspection)	Weight: 3 szt. x 80,100 kg Pressure: 22 bar Temperature: 350 °C Medium toxic, flammable, explosive
	Materials: Carbon steels, austenitic stainless steels, chromium-molybdenum steels (SA-182 Gr. F12 – UNS K11564 – EN 1.7335 – 13CrMo4-5) Additional description: We designed a thermal expansion compensation system to prevent damage to the brickwork lining on the hot tubesheet; heat-resistant brickwork lining on the tubesheet.
Boiler for potassium washing
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Gas preparation plant at the Ammonia Division Design code: EN 13445, 2014/68/EU, TEMA R	Weight: 17,900 kg Pressure: 30 bar Temperature: 150 °C Medium toxic, flammable, explosive
	Materials: Austenitic stainless steels, carbon steels Process: Heating caustic potash with process gas to concentrate the solution and obtain steam.
Boiler Feed Water Preheater
	Client: Hyundai Heavy Industries Power Systems Plant: Olefins Design code: EN 13445, 2014/68/EU	Weight: 15,600 kg Pressure: 173 bar Temperature: 280 °C
	Materials: Low-vanadium steels Cr-Mo-(Ni) (1.6308 – 18MnMoNi5-5), 16Mo3 – 1.5415 Additional description: post weld heat treatment (PWHT) of weldments.
Heat exchanger SV12 B010
	End user: Mariehamns Energi AB Location: Mariehamn, Aland Islands, Finland Design code: EN 13445, 2014/68/EU	Weight: 1,900 kg Pressure: 16 bar Temperature: 100 °C
	Materials: Austenitic stainless steels, carbon steels Additional description: Thermal expansion compensation (fixed tubesheets) using a lens expansion joint.
Reactor feed heater
	End user: Rafineria Location: Polska Plant: Pyrolysis petrol hydrogenation plant PGH Design code: ASME BPVC Sec. VIII Div. 1, API 660, TEMA, 2014/68/EU	Weight: 27,104 kg Pressure: 69.2 bar Temperature: 400 °C Medium toxic, flammable, explosive
	Materials: Chromium-molybdenum steels (SA–387 Gr. 12, Cl. 2 – UNS K11757 / SA–182 Gr. F12, Cl. 2 – UNS K11564 – EN 1.7335 – 13CrMo4-5), stainless steels Additional description: Shell wall thickness: 40 mm.
Cyclohexanone vapour condenser
	End user: Zakłady Azotowe “Puławy” Location: Puławy Quantity: 2 pcs Design code: EN 13445, 2014/68/EU	Weight: 2 pcs x 17,200 kg Pressure: 1/-1 bar Temperature: 100 °C Medium toxic, flammable, explosive
	Materials: Carbon steels Additional description: Design, manufacturing and installation.
Extractive distillation column condenser
	End user: Oil refinery Location: Poland Plant: Extractive distillation plant Design code: ASME BPVC Sec. VIII Div. 1, TEMA R	Weight: 24,200 kg Pressure: 7/-1 bar Temperature: 65 °C Medium toxic, flammable, explosive
	Materials: Carbon steels Additional description: The tube side (tubes, tubesheets, chamber, head) was protected against corrosion with a phenolic epoxy-based coating (Säkaphen coating).
Syngas water cooler
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Ammonia Division, Synthesis Section Amount: 5 pcs Design code: EN 13445, 2014/68/EU, TEMA R	Weight: 5 pcs. x 7,615 kg Pressure: 360 bar Temperature: 100 °C Medium toxic, flammable, explosive
	Materials: Austenitic-ferritic stainless steels (Duplex – UNS S31803 – 1.4462 – X2CrNiMoN22-5-3), stainless steels, carbon steels Additional description: Hair-pin and gland joint, to facilitate installation we replaced regular bolts with superbolts, which allowed us to reduce bolt assembly tension from 6800 Nm to 380 Nm
Process gas cooler
	End user: Rafineria Location: Polska Design code: ASME BPVC Sec. VIII Div. 1. EN 13445	Weight: 1,950 kg Pressure: 17 bar Temperature: 145 °C Medium toxic, flammable, explosive
	Materials: Titanium (gr. 2 / F2 – UNS R50400 – 3.7035 / Gr. 1 – UNS R50250 – 3.7025 – Ti), austenitic stainless steels, carbon steels Additional description: Titanium-cladded tubesheets by explosive cladding method, lens expansion joint.
Vapour condenser
	End user: Zakłady Azotowe “Puławy” Location: Puławy Design code: EN 13445, 2014/68/EU	Weight: 5,350 kg Pressure: 2/-1 bar Temperature: 200 °C Medium: toxic, flammable, explosive
	Materials: Austenitic-ferritic stainless steels (Duplex – UNS S31803 – 1.4462 – X2CrNiMoN22-5-3), austenitic stainless steels, carbon steels
Natural gas preheater using hydrogen gas
	End user: Rafineria Location: Polska Plant: Hydrogen Plant Design code: ASME BPVC Sec. VIII Div. 1.	Weigh: 260 kg Pressure: 25 bar Temperature: 625 °C Medium: toxic, flammable, explosive
	Materials: Nickel-chromium-molybdenum alloys (Alloy 601 – UNS N06601 – 2.4851 – NiCr23Fe), austenitic stainless steels Additional description: We increased the heat resistance of the tube side by diffusion coating with aluminium of tubesheet surface and the inner surface of the process tubes and chamber.
Ammonia evaporator
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Nitrogen gas neutralisation plant Design code: EN 13445, 2014/68/EU, TEMA R	Weight: 21,110 kg Pressure: 25/-1 bar Temperature: 60 °C Medium: toxic
	Materials: Austenitic stainless steels, carbon steels Process: Evaporation of liquid ammonia by heating water.
Steam boiler condenser
	End user: Rafineria Location: Polska Plant: Claus Design code: WUDT (Conditions of the Office of Technical Inspection), 2014/ 68/EU	Weight: 80,100 kg Pressure: 22 bar Temperature: 350 °C Medium: toxic, flammable, explosive
	Materials: Carbon steels, austenitic stainless steels, chromium-molybdenum steels (EN 1.7335 – 13CrMo4-5) Additional description: Lens expansion joint, pickling.

Air coolers

Syngas air cooler
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Ammonia synthesis loop Quantity: 2 units Design code: EN 13445, 97/23/EC	Weight: 42,000 kg / 1 unit Working pressure: 312.7 bar Temperature: 42 °C
	Materials: Carbon steels + tubes with extruded aluminium fins Additional description: The cooling process in the cooler is intensified by installing four fans for continuous operation in the open space in a supply configuration with anti-explosive electric engines, equipment and frequency converters. The rotor diameter is ∅ 3048 mm. Fan capacity: 4 × 171,000 m³/h.
Air cooler for circulating water
	End user: Refinery plant Location: Poland Quantity: 4 pcs Design code: ASME BPVC Sec. VIII Div. 1.	Weight: 4 pcs x 11,850 kg Pressure: 12 bar Temperature: 100 °C
	Materials: Carbon steels + tubes with extruded aluminium fins
Air coolers for steam+CO₂+H₂S / butane / Leam Mea / propane
	End user: Warri Refining and Petrochemical Company Location: Warri, Nigeria Quantity: 9 pcs Design code: ASME BPVC Sec. VIII Div. 1.	Weight: 6 pcs x 6,500 kg, 1 pc x 5,500 kg, 1 pc x 2,100 kg, 1 pc x 5,300 kg Pressure: 22.9 bar Temperature: 130 °C
	Materials: Carbon steels + tubes with extruded aluminium fins
Nitrogen air cooler
	End user: Alkat (AirLiquide group) Location: Dąbrowa Górnicza Design code: EN 13445, 97/23/EC	Weight: 18,000 kg Temperature: 180 °C
	Materials: Carbon steels + tubes with extruded aluminium fins Additional description: The modernisation design according to which we manufactured the cooler was intended to increase the flow of the medium to 26,000 Nm³/h.
Air cooler for heavy diesel oil
	End user: Refinery plant Location: Poland Plant: Fractional distillation plant Quantity: 6 pcs Design code: AD 2000-Merkblatt, WUDT (Conditions of the Office of Technical Inspection), 97/23/EC	Weight: 6 pcs x 2,748 kg Pressure: 4.5 bar Temperature: 180 °C
	Materials: Carbon steels + tubes with extruded aluminium fins
Air cooler for warm water
	End user: Zakłady Chemiczne “Kędzierzyn” Location: Kędzierzyn-Koźle Plant: Aldehyde Division of JB OXOPLAST Quantity: 2 pcs Design code: WUDT (Conditions of the Office of Technical Inspection)	Weight: 2 pcs x 4,276 kg Pressure: 20 bar Temperature: 220 °C Medium toxic, flammable, explosive
	Materials: Carbon steels + tubes with extruded aluminium fins
A41 fraction air cooler
	End user: Refinery plant Location: Poland Plant: Fractional distillation plant Quantity: 2 pcs Design code: EN 13445, WUDT (Conditions of the Office of Technical Inspection)	Weight: 2 pcs x 3,600 kg Pressure: 4 bar Temperature: 150 °C Medium toxic, flammable, explosive
	Materials: Brass / copper and zinc alloys (CuZn3 explosive cladding on tubesheet, CuZn20Al2 exchanger tubes + extruded aluminium fins, carbon steels) Additional description: Brass-cladded tubesheets by explosive cladding method.
Argon air cooler
	End user: Alkat (AirLiquide group) Location: Dąbrowa Górnicza Design code: WUDT (Conditions of the Office of Technical Inspection)	Weight: 7,500 kg Pressure: 8 bar Temperature: 550 °C
	Materials: Austenitic stainless steels Additional description: We used austenitic steel lamella fins (instead of extruded aluminium fins) increasing the performance and durability of equipment – our own production technology.
Process gas air cooler
	End user: LNG Silesia Location: Hard coal mine in Suszec Plant: LNG liquefaction plant Design code: ASME BPVC Sec. VIII Div. 1., 97/23/EC	Weight: 1,643 kg Pressure: 2.5 bar Temperature: 40 °C
	Materials: Austenitic stainless steels + extruded aluminium fins Additional description: In addition to manufacturing, the project involved thermal balance analysis, selection of materials, fan and technologies.
Light vacuum gas oil cooler
	End user: Refinery plant Location: Poland Plant: Soft asphalt hydro-desulphurization plant Quantity: 2+2 pcs Design code: ASME BPVC Sec. VIII Div. 1	Weight: 2 x 17,120 kg, 2 x 15,900 kg Pressure: 23/38,2 bar Temperature: 170/285 °C
	Materials: carbon steels
Deflegmator
	End user: Refinery plant Location: Poland Quantity: 4 pcs Design code: ASME BPVC Sec. VIII Div. 1	Weight: 4 x 7,650 kg Pressure: 0.35 bar Temperature: 121 °C
	Materials: carbon steels + tubes with extruded aluminium fins

