Urea Written Report

Designing
of Urea
Plant
Under the guidance of
Dr. Ajay Bansal
Submitted by:
Nitish Bir (13112022)
Chetan Mahajan (13112051)
Roshan Kudari (13112054)
1|Page Designing of Urea Plant
CANDIDATE DECLARATION
We hereby certify that the work is being presented in this project entitled
Designing of urea plant submitted towards the partial fulfilment of the
requirement for the award of Degree of Bachelor of Technology in Chemical
Engineering, is an authentic record of our own work carried out from August
2016 to May 2017 under the supervision of Dr. Ajay Bansal, Head &
Associate Professor, Department of Chemical Engineering, Dr. B R
Ambedkar National Institute of Technology, Jalandhar.
The matter embodied in this project has not been submitted by any of us for
the award of any other degree in this or any other University/Institute.
Nitish Bir (13112022)
Place: Jalandhar Chetan Mahajan (13112051)
Date: Roshan Kudari (13112054)
CERTIFICATE
This is to certify that the above statement made by the candidates is correct to
the best of my knowledge.
Date: Dr Ajay Bansal
(Supervisor & Head)

Table of Contents
1. Chapter 1: Basics of Urea1

2. Chapter 2: Process Selection...9
3. Chapter 3: Mass Balance...19
4. Chapter 4: Heat Balance27
5. Chapter 5: Designing of Equipments41
6. Chapter 6: Cost Analysis..50
7. Chapter 7: Environmental Considerations56
8. Chapter 8: Summary and Conclusion63
9. References.64
Chapter 1
Basics of Urea
1. INTRODUCTION
1.1. History of Urea

Urea is being discovered in the urine by H.M Rouelle in 1773. It was synthesized in
1828 by Friedrich Wohler and urea is the first organic compound that has being
synthesized from inorganic starting materials. It was found when Wohler attempt to
synthesis ammonia cyanate. When he react silver cyanate with ammonium chloride, the
reaction produce white crystalline materials which is quite identical with the urea in the
urine. In the year 1870, urea had being produced by heating in ammonium carbonate in a
sealed vessel.
1.2. Literature Survey

Urea (NH2CONH2) is an organic compound and it is also known as carbamide.
Ammonia is usually used in agriculture sector especially to make fertilizers. Urea is
made from ammonia (NH3) and carbon dioxide (CO2). The production of ammonia and
urea are being done separately.
1.3. Commercial Production
Urea is a nitrogen-containing chemical product which is produced in excess of

140,000,000 tonnes per year worldwide, of which more than 90% of world
production is destined for used as fertilizer.
Ammonia is being produce from the reaction of ammonia and carbon dioxide and
it is also being produced commercially. Urea can be produced as prills, granules,
flakes, pellets, crystals and also solutions.
In the urea containing the highest nitrogen in all solids nitrogenous fertilizers in
common used (46.4%N). It also containing the highest concentration dries
nitrogen fertilizer available. So it has the lowest transportation costs per unit of
nitrogen nutrient.
Urea also suitable for liquid fertilizer because it is soluble in the water.
The solid ureas are being market as prills or granules. Prills are cheaper compare
to granules since prills has the narrower size particles. Narrow size of particles has
the advantage if it is applied mechanically to soil.
1.4. Chemical and Physical properties of Urea

1.4.1. CHEMICAL PROPERTIES
The urea molecule is planar and retains its full molecular point symmetry, due to
conjugation of one of each nitrogen's P orbital to the carbonyl double bond. Each
carbonyl oxygen atom accepts four N-H-O hydrogen bonds, a very unusual feature for
such a bond type.
This dense (and energetically favourable) hydrogen bond network is probably established
at the cost of efficient molecular packing: The structure is quite open, the ribbons
forming tunnels with square cross-section. Urea is stable under normal conditions.
Table 1: Chemical Properties of Urea
IUPAC Name Diaminomethanal

Chemical Formula (NH2)2CO
Molecular Mass 60.07 g/mol

Dipole Moment 4.56 p/D
Melting Point 132 F

pH (100 g/l in water, 20 C) ~9
Solubility Highly water soluble
Figure 1: Chemical Structure of Urea

1.4.2. PHYSICAL PROPERTIES
Urea is a white odourless solid. Due to extensive hydrogen bonding with water (up to six
hydrogen bonds may form - two from the oxygen atom and one from each hydrogen)
urea is very soluble. Solid urea will melt at 135C.
Table 2: Physical Properties of Urea
Density 1.33 x 103 kg/m3 , solid
Melting Point 132.7oC decomposes
Color Colorless
Odor odorless
Solubility in Water 108 g/100 ml (20oC)

167 g/100 ml (40oC)
251 g/100 ml (60oC)
400 g/100 ml (80oC)
733 g/100 ml (100oC)
Vapor Pressure < 10 Pa
Bulk Density 0.8 kg.mg -3
Figure 2: Urea crystals

1.6. APPLICATION OF UREA
1.6.1 In Agriculture:
Urea is being used as fertilizers and animals feed. As known urea is containing
nitrogen and the nitrogen in it can help to promote growth for both animals and
plants. Urea is also used in much multi-component solid fertilizer formulation.
There are some advantages by using urea as fertilizers which are urea are more
safer to ship and handle, it also not corrosive to equipment compare if using
nitrogen fertilizers, urea is high solubility in water so it is easy to move in the soils
and the last one is by using urea as fertilizers it can be applied in many ways such
as using equipment or by spreading it by using hand.
1.6.2 In Industrial:
With the mixed with many organics compounds urea has the ability to form a
loose compound.
The organic compounds are held in channels formed by interpenetrating helices
comprising of hydrogen bonded area molecules. This kind of behavior has been
used to separate mixture. This has been apply in production of lubricating oils.
Ureas are also use as raw materials for manufactured plastics (example urea-
formaldehyde rasins) and glue (example urea-melamine-formaldehyde).
It also used as additive ingredient in cigarette, some ingredients for making facial
cleanser and also as a reactant in some ready to use cold compresses for first aid
used.
1.6.3. In Medicals:
In medicals urea has been used to produce barbituric acids. Urea is reacting with
the malonic acids to form barbituric acids. Barbituric acids are the parents of
barbiturate drugs. Barbiturate drug is act as central nervous system depressant.
Urea also has been used to produce acylureas and urethanes for use as sedatives
and hypnotic. It is being made as sleeping pills. It is used in the treatment of
insomnia and in surgical anesthesia.
1.7 Raw materials of urea manufacturing
1.7.1 Ammonia
Ammonia, NH3, is a comparatively stable, colourless gas at ordinary temperatures, with

a boiling point of 33 C. Ammonia gas is lighter than air, with a density of
approximately 0.6 times that of air at the same temperature. The characteristic pungent
odors of ammonia can be detected as low as 1-5ppm. Ammonia can be highly toxic to a
wide range of organisms. In humans, the greatest risk is from inhalation of ammonia
vapour, with effects including irritation and corrosive damage to skin, eyes and
respiratory tracts. At very high levels, inhalation of ammonia vapour can be fatal. When
dissolved in water, elevated levels of ammonia are also toxic to a wide range of aquatic
organisms. Ammonia is highly soluble in water, although solubility decreases rapidly
with increased temperature. Ammonia reacts with water in a reversible reaction to
produce ammonium (NH4)+ and hydroxide (OH)- ions, as shown in equation.
Ammonia is a weak base, and at room temperature only about 1 in 200 molecules are
present in the ammonium form (NH4)+. The formation of hydroxide ions in this reaction
increases the pH of the water, forming an alkaline solution. If the hydroxide or
ammonium ions react further with other compounds in the water, more ammonia with
react to re-establish the equilibrium.
NH3 + H2O (NH4)+ + OH-
While ammonia-air mixtures are flammable when the ammonia content is 16-25% by
volume, these mixtures are quite difficult to ignite. About 85% of the ammonia produced
worldwide is used for nitrogen fertilizers. The remainder is used in various industrial
products including fibers, animal feed, and explosives.
1.7.2 Carbon Dioxide
CO2 is an odourless and colourless gas which contains 0.03% in the atmosphere. It is
emitted as a pollutant from number of industries. CO2 can be obtained from ammonia
production process as a by-product.
Chapter 2
Process Selection
10 | P a g e Designing of Urea Plant
2.1 Processes for Urea Production
Several processes are used to urea manufacturing. Some of them are used conventional
technologies and others use modern technologies to achieve high efficiency. These
processes have several comparable advantages and disadvantages based on capital cost,
maintenance cost, energy cost, efficiency and product quality. Some of the widely used
urea production processes are:
1. Once through Process
2. Conventional Recycle processes
3. Stamicarbon CO2 stripping process
4. Snamprogetti Ammonia and self-stripping processes
5. Isobaric double recycle process
6. ACES process
2.1.1 Once through Process

In this process non converted ammonia was neutralized with acid such as nitric acid to
produce ammonium salt such as ammonium nitrate as co products of urea production. In
this way, a relatively simple urea process scheme was realized. The main disadvantages
of this process are the large quantity of ammonia salt formed as co product and the
limited amount of overall carbon dioxide conversion that can be achieved.
2.1.2 Conventional Recycle Process

