Introduction:

Chittagong Urea Fertilizer Limited (CUFL) is a Public Sector Enterprise engaged in manufacturing
Nitrogenous Fertilizer, under administrative control of Bangladesh Chemical Industries
Corporation (BCIC), a statutory autonomous corporation under the Government of the People's
Republic of Bangladesh. It is managed by a Company Board constituted by BCIC. The Managing
Director is the Chief Executive Officer (CEO). It is located at Rangadia, Chittagong, on the
Southern Bank of the Karnaphuli River, meets the Bay of Bengal. Total area of land occupied by
the Company at Rangadia is 390.73 acres in addition to 3.77 acres occupied for water intake
installation located at 30 kilometers away up stream at Kalurghat Bridge of Karnaphuli River. The
Government of Bangladesh (GOB) set up this company in 1980 having annual installed capacity
of 5,61,000 MT Urea and 3,30,000 MT Ammonia based on indigenous natural gas as main raw
material and fuel to be piped from Bakhrabad Gas Field, Comilla located at a distance of 20
Kilometers from Chittagong City. Ammonia is produced in Kellogg Process whereas Urea is
produced by utilizing TOKYO, MITSUI TOATSU total Recycle process.
Objectives of the Company are to meet the domestic demand of Nitrogenous fertilizer for
increasing crop production, saving of foreign currency.

Raw materials and products:

Raw materials Products
For ammonia plant: NH3
1. Natural gas
2. Air
3. Steam

For Urea plant: UREA

1. Ammonia
2. Carbon dioxide

For Utility plant:

1.Natural Gas
2. Air
3. Water
Utilities and utility consumption:
Natural Gas 53.000 Nm3/Hr.
Raw Water from River Karnaphuli about 30 1009 MT/hr. (Max)
km upstream
Steam 40 kg/ Cm2G 160 MT/Hr.
Steam 105 Kg/Cm2G 230 MT/Hr.
Electric Power (normal load) 6.5 MW

Process description:
AMMONIA:
Ammonia production process may be divided into three major steps:
1. Preparation of Raw Synthesis Gas:
This section consists of reforming section
(a) Primary Reformer (PRF) and
(b) Secondary Reformer (SRF)
2. Raw Synthesis Gas Purification Section: This section includes
(a) High Temperature Shift Converter (HTS)
(b) Low Temperature Shift Converter (LTS)
(e) Carbon dioxide Removal Section
(d) Methanation Section
3. Synthesis and Refrigeration Section: This section includes:
(a) Ammonia Converter and
(b) Ammonia Liquefaction and Storage Section
DESCRIPTION OF MAJOR UNITS:
Desulphurization:
The natural gas feed stock is preheated and passed over a catalyst bed through which sulphur is
removed. The sulphur may be present in natural gas as organic or as inorganic form. The
inorganic sulphur mainly present as hydrogen sulfide, which reacts with zinc oxide catalyst and
removed from natural gas. To remove organic sulfur from natural gas the gas is passed initially
through Co-Mo catalyst bed, where hydrogenation reaction takes place, and organic sulfur
converted to inorganic sulfur as hydrogen sulfide.
Reaction:
Zno + H2S ZnS+H2
Unsaturated Organic S+ H2 H2S + Saturated Organic Compound
Primary Reformer
Steam is mixed with the natural gas and the combined stream further heated and routed through
tubes in a reforming furnace containing nickel catalyst. Here a reforming reaction occurs in
which methane in the natural gas is predominantly converted into hydrogen, carbon dioxide and
carbon monoxide.
Reaction
CH4 + H20 CO + 3H2
CH +2H20 CO2+4H
Secondary Reformer
The process gas leaving the primary reformer usually contains 5% to 15% methane. The object
of secondary reforming step is to complete the conversion of methane into H. CO, CO, and to
supply the required amount of nitrogen for ammonia synthesis reaction.
Reactions
2H2+ O2 = 2H20
CH + H20 = CO + 3H2
CH4 + 2H20 = Co2 + H2.
The process gas leaving the primary reformer is routed to the secondary reformer, which is a
refractory lined vessel, filled with nickel catalyst. A controlled proportion of air is also
introduced after pre heating into the secondary reformer. In the upper hollow space of the
secondary reformer, a highly exothermic reaction between hydrogen and oxygen takes place
which raising its temperature high enough to virtually complete the conversion of the residual
methane into additional hydrogen, carbon dioxide and carbon monoxide.
Shift Converter
In shift conversion, carbon monoxide formed in the primary and secondary reforming steps is
further reacted in a two-stage process. During this stage the carbon monoxide is almost
completely converted to hydrogen and carbon dioxide by reacting with steam.
Reaction
CO+H2O = H2 + CO2
The reaction is exothermic; therefore it is carried out with two steps with heat removal between
steps. The rate of reaction is more rapid at high temperature, but equilibrium is more favorable at
low temperature. The process gas is first passed over an iron - chromium catalyst followed by
further cooling and heat recovery, and then over a copper -zinc catalyst.
Carbon Dioxide Removal
Carbon dioxide is removed from the process gas by absorption in a solution of Hot Potassium
Carbonate known as Benfield solution. The gas is contacted with the Benfield solution in an
Absorber and leaves at the top. The solution itself is regenerated by reducing pressure, heating in
a stripper column and flushing in a flush drum. The released CO, is either vented to atmosphere
or used as a feedstock in the production of methanol, urea etc.