Pressure vessels

Deaerator with column
	End user: Refinery plant Location: Poland Plant: Claus Design code: EN 13445, 2014/68/EU	Weight: 13,150 kg Pressure: 1 bar Temperature: 160 °C
	Materials: Carbon steels
Nitric acid reflux tank
	End user: Zakłady Azotowe “Puławy” Location: Puławy Design code: EN 13445, 2014/68/EU	Weight: 3,980 kg Pressure: 5/-1 bar Temperature: 170 °C Medium toxic
	Materials: Austenitic stainless steels
Intermediate tank for resin solution
	End use: Synthos Location: Oświęcim Design code: EN 13445, 2014/68/EU	Weight: 2,165 kg Pressure: 14 bar Temperature: 250 °C Medium toxic, flammable
	Materials: Nickel-chromium-molybdenum alloys (Alloy C22 – UNS N06022 – 2.4602 – NiCr21Mo14W), stainless steels.
Boiler water tank – degassing system
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Nitric acid plant	Weight: 13,000 kg Pressure: 3.5 bar Temperature: 270 °C
	Materials: Carbon steels Process: Degassing boiler feed water. Additional description: We provided the technological, process and mechanical designs for the degassing system using Computation Fluid Dynamics (CFD) and the Finite Element Method (FEM) Design code: EN 13445, 2014/68/EU.
Steam condensate separator
	End user: Refinery plant Location: Lithuania Design code: ASME BPVC Sec. VIII Div. 1.	Weight: 1,671 kg Pressure: 16 bar Temperature: 250 °C
	Materials: Carbon steels Additional description: – A design maintaining the maximum pressure drops provided by the client – Analysis using the Finite Element Method (FEM) – Analysis using Computational Fluid Dynamics (CFD)
Nitrous gas separator
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Nitric acid plant Design code: ASME BPVC Sec. VIII Div. 1, TEMA R	Weight: 6,000 kg Pressure: 4.8 bar Temperature: 100 °C Medium toxic, flammable, explosive
	Materials: Austenitic stainless steels Additional description: We selected the internal particle separation system.
Neutralisation steam saturator
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Nitric acid neutralisation plant Design code: EN 13445, 2014/68/EU	Weight: 3,600 kg Pressure: 13/-1 bar Temperature: 270 °C
	Materials: Austenitic stainless steels
Evaporation steam saturator
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Nitrogen gas neutralisation plant Design code: EN 13445, 2014/68/EU	Weight: 2,900 kg Pressure: 13/-1 bar Temperature: 270 °C
	Materials: Nickel-chromium-molybdenum alloys (904L – UNS N08904 – 1.4539 – X1NiCrMoCu25-20-5), austenitic stainless steels

Reactors

Autoclave (1311)
	End user: Larkis Location: Dobczyce Process: Vulcanisation of rubber components. Design code: EN 13445, 2014/68/EU	Weight: 4,925 kg Pressure: 8/-1 bar Temperature: 200 °C
	Materials: Carbon steels Additional description: Turnkey project; the design of a whole pressure set, including the vessel, automatics, hydraulics & electrics. Commissioning and personnel training.
Reactor for rosin disproportionation
	End user: Synthos Location: Oświęcim Design code: EN 13445, 97/23/EC	Weight: 3,240 kg Pressure: 6 bar Temperature: 320 °C Medium toxic, flammable
	Materials: Nickel-chromium-molybdenum alloys (Alloy C22 – UNS N06022 – 2.4602 – NiCr21Mo14W), austenitic stainless steels, carbon steels
Steam boiler unit: Combustion chamber
	End user: Refinery plant Location: Poland Plant: Claus Quantity: 3 Design code: WUDT (Conditions of the Office of Technical Inspection)	Weight: 3 pcs x 19,160 kg (without brickwork lining) Pressure: 1,5 bar Temperature: 350 °C Medium toxic, flammable, explosive
	Materials: Carbon steels, stainless steels, chromium-molybdenum steels (SA–387 Gr. 12 – UNS K11757 – EN 1.7335 – 13CrMo4-5) Process: Burning of hydrogen sulphide gas and ammonia in the presence of oxygen enriched air. Additional description: Equipped with burners and a heat-resistant brickwork lining in chambers.
Autoclave (689)
	End user: Hannecard Polska Location: Kraków Design code:EN 13445, 97/23/EC	Weight: 9,000 kg Pressure: 8/-1 bar Temperature: 175 °C
	Materials: Carbon steels Process: Vulcanisation of rubber and ebonite coatings applied to machine and equipment parts: in steam or a mixture of air and steam. Additional description: An autoclave with full mechanics and a hydraulic control system: trolleys, actuators, head opening system.

Installations

Heterogeneous catalyst drying installation for hydrogenation reactors – turnkey project
	End user: PCC MCAA Location: Brzeg Dolny Plant: Monochloroacetic acid production plant Design code: EN 13445, 97/23/EC	Pressure: 12.5 bar Temperature: 220 °C
	Materials: Austenitic stainless steels, carbon steels Additional description: We designed and completed a turnkey project for a catalyst drying system in an ultra-pure monochloroacetic acid production plant. The process of drying the heterogeneous catalyst was divided into two stages: 1. Steam drying system: Pre-drying using superheated steam at 150 °C i and pressure of 2 bar(g). 2. Nitrogen drying system: Nitrogen heated to 150 °C circulating in a closed system was used for the second stage. Range of works: 1. Technological preparation and design for construction of the installationi 2. The manufacturing and supply of shell and tube heat exchangers: Water cooler for steam, nitrogen heater, steam condenser; Roots DR240T 55kV blowers; pipelines; tubing; control and measurement instrumentation 3. Registration of equipment in the Office of Technical Inspection (UDT) 4. Plant assembly 5. Plant start-up
Benzoyl peroxide plant – turnkey project
	End user: Novichem Location: Chorzów Range of work: – Design documentation: mechanical, technological, automatics, electrical, drencher, structural, construction, fire detection and alarm system (SAP) – Prefabrication and installation of process pipelines and steel structures – Supply and installation of the electrical section, drencher system, fittings, reactors and engines – Construction work connected with modernising the industrial wastewater plant, unloading station, transport routes, ground hardening – Construction works involving the construction of new buildings: holding tank for industrial wastewater along with connection – Plant start-up
Nitric acid loading station
	End user: Zakłady Azotowe “Puławy” Lokalizacja: Puławy Range of work: Turnkey project of a nitric acid loading station on the premises of Zakłady Azotowe “Puławy”. The project included industrial valves, control systems, loading arm, and the systems of absorption and purification of vapours generated in the process of loading. Polimer performed a full range of earthworks including plumbing installations, maintenance surveying, foundations, dispensing tray, prefabrication, installation and construction of steel pipelines, insulation and electrical works, instrumentation and automation works. The loading arm was registered with the Transport Technical Inspection (TDT) as per the applicable regulations. We performed the test run and start-up of the entire system.
Cryogenic pipeline
	End user: Alkat (AirLiquide group) Location: Dąbrowa Górnicza Quantity: 240 m x DN65 Materials: Austenitic stainless steels Description: Supply and assembly of a DN 65 vacuum-insulated cryogenic pipeline for transporting liquid nitrogen.