Here all of the non-converted ammonia and carbon dioxide were recycled to the urea
reactor. In first generation of this process the recirculation of non-converted NH3 and
CO2 was performed in two stage. The first recirculation was operated at medium pressure
(18-25 bar); the second at low pressure (2-5 bar). The first recirculation comprises at
least a decomposition heater, in which carbamate decompose into gaseous NH3 and CO2,
and while excess NH3 evaporate simultaneously. The off gas from this first
decomposition step was subjected to rectification, from which relatively pure ammonia at
the top and a bottom product consisting of an aqueous ammonium carbamate solution
were obtained. Both products are recycled separately to the urea reactor. In these
processes, all non-converted CO2 was recycled as associated water recycle. Because of
the detrimental effect of water on reaction conversion, achieving a minimum CO2 recycle
so achieve maximum CO2 conversion was more important than achieving a low NH3
recycle. All conventional processes therefore typically operate at high NH3:CO2 ratios (4-
5 mol/mol) to maximize CO2 conversion per pass. Although some of these conventional
processes partly equipped with ingenious heat exchanging networks have survived until
now. Their importance decreased rapidly as the so-called stripping process was
developed.
2.1.3 Stamicarbon CO2 stripping process

In this process to achieve maximum urea yield per pass through the reactor at the
stipulated optimum pressure of 140 bar, an NH3:CO2 molar ratio of 3:1 is applied. The
greater part of the unconverted carbamate is decomposed in the stripper, where ammonia
and carbon dioxide are stripped off. This stripping action is effected by countercurrent
contact between the urea solution and fresh carbon dioxide at synthesis pressure. Low
ammonia and carbon dioxide concentration in the stripped urea solution are obtained.
Such that the recycle from the low pressure recirculation stage is minimized. These low
concentration of both ammonia and carbon dioxide in the stripper effluent can be
obtained at relatively low temperatures of the urea solution because carbon dioxide is
only sparingly soluble under such conditions.
Condensation of ammonia and carbon dioxide gases, leaving the stripper, occurs in the
high pressure carbamate condenser as synthesis pressure. As a result, the heat liberated
from ammonium carbamate formation is at a high temperature. This heat is used for the
production of 4.5bar steam for use in the urea plant itself. The condensation in the high
pressure carbamate condenser is not effected completely. Remaining gases are
condensed in the reactor and provide the heat required for the dehydration of carbamate,
as well as for heating the mixture to its
equilibrium temperature. In recent improvement to this process, the condensation of off
gas from the stripper is carried out in a pre-reactor, where sufficient residence time for
the liquid phase is provided. As a result of urea and water formation in condensing zone,
the condensation temperature is increased, thus enabling the production of steam at
higher pressure level.
The feed carbon dioxide, invariably originating from an associated ammonia plant,
always contains hydrogen. To avoid the formation of explosive hydrogen-oxygen
mixture in the tail gas of the plant, hydrogen is catalytically removed from the CO2 feed.
Apart from the air required for this purpose, additional air is supplied to the fresh CO2
input stream. This extra potion of oxygen is needed to maintain a corrosion-resistance
layer on the stainless steel in the synthesis section. Before the inert gases, mainly oxygen
and nitrogen, are purged from the synthesis section, they are washed with carbamate
solution from the low pressure recirculation stage in the high pressure scrubber to obtain
a low ammonia concentration in the subsequently purged gas. Further washing of the off
gas is performed in a low pressure absorber to obtain a purge gas that is practically
ammonia free. Only one low pressure recirculation stage is required due to the low
ammonia and carbon dioxide in the stripped urea solution. Because of the ideal ratio
between ammonia and carbon dioxide in the recovered gases in this section, water
dilution of the resultant ammonium carbamate is at a minimum despite the low pressure
(about 4bar). As a result of efficiency of the stripper, the quantities of ammonium
carbamate for recycle to the synthesis section are also minimized, and no separate
ammonia recycle is required.
The urea solution coming from the recirculation stage contains about 75 wt% urea. This
solution is concentrated in the evaporation section. If the process is combined with a
prilling tower for final product shaping, the final moisture content of urea from the
evaporation section is 0.25 wt%. If the process is combined with a granular unit, the final
moisture content may wary from 1 to 5 wt%, depending on granulation requirements.
Higher moisture content can be realized in a single stage evaporator; whereas low
moisture content are economically achieved in a two stage evaporation section.
When urea with an extremely low biuret content is required (at maximum of 0.3 wt%)
pure urea crystals are produced in a crystallization section. These crystals are separated
from the mother liquor by combination of sieve bends and centrifuges and are melted
prior to final shaping in a prilling tower or granulation unit.
The process condensate emanating from water evaporation from the evaporation or
crystallization sections contains ammonia and urea. Before this process condensate is
purged, urea is hydrolyzed into ammonia and carbon dioxide, which are stripped off with
steam and return to urea synthesis via the recirculation section. This process condensate
treatment section can produce water with high purity, thus transforming this waste
water treatment into the production unit of a valuable process condensate, suitable for,
e.g., cooling tower or boiler feed water makeup. Since the introduction of the
Stamicarbon CO2 stripping process, some 125 units have been built according to this
process all over the world.
2.1.4 Snamprogetti Ammonia and self-stripping processes

In the first generation of NH3 and self-strip ping processes, ammonia was used as
stripping agent. Because of the extreme solubility of ammonia in the urea containing
synthesis fluid, the stripper effluent contained rather large amount s of dissolved
ammonia, causing ammonia overload in downstream section of the plant. Later versions
of the process abandoned the idea of using ammonia as stripping agent; stripping was
achieved only by supply of heat.
Even without using ammonia as a stripping agent, the NH3:CO2 ratio in the stripper
effluent is relatively high. So the recirculation section of the plant requires an ammonia-
carbomate separation section
The process uses a vertical layout in the synthesis section. Recycle within the synthesis
section, from the stripper via the high pressure carbamate condenser, through the
carbamate separator back to the reactor, is maintained by using an ammonia-driven
liquid-liquid ejector. In the reactor, which is operated at 150 bars, NH3:CO2 molar feed
ratio of 3.5 is applied.
The stripper is of the falling film type. Since stripping is achieved thermally, relatively
high temperatures (200-210 0C) are required to obtain a reasonable stripping efficiency.
Because of this high temperature, stainless steel is not suitable as a construction material
for the stripper from a corrosion point of view; titanium and bimetallic zircornium
stainless steel tubes have been used
Off gas from the stripper is condensed in a kettle type boiler. At the tube side of this
condenser the off gas is absorbed in recycled liquid carbamate from the medium pressure
recovery section. The heat of absorption is removed through the tubes, which are cooled
by the production of low pressure steam at the shell side. The steam produced is used
effectively in the back end of the process.
In the medium pressure decomposition and recirculation section, typically operated
at 18 bar, the urea solution from the high pressure stripper is subjected to the
decomposition of carbamate and evaporation of ammonia. The off gas from this medium
pressure decomposer is rectified. Liquid ammonia reflux is applied to the top of this
rectifier; in this way a top product consisting of pure gaseous ammonia and a bottom
product of liquid ammonium carbamate are obtained. The pure ammonia off gas is
condensed and recycled to the synthesis section. To prevent solidification of ammonium
carbamate in the rectifier, some water is added to the bottom section of the column to
dilute the ammonium carbamate below its crystallization point. The liquid ammonium
carbamate-water mixture obtained in this way is also recycled to the synthesis section.
The purge gas of the ammonia condenser is treated in a scrubber prior to being purged to
the atmosphere.
The urea solution from the medium pressure decomposer is subjected to a second low
pressure decomposition step. Here further decomposition of ammonium carbamate is
achieved, so that a substantially carbamate free aqueous urea solution is obtained. Off
gas from this low pressure decomposer is condensed and recycled as an aqueous
ammonium carbamate solution to the synthesis section via the medium pressure recovery
section.
Concentrating the urea water mixture obtained from the low pressure decomposer is
performed in a single or double evaporator depending on the requirement of the finishing
section. Typically, if prilling is chosen as the final shaping procedure, a two stage
evaporator is required, whereas in the case of a fluidized bed granulator a single
evaporation step is sufficient to achieve the required final moisture content of the urea
melt. In some versions of the process, heat exchange is applied between the off gas from
the medium pressure decomposer and the aqueous urea solution to the evaporation
section. In this way, the consumption of low pressure steam by the process is reduced.
The process condensate obtained from the evaporation section is subjected to a
desorption hydrolysis operation to recover the urea and ammonia contained in the
process condensate.
2.1.5 Isobaric double recycle process

This process is developed by Montedison, is characterized by recycle of most of the
unreacted ammonia and ammonium carbamate in two decomposer in series, both
operating at the synthesis pressure. A high molar NH3:CO2 ratio (4:1 to 5:1) in the reactor
is applied. As a result of this choice ratio, the reactor effluent contains a relatively high
amount of non-converted ammonia. In the first, steam heated, high pressure decomposer,
this large quantity of free ammonia is mainly removed from the urea solution. Most of
the residual solution, as well as some ammonium carbamate, is removed in the second
high pressure decomposer where steam heating and CO2 stripping are applied. The high
pressure synthesis section is followed by two low pressure decomposing stages of
traditional design, where heat exchange between the condensing off gas of the medium
pressure decomposition stage and the aqueous urea solution to the final concentration
section improves the overall energy consumption of the process. Probably because of the
complexity of this process, it has not achieved great popularity so far. This process or
parts of the process are used in four revamps of older conventional plant.
2.1.6 ACES process