Reaction: K2CO3 + CO2 +H2O = 2KHCO3 (For Absorption)

DEA: Acts as an activator by lowering vapor pressure of CO2
VO: Acts as a corrosion inhibitor.
Methanator
The gas stream leaving the Absorber consists primarily of hydrogen and nitrogen in addition to
small quantities (ppm) of unabsorbed carbon oxides and unconverted carbon monoxide, Since
these will cause poison the ammonia synthesis catalyst the concentration must be reduced to less
than 10 ppm. In the Methanator the carbon oxide is converted back to methane over a nickel
catalyst in a reaction, which is reversed to that of steam reforming

Reaction:
CO + 3H2 = CH4 + H2O + HEAT
CO2 + 4H2 = CH4 + 2H2O + HEAT
Ammonia Converter
The gas leaving the Methanator (27.5 kg/em G pressure and 40°C temperature) is compressed to
132.5 kg/cmG pressure (called make-up gas), mixed with recycled gas, and sent to the ammonia
synthesis reactor, which is a vessel containing catalyst. The single pass conversion of ammonia is
not more than 25% and the reaction is exothermic. Synthesis gas comes out from converter at
450°C with 17.1% ammonia and passes through waste heat boiler, boiler feed water preheater
and hot exchange (exchanged heat with recycled stream i.e. feed gas) etc to recover energy. To
separate product ammonia from other components in the product stream, further cooling and
chilling is done. Ammonia itself is used as refrigerant in the chiller shell side (product mixture is
passed through the chiller tube side). Ammonia form mist in the product gas mixture which is
separated in a separator at 118 kg/cmG pressure. The separated ammonia is flushed, stored or
sent to urea plant for producing urea. The gas mixture separated from ammonia in ammonia
separator is mixed with make-up gas and recycled to the converter after compressing and
attaining to inlet temperature by exchanging heat with converter outlet gas. Some percent of
recycled gas is purged to maintain the inert level in the synthesis loop. Normally purging is done
before mixing with make-up gas.
Reaction
3H2 + N2 = 2NH3 + HEAT
The rate of ammonia synthesis process depends on
a. Temperature
b. Pressure
c. Space velocity
d. Concentration of Zn, Hg, and NH3 in the feed gas
e. Content of inert impurities
f Activity of the Catalyst
The natural gas received is metered and then divided into in two flows, one as the raw material
and the other as fuel. The raw material gas enters the pre-treatment process where sulfur is
removed. The pretreated gas is mixed with steam and passed through the catalyst- filled tubes of
the primary reformer where steam reacts with the gas to produce hydrogen, carbon monoxide
and carbon dioxide. From the primary reformer the gas flows through a secondary reformer
where it is mixed with air in a quantity required to reform the remaining unconverted
hydrocarbons and provide the required amount of nitrogen to produce ammonia. Leaving the
secondary reformer, the process gas flows through catalyst beds where the remaining steam
reacts with carbon monoxide to produce additional hydrogen and carbon dioxide. The process
gas, consisting of hydrogen, nitrogen, carbon dioxide, methane and argon, in scrubbed with an
activated potassium carbonate solution to remove the carbon dioxide. The remaining carbon
dioxide, and carbon monoxide are removed from the process gas by reconversion to methane by
reaction with hydrogen in the presence of a catalyst. The final synthesis gas contains hydrogen
and nitrogen in the ratio of 3 to 1, which is compressed to about 150 kg/Cm2G and recirculated
through a converter, where the hydrogen and nitrogen react to produce ammonia.
UREA
Raw Materials:
1. Ammonia
2. Carbon dioxide
Product: Urea
Physical Properties of Urea:
Urea is a white crystal, which is not inflammable, non conductive and has the following
properties:
Density (solid, 20°C)
Melting heat (melt point):13.6kJ/mol
Specific heat (melt):126 J/mol/c
Molecular weight: 60.056
Formula: NH2-CO-NH2
The urea plant has 5 sections excluding utility system.
1. Synthesis sections
2. Purification section
3. Concentration and prilling section
4. Recovery section 5. Process condensate treatment section
Chemical reaction:
NH3 + CO2 NH4COONH2 ; ∆H = -28.5 kcal/mol
NH4COONH2 NH2-CO-NH2 + H2O ; ∆H =3.6 kcal/mol