Columns

Depropaniser
	End user: Refinery plant Design code: ASME BPVC Sec. VIII Div. 1., TEMA R Materials: Carbon steels Medium: hydrocarbons, HF acid (toxic, caustic)	Weight: 15 400 kg Pressure: 24,6 bar/ FV Temperature: 135°C
	Additional description: The depropaniser is used to recover isobutane from the propane fraction. It is a two-diameter column with Ø1250 mm lower part diameter and Ø950 mm upper part diameter. The column contains 36 distillation trays. The materials used are carbon steels SA516 Gr. 70, SA106 Gr. B, SA350 Gr. LF2, S235JR. The lower part of the column houses a heater which supplies heat for distillation. The equipment was designed to operate with a toxic and caustic medium at pressures up to 24.6 bar and temperatures up to 135°C.
Gas scrubber
	End user: Refinery plant Design code: ASME BPVC Sec. VIII Div. 1., 2014/68/EC Materials: nickel-copper alloys, carbon steels Medium: hydrocarbons and HF acid (toxic, caustic)	Weight: 34,600 kg Pressure: 10.6/3.5 bar Temperature: 145°C
	Additional description: The discharge gas scrubber is used to neutralise gases fed to the acid discharge unit. An appropriate control system is used to control the level of caustic potash in the scrubber. Due to the medium applied, chemical-corrosion resistant materials were used: SB127 UNS N04400, SA516 Gr.70 and SA106 Gr.B. Alloy 400 is resistant to HF acid in concentrations of 85 to 95%, including anhydrous, in a wide range of temperatures, oxygen- and sulphur-dioxide free.
Acid stripper
	End user: Refinery plant Design code: ASME BPVC Sec. VIII Div. 1., 2014/68/EC Materials: carbon steels, Monel Medium: propane, HF acid (toxic, flammable, caustic)	Weight: 4,380 kg Pressure: 26 bar Temperature: 120°C
	Additional description: The purpose of the acid stripper is to remove potential hydrogen fluoride from propane in the process of distillation occurring on 20 trays. The column has two diameters: Ø600 mm in the lower part, and Ø437 mm in the upper part. The lower part of the column houses a steam heater supplying additional heat to the process. Materials: SA516 Gr. 70, SA106 Gr. B, SA350 Gr. LF2, S235JR, UNS N04400.
Absorption column
	End user: Zakłady Azotowe “Puławy” Location: Puławy Design code: EN 13445, 2014/68/EU Materials: Austenitic stainless steels Additional description: Equipped with a demister, Thormann trays and liquid distributor.	Weight: 1600 kg Pressure: 2/-1 bar Temperature: 190 °C

Bleaching tower
	End user: Grupa Azoty Zakłady Azotowe “Puławy” Location: Puławy Plant: Nitric Acid Quantity: 2 Design code: EN 13445, 2014/68/EU	Weight: 5015 kg Pressure: 5 bar Temperature: 200°C Medium: Toxic
	Materials: Austenitic stainless steels (Sandvik 2RE10 – UNS S31002 – 1.4335 – X1CrNi25-21) Additional description: the scope of performance included the design, manufacturing and installation at the plant.

Tube bundles

Superheated steam boiler Babcock- tube bundle
	End user: fertilizer producer Location: Poland Plant: Gas Preparation Unit A-11 Design code: EN 13445, WUDT (Conditions of the Office of Technical Inspection)	Weight: 39, 300 kg Pressure: 130 bar Temperature: 461°C Medium: toxic, flammable
	Materials: Nickel-chromium-molybdenum alloys (Alloy 600 – UNS N06600 – 2.4816 – NiCr15Fe8), NF A 49-213 15CD2-05 Additional description: – Collector and process pipes made of material 15-CD2-05. The parts exposed to high temperatures protected with Alloy 600 covers. – Alignment of welded pipe joints with a deviation of no more than 1mm/1m. – Plumbing process performed – diameter control along the entire length of the apparatus using a ring. – Refractory lining in the dome (bottom) and outer casing of the insert was performed. – Chemical etching was performed. – 100% RT, PMI and PWHT
Syngas water coolers – tube bundles
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Synthesis Plant at the Ammonia Division II Quantity: 2 pcs Design code: EN 13445	Weight: 2 pcs x 5,600 kg Pressure: 314 bar Temperature: 100 °C Medium toxic, flammable, explosive
	Materials: Austenitic-ferritic stainless steels (duplex – UNS S31803 – UNS S32205 – F51 – F60 – 1.4462 – X2CrNiMoN22-5-3) Additional description: Pressure test at 449 bar.
Evaporator – U-tube bundle
	End user: Refinery plant Location: Poland Plant: Isomerisation plant	Weight: 21 442 kg Pressure: 10 bar Temperature: 220°C
	Materials: Carbon steels Additional description: We used low-finned tubes to increase the heat exchange area.
Syngas water coolers – tube bundles
	End user: Zakłady Azotowe “Puławy” Location: Puławy Plant: Synthesis Division at the Ammonium Nitrate Production Centre Quantity: 3 pcs Design code: EN 13445	Weight: 1 pc x 1,800 kg, 1 pc x 968 kg, 1 pc x 462 kg Pressure: 498 bar Temperature: 150 °C Medium toxic, flammable, explosive
	Materials: Austenitic-ferritic stainless steels (duplex – UNS S31803 – UNS S32205 – F51 – F60 – 1.4462 – X2CrNiMoN22-5-3)
CO₂ stripper shift effluent reboiler – u-tube bundles
	End user: Nitrogénművek Location: Pétfürdő, Hungary Quantity: 2 pcs Design code: EN 13445	Weight: 2 pcs x 21,970 kg Pressure: 33 bar Temperature: 300 °C
	Materials: Austenitic stainless steels (1.4541), 2 pcs x 891 U-tubes
Rotodynamic compressor cooler – tube bundle
	End user: Kompania Węglowa Location: Rybnik Plant: Combined heat and power plant
	Materials: Austenitic stainless steels, copper Additional description: We used copper exchanger tubes with copper lamella fins made with our own technology.
Evaporator – U-tube bundle
	End user: Refinery plant Location: Poland Plant: Hydrocracking plant Design code: WUDT (Conditions of the Office of Technical Inspection)	Weight:15,820 kg Pressure: 10 bar Temperature: 240 °C
	Materials: Austenitic stainless steels (1.4541), 712 U-tubes Process: Supplying heat to the stripping column through the partial evaporation of the circulating amine at the expense of heat of the condensing vapour.