ACSE (Advanced Process for Cost and Energy Saving) process has been developed by
Toyo Engineering Corporation. Its synthesis section consists of the reactor, stripper, two
parallel carbamate condensers and a scrubber all operated at 175 bar.
The reactor is operated at 1900C and an NH3:CO2 molar feed ratio of 4:1. Liquid
ammonia is fed directly to the reactor, whereas gaseous carbon dioxide after compression
is introduced into the bottom of the stripper as a stripping aid. The synthesis mixture
from the reactor, consisting of urea, unconverted ammonium carbamate, excess
ammonia, and water, is fed to the top of the stripper.
2.2 Comparison of Various Processes
Table 3: Comparison of various processes

Process Advantages Disadvantages
Once through process Simple process Large quantity of
ammonia salt is
produced
Overall co2
conversion is low
High production
cost
High energy cost
High
environmental
pollution
Conventional Recycle High CO2 High production
Process conversion and energy cost
High environment
pollution
Stamicarbon CO2- High urea yield per High production
stripping Process pass cost
High purity High energy cost
Snamprogetti Process Less consumption High production
of low pressure cost
steam High energy cost
Isobaric double recycle Complex process
process
ACES Process Low production High capital cost
cost
High energy
recovery
Low
environmental
Pollution
High efficiency
Figure 3: Flow sheet of Snam Progetti Process

The process selected for the formation of urea is Snam - Pragetti Process . This is self-
stopping process.
The basic raw material for the formation of urea is Ammonia & Carbon Dioxide. The
formation of urea is taking place in following manner:
2NH3 + CO2 NH4COONH2 + Heat

(Ammonium carbamate)
NH4COONH2 NH2CONH2 + H2O - Heat
(UREA)
First reaction is takes place at high pressure and temperature that is P = 150kg/cm2 (g) &
T = 1700C. In this reaction carbamate is formed. At high pressure reaction is taking
place at in forward direction and at low pressure reaction is taking place in backward
direction. It is exothermic reaction. In the 2nd reaction carbamate is dehydrated to form
Urea. This is endothermic process. The heat which is generated in reaction first is
utilized in reaction two. At a very high temperature reaction two precede backward
direction.
The process root is summarized in the following steps:
a. COMPRESSION OF CARBON DIOXIDE

In this step carbon dioxide is compressed through compressor. The carbon dioxide enters
in the compressor at 1.4 atm. & around 400C for increasing pressure up to 155kg/cm2
(g). This is achieved by using two centrifugal pumps driven by an extraction cum
condensing turbine. Ammonia is comes from the Ammonia Plant or from the Ammonia
Storage Tank. The ammonia is passed through the preheated tank to high pressure
synthesis loop. The high pressure synthesis loop is combination of booster centrifugal
pump and reciprocating pressure pump. The pressure of ammonia comes out from the
high pressure synthesis loop is 240kg/cm2. The high pressure liquid ammonia is also
provided for motive force for ejector, which recycles carbamate solution to urea reactor.
The ammonia is kept in excess for the complete conversion of carbon dioxide. The ration
of ammonia to carbon dioxide is 3.33:1.
b. UREA SYNTHESIS AND HIGH PRESSURE RECOVERY

This section consists of reactor, high pressure stripper, horizontal carbamate condenser
(two units placed in series). The compressed carbon dioxide and excess ammonia are
entered in the reactor to form the urea at the temperature of 1900C & pressure
150kg/cm2 (g). The concentration of urea formed in the reactor is nearly 32%. The
effluent of reactor is consisting of ammonia, Carbon dioxide, carbamate, vapour and
urea. This effluent is passed to stripper in which CO2 is absorbed according to the
Henery Law. Heat required for stripping is supplied by 26kg/cm2 (g) steam obtained
from extraction of carbon dioxide compression turbine. The concentration of urea
obtained from the stripper is 45%. The off gases obtained from the stripper ammonia,
CO2 and vapour are entered into horizontal carbamate condenser where the total
mixture, except for some inert, is condensed as carbamate and recycled to the reactor.
c. UREA PURIFICATION AND LOW PRESSURE RECOVERIES

Urea purification takes place in two stages at decreasing pressures as follows:
i. Medium Pressure at 18 atm. pressure
ii. Low Pressure at 4.5 atm. pressure
Medium Pressure Purification and Recovery stage (at 18 atm.)

The solution, with a low residual CO2 content, leaving the bottom of the stripper at
synthesis pressure is let down to18 atm. and enters medium pressure decomposer The
M.P. decomposer and divided in two parts:
1) Top separated: where the released flash gases are removed before the solution enters
the tube bundle
2) Decomposition section (falling film type): where residual carbamate is decomposed
and the heat require for the decomposition is applied by means of 26 atm. steam
condensate flowing out of the shell side of stripper
The NH3 and CO2 rich gases leaving the top separator are sent to medium pressure
condenser where they are partially absorbed in aqueous carbonate solution coming from
low pressure recovery section .The absorption heat is removed by tempered cooling
water circulation in the tube side of the medium pressure condenser. In the M.P.
condenser CO2 is almost totally absorbed. The effluents flow to medium pressure
absorber. The gaseous phase enters the rectification section of the M.P. absorber. The
rectification section has bubble trays. The bubble cap trays are fed by pure reflux
ammonia at the top trays which eliminates residual CO2 and H2O from gases leaving
M.P. absorber. The reflux ammonia is pumped to rectification column. NH3 with inert
gases leaving the M.P. absorber is condensed in ammonia condenser.
The inert gases, saturated with ammonia enter ammonia preheater where an additional
amount of ammonia is condensed by heating cold ammonia coming from ammonia
storage area and used as make up feed to Urea plant.
The inert gases with residual ammonia content are sent to medium pressure ammonia
absorber, which is a falling film type and where they meet a condensate flow which
absorbs ammonia from bottom of ammonia absorber the water ammonia solution is
pumped to medium pressure absorber. The inerts leaving the top are free from ammonia.
Low pressure purification and recovery stage (at 4.5 atm.)

Low pressure decomposer consists of:
1) Top separator: where the released gases are removed before the solution enters the
lower tube bundle
2) Decomposition section (falling film type): where residual carbamate is decomposed
and the heat require for the decomposition is applied by means of saturated steam at 4.5
atm.
The urea solution from the M.P. decomposer bottom enters the L.P. decomposer after
expansion through a level controller. Consequently most of the residual carbamate is
decomposed and in the process urea solution gets concentrated. The remaining carbamate
is decomposed in a falling film exchanger, which is a part of L.P. decomposer.
The vapors from the L.P. decomposer enter the L.P. condenser where they get cooled and
liquefied. Prior to the entry of L.P. off gases in L.P. condenser the vapor gets mixed with
the aqueous solution from waste water section. The vapor thus formed get condensed in
L.P condenser goes to carbonate solution tank from where it is send back to M.P.
condenser. The inert gases in the tank contains considerable amount of ammonia and
thus are absorbed in cool condensate before being sent to vent stack.
The urea solution at the bottom of the L.P. decomposer is sent to pre vacuum
concentrator through a level control valve.
d. Urea concentration section:
As it is necessary in order to prill urea to concentrate urea solution up to 99.8 % wt., a

vacuum concentration section in two stages is provided.
The two concentrator use saturated steam at 4.5 atm. The liquid - vapor phase coming
out of second vacuum concentrator enters gas - liquid separator where the vapours are
extracted by second vacuum system.
First vacuum system:
First evaporator is operated at 1300C and 0.3 Kg/cm2 pressure. Overhead vapor from the
top of the first vacuum separator is directed to the shell side of pre condenser and heat of
condensation is removed by cooling water in the tube side. Ammonia vapor and residual
CO2 is absorbed in condensate forming dil. Ammonium carbonate sol. and flows down
through barometric leg of waste water tank.
Uncondensed gases are sucked by the ejector (motive fluid being 44.5 atm. steams) and
discharged in the shell side after condenser, which also receives uncondensed gases from
second vacuum system. Heat of condensation is removed by cooling water in the tube
side.
Second vacuum system:
It operates at 14000 C and 0.03 Kg/cm2 pressure. Overhead gases from second vacuum
separator are sucked by a booster ejector and discharged at slightly higher pressure
where heat of condensation is removed by cooling water in the tube side.
Uncondensed gases are drawn by ejector and discharged to shell side of second inter
condenser where heat of condensation is again removed by cooling water.
e. Urea prilling:
The molten urea leaving second vacuum separator is pumped to the prilling bucket by
means of centrifugal pump.
The molten urea coming out of the prilling bucket in the form of drops fall along the
prilling tower and encounters air flow which causes its solidification and subsequent
cooling solid prills are sent to the conveyer belt by rotary scraper which carries urea to
bagging plant or storage. The heated air containing few ppm of NH3 is released from the
top into the atmosphere.
CHAPTER 3
MASS BALANCE
3.1 Data given
Selected capacity 478500 MTPA [5]

No. of working days 300 day
Daily production 478500/300 =66458.33 kg/hr
3.2 Composition of final products:

(Assumption)
Urea : 98% (65129.1667) kg/hr
Water : 1% (664.5833) kg/hr
Biuret : 1% (664.5833) kg/hr
Assumption: Overall conversion to urea is assumed to be 95%.
3.3 Reactions
Main reactions:
1) CO2+ 2NH3 NH2COONH4