Ammonia and carbon dioxide produced in Ammonia Unit are reacted in the Synthesis Reactor at
a pressure of about 210Kg/Cm2G and temperature, 180-190°C to produce ammonium carbamate
which is subsequently dehydrated to form urea, the reactor effluent solution is composed of urea,
ammonium carbamate, water and free ammonia. The ammonium carbamate is decomposed into
ammonia and carbon dioxide in decomposers operated under successively reduced pressure. The
ammonia and carbon dioxide are then recovered as carbamate solution which is recycled back to
the reactor through mixer where low pressure steam is generated by utilizing the heat of reactions.
The purified urea solution is concentrated in vacuum concentrator and then it is further
concentrated to form molten urea in air swept type Evaporator. The molten urea is sprayed from
the top of Prillng Tower to form prilled urea. The Prills are finally conveyed as product urea to
either bulk storage or bagging unit.

UTILITY PLANT
Raw Materials:
1. Natural Gas
2. Air
3. Water
Product:
1. Steam (HP, MP, LP)
2. Power
3. Natural Gas (Process, Fucl, Flare Stack, Kitchen)
4. Boiler Feed Water
5. Cooling Water (Utility, Main)
6. Drinking Water
7. Service Water
8. Plant Air
9. Instrument Air
10. Nitrogen

Major Units:
1. Clarifier
2. Sand filter
3. Cooling Tower
4. Demineralization Unit:
• Carbon Filter
• Cation Exchanger
• Degasifier
• Anion Exchanger
• Mixed Bed Polisher
5. Boiler
6.Instrument Air and Plant Air Supply
7.Nitrogen Production Plant
8.Waste Water Treatment Section
PFD:

Fig: PFD of ammonia and urea plant of CUFL

Storage system:
Due to corrosive nature, special stainless steels are used in the construction of storage tank. The
prill size is maintained between ( 8+ to 20 - ). The allowable vessel draft for full load draft is 8.5
M where for dead weight tonnage is about 15,000 MT. Bagging capacity is about 8 sewing machine
each of 30 MT/H Capacity. Loading capacity for export bulk is 3,500 MT/D and for export bagged
2,500 MT/D.

Fire and safety:

Industrial safety is important as it safeguards human life, especially in high risk industries like
ammonia-urea plant operating under high pressure and temperature. The first step in any risk
assessment procedure for any industrial safety involves hazard identification. However, hazard
identification is easier said than done. In CUFL, hazard identification and safety evaluation are
present which ensures the safety of the workers. A modern fire protection system is there to
overcome any unexpected situation. But it was quite sad to see that workers or employees were
not using any helmet or apron although facility was available

Discussion:
CUFL is under the control of Bangladesh Chemical Industries Corporation (BCIC).The authorities
were really helpful and encouraged us greatly about visiting at industries. Before going directly to
the main plant they gave us brief description of the process.However, they have small model of
the whole plant in their office, which helped us greatly to identify the equipments of the plant
when we went to the field. But their safety system is not reasonable. When we went to ammonia
plant , the smell of ammonia was spreading everywhere, we could not breath easily, which was
sharmful for us.

Recommendation:
1. The authority should be serious about safety issues.
2. They should use mask and helmet.
3. The environment and the foods of CUFL canteen should be more hygienic.

Reference:
https://bcic.portal.gov.bd/sites/default/files/files/bcic.portal.gov.bd/page/cce52
ec6_77d2_4f59_a272_4fc81985fe98/Annual%20report-CUFL.pdf
https://www.chemicals-technology.com/projects/chittagong-urea/
Industrial Chemistry By B.K Sharma.