Miscellanea

Sub-manifolds for a natural-gas steam reforming furnace
	End user: Chemical plant Location: Poland Plant: Natural gas preparation plant Design code: ASME BPVC Sec. VIII Div. 1.	Weight: 9 pcs x 775 kg Pressure: 37 bar Temperature: 815 °C
	Materials: Nickel-iron-chromium (UNS N08810) Additional description: – We selected a material (centrifugally-cast tubes of Group 45 material) to meet the anti-corrosion requirements (planned operation time of equipment at least 100,000 h) at an extremely high (815 °C) allowable temperature of the device – Two cycles of simulated post weld heat treatment (SPWHT)
Oven convection box
	End user: Oil refinery Location: Poland Plant: diesel oil hydrodesulphurisation Design code: WUDT (Conditions of the Office of Technical Inspection)	Weight: 17,200 kg Pressure: 42 bar Temperature: 400°C
	Materials: chromium molybdenum boiler steel for elevated temperatures (A335 Gr.P11 – EN 1.7335 – 13CrMo4-5), heat-resistant ferritic steels H13JS – EN 1.4724 – X10CrAlSi18 Additional description: – The coil consists of 16 process pipes Ø168.3×10.97 studded over a length of 2576 mm and 8 smooth pipes Ø168.3×11, connected by elbows to form two circuits, each with a separate inlet and outlet. – Insulating concrete lining with an operating temperature of up to 1100 °C. – Anti-corrosion coating. – Heat treatment of welded joints (PWHT) on our own machines.
Sulphuric acid circulation tank
	End user: Grupa Azoty (Tarnów) Location: Tarnów Plant: Acid absorption station at the WKS and SHA department Design code: EN 13445	Weight: 8519 kg Pressure: 0.48 bar Temperature: 65°C Medium Toxic & caustic
	Materials: Nickel-chromium-molybdenum alloys (904L – UNS N08904 – 1.4539 – X1NiCrMoCu25-20-5), austenitic stainless steels. Process: the circulation tank is used in the processing system of sulphuric acid for drying towers. Scope of performance: The design and manufacturing of a circulation tank for sulphuric acid The design and manufacturing of platforms for the tank Repairing the foundations and acid-resistant brick tray Replacement of the circulation tank along with the construction, removal and installation of piping and pumps
Steel structures
	End user: ArcelorMittal Location: Kraków Prefabrication of eaves purlins for the extension of the ArcelorMittal hall in Kraków. General contractor: SKANSKA. In total, we provided 60 tonnes of ready-made elements.
Boiler feed water preheater
	End user: Fatima Group Pakarab Fertilizers Location: Multan, Pakistan Quantity: 4 pcs Design code: ASME BPVC Sec. VIII Div. 1. Materials: Titanium (gr. 1 – UNS R50250 – 3.7025 – Ti), nickel-chromium-molybdenum alloys (Alloy C22 – UNS N06022 – 2.4602 – NiCr21Mo14W), austenitic stainless steels (Sandvik 2RE10 – UNS S31002 – 1.4335 – X1CrNi25-21) Additional description: Titanium inner shell.	Weight: 4 pcs x 828 kg Pressure: 16.7/-1 bar Temperature: 270 °C
Drainage for a pump
	End user: Jordan Phosphate Mines Location: Amman, Jordania	Weight: 3000 kg
	Materials: Nickel-iron-chromium alloys (Sanicro 28 – UNS N08028 – 1.4563 – X1NiCrMoCu31-27-4), nickel-chromium-molybdenum alloys (904L – UNS N08904 – 1.4539 – X1NiCrMoCu25-20-5), austenitic stainless steel
Foundation frames of gas compressors
	Client: Siemens Quantity: 3 pcs Weight: 3 pcs x 10,000 kg Materials: Carbon steels
Electric nitrogen heater 400 kW
	End user: AirLiquide Location: Kraków Materials: Austenitic stainless steels, carbon steels Additional description: The works involved the heater and the thermocouple.	Weight: 750 kg
Expert survey and determination of the causes of column vibrations
	Conducting an expert survey of the column in connection with its periodic undesirable vibrations during operation. The survey was performed to: • Determine the reasons for column vibrations. • Assess the possible actions aimed at eliminating or reducing vibrations and potentially reducing the time of exposure to them. • Analyse the influence of vibration loads on the level of wear of the column and its foundation. • Draw up final recommendations, including the safe usage methods and conditions for the column. The following were performed: • Static structural analysis • Static FEM analysis • Modal analysis • CFD flow calculations • Analysis of building design correctness for the foundation

Parts

HP Reaction Water Condenser
	End user: Nitrogénművek Location: Pétfürdő, Hungary Design code: EN 13445	Weight: 15,850 kg Pressure: 11.66 bar Temperature: 121 °C
	Materials: Tubes – titanium (SB–338 Gr. 2 – UNS R50400 – 3.7035 – Ti), other: austenitic stainless steels, carbon steels Additional description: 2083 tubes ∅25.4×1.2.
Vessel for filter with external coil
	End user: Oil rafinery Location: Poland Design code: ASME VIII Div.1	Weight: 20,800 kg Pressure: 98 bar Temperature: 335 °C
	Materials: nickel-molybdenum-chromium alloys with addition of tungsten (Hastelloy C276), carbon steels (SA-266 Gr. 4 S13, SA-516 Gr. 70 S5), stainless steel TP321/347 Process: Removal of contaminants in the form of solid particles, mainly on the catalytic converter side. The suspension undergoing the filtration process is heated using a coil in the space in which the hot high-temperature oil flows. Additional description: – The repair of the filter tank consisted of making a new lower part – the tank – to replace the worn-out part of the apparatus. – The inner space was additionally coated with stainless steel using the explosive surfacing and plating method. – On the outside of the apparatus was made a carbon steel coil.
Components for a kerosene and hydrogen heat exchanger
	End user: Refinery plant Location: Lithuania	Total weight: 1,150 kg Medium toxic, flammable, explosive
	Additional description: All components made of chromium-molybdenum steel SA 336 Gr. F11 Cl.2 / 1.7335 and cladded by welding with austenitic steel 19 9 Nb Si – 347Si). The works covered the reversal chamber, connectors and flanges.
Column’s courses made of Noram SX
	End user: Uralchem Location: Berezniki, Russia Quantity: 2 courses Design code: EN 13445, GOST	Weight: 1,650 kg + 1,350 kg Pressure: 0.87 bar Temperature: 100 °C
	Materials: Sandvik Noram SX / SA-312 / SA-240 UNS S32615 Additional description: Following testing we picked the material for the medium (nitric acid, 99%) to extend the product life of the courses.
Oxidation plant beehive grate
	End user: Grupa Azoty Zakłady Chemiczne “Kędzierzyn” Location: Kędzierzyn-Koźle Plant: Nitric Acid Department, Fertiliser Production Unit	Diameter: 5000 mm x 1 pc, 3700 mm x 1 pc Quantity: 2
	Materials: Nickel-chromium-molybdenum alloys (INCONEL 601H – SB-168 UNS N06601 – 2.4851 – 60Ni-22Cr-1.2Al-0.02C) Additional description: Grate divided into segments. The contact points of grate segments are welded from both sides with an edge weld.
Toluene condenser – middle part
	End user: Refinery plant Location: Poland Design code: AD 2000-Merkblatt, 97/23/EC, EN 13445	Weight: 6,850 kg Pressure: 10 bar Temperature: 150 °C
	Materials: Carbon steels Additional description: The tube side surfaces (tubes, tubesheets) were protected against corrosion with a phenolic epoxy-based coating (Säkaphen coating).
Boiler membrane walls
	End user: Power plant Location: Greece Quantity: 10 pcs
	Materials: 16Mo3 – 1.5415 Additional description: Welded tubes 20 pcs, longitudinal sets. Pressure tests of each set. Dimensions: Width: 1210 mm. Tube diameter: 38 mm.
Cladding by welding of flanges with Inconel 625 – 2.4856
	Client: Naftoremont Location: Płock Additional description: Inconel 626 – 2.4856 cladding + mechanical processing for final dimensions.
Syngas water intercooler
	End user: Zakłady Chemiczne “Police” Location: Police Quantity: 4 pcs Design code: ASME BPVC Sec. VIII Div. 1.	Weight: 4 pcs x 10,200 kg Pressure: 186 bar Temperature: 193 °C
	Materials: Carbon steels Additional description: Chamber shell thickness: 90 mm.
TK-106 exchanger components
	End user: Refinery plant Location: Lithuania Quantity: 2 pcs Design code: EN 13445, 97/23/EC	Weight: 2 pcs x 10,300 kg Pressure: 91.1 bar Temperature: 400 °C Medium toxic, flammable, explosive
	Materials: Chromium-molybdenum steels (SA-387 Gr.11 Cl2, SA-182 Gr. F11 Cl2, SA-213 Gr. T5) Additional description: All components made of chromium-molybdenum steel and the internal surfaces of chambers were cladded by welding with Cr25Ni13. PWHT. The manufactured components included a tube bundle with the chamber and floating head.

Example projects

Shell and tube heat exchangers

Acetic acid condenser – steam generator

End user: Refinery plant
Location: Poland
Design code: EN 13445, 2014/68/EU
Weight: 23,060 kg
Pressure: 19 bar
Temperature: 175 °C
Medium flammable
Materials: Titanium (Gr. 1 – UNS R50250 – 3.7025 / Gr. 2 – UNS R50400 – 3.7035), austenitic stainless steels, carbon steels
Process: Condensing reaction gas (acetic acid) and utilising the steam produced in this process by transporting it to the turbine
Additional description:
– Tubesheets, heads, and conical and cylindrical chambers were explosively cladded (titanium with carbon steel). Polimer developed its own butt welding technology for connecting titanium-cladded carbon steel plates to ensure hermeticity.
– 2330 titanium tubes of 7000 mm length were applied, and eddy current tested after production and assembly.
– A helium leak test was performed, and the maximum leakage recorded was 10-7 Pa*m³/s.
– Lens expansion joint.

Process gas cooler

End user: Zakłady Azotowe „Kędzierzyn”
Location: Kędzierzyn, Poland
Design code: EN 13445, 2014/68/EU

Weight: 67 950 kg
Pressure: 93 bar
Temperature: 460 °C
Medium toxic, flammable
Materials: chromium molybdenum boiler steel for elevated temperatures (13CrMo4-5 – UNS K11564 – EN 1.7335, SA182 F11 CL2 – UNS K11572), SA266 Gr.3
Process: cooling of process gas with the generation of process steam
Additional description:
– Shell ø1708×74, total length ~15620 mm;
– Safety fittings to prevent pressure rise above the permissible pressure;
– Disassembly of the existing equipment and assembling of new equipment, including piping;
– Management of foundation repair. Connecting the apparatus to the grounding and lightning protection system with measurement protocols.