(Ammonium Carbamate)
2) NH2COONH4 NH2CONH2 + H2O
(Urea)
3) CO2 + 2NH3 NH2CONH2 + H2O
(overall reaction)
Side reaction:
4)2NH2CONH2 NH2CONHCONH2 + NH3
(Biuret)
Based on these reactions, we get
Urea produced from reaction 4 = 664.588*(2*60/103)

=774.277 kg/hr
Urea produced from reaction 2 = 774.277+65129.1667
=65903.44 kg/hr
NH3 produced from reaction 3 = 65903.44*(2*17/60)
= 37345.28 kg/hr
CO2 reacted from reaction 1 = (44/60)*65903.44
= 48329.189 kg/hr
3.4 REACTOR
At Reactors inlet
Assuming 95% conversion of urea
NH3 input to the reactor = 37345.28/0.95 = 39310.82 kg/hr

CO2 input to the reactor = 48329.189/0.95 = 50872.83 kg/hr
Urea produced from reaction 3 in reactor = (60/44)*50872.83*0.95
=65903.43kg/hr
Urea converted to NH3 & Biuret in reaction 4 =65903.43- 65129.1667
=774.26kg/hr
Biuret produced in reaction 4 in reactor = (103/2*60)*774.26
= 664.575kg/hr
Water produced in reaction 2 in reactor = (18/60)*65903.43
= 19771.029 kg/h
At reactor's exit (Urea=34%)
Flow rate of stream = 65903.43/0.34= 193833.6176 kg/hr

NH3 reacted in reaction 1 = (2*17/60)*65903.43
= 37345.277 kg/hr
NH3 produced in reaction 4 = (17/2*103)*774.26
= 63.89 kg/hr
NH3 unreacted= NH3 input - NH3 reacted + NH3 produced
= 39310.82 37345.277+63.89
= 2029.433 kg/hr
CO2reacted in reaction 1 = (44/60)* 65903.44 = 48329.189 kg/hr
CO2 unreacted = CO2input-CO2 reacted= 50872.83 -48329.189
= 2543.641 kg/hr
Flow rate of carbamate = Total flow rate of stream exit
(flow rate ofurea+CO2+NH3+Biuret+Water)
=193833.617-(65903.43+2543.641+2029.433+664.59+19771.029)
=102921.494 kg/hr
CO2=50872.83kg/hr
CO2=2543.641 kg/hr
NH3=2029.433 kg/hr
REACTOR
NH3=39310.82 kg/hr Urea=65903.43kg/hr
Water=19771.029 kg/h
Carbamate=102921.494Kg/hr
Biuret=664.575 kg/h
Carbamate=102921.494 kg/hr
Figure 4: Mass balance across reactor
3.5 STRIPPER
There is no chemical reaction taking place in stripper. Only carbamate gets

recycled back to the Reactor. Therefore, the amount of ammonia, NH3, CO2,
Water & biuret in the outlet stream of stripper will be the same as inlet
stream.
STRIPPER
NH3=2029.433 kg/hr
CO2=2543.641 kg/hr
NH3=2029.433 kg/hr
Urea=65903.43kg/hr
CO2=2543.641 kg/hr
Water=19771.029 kg/h Urea=65903.43kg/hr
Biuret=664.575 kg/h Water=19771.029 kg/h
Carbamate=102921.494 kg/hr Biuret=664.575 kg/h
Figure 5: Mass Balance across stripper
3.6 MEDIUM PRESSURE DECOMPOSER
The amount of ammonia, CO2, Biuret, Water and carbamate will be the same
as no reaction takes place. 50% of ammonia and CO2 and 10% of carbamate
are assumed to escape from the top of separator and the rest goes with the
bottom product.
NH3=1014.716 kg/hr
CO2=1271.82kg/hr
Carbamate=19006.2 kg/h
MEDIUM PRESSURE
DECOMPOSER
NH3=2029.433 kg/hr NH3=1014.716 kg/hr
Urea=65903.43kg/hr CO2=1271.82kg/hr
CO2=2543.641 kg/hr Urea=65903.43kg/hr
Biuret=664.575 kg/h
Biuret=664.575 kg/h
Figure 6: Mass balance across Medium Pressure Decomposer
3.7 LOW PRESSURE DECOMPOSER
No reaction take place and the remaining NH3, CO2 and Carbamate are escaped from
the top of decomposer.
NH3=1014.716 kg/hr
CO2=1271.82kg/hr
Carbamate=2118.5552 kg/h
LOW PRESSURE
DECOMPOSER
NH3=1014.716 kg/hr
CO2=1271.82kg/hr
Urea=65903.43kg/hr
Urea=65903.43kg/hr
Water=19771.029 kg/hr
Biuret=664.575kg/hr Biuret=664.575kg/hr
Carbamate=2118.5552 kg/h Water=19771.029 kg/hr
Figure 7: Mass Balance across Low Pressure Decomposer
3.8 VACUUM EVAPORATOR
Total output from low pressure decomposer = 86339.034 kg/hr

Let X mass fraction of urea in feed(F) =0.7633
Y mass fraction of urea in product(P) =0.9788
E water losses in vacuum evaporator
Urea balance
Input=output
F*X=P*Y
P=(F*X)/Y
P=(86339.034*0.7633)/0.9788 =67329.98 kg/hr
Overall material balance
F=P+E E=F-P
E=86339.034-67329.98=19009.05 kg/hr
Water=19009.053kg/hr
EVAPORATOR
Urea=65903.43kg/hr
VACUUM
Biuret=664.575kg/hr
Urea=65903.43kg/hr
Water=19771.029 kg/hr Biuret=664.575kg/hr

Water=761.97kg/hr
Figure 8: Mass balance across vacuum evaporator
3.9 PRILLING TOWER
Output from vacuum evaporator = 67329.975 kg/hr

Let
X mass fraction of urea in feed (F) =0.9788
Y mass fraction of urea in product(P) =0.979913
Urea balance
Input=output
P=(F*X)/Y P
P=(67329.975*0.9788)/0.979913 =67255.26 kg/hr
Overall material balance
F=P+E E=F-P
E=Water removed=67329.975-67255.26=74.715 kg/hr
Water in the final product=686.76 kg/hr
Water=74.715 kg/hr
PRILLING TOWER
Urea=65903.43kg/hr
Water=761.97 kg/hr
Biuret=664.575kg/hr
Air
Urea=65903.43kg/hr
Biuret=664.575kg/hr
Water=686.78 kg/hr
Figure 9: Mass balance across Prilling Tower

Chapter 4
Heat Balance
Specific Heat Constants for different components

Table 4: Specific Heats of Various Components
Component a b*10-2 c*10-5 d*10-7
NH3(gas) 8.4017 0.70601 0.10567 -0.01598
NH3(liquid) 4.6356 --- --- ---
C02 6.393 1.01 -0.3405 ---
Urea 38.43 4.98 0.705 -8.61
Water 7.88 0.32 --- -4.833
Carbamate 2.596 ---- --- ---
Biuret 183.8 ---- --- ---
Calculation of specific heats for different components at different

temperatures is done by:
Cp = a + bT + cT2 + dT3
4.1 Reactor
2NH3+CO2 NH2CONH2+H2O (main reaction)
H298=(niHf )p(niHf )r
Hf (urea)= 333.6 KJ/gm mol , Hf (NH3)=46.16 KJ/gm mol
Hf (CO2)=393.5 KJ/gm mol , Hf (H2O)=285.84 KJ/gm mol
H298= (-333.6+(-285.84)((2*-46.16)+(-393.6))
=133.62 KJ/gm mol
Moles of urea formed during the reaction=68055.56/60=1134.259kmole/hr
=1134259 g mol/hr
H298=133.62 KJ/ g mol*1134259gm mole/hr
=151559722.2 KJ/hr
For Inlet Stream
Reference Temperature 25 C
Inlet Temperature 40 C
Component Specific heat Flow rate (kg/hr)

(kJ/kg)
NH3 69.534 39310.82
CO2 9.01033 50872.83
25
Hr=m40
Hr=(69.534*39310.829.01033*50872.83)
=3191819.544 KJ/hr
For Outlet stream
Reference Temperature 25 C
Inlet Temperature 180 C
Component Specific heat Flow rate

Urea 121.7623 65903.43
Water 292.703 19771.029
Hp=(121.7623 *65903.43 +292.7034*19771.029 ) = 13811646.76 KJ/hr

H = H298 +Hp+ Hr=151559722.2- 3191819.544 +13811646.76
=140939895 kJ/hr
Q=H=140939895 KJ/hr
Assumption: Cooling water at 25 C is used to remove heat from reactor.

