NIIK completes urea reactor lining overhaul in Egypt under extreme conditions

A team of specialists from Russia-based engineering firm NIIK has completed a critical overhaul of the upper lining of a urea synthesis reactor at the Helwan Fertilizers Company (HFC) production site in Egypt. The repair was conducted between May 24 and June 2, 2025, under challenging environmental conditions, with temperatures exceeding 40 °C.

The project involved the replacement of the upper lining belt of the reactor’s cylindrical section, along with the conical section of the upper bottom and neck. The refurbishment was part of routine maintenance to ensure the integrity and efficiency of the high-pressure equipment used in urea production.

Despite the extreme heat, the work was carried out on schedule and in full compliance with quality and safety standards. HFC personnel provided continuous logistical support, including tools, equipment, and materials needed to maintain workflow without interruption.

Technical oversight was maintained by NIIK’s specialists in non-destructive testing, diagnostics, corrosion analysis, and welding. To facilitate effective on-site coordination and address language barriers, the head of NIIK’s foreign licensors support department also participated in the operation, managing communication and helping resolve technical and operational issues.

Final hydraulic tests confirmed the system’s integrity, showing no pressure loss or leakage. Subsequent internal inspections and weld testing further verified the quality of the repairs.

HFC management expressed strong satisfaction with the outcome of the project, praising the NIIK team’s professionalism and efficiency, and indicated willingness to pursue additional collaborative projects in the future.