Neutralisation vapour condenser

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Design code: EN 13445, 2014/68/EU
Weight: 19,100 kg
Pressure: 2/-1 bar
Temperature: 160 °C
Medium toxic, flammable, explosive
Materials: Austenitic-ferritic stainless steels (Duplex – UNS S31803 – 1.4462 – X2CrNiMoN22-5-3), austenitic stainless steels, carbon steels

Secondary Waste Heat Boiler

End user: Nitrogénművek
Location: Pétfürdő, Hungary
Design code: ASME BPVC Sec VIII Div 1, TEMA R
Weight: 43,350 kg
Pressure: 120 bar
Temperature: 450 °C
Materials: Chromium-molybdenum steels (SA–387 Gr. 11/12, Cl. 2 – UNS K11789/K11757 / SA–182 Gr. F11, Cl. 2 – UNS K11572 / SA–213 Gr. T11 – UNS K11597 – EN 1.7335 – 13CrMo4-5), carbon steels
Additional description: We modernised the equipment by designing an insulation system for the hot tubesheet to reduce its operating temperature.

Steam boiler unit: Reactor sulphur condenser

End user: Refinery plant
Location: Poland
Plant: Claus
Quantity: 3
Design code: WUDT (Conditions of the Office of Technical Inspection)
Weight: 3 szt. x 80,100 kg
Pressure: 22 bar
Temperature: 350 °C
Medium toxic, flammable, explosive
Materials: Carbon steels, austenitic stainless steels, chromium-molybdenum steels (SA-182 Gr. F12 – UNS K11564 – EN 1.7335 – 13CrMo4-5)
Additional description: We designed a thermal expansion compensation system to prevent damage to the brickwork lining on the hot tubesheet; heat-resistant brickwork lining on the tubesheet.

Boiler for potassium washing

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Gas preparation plant at the Ammonia Division
Design code: EN 13445, 2014/68/EU, TEMA R
Weight: 17,900 kg
Pressure: 30 bar
Temperatura: 150 °C
Medium toxic, flammable, explosive
Materials: Austenitic stainless steels, carbon steels
Process: Heating caustic potash with process gas to concentrate the solution and obtain steam.

Boiler Feed Water Preheater

Client: Hyundai Heavy Industries Power Systems
Plant: Olefins
Design code: EN 13445, 2014/68/EU

Weight: 15,600 kg
Pressure: 173 bar
Temperature: 280 °C

Materials: Low-vanadium steels Cr-Mo-(Ni) (1.6308 – 18MnMoNi5-5), 16Mo3 – 1.5415
Additional description: post weld heat treatment (PWHT) of weldments.

Heat exchanger SV12 B010

End user: Mariehamns Energi AB
Location: Mariehamn, Aland Islands, Finland
Design code: EN 13445, 2014/68/EU
Weight: 1,900 kg
Pressure: 16 bar
Temperature: 100 °C
Materials: Austenitic stainless steels, carbon steels
Additional description: Thermal expansion compensation (fixed tubesheets) using a lens expansion joint.

Reactor feed heater

End user: Refinery plant
Location: Poland
Plant: Pyrolysis petrol hydrogenation plant PGH
Design code: ASME BPVC Sec. VIII Div. 1, API 660, TEMA, 2014/68/EU
Weight: 27,104 kg
Pressure: 69.2 bar
Temperature: 400 °C
Medium toxic, flammable, explosive
Materials: Chromium-molybdenum steels (SA–387 Gr. 12, Cl. 2 – UNS K11757 / SA–182 Gr. F12, Cl. 2 – UNS K11564 – EN 1.7335 – 13CrMo4-5), stainless steels
Additional description: Shell wall thickness: 40 mm.

Cyclohexanone vapour condenser

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Quantity: 2 pcs
Design code: EN 13445, 2014/68/EU
Weight: 2 pcs x 17,200 kg
Pressure: 1/-1 bar
Temperature: 100 °C
Medium toxic, flammable, explosive
Materials: Carbon steels
Additional description: Design, manufacturing and installation.

Extractive distillation column condenser

End user: Refinery plant
Location: Poland
Plant: Extractive distillation plant
Design code: ASME BPVC Sec. VIII Div. 1, TEMA R
Weight: 24,200 kg
Pressure: 7/-1 bar
Temperature: 65 °C
Medium toxic, flammable, explosive
Materials: Carbon steels
Additional description: The tube side (tubes, tubesheets, chamber, head) was protected against corrosion with a phenolic epoxy-based coating (Säkaphen coating).

Syngas water cooler

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Ammonia Division, Synthesis Section
Amount: 5 pcs
Design code: EN 13445, 2014/68/EU, TEMA R
Weight: 5 pcs. x 7,615 kg
Pressure: 360 bar
Temperature: 100 °C
Medium toxic, flammable, explosive
Materials: Austenitic-ferritic stainless steels (Duplex – UNS S31803 – 1.4462 – X2CrNiMoN22-5-3), stainless steels, carbon steels
Additional description: Hair-pin and gland joint, to facilitate installation we replaced regular bolts with superbolts, which allowed us to reduce bolt assembly tension from 6800 Nm to 380 Nm

Process gas cooler

End user: Refinery plant
Location: Poland
Design code: ASME BPVC Sec. VIII Div. 1. EN 13445
Weight: 1,950 kg
Pressure: 17 bar
Temperature: 145 °C
Medium toxic, flammable, explosive
Materials: Titanium (gr. 2 / F2 – UNS R50400 – 3.7035 / Gr. 1 – UNS R50250 – 3.7025 – Ti), austenitic stainless steels, carbon steels
Additional description: Titanium-cladded tubesheets by explosive cladding method, lens expansion joint.

Vapour condenser

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Design code: EN 13445, 2014/68/EU
Weight: 5,350 kg
Pressure: 2/-1 bar
Temperature: 200 °C
Medium: toxic, flammable, explosive
Materials: Austenitic-ferritic stainless steels (Duplex – UNS S31803 – 1.4462 – X2CrNiMoN22-5-3), austenitic stainless steels, carbon steels

Natural gas preheater using hydrogen gas

Natural gas preheater using hydrogen gas

End user: Refinery plant
Location: Poland
Plant: Hydrogen Plant
Design code: ASME BPVC Sec. VIII Div. 1.
Weigh: 260 kg
Pressure: 25 bar
Temperature: 625 °C
Medium: toxic, flammable, explosive
Materials: Nickel-chromium-molybdenum alloys (Alloy 601 – UNS N06601 – 2.4851 – NiCr23Fe), austenitic stainless steels
Additional description: We increased the heat resistance of the tube side by diffusion coating with aluminium of tubesheet surface and the inner surface of the process tubes and chamber.

Ammonia evaporator

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Nitrogen gas neutralisation plant
Design code: EN 13445, 2014/68/EU, TEMA R
Weight: 21,110 kg
Pressure: 25/-1 bar
Temperature: 60 °C
Medium: toxic
Materials: Austenitic stainless steels, carbon steels
Process: Evaporation of liquid ammonia by heating water.

Steam boiler condenser

End user: Refinery plant
Location: Poland
Plant: Claus
Design code: WUDT (Conditions of the Office of Technical Inspection), 2014/ 68/EU
Weight: 80,100 kg
Pressure: 22 bar
Temperature: 350 °C
Medium: toxic, flammable, explosive
Materials: Carbon steels, austenitic stainless steels, chromium-molybdenum steels (EN 1.7335 – 13CrMo4-5)
Additional description: Lens expansion joint, pickling.

Air coolers

Syngas air cooler

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant:: Ammonia synthesis loop
Quantity: 2 units
Design code: EN 13445, 97/23/WE

Weight: 42,000 kg / 1 unit
Ciśnienie robocze: 312.7 bar
Temperature: 42 °C

Materials: Carbon steels + tubes with extruded aluminium fins
Additional description: The cooling process in the cooler is intensified by installing four fans for continuous operation in the open space in a supply configuration with anti-explosive electric engines, equipment and frequency converters. The rotor diameter is ∅ 3048 mm. Fan capacity: 4 × 171,000 m³/h.

Air cooler for circulating water

End user: Refinery plant
Location: Poland
Quantity: 4 pcs
Design code: ASME BPVC Sec. VIII Div. 1
Weight: 4 pcs x 11,850 kg
Pressure: 12 bar
Temperature: 100 °C
Materials: Carbon steels + tubes with extruded aluminium fins

Air coolers for steam+CO₂+H₂S / butane / Leam Mea / propane

End user: Warri Refining and Petrochemical Company
Location: Warri, Nigeria
Quantity: 9 pcs
Design code: ASME BPVC Sec. VIII Div. 1
Weight: 6 pcs x 6,500 kg, 1 pc x 5,500 kg, 1 pc x 2,100 kg, 1 pc x 5,300 kg
Pressure: 22,9 bar
Temperature: 130 °C
Materials: Carbon steels + tubes with extruded aluminium fins

Nitrogen air cooler

End user: Alkat (AirLiquide group)
Location: Dąbrowa Górnicza
Design code: EN 13445, 97/23/WE
Weight: 18,000 kg
Temperature: 180 °C
Materials: Carbon steels + tubes with extruded aluminium fins
Additional description: The modernisation design according to which we manufactured the cooler was intended to increase the flow of the medium to 26,000 Nm³/h.