The outlet is steam at an absolute pressure of 4.5 bar (Ts=147.9 C).
Heat gained by cooling water = 140939895 KJ/hr
M(cpT+)= 140939895 KJ/hr
=2120.8 KJ/kg (from steam table)
Cp=4.187 KJ/kg C,
T=TsT (Ts=147.9 C , T=25 C)
M(4.187*(147.925)+2120.8)= 140939895
M= 53479.86 kg/hr
REACTOR
Qin=65903.43kg/hr Qout=65903.43kg/hr
Tin=40C Tout=180 C
Figure 10: Heat balance across Reactor

4.2 STRIPPER
Total heat input= 140939895 KJ/hr
Outlet stream
Liquid
185
Q=m25
Materials Specific Heat Flow rate (kmol/hr) Mole fraction

(KJ/kg)
NH3 6009.302 2029.433/17=119.37 0.0454
CO2 4801.186 2543.641/44=57.81 0.0217
Urea 7607.734 65903.43/60=1098.39 0.4141
Water 5443.803 19771.029/18=1098.39 0.4141
Biuret 29408 664.575/103=6.452 0.00243
Carbamate 32398 21185.52/78=271.60 0.1024
Total=2652.01
CP of mixture=XCPi=(6009.302*0.0454+ 4801.186 *0.0217+

7607.734*0.4141+5443.803*0.4141+ 29408*0.00243 + 32398*0.1024)
= 9071.611 KJ/kmole
Heat carried by outlet stream=2748.319*9071.611
=24931683 KJ/hr
Vapor Stream: ammonium carbamate
Material Specific Heat (kJ/kgmol) Flow rate (kmol/hr)

Carbamate 32398.08 1086.436
For carbamate, =210 KJ/kg

Heat carried by carbamate= m*cp*T+ m*
=32398.08*1086.436+84722.085*210
= 52994311 KJ/hr
Here, steam at 24 atm is used (Ts=221.8 C)
of steam =1855.3 KJ/kg from steam table
Heat supplied by steam= heat outputheat input
M*=(52994311+2493168314333675)= 52994311KJ/hr
M= 63592318 kg/hr
Carbamate
Qout=52994311 kJ/hr
Tout=185C
STRIPPER
Feed
Qin=14333675 kJ/hr
Tin= 180C
Products
Qout=24931683 kJ/hr
Figure 11: Heat flow across Stripper
Tout=185C
4.3 CARBAMATE CONDENSER

Energy balance
Mv*v=msCp *(Ts25)+ms s
Where V : vapor of carbamate, S: steam
Putting the values we get
105927.6*210=ms[4.187x (147.925)+2120.8]
Ms =8440.824kg/hr
Carbamate vapor Carbamate liquid

CONDENSER
Qout=105927.6kJ/h
Figure 12 : Heat flow across carbamate condenser
4.4 MEDIUM PRESSURE DECOMPOSER

Heat input=24931683 KJ/hr
Outlet stream
Liquid
140
Q=m25
Material Cp Flow rate Mole fraction

NH3 4241.15 1014.716/17=59.68 0.0257
CO2 3348.267 1271.82/44=28.905 0.0124
Urea 5068.511 65903.43/60=1098.39 0.4736
Water 3879.049 19771.029/18=1098.39 0.4736
Biuret 19655.8 664.575/103=6.452 0.00278

Carbamate 23286.12 27.16092 0.0117
Total 2318.977
Cp Of mixture=XiCpi
=(4241.15*0.026465+3348.267*0.012533+5068.511*0.470669+3879.049*0.
476264+19655.8* 0.002798+23286.12* 0.011271)
= 4715.171 KJ/kmol
Heat output=4704.691*2409.888=11337780KJ/hr
For Gasses Escaping From The Top
Material Cp Flow rate Mole Fraction
NH3 4241.15 1014.716/17=59.68 0.188454
CO2 3348.267 1271.82/44=28.90 0.089247
Carbamate 23286.12 244.44 0.72229
Cp of mixture=Xi Cpi=(4241.15*0.188454+3348.267* 0.089247

+23286.12*0.722299)= 17917.63 KJ/kmole
Component Flow rate Mole fraction

NH3 22777 63.778 0.1884
CO2 20265 30.203 0.08924
Carbamate 16380 244.44 0.722
Total 338.43
of mixture=xii
=(0.188454*22777+0.089247*20265+16380*0.722299)
=17932.26 KJ/kmole
Heat escaping from the top =m (cp*T+ )
=338.4308(17917.63 +17932.26)= 12132708 KJ/hr
Assumption: cooling water enters at 25C & leaves at 50C
Heat gained by cooling water =heat inputheat output
=(249316831213270811337780)
=1461196 KJ/hr
M*cp*T=1461196
M=1461196 /(4.184*25)= 13969.37 Kg/hr
Off gases
Qout=12132708 kJ/h
MEDIUM PRESSURE
DECOMPOSER
Feed
Qin=24931683 kJ/h
Qout=11337780 kJ/h
Products
Figure 13: Heat flow across Medium Pressure Decomposer

4.5 LOW PRESSURE DECOMPOSER
Heat input=11337780KJ/hr
Outlet stream
Liquid
80
Q =m25
Component Cp Flow rate Mole Fraction
Urea 2226.101 1134.259 0.4955
Water 1833.48 1147.744 0.50147
Biuret 8195 6.7421 0.002946
Total 2288.74
Cp of mixture=Xi*Cpi
=(2226.101*0.495581+1833.484*0.501473+8195*0.002946)
=2046.797 KJ/kmole
Heat output= 4684597 KJ/hr
Component Cp Flow rate Mole fraction

NH3 1978 63.77 0.524
CO2 1534.28 30.203 0.245
Carbamate 11136.84 27.1609 0.224
Total 121.143
=(1978.934* 0.526473+1534.283*0.249323+11136.84*0.224202)
= 3919.077 KJ/kmole
of mixture =Xi
Cpi=(0.526473*1851 +0.249323*1566 +0.224202*16380 )
=5073.415 KJ/kmol
Heat escaping from the top =m(cp*T+ )
=121.1434(3919.077 +5073.415)= 1085019 KJ/hr
Assumption : cooling water enters at 25 C & leaves at 50C
Heat gained by cooling water=heat inputheat output
=(1133778010850194684597)
=5568163 KJ/hr
M*cp T=5568163 KJ/hr
M=5568163 /(4.187*25)
= 5394.177 kg/hr
Off gases
Qout=1085019 kJ/h
LOW PRESSURE
DECOMPOSER
Feed
Qin=11337780 kJ/h
Qout=4684597 kJ/h
Product
Figure 14: Heat flow across Low Pressure Decomposer

4.6 VACUUM EVAPORATOR

For product stream coming out from 1St evaporator
Component cp Flow rate Mole fraction
Urea 2443.41 1134.259 0.7504
Water 2002.149 370.433 0.245
Biuret 8490 6.74 0.004461
Total 1511.412
=(2443.41*0.750452+2002.149 * 0.245087+ 8940* 0.004461)
=2364.243 KJ/kmole
M*cp* T=2364.243*1511.435=3573399 KJ/hr
Heat balance
1st Evaporator
Heat input(by feed)+Heat input by steam=Heat carried by water vapor
+Energy of bottom product
Heat input by feed+ S1*= E1HE1 +energy of bottom product
4684597+S1* 2123.8=13991.58*2614.97+3573399
S1=16687.25 kg/hr
2nd Evaporator
Heat input(by feed)+Heat input by steam=Heat carried by water vapor
+Energy of bottom product
3573399+S1 * 2123.8=5894.424*2545.7+2464.393*1183.967
S2= 6756.660 kg/hr
E1=13991.58 kJ/hr E2=5894.424kJ/hr
Feed
Qin=4684597 kJ/hr
Qout=2917759 kJ/hr
Product
Qout=3573399 kJ/hr
Figure 15: Heat flow across Vacuum Evaporator
4.7 PRILLING TOWER
Heat input= energy of bottom product of evaporator =m*cp*T

=2464.393 *1183.967
=2917759 KJ/hr
Outlet Stream
30
Q =m25
Component cp Flow rate Mole fraction
Urea 192.8017 65903.43 0.9799

Water 165.0169 686.78 0.0102
Biuret 745 664.575 0.00988
Total 67254.785
=( 192.8017*0.9799+ 165.0169*0.0102+745*0.00988)
= 197.988 KJ/kmole
Heat output=195.0492*1179.581
=230076.4 KJ/hr
Heat carried away by air=heat inputheat output
= 2917759230076.4 =2687683 KJ/hr
(m*cp*T)dry air=2687683 KJ/hr
Cpair=1.009 KJ/kgC, T=2620=6C
M=2687683/(1.009*6)= 443951.6 kg
Air
Qout=2687683 kJ/h
PRILLING
TOWER
Feed
Qin=2917759 kJ/h
Air
Qout=230076.4 kJ/h
Product
Figure 16: Heat flow across Prilling Tower

Chapter 5
Designing of Equipments
5.1 REACTOR
2NH3+CO2 NH2CONH2+H2O (main reaction)
Let Ca= NH3, Cb= CO2, Cs= Urea, Cd = water
Density of liquid NH3 at 40C = 618 kg/m3

Density of CO2 gas at 40C =277.38 kg/m3
(density =P*Mwt/R*T, P=162 atm)
Density of carbamate=1600 kg/m3
So, NH3 flowing into the reactor =41077.14/618
=66.46786m3/hr
CO2 flowing into the reactor =53158.65/277.38
=191.6456 m3/hr
Carbamate flowing into the reactor=105927.6/1600

= 66.20475 m3/hr
Total flow rate into the reactor =66.46786+191.6456+66.20475
=322.7663m3/hr

=Cbo 0 /
Where,
= Residence time
rb= rate of the reaction
Cbo= initial concentration of the limiting reactant
CO2 is the limiting reactant= Cb, xb=0.65
b=(21/3)=1/3
rb=K1*Ca*Cb K2Cs*Cd
Ca=Cao xb*Cbo
Cb=Cbo(1xb)/(1+b*xb)
Cs=xb*Cbo, Cd=xb*Cbo
rb=K1* Cbo2(Cao/Cboxb)(1 xb)/(1+1/3 *xb)K2* Cbo2*xb2

Cao=7.322205 kmol/m3, Cbo=3.743114 kmol/m3
k1& k2 from Arrhenius equation k=ko*exp(Ea/RT)

For k1 : Ea1=139500J/mol , ko1=2.07 *1010 1/s
For k2 : Ea2=98500 J/mol, ko2=9*1011 1/s
At T=180+273=453 K, R=8.314 J/mol K
k1=1.6978E-06, k2=3.944292121 1/s

Now,
0.65
= 1/Cbo0 /(( )/ (1+1/3*xb)-k2*xb2

Using Simpson's rule to solve the above equation we get
=22.30223 min = 0.371704hr
Volume of reactor (V) =*Vo
Volume of reactor=0.371704*322.7663= 119.9735m3
Assuming L/D= 6
V=/4 D2*6*D = 3/2 D3
D=2.942308 m, L=17.65385 m
5.2 CARBAMATE CONDENSER
Design Procedure
Step 1
Thermo-physical properties of Water at 86.45 C
Specific heat (Cp) = 4.2 KJ/kg C

Thermal conductivity (k) = 0.746 W/m C
Density = 966 kg/m3
Viscosity () = 3.2*10-4 Pa. sec
Thermo-physical properties of Carbamate at 185 C
Specific heat (Cp) =2.596 KJ/kg C

Thermal conductivity (k) = 0.531 W/m C
Density =1600 kg/m3
Viscosity () = 5*10-4 Pa. sec
Step 2
Water Flow Rate
Mass flow rate of carbamate = 105927.6 kg/hr =29.42433 kg/sec
Q =m *, of carbamate = 210 KJ/kg
Q = 29.42433 * 210= 6179.11 KJ/sec
Q =m*cp*T + m (for water), m= 6179.11/(4.2*(147.925)+2120.8)
M= 2.343 kg/s
Step 3
Log mean temperature difference Tm
T1=T2 =185 C,
t1=25 C
t2=147.9 C
Tlm = ((T1t2)(T2t1))/ln((T1t2)/ (T2t1))
Tlm =((185147.9)(18525))/ln((185147.9)/ (18525))
Tlm =84.088 C
R= (T1-T2)/(t2-t1), S= (t2-t1)/(T1-t1)
Ft =1 (from graph)
Tm=Tlm* Ft
Tm=84.088*1= 84.088 C
Step 4
Overall heat transfer coefficient assuming
Assuming Uo= 500 W/m2 C
Step 5
Total area and number of tubes
A=Q*1000/Uo*Tm
A= (6179.11*1000)/(500*84.088)= 146.967 m2
Assumption: do= 20 mm, di= 16 mm, L= 4.88 m
Area of one tube =* do* L = * 20*10-3 * 4.88 =0.306464 m2
Number of tubes (Nt)= total area/area of one tube = 146.967/0.306464
=480
Step 6
Shell side diameter
For a triangular pitch (1 shell pass and 4 tube passes)
Pt =1.25 do, n=2.28, k= 0.175
Db= do*(Nt/k)1/n, Db= 20*(480/0.175)1/2.285 = 639.31 mm
From split ring floating head
C=61, Ds= Db+ C, Ds=700.3138 mm
Where
Pt = tube pitch
Db= Bundle diameter
C = Clearance
Ds= Shell diameter
Step 7
Tube side heat transfer coefficient (hi)
Tmean = 25+147.9/2 = 86.45 C

Tube cross-sectional area, A=/4 *di2
Tubes per pass=Nt/Np
Np=No. of tube passes
Total flow area, At =/4 *(16*0.001)2 *480/4 =0.024115 m2
Mass velocity, Gt =Wt/At, Gt= 2.343/0.024115= 97.17648 kg/m2sec
Linear velocity, Ut =Gt/
=97.17648 /966=0.100597 m/s
hi =4200(1.35+0.02 t mean)Ut0.8/di0.2
=1182.775 W/m2 C
Step 8
Shell side heat transfer coefficient (ho)
Area of shell, As=(ptdo)/pt*lb*Ds, pt=1.25* do, lb= Ds/5
Where,
pt= tube pitch
lb= Baffle spacing
As=0.019618 m2
Mass velocity, Gs=Ws/As, Gs=29.42433/0.019618
=1499.89 kg/m2sec
Equivalent diameter, De=1.1/do (pt20.917 do2)
=1.1/20*(2520.917*202) =14.201 mm
Re=Gs*de/= 42600.05
Pr= cp */k = 2.596*1000*5*10-4/0.531 =2.444
jh =0.0028
ho*de/k=jh*Re*Pr0.33, ho=5990.226 W/m2 C
Step 9
Dirt coefficients (Ref: Coulson and Richardson, Chemical Engg vol 6)
hid= 5000 W/m2 C
hod=5000 W/m2 C
Step 10
Calculated overall heat transfer coefficients (Uo)
1/Uo =1/ho+1/hod + do*ln(do/di))/2*kw+(1/hi+1/hid)*do/di
kw= Thermal conductivity of MOC= 50 W/m C
1/Uo=0.001718Uo =518.9354 W/m2 C
UcaL > Uassume
Step 11
Tube side pressure drop
For Re=4858.824, jf=5.9*10-3
Pt= Np*(8*jf*(L/di)+2.5)**ut2/2
Pt= 4(8*5.9*10-3*(4.88*1000/16) +2.5)* 966*(0.100597)2/2
Pt =330.3384 Pa =0.3303384 KPa
Step 12
Shell side pressure drop
For Re=42600.05, jf=4*10-2
Ps=8*jf* (L/LB)*(Ds/de)*(*us2/2)
Ps=8*4*102*(4.88/0.140063)*(700.3138/14.201)*(1600*(0.937)2/2)
Ps=386539 Pa =386.539 kPa
This will give overall coefficient of 511 W/m2 C which is till above the
assumed value of 500 W/m2 C.
5.3 Low Pressure Decomposer
Design Calculation
Density of urea=1230 kg/m3

Density of biuret=1467 kg/m3
Density of water= 1000 kg/m3
Density of liquid (l) =(0.7611*1230+0.00776*1467+0.231*1000)
=1178.696 kg/m3
Density of NH3(gas) = P*Mwt/R*T=(4.5*17)/(0.082*353)
=2.64kg/m3
Density of CO2(gas) = P*Mwt/R*T=(4.5*44)/(0.082*353)=6.8 kg/m3
Density of carbamate = P*Mwt/R*T=4.5*78/(0.082*353)
=12.126 kg/m3
Density of gases(v)=2.64+6.8+12.126=21.526 kg/m3
Mass flow rate of gases=4531.755 kg/hr
Qv = mass flow rate of gases/ density of gases (v)
=4531.755/21.526=75.854 m3/hr
=0.0210 m3/sec
Mass flow rate of liquid=89409.39 kg/hr
Ql=89409.39 /1178.696 =210.524 m3/hr =0.0584 m3/sec
Ut = 0.07*(v-l)/v)1/2
=0.07*(1178.69621.526/21.526)1/2
=0.513 m/sec
Without demister
Uv=0.15 ut , Uv=0.0769 m/sec
Dv=(4*Qv/* Uv)=0.983 m
A=Qv/uv= 0.0210/0.0769=0.7596 m2
Setting time=10 min=600 sec
Volume held in the vessel=600* 0.0584=35.087 m3
Liquid height (HL)=V/A=35.087/ 0.7596=16.643 m
Feed height (Hf)=0.5* Dv=0.491 m
Vapor or gas height(Hv)= Dv=0.983 m
Total height=0.983 + 0.491+16.643=18.8711 m
Wall thickness of vessel
T=P*Di/2*J*f P
Where
P: design pressure
D: diameter of vessel
J: welding joint factor
F: design stress
Operating pressure (P) =4.5 atm
D=938 mm
Design pressure (Pd) =1.2*P=5.472 bar=0.5472 N/mm2
F=125 N/mm2
T= (0.5472 *983)/(2*125*10.5472) =2.157 mm
5.4 PRILLING TOWER
Urea physical properties:

To=132.6 (To= melting point)
Hf =224457 J/kg (Hf = heat of fusion)
l=1230 kg/m3 (l= melt density)
s=1335 kg/m3 (s= Solid density)
Cp (l)=2098 J/kg. k (melt specific heat)
Cp (s)=1748 J/kg. k (solid specific heat)
K(l)=0.83 w/m. k (melt thermal conductivity)
K(s)=1.19 w/m. k (solid thermal conductivity)
Viscosity( )= 2.16*10-3Pa.sec
Air physical properties

Density(g)=1.168 kg/m3
Viscosity =18.48*10-6Pa.sec
Cp air=1.009 KJ/kg C
Heat carried away by air =heat inputheat output
= 2917759230076.4
=2687683 KJ/hr
(m*cp*T)dry air=2687683 KJ/hr
Cpair=1.009 KJ/kg C, T=2620=6 C
M=2687683/(1.009*6)= 443951.6 kg/hr
Tower diameter
Volumetric flow rate=380095.548 m3/hr= 105.5821 m3/sec
Assuming an air superficial velocity=1.2 m/sec
A=Q/u = 105.5821/1.2=87.985 m2
D=(87.985 *4/3.14)0.5=10.586 m
Absolute velocity
Dp=1.5*10-3m (Dp: particle diameter)