Air cooler for heavy diesel oil

End user: Refinery plant
Location: Poland
Plant: Fractional distillation plant
Quantity: 6 pcs
Design code: AD 2000-Merkblatt, WUDT (Conditions of the Office of Technical Inspection), 97/23/EC
Weight: 6 pcs x 2,748 kg
Pressure: 4.5 bar
Temperature: 180 °C
Materials: Carbon steels + tubes with extruded aluminium fins/td>

Air cooler for warm water

End user: Zakłady Chemiczne “Kędzierzyn”
Location: Kędzierzyn-Koźle
Plant:: Aldehyde Division of JB OXOPLAST
Quantity: 2 pcs
Design code: WUDT (Conditions of the Office of Technical Inspection)
Weight: 2 pcs. x 4,276 kg
Pressure: 20 bar
Temperature: 220 °C
Medium toxic, flammable, explosive
Materials: Carbon steels + tubes with extruded aluminium fins

A41 fraction air cooler

End user: Refinery plant
Location: Poland
Plant: Fractional distillation plant
Quantity: 2 pcs
Design code: EN 13445, WUDT (Conditions of the Office of Technical Inspection)
Weight: 2 pcs x 3,600 kg
Pressure: 4 bar
Temperature: 150 °C
Medium toxic, flammable, explosive
Materials: Brass / copper and zinc alloys (CuZn3 explosive cladding on tubesheet, CuZn20Al2 exchanger tubes + extruded aluminium fins, carbon steels)
Additional description: Brass-cladded tubesheets by explosive cladding method.

Argon air cooler

End user: Alkat (AirLiquide group)
Location: Dąbrowa Górnicza
Design code: WUDT (Conditions of the Office of Technical Inspection)
Weight: 7,500 kg
Pressure: 8 bar
Temperature: 550 °C
Materials: Austenitic stainless steels
Additional description: We used austenitic steel lamella fins (instead of extruded aluminium fins) increasing the performance and durability of equipment – our own production technology.

Process gas air cooler

End user: LNG Silesia
Location: Hard coal mine in Suszec
Plant: LNG liquefaction plant
Design code: ASME BPVC Sec. VIII Div. 1 / 97/23/WE
Weight: 1,643 kg
Pressure: 2.5 bar
Temperature: 40 °C
Materials: Austenitic stainless steels + extruded aluminium fins
Additional description: In addition to manufacturing, the project involved thermal balance analysis, selection of materials, fan and technologies.

Light vacuum gas oil cooler

End user: Refinery plant
Location: Poland
Plant: Soft asphalt hydro-desulphurization plant
Quantity: 2+2 pcs
Design code: ASME BPVC Sec. VIII Div. 1
Weight: 2 x 17,120 kg, 2 x 15,900 kg
Pressure: 23/38,2 bar
Temperature: 170/285 °C
Materials: carbon steels

Deflegmator

End user: Refinery plant
Location: Poland
Quantity: 4 pcs
Design code: ASME BPVC Sec. VIII Div. 1
Weight: 4 x 7,650 kg
Pressure: 0.35 bar
Temperature: 121 °C
Materials: carbon steels + tubes with extruded aluminium fins

Pressure vessels

Deaerator with column

End user: Refinery plant
Location: Poland
Plant:: Claus
Design code: EN 13445, 2014/68/UE
Weight: 13,150 kg
Pressure: 1 bar
Temperature: 160 °C
Materials: Carbon steels

Nitric acid reflux tank

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Design code: EN 13445, 2014/68/UE
Weight: 3,980 kg
Pressure: 5/-1 bar
Temperature: 170 °C
Medium toxic
Materials: Austenitic stainless steels

Intermediate tank for resin solution

End user: Synthos
Location: Oświęcim
Design code: EN 13445, 2014/68/UE
Weight: 2,165 kg
Pressure: 14 bar
Temperature: 250 °C
Medium toxic, flammable
Materials: Nickel-chromium-molybdenum alloys (Alloy C22 – UNS N06022 – 2.4602 – NiCr21Mo14W), stainless steels.

Boiler water tank – degassing system

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant:: kwasu azotowego
Weight: 13,000 kg
Pressure: 3.5 bar
Temperature: 270 °C
Materials: Carbon steels
Process: Degassing boiler feed water.
Additional description: We provided the technological, process and mechanical designs for the degassing system using Computation Fluid Dynamics (CFD) and the Finite Element Method (FEM)
Design code: EN 13445, 2014/68/UE

Steam condensate separator

End user: Refinery plant
Location: Lithuania
Design code: ASME BPVC Sec. VIII Div. 1
Weight: 1,671 kg
Pressure: 16 bar
Temperature: 250 °C
Materials: Carbon steels
Process: odgazowywanie wody kotłowej
Additional description:
– A design maintaining the maximum pressure drops provided by the client
– Analysis using the Finite Element Method (FEM)
– Analysis using Computational Fluid Dynamics (CFD)

Nitrous gas separator

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Nitric acid plant
Design code: ASME BPVC Sec. VIII Div. 1, TEMA R
Weight: 6,000 kg
Pressure: 4.8 bar
Temperature: 100 °C
Medium toxic, flammable, explosive
Materials: Austenitic stainless steels
Process: degassing of boiler water
Additional description: We selected the internal particle separation system.

Neutralisation steam saturator

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant:: Nitric acid neutralisation plant
Design code: EN 13445, 2014/68/UE
Weight: 3,600 kg
Pressure: 13/-1 bar
Temperature: 270 °C
Materials: Austenitic stainless steels

Evaporation steam saturator

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant:: Nitrogen gas neutralisation plant
Design code: EN 13445, 2014/68/UE
Weight: 2,900 kg
Pressure: 13/-1 bar
Temperature: 270 °C
Materials: Nickel-chromium-molybdenum alloys (904L – UNS N08904 – 1.4539 – X1NiCrMoCu25-20-5), austenitic stainless steels

Reactors

Autoclave (1311)

End user: Larkis
Location: Dobczyce
Process: Vulcanisation of rubber components.
Design code: EN 13445, 2014/68/UE
Weight: 4,925 kg
Pressure: 8/-1 bar
Temperature: 200 °C
Materials: Carbon steels
Additional description:Turnkey project; the design of a whole pressure set, including the vessel, automatics, hydraulics & electrics. Commissioning and personnel training.

Reactor for rosin disproportionation

End user: Synthos
Location: Oświęcim
Design code: EN 13445, 97/23/WE
Weight: 3,240 kg
Pressure: 6 bar
Temperature: 320 °C
Medium toxic, flammable
Materials: Nickel-chromium-molybdenum alloys (Alloy C22 – UNS N06022 – 2.4602 – NiCr21Mo14W), austenitic stainless steels, carbon steels

Steam boiler unit: Combustion chamber

End user: Refinery plant
Location: Poland
Plant:: Claus
Quantity: 3 pcs.
Design code: WUDT (Conditions of the Office of Technical Inspection)
Weight: 3 pcs x 19,160 kg (without brickwork lining)
Pressure: 1.5 bar
Temperature: 350 °C
Medium toxic, flammable, explosive
Materials: Carbon steels, stainless steels, chromium-molybdenum steels (SA–387 Gr. 12 – UNS K11757 – EN 1.7335 – 13CrMo4-5)
Process: Burning of hydrogen sulphide gas and ammonia in the presence of oxygen enriched air.
Additional description: Equipped with burners and a heat-resistant brickwork lining in chambers.

Autoclave (689)

End user: Hannecard Polska
Location: Kraków
Design code: EN 13445, 97/23/WE
Weight: 9,000 kg
Pressure: 8/-1 bar
Temperature: 175 °C
Materials: Carbon steels
Process: Vulcanisation of rubber and ebonite coatings applied to machine and equipment parts: in steam or a mixture of air and steam
Additional description: An autoclave with full mechanics and a hydraulic control system: trolleys, actuators, head opening system.

Installations

Heterogeneous catalyst drying installation for hydrogenation reactors – turnkey project

End user: PCC MCAA
Location: Brzeg Dolny
Plant: Monochloroacetic acid production plant
Design code: EN 13445, 97/23/WE
Pressure: 12.5 bar
Temperature: 220 °C
Materials: Austenitic stainless steels, carbon steels
Additional description: We designed and completed a turnkey project for a catalyst drying system in an ultra-pure monochloroacetic acid production plant.
The process of drying the heterogeneous catalyst was divided into two stages:
1. Steam drying system: Pre-drying using superheated steam at 150 °C i and pressure of 2 bar(g).
2. Nitrogen drying system: Nitrogen heated to 150 °C circulating in a closed system was used for the second stage.
Range of works:
1. Technological preparation and design for construction of the installationi
2. The manufacturing and supply of shell and tube heat exchangers: Water cooler for steam, nitrogen heater, steam condenser; Roots DR240T 55kV blowers; pipelines; tubing; control and measurement instrumentation
3. Registration of equipment in the Office of Technical Inspection (UDT)
4. Plant assembly
5. Plant start-up

Benzoyl peroxide plant – turnkey project

End user: Novichem
Location: Chorzów
Range of work:
– Design documentation: mechanical, technological, automatics, electrical, drencher, structural, construction, fire detection and alarm system (SAP)
– Prefabrication and installation of process pipelines and steel structures
– Supply and installation of the electrical section, drencher system, fittings, reactors and engines
– Construction work connected with modernising the industrial wastewater plant, unloading station, transport routes, ground hardening
– Construction works involving the construction of new buildings: holding tank for industrial wastewater along with connection
– Plant start-up

Nitric acid loading station

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Range of work: Turnkey project of a nitric acid loading station on the premises of Zakłady Azotowe “Puławy”. The project included industrial valves, control systems, loading arm, and the systems of absorption and purification of vapours generated in the process of loading. Polimer performed a full range of earthworks including plumbing installations, maintenance surveying, foundations, dispensing tray, prefabrication, installation and construction of steel pipelines, insulation and electrical works, instrumentation and automation works. The loading arm was registered with the Transport Technical Inspection (TDT) as per the applicable regulations. We performed the test run and start-up of the entire system.

Cryogenic pipeline

End user: Alkat (AirLiquide group)
Location: Dąbrowa Górnicza
Quantity: 240 m x DN65
Materials: Austenitic stainless steels
Description: Supply and assembly of a DN 65 vacuum-insulated cryogenic pipeline for transporting liquid nitrogen.

Columns

Depropaniser

Additional description: The depropaniser is used to recover isobutane from the propane fraction. It is a two-diameter column with Ø1250 mm lower part diameter and Ø950 mm upper part diameter. The column contains 36 distillation trays. The materials used are carbon steels SA516 Gr. 70, SA106 Gr. B, SA350 Gr. LF2, S235JR. The lower part of the column houses a heater which supplies heat for distillation. The equipment was designed to operate with a toxic and caustic medium at pressures up to 24.6 bar and temperatures up to 135°C.

Gas scrubber

End user: Refinery plant
Design code: ASME BPVC Sec. VIII Div. 1., 2014/68/EC

Materials: nickel-copper alloys, carbon steels
Medium: hydrocarbons and HF acid (toxic, caustic)

Weight: 34,600 kg
Pressure: 10.6/3.5 bar
Temperature: 145°C

Additional description: The discharge gas scrubber is used to neutralise gases fed to the acid discharge unit. An appropriate control system is used to control the level of caustic potash in the scrubber. Due to the medium applied, chemical-corrosion resistant materials were used: SB127 UNS N04400, SA516 Gr.70 and SA106 Gr.B. Alloy 400 is resistant to HF acid in concentrations of 85 to 95%, including anhydrous, in a wide range of temperatures, oxygen- and sulphur-dioxide free.

Acid stripper

End user: Refinery plant
Design code: ASME BPVC Sec. VIII Div. 1., 2014/68/EC

Materials: carbon steels, Monel
Medium: propane, HF acid (toxic, flammable, caustic)

Weight: 4,380 kg
Pressure: 26 bar
Temperature: 120°C

Additional description: The purpose of the acid stripper is to remove potential hydrogen fluoride from propane in the process of distillation occurring on 20 trays. The column has two diameters: Ø600 mm in the lower part, and Ø437 mm in the upper part. The lower part of the column houses a steam heater supplying additional heat to the process. Materials: SA516 Gr. 70, SA106 Gr. B, SA350 Gr. LF2, S235JR, UNS N04400.

Vent scrubber – column

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Design code: EN 13445, 2014/68/EU

Materials: Austenitic stainless steels
Additional description: Equipped with a demister, Thormann trays and liquid distributor.

Weight: 1600 kg
Pressure: 2/-1 bar
Temperature: 190 °C

Bleaching tower

End user: Grupa Azoty Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Nitric Acid
Quantity: 2
Design code: EN 13445, 2014/68/EU

Weight: 5015 kg
Pressure: 5 bar
Temperature: 200°C
Medium: Toxic

Materials: Austenitic stainless steels (Sandvik 2RE10 – UNS S31002 – 1.4335 – X1CrNi25-21)
Additional description: the scope of performance included the design, manufacturing and installation at the plant.

Tube bundles

Superheated steam boiler Babcock- tube bundle

End user: fertilizer producer
Location: Poland
Plant: Gas Preparation Unit A-11
Design code: EN 13445, WUDT (Conditions of the Office of
Technical Inspection)

Weight: 39, 300 kg
Pressure: 130 bar
Temperature: 461°C
Medium: toxic, flammable”

Materials: Nickel-chromium-molybdenum alloys (Alloy 600 – UNS N06600 – 2.4816 – NiCr15Fe8), NF A 49-213 15CD2-05
Additional description:
– Collector and process pipes made of material 15-CD2-05. The parts exposed to high temperatures protected with Alloy 600 covers.
– Alignment of welded pipe joints with a deviation of no more than 1mm/1m.
– Plumbing process performed – diameter control along the entire length of the apparatus using a ring.
– Refractory lining in the dome (bottom) and outer casing of the insert was performed.
– Chemical etching was performed.
– 100% RT, PMI and PWHT

Syngas water coolers – tube bundles

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Synthesis Plant at the Ammonia Division II
Quantity: 2 pcs
Design code: EN 13445

Weight: 2 pcs x 5,600 kg
Pressure: 314 bar
Temperature: 100 °C
Medium toxic, flammable, explosive

Materials: Austenitic-ferritic stainless steels (duplex – UNS S31803 – UNS S32205 – F51 – F60 – 1.4462 – X2CrNiMoN22-5-3)
Additional description: Pressure test at 449 bar.

Evaporator – U-tube bundle

End user: Refinery plant
Location: Poland
Plant: Isomerisation plant

Weight: 21 442 kg
Pressure: 10 bar
Temperature: 220°C

Materials: Carbon steels
Additional description: We used low-finned tubes to increase the heat exchange area.” #colspan#

Syngas water coolers – tube bundles

End user: Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Synthesis Division at the Ammonium Nitrate Production Centre
Quantity: 3 pcs
Design code: EN 13445

Weight: 1 pc x 1,800 kg, 1 pc x 968 kg, 1 pc x 462 kg
Pressure: 498 bar
Temperature: 150 °C
Medium toxic, flammable, explosive

Materials: Austenitic-ferritic stainless steels (duplex – UNS S31803 – UNS S32205 – F51 – F60 – 1.4462 – X2CrNiMoN22-5-3)

CO₂ stripper shift effluent reboiler – u-tube bundles

End user: Nitrogénművek
Location: Pétfürdő, Hungary
Quantity: 2 pcs
Design code: EN 13445

Weight: 2 pcs x 21,970 kg
Pressure: 33 bar
Temperature: 300 °C

Materials: Austenitic stainless steels (1.4541), 2 pcs x 891 U-tubes

Rotodynamic compressor cooler – tube bundle

End user: Kompania Węglowa
Location: Rybnik
Plant: Combined heat and power plant

Materials: Austenitic stainless steels, copper
Additional description: We used copper exchanger tubes with copper lamella fins made with our own technology.

Evaporator – U-tube bundle

End user: Refinery plant
Location: Poland
Plant: Hydrocracking plant
Design code: WUDT (Conditions of the Office of Technical Inspection)

Weight:15,820 kg
Pressure: 10 bar
Temperature: 240 °C

Materials: Austenitic stainless steels (1.4541), 712 U-tubes
Process: Supplying heat to the stripping column through the partial evaporation of the circulating amine at the expense of heat of the condensing vapour.

Miscellanea

Sub-manifolds for a natural-gas steam reforming furnace

End user: Chemical plant
Location: Poland
Plant:: Natural gas preparation plant
Quantity: 9 pcs.
Design code: ASME BPVC Sec. VIII Div. 1
Weight: 9 pcs. x 775 kg
Pressure: 37 bar
Temperature: 815 °C
Materials: Nickel-iron-chromium (UNS N08810)
Additional description:
– We selected a material (centrifugally-cast tubes of Group 45 material) to meet the anti-corrosion requirements (planned operation time of equipment at least 100,000 h) at an extremely high (815 °C) allowable temperature of the device
– Two cycles of simulated post weld heat treatment (SPWHT)

Oven convection box

End user: Oil refinery
Location: Poland
Plant: diesel oil hydrodesulphurisation
Design code: WUDT (Conditions of the Office of Technical Inspection)
Weight: 17,200 kg
Pressure: 42 bar
Temperature: 400°C
Materials: chromium molybdenum boiler steel for elevated temperatures (A335 Gr.P11 – EN 1.7335 – 13CrMo4-5), heat-resistant ferritic steels (H13JS – EN 1.4724 – X10CrAlSi18)
Additional description:
– The coil consists of 16 process pipes Ø168.3×10.97 studded over a length of 2576 mm and 8 smooth pipes Ø168.3×11, connected by elbows to form two circuits, each with a separate inlet and outlet.
– Insulating concrete lining with an operating temperature of up to 1100 °C.
– Anti-corrosion coating.
– Heat treatment of welded joints (PWHT) on our own machines.