Assume ur=6.3 m/s (ur:Relative velocity)
Re = dp*ur*g/g
Re =1.5*10-3*6.3*1.168/18.48*10-6 =597
Cw=0.65 (Cw: resistance coefficient(falling particle))
/6 *dp3*(sg)g=cw*/4*dp2*1/2*g*ut
LHS=/6*(1.5*10-3)3*(13351.168) =2.31112*10-5
RHS= 0.65*/4*1/2*1.168*6.3 =2.66109*10-5
LHS=RHS, the assumption ur=6.3 m/sec is correct
Ua=ursuperficial velocity from new diameter (ua: absolute velocity)
Ua=6.31.156=5.144 m/s
Heat transfer coefficient

Re =597, Pr=g*cp/k ,Pr=18.48*10-6*1009/0.02606=0.7155
Nu =2+0.552 Re 0.5 Pr 0.33=14.07952
Nu=ho*dp/k , ho=244.6082 W/m2k
Solidification time
Average air temperature =(20+26/2)=23 C

Ph=Hf + cp(l)*(Tf To)/cp(s)*(ToTc) (ph= phase transfer number)
Tf =135 C (Tf : melt temperature)

To=132.6 C (To: melting point)
Tc=23 C (Tc: average air temperature)
Ph=224457+2098*(135132.6)/1748*(132.623)
=1.198
Bi=ho*dp/2*k(s) , Bi=0.154164 (Bi: Biot number)
Fo=ph(1/6+1/3*Bi)=2.7922 (Fo: Fourier number)
-7
A=k(s)*/cp(s)*s =1.19/1748*1335=5.099*10 (A: thermal diffusivity)
Ts1=dp*Fo/4*A =1.5*10-3*3.132/4*5.099*10-7
=3.08 sec (ts1= time forsolidification)
e/e,min=1.15
Corrected solidification time
Ts2=(e/e,min)* Ts1=1.15*3.08=3.542 sec
Tower height for solidification=3.542*5.144=18.220 m
Prill cooling time

R=dp/2 =1.5*10-3/2=7.5*10-4m (R: sphere radius)
1/ho2*R =1/7.5*10-4*(244.6082)2=7267.859 k/w
2(RR/2)/k(s)*R2= 2*(7.5*10-47.5*10-4/2)/1.19*(7.5*10-4)2=1120.448
(1/kc)*R2=8388.307+211.93=7267.859+211.93=8388.307
kc=211.93 W/m2k
Cooling time tc=s*dp*cp(s)/6*kc ln(ToTc/TsTc)
Tc =1335*1.5*10-3*1748/6*211.93 *ln(132.623/6023)=1.494 sec
Prill cooling height=1.494*5.144=7.688 m
Total height=7.688+18.22=25.908 m.
Chapter 6
Cost Analysis
6.1 Introduction
Cost analysis is very important aspect of chemical industries. Different types
of costs are involved in designing of a chemical plant and it is out of scope at
this time to consider all the factors. This project involves an approximate
value of capital and working investment.
6.2 Types of Costs

Types of Costs Involved In Manufacturing Process
1. Total capital investment
a. Fixed capital investment (manufacturing and non-manufacturing)
b. Working capital
2. Operating costs (total production cost)
a. Direct expenses: variable and fixed charges
b. Indirect expenses
6.2.1 Total cost of equipments
Table 5: Cost of various equipments
Name of No. of Estimated cost of Total Cost

Equipment Equipment Equipment ()
()
Reactor 1 4355000 4355000
Medium 1 938000 938000
Pressure
Decomposer
Low Pressure 1 3015000 3015000
Decomposer
CO2 1 11390000 11390000
Compressor
Vacuum 1 10050000 10050000
Evaporator
Prilling 1 36557679 36557679
Tower
Ammonia 1 422234 422234
Pump
Conveying 4 26800 107200
System
Stripper 1 8085828 8085828
Pumps 2 469000 938000
Total 75858941
6.2.2 Total capital investment
1. Fixed capital investment
a. Direct cost
Table 6: Direct cost
Item % Purchased Equipment Total Cost

Cost ()
Equipment cost 100 75858941
Installation 25 18964735.25
Instrumentation 10 7585894.1
and control
Piping 25 18964735.25
Electrification 20 15171788.2
Building 30 22757682.3
Service facilities 40 30343576.4
Land requisition 4 3034357.64
Total 192681710.1
b. Indirect Cost
Table 7: Indirect cost
Item % purchased equipment Total Cost

cost
()
Engineering 10 7585894.1
and
supervision
Construction 10 7585894.1
Contactor 5 3792947.05
Contingency 5 3792947.05
Total 22757682.3
Fixed capital investment (FCI)

FCI=DC+IC =192681710.1+22757682.3
=215439392.4
b) Working capital investment (WCI)
=15% of FCI= 0.15*215439392.4=32315908.86
Total capital investment
FCI+WCI=215439392.4+32315908.86
=247755301.3
Fixed charges
1. Deprecation
=10% of FCI=0.1*215439392.4=21543939.24
2. Local taxes
=1.5% of FCI=0.015*215439392.4=3231590.886
3. Insurance
=1% of FCI =0.01*215439392.4=2154393.924
Fixed charges= 21543939.24+3231590.886+2154393.924
=46319470.05
Chapter 7
Environmental Consideration
7.1. EMISSION IN LAND
Under the National Pollutant Inventory (NPI), three ways can be accomplish
to emit the product to the land:
Discharges of substances to sewer or tailings dam.
Deposit of substances to landfill.
Removal of substances from a facility for destruction, treatment,
recycling, reprocessing, recovery, or purification.
Emissions of substances to land on-site include solid wastes, slurries, and

sediments. Emissions arising from spills, leaks, and storage and distribution
of materials containing listed substances may also occur to land. These
emission sources can be broadly categorized as:
surface impoundments of liquids and slurries
Unintentional leaks and spills.
7.2. EMISSION IN AIR
There are two categories of air emission which is either fugitive or point
source emissions. The fugitive type of emission do not released through a
vent or stack. Examples of fugitive emissions include dust from stockpiles,
volatilization of vapour from vats, open vessels, or spills and materials
handling. Emissions emanating from ridgeline roof-vents, louvres, and open
doors of a building as well as equipment leaks, leaks from valves and flanges
is one of fugitive emission. While for point source emission is emissions that
exhausted into a vent or stack and emitted through a single point source into
the atmosphere.
In production of urea, when ammonia is mixed with oxygen, it burns with a
pale yellowish-green flame. Ammonia is decomposed into its constituent
element at high pressure and with the presence of catalyst. The process where
chlorine is passed into ammonia, forming nitrogen and hydrogen chloride
caused the ignition to occur. The highly explosive nitrogen trichloride (NCl3)
is formed if there is excess chlorine present.
In the absence of a catalyst (such as platinum gauze), the combustion of
ammonia is quite difficult as the temperature of the flame is usually lower
than the ignition temperature of the ammonia-air mixture. The flammable
range of ammonia in air is 1625%.
7.3. EMISSION IN WATER
Ammonia is miscible with water. In a basic aqueous solution of ammonia, it

can be expelled by boiling. The maximum concentration of ammonia in
saturated water solution has a density of 0.880 g/cm3 and is often known as
'.880 ammonia'. Ammonia does not burn readily or sustain combustion except
under narrow fuel-to-air mixtures of 1525% air.
Emissions of substances to water can be categorized as discharges to:
Surface waters such as lakes, rivers, dams, and estuaries
Coastal or marine waters
Stormwater.
7.4. WASTE MANAGEMENT
Waste management is the process of collection, transport, processing or

disposal, managing and monitoring of waste materials. It is usually relates to
materials produced by human activity, and the process is generally
undertaken to reduce their effect on health, environment or aesthetics. Waste
management is a distinct practice from resource recovery which focuses on
delaying the rate of consumption of natural resources. The waste materials
whether solid, liquid, gaseous or radioactive are fall within the remit of waste
management.
The practices of waste management can be differed for develop and
developing nations, for urban and rural areas and for residential and industrial
producers. Management of non-hazardous waste residential and institutional
waste in metropolitan areas is usually the responsibility of local government
authorities, while management for non-hazardous commercial
7.5. SMELL
Ammonia is a colourless gas with a characteristic pungent smell.
7.6. NOISE
Noise pollution is the disturbing or excessive noise that may harm the activity
or balance of human or animal life. There are two types in describing noise
which is indoor and outdoor noise. The source of most outdoor noise
worldwide is mainly caused by machines and transportation systems, motor
vehicles, aircraft, and trains. While for Indoor noise is caused by machines,
building activities, music performances, and especially in some workplaces.
In our designed plant, the noise pollution involve comes from pump, heater,
cooler, liquid-liquid extraction, absorber, separator, conversion reactor and
distillation column. Increases in plant size and the advent of a single stream
plant have inevitably led to equipment size being increased and this, together
with the use of higher fluid velocities aimed at minimizing capital cost, has
produced noise problems of a scale not seen on older plant designed to more
conservative criteria. The impacts of noise are permanent hearing loss, a rise
in blood pressure, and increases in stress and also can cause death to human
and also to animal.
7.7. VISUAL IMPACT
There are three step that play the main role in this aspect thats are
Reduction
Remediation
Compensation
It is to demonstrate how significant environmental effects have been avoided,
reduced or remediated. That means landscape must be an integral part of the
project design process, with the plant extent, form and design emerging from
locality of that plant development area.
7.7.1. Matching the local landscape
Restoration design should also be considered at the earliest stage. There are
an enormous variety of options which can be considered as part of a
restoration scheme, which will be agreed between the operator, the mineral
product association (MPA) and the local communities and interest groups. It
will need to fit in with other development plans as part of the overall Spatial
Plan. For example there may be a need for residential housing or an industrial
estate. Restoration to include some aspect of public amenity is possible, and
most schemes now contain elements of habitat conservation or creation, to
enable Local Authorities to fulfill some of the objectives in their Biodiversity
Action Plans. In rural setting the most successful restoration schemes are
those that look to be part of the local landscape
7.7.2. Mitigation Strategies
Landscape measures that may be used under a number of different strategies