Sulphuric acid circulation tank

End user: Grupa Azoty (Tarnów)
Location: Tarnów
Plant: Acid absorption station at the WKS and SHA department
Quantity: 1
Design code: EN 13445

Weight: 8519 kg
Pressure: 0.48 bar
Temperature: 65°C
Medium Toxic & caustic
Materials: Nickel-chromium-molybdenum alloys (904L – UNS N08904 – 1.4539 – X1NiCrMoCu25-20-5), austenitic stainless steels.
Process: the circulation tank is used in the processing system of sulphuric acid for drying towers.

Scope of performance:

The design and manufacturing of a circulation tank for sulphuric acid

The design and manufacturing of platforms for the tank

Repairing the foundations and acid-resistant brick tray

Replacement of the circulation tank along with the construction, removal and installation of piping and pumps

Bleaching tower

End user: Grupa Azoty Zakłady Azotowe “Puławy”
Location: Puławy
Plant: Nitric Acid
Quantity: 2
Design code: EN 13445, 2014/68/EU

Weight: 5015 kg
Pressure: 5 bar
Temperature: 200°C
Medium: Toxic
Materials: Austenitic stainless steels (Sandvik 2RE10 – UNS S31002 – 1.4335 – X1CrNi25-21)
Additional description: the scope of performance included the design, manufacturing and installation at the plant.

Steel structures

End user: ArcelorMittal
Location: Kraków
Prefabrication of eaves purlins for the extension of the ArcelorMittal hall in Kraków. General contractor: SKANSKA. In total, we provided 60 tonnes of ready-made elements.

Boiler feed water preheater

End user: Fatima Group Pakarab Fertilizers
Location: Multan, Pakistan
Quantity: 4 pcs.
Design code: ASME BPVC Sec. VIII Div. 1

Materials: Titanium (gr. 1 – UNS R50250 – 3.7025 – Ti), nickel-chromium-molybdenum alloys (Alloy C22 – UNS N06022 – 2.4602 – NiCr21Mo14W), austenitic stainless steels (Sandvik 2RE10 – UNS S31002 – 1.4335 – X1CrNi25-21)
Additional description: Titanium inner shell.
Weight: 4 pcs x 828 kg
Pressure: 16,7/-1 bar
Temperature: 270 °C

Drainage for a pump

End user: Jordan Phosphate Mines
Location: Amman, Jordania
Weight: 3,000 kg
Materials: Nickel-iron-chromium alloys (Sanicro 28 – UNS N08028 – 1.4563 – X1NiCrMoCu31-27-4), nickel-chromium-molybdenum alloys (904L – UNS N08904 – 1.4539 – X1NiCrMoCu25-20-5), austenitic stainless steel

Foundation frames of gas compressors

Odbiorca: Siemens
Quantity: 3 pcs.
Weight: 3 pcs. x 10,000 kg
Materials: Carbon steels

Electric nitrogen heater 400 kW

End user: AirLiquide
Location: Kraków
Materials: Austenitic stainless steels, carbon steels
Additional description: The works involved the heater and the thermocouple.
Weight: 750 kg

Expert survey and determination of the causes of column vibrations

Conducting an expert survey of the column in connection with its periodic undesirable vibrations during operation. The survey was performed to:

• Determine the reasons for column vibrations.
• Assess the possible actions aimed at eliminating or reducing vibrations and potentially reducing the time of exposure to them.
• Analyse the influence of vibration loads on the level of wear of the column and its foundation.
• Draw up final recommendations, including the safe usage methods and conditions for the column.

The following were performed:

• Static structural analysis
• Static FEM analysis
• Modal analysis
• CFD flow calculations
• Analysis of building design correctness for the foundation

Parts

HP Reaction Water Condenser

End user: Nitrogénművek
Location: Pétfürdő, Hungary
Design code: EN 13445
Weight: 15,850 kg
Pressure: 11.66 bar
Temperature: 121 °C
Materials: Tubes – titanium (SB–338 Gr. 2 – UNS R50400 – 3.7035 – Ti), other: austenitic stainless steels, carbon steels
Additional description: 2083 tubes ∅25.4×1.2.

Filter vessel with external coil

End user: Oil rafinery
Location: Poland
Design code: ASME VIII Div.1
Weight: 20,000 kg
Pressure: 98 bar
Temperature: 335 °C
Materials: nickel-molybdenum-chromium alloys with addition of tungsten (Hastelloy C276), carbon steels (SA-266 Gr. 4 S13, SA-516 Gr. 70 S5), stainless steel TP321/347
Process: Removal of contaminants in the form of solid particles, mainly on the catalytic converter side. The suspension undergoing the filtration process is heated using a coil in the space in which the hot high-temperature oil flows.

Additional description:
– The repair of the filter tank consisted of making a new lower part – the tank – to replace the worn-out part of the apparatus.
– The inner space was additionally coated with stainless steel using the explosive surfacing and plating method.
– On the outside of the apparatus was made a carbon steel coil.

Components for a kerosene and hydrogen heat exchanger

End user: Refinery plant
Location: Lithuania
Ciężar w sumie: 1,150 kg
Medium toxic, flammable, explosive
Additional description: All components made of chromium-molybdenum steel SA 336 Gr. F11 Cl.2 / 1.7335 and cladded by welding with austenitic steel 19 9 Nb Si – 347Si). The works covered the reversal chamber, connectors and flanges.

Column’s courses made of Noram SX

End user: Uralchem
Location: Bereżniki, Russia
Quantity: 2 courses
Design code: EN 13445, GOST
Weight: 1,650 kg + 1,350 kg
Pressure: 0.87 bar
Temperature: 100 °C
Materials: Sandvik Noram SX / SA-312 / SA-240 UNS S32615
Additional description: Following testing we picked the material for the medium (nitric acid, 99%) to extend the product life of the courses.

Oxidation plant beehive grate

End user: Grupa Azoty Zakłady Chemiczne “”Kędzierzyn””
Location: Kędzierzyn-Koźle
Plant: Nitric Acid Department, Fertiliser Production Unit
Diameter: 5000 mm x 1 pc, 3700 mm x 1 pc
Quantity: 2
Materials: Nickel-chromium-molybdenum alloys (INCONEL 601H – SB-168 UNS N06601 – 2.4851 – 60Ni-22Cr-1.2Al-0.02C)
Additional description: Grate divided into segments. The contact points of grate segments are welded from both sides with an edge weld.

Toluene condenser – middle part

End user: Refinery plant
Location: Poland
Design code: AD 2000-Merkblatt, 97/23/WE, EN 13445
Weight: 6,850 kg
Pressure: 10 bar
Temperature: 150 °C
Materials: Carbon steels
Additional description: The tube side surfaces (tubes, tubesheets) were protected against corrosion with a phenolic epoxy-based coating (Säkaphen coating).

Boiler membrane walls

End user: Power plant
Location: Greece
Quantity: 10 pcs.
Materials: 16Mo3 – 1.5415
Additional description: Welded tubes 20 pcs, longitudinal sets. Pressure tests of each set. Dimensions: Width: 1210 mm. Tube diameter: 38 mm.

Cladding by welding of flanges with Inconel 625 – 2.4856

Klient: Naftoremont
Location: Płock
Opis: Inconel 626 – 2.4856 cladding + mechanical processing for final dimensions.

Syngas water intercooler

End user: Zakłady Chemiczne “Police”
Location: Police
Quantity: 4 pcs.
Design code: ASME BPVC Sec. VIII Div. 1
Weight: 4 pcs. x 10,200 kg
Pressure: 186 bar
Temperature: 193 °C
Materials: Carbon steels
Additional description: Chamber shell thickness: 90 mm.

TK-106 exchanger components

End user: Refinery plant
Location: Lithuania
Quantity: 2 pcs.
Design code: EN 13445, 97/23/WE
Weight: 2 pcs. x 10,300 kg
Pressure: 91.1 bar
Temperature: 400 °C
Medium toxic, flammable, explosive
Materials: Chromium-molybdenum steels (SA-387 Gr.11 Cl2, SA-182 Gr. F11 Cl2, SA-213 Gr. T5)
Additional description: All components made of chromium-molybdenum steel and the internal surfaces of chambers were cladded by welding with Cr25Ni13. PWHT. The manufactured components included a tube bundle with the chamber and floating head.