are outlined below
7.7.3. Screening
The area that being develop, is a new area, it will be estimate that the
residence area will increase, especially in the radius of plant area. This is
because of the job opportunities offered. Beside that their might other plant
will be develop.
7.8. THE ENVIRONMENTAL FRIENDLINESS OF THE PRODUCT
Refer to the air pollution Index (API) scale between 0-50 is good. 51-100 is
moderate. 101-200 in scale is unhealthy meaning that human being should be
prevented from going outside if not an emergency case. Scale 201-300 is very
unhealthy. This situation should be prevented by staying at home and drinks a
lot of water. Scale 301 and above hazardous. If this situation happens,
emergency degree should be applied throughout the country because this
could fatal to human being.
The production of urea will not affect the air quality, due to less waste
product dispose to the air. There are some waste water dispose but the
quantity is small, and the effect on environmental can be neglect. The effect
on environmental friendly is reduced because of the recycle system is
practiced. If there are equipment leak during the reaction, NH3 and CO2 is
not harmful to environment.
Ammonia contributes significantly to the nutritional needs of terrestrial
organisms by serving as a precursor to food and fertilizers. Ammonia, either
directly or indirectly, is also a building-block for the synthesis of many
pharmaceuticals. Ammonia also used in many commercial cleaning products.
Although in wide use, ammonia is both caustic and hazardous. The various
control technologies available to control ammonia emissions include both
add-on control devices and pollution prevention techniques. There are
pollution prevention techniques that are recommended:
Use natural gas as feedstock for the ammonia plant to minimize air
emission if possible.
To reducing the need for natural gas, use hot process gas from the
secondary reformer to heat to heat the primary reformer tubes.
Direct hydrogen cyanide (HCN) gas in a fuel oil gasification plant to a
combustion unit to prevent its release.
Chapter 8
Summary and Conclusion
8.1. SUMMARY
The process of production of urea from ammonia and carbon dioxide plant is
to be designed for the production of 478500 MTPA (66458.33 kg/hr) of urea
at elevated temperature and pressure, using a snamprogetti process in which
the mixture leaving the reactor is stripped by the carbon dioxide feed. The
feed pure liquid ammonia is at 20oC and 9 bars and pure gaseous carbon
dioxide also 20oC and atmospheric pressure. This reaction takes place in two
stages, in the first, ammonium carbamate is formed in exothermic and the
second the carbamate is dehydrated in endothermic. Both reaction are
reversible and conversion is assumed to be 95%. The waste produce are
water, ammonia and carbon dioxide but ammonia and carbon dioxide are
directly stored into the storage tank to be used as raw material. Only water
flows out. The removal of water is formed to produce granule of urea. The
overall equipments used are reactor, condenser, decomposer, stripper,
evaporator, prilling tower, compressor and storage tank. These flow processes
will produce 0.985 of purity.
8.2. CONCLUSION
For the production of urea at 66458.33 kg/hr, the raw material need is at least
37345.28 kg/hr of ammonia and 48329.189 kg/day of carbon dioxide. This
considered the worst operating condition with only 55% conversion where in
real production, the conversion varies up to 95% where in result higher
production can be obtain with given raw material. Because of this, the
ammonia and carbon dioxide removed is stored and will be reuse in batch
process. The fertilizer granules contain 98.0% urea, 1.0% water and 1.0%
biuret.
The mass and heat balance of whole plant gives result of mass flow rate and
heat going and coming out from each component of plant. Designing of
various equipments reveals the mechanical design of various equipments as
well capacity of equipments.
Cost analysis reveals the purchase cost of various equipments and operating
cost involved in plant. It also includes fixed charges which involve
depreciation, local taxes and insurance.
Overall whole chemical engineering knowledge was applied for the designing
of urea plant.
References
R.K. Agarwal, Y.-K. Li, O.J. Santollani, M.A. Satyro, Modeling of Urea
Production Processes, in: 52nd Canadian Chemical Engineering
Conference, Vancouver, Canada, 2002.
Ref: Hamidipour Mohsen , Modeling the synthesis section of an
industrial urea plant, Chemical Engineering Journal 106 (2005) 249
260.
S. O. Duffuaa, A mathematical optimization model for chemical
production at Saudi Arabia Fertilizer Company, Applied Mathematical
Modelling Volume 15, Issues 1112, NovemberDecember 1991, Pages
652-656
Richardon and Coulson, Chemical Engineering Vol 6
Kern, Process Heat Transfer
Max S. Peters Klaus D. Timmerhaus, Plant design and economics for
chemical engineers
Dutta B K, Heat Transfer
Treybal, Mass transfer operations
Perry, Chemical Engineers Handbook
Wikipedia
NFL, Nangal

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Designing

Nitish Bir (13112022)

Place: Jalandhar Chetan Mahajan (13112051)

Date: Roshan Kudari (13112054)

Date: Dr Ajay Bansal

(Supervisor & Head)

1. Chapter 1: Basics of Urea1

1.1. History of Urea

1.2. Literature Survey

1.3. Commercial Production

Urea is a nitrogen-containing chemical product which is produced in excess of

1.4. Chemical and Physical properties of Urea

Table 1: Chemical Properties of Urea

IUPAC Name Diaminomethanal

Molecular Mass 60.07 g/mol

Melting Point 132 F

Solubility Highly water soluble

Figure 1: Chemical Structure of Urea

1.4.2. PHYSICAL PROPERTIES

Table 2: Physical Properties of Urea

Density 1.33 x 103 kg/m3 , solid

Melting Point 132.7oC decomposes

Solubility in Water 108 g/100 ml (20oC)

Bulk Density 0.8 kg.mg -3

Figure 2: Urea crystals

1.6. APPLICATION OF UREA

1.7 Raw materials of urea manufacturing

Ammonia, NH3, is a comparatively stable, colourless gas at ordinary temperatures, with

NH3 + H2O (NH4)+ + OH-

1.7.2 Carbon Dioxide

2.1 Processes for Urea Production

2.1.1 Once through Process

2.1.2 Conventional Recycle Process

2.1.3 Stamicarbon CO2 stripping process

2.1.4 Snamprogetti Ammonia and self-stripping processes

2.1.5 Isobaric double recycle process

2.1.6 ACES process

2.2 Comparison of Various Processes

Table 3: Comparison of various processes

Figure 3: Flow sheet of Snam Progetti Process

2NH3 + CO2 NH4COONH2 + Heat

a. COMPRESSION OF CARBON DIOXIDE

b. UREA SYNTHESIS AND HIGH PRESSURE RECOVERY

c. UREA PURIFICATION AND LOW PRESSURE RECOVERIES

Medium Pressure Purification and Recovery stage (at 18 atm.)

Low pressure purification and recovery stage (at 4.5 atm.)

d. Urea concentration section:

As it is necessary in order to prill urea to concentrate urea solution up to 99.8 % wt., a

3.1 Data given

Selected capacity 478500 MTPA [5]

3.2 Composition of final products:

Assumption: Overall conversion to urea is assumed to be 95%.

1) CO2+ 2NH3 NH2COONH4

Based on these reactions, we get

Urea produced from reaction 4 = 664.588*(2*60/103)

Assuming 95% conversion of urea

NH3 input to the reactor = 37345.28/0.95 = 39310.82 kg/hr

At reactor's exit (Urea=34%)

Flow rate of stream = 65903.43/0.34= 193833.6176 kg/hr

Figure 4: Mass balance across reactor

There is no chemical reaction taking place in stripper. Only carbamate gets

3.6 MEDIUM PRESSURE DECOMPOSER

NH3=2029.433 kg/hr NH3=1014.716 kg/hr

Figure 6: Mass balance across Medium Pressure Decomposer

Urea produced from reaction 4 = 664.588(260/103)

Component a b10-2 c10-5 d*10-7

Hp=(121.7623 65903.43 +292.703419771.029 ) = 13811646.76 KJ/hr

CP of mixture=XCPi=(6009.3020.0454+ 4801.186 0.0217+

Cp of mixture=Xi Cpi=(4241.150.188454+3348.267 0.089247

Heat input= energy of bottom product of evaporator =mcpT