Material No.

of Mole Molecular Wight Final Production

Ammonia (NH3) 1 17 UREA
Ammonia (NH3) 2 34 Biuret
Carbon dioxide (CO2) 1 44 Water
Ammnium Carbamate 1 78 Total
Water (H20) 1 18
Urea Reaction_4 2 120
Urea 1 60
Biuret 1 103

Main Reaction:
𝐶𝑂_2+2𝑁𝐻_3→𝑁𝐻_2 𝐶𝑂𝑂𝑁𝐻_4 (1)

𝑁𝐻_2 𝐶𝑂𝑂𝑁𝐻_4→𝑁𝐻_2 𝐶𝑂𝑁𝐻_2+𝐻_2 𝑂

(2)
𝐶𝑜_2+2𝑁𝐻_3→𝑁𝐻_2 𝐶𝑂𝑁𝐻_2+𝐻_2 𝑂 (𝑂𝑣𝑒𝑟𝑎𝑙𝑙) ( 3)

2𝑁𝐻_2 𝐶𝑂𝑁𝐻_2→𝑁𝐻_2 𝐶𝑂𝑁𝐻𝐶𝑂𝑁𝐻_2+𝑁𝐻_3

(4)
 Material Balance of Urea
Percentage Values (Kg/hr)
98% 55936.0730593607
1% 570.776255707762
1% 570.776255707762
100% 57077.63

Results from reaction (1-2-3-4) Values (Kg/hr)

Urea produced by reaction 4 664.982045484771
urea produced by reaction (2) 56601.0551048455
urea produced by NH3 32073.9312260791
CO2 reacted in reaction (1) 41507.44041022
Assuming 95 % conversion we get 0.95
NH3 actually required 33762.032869557
CO2 actually required 43692.0425370737
Water produced in reaction (2) 16980.3165314537

Matireal Flow Rate (Kg/hr) Concentration

NH3 33762.032869557 44%
CO2 43692.0425370737 56%
Total 77454.0754066307 100%
Annual Production (Tons/Year) Daliy production (Kg/hr)
500000 57077.6255707763 Ton
1
year
At the reactor’s exit Urea 34% 1
Kg/hr day
Flow rete of stream 164517.861939296 1
NH3 reacted in reaction (1) 32073.9312260791 Double chick
NH3 produced in reaction (4) 94.2057897770093
NH3 unreacted 1782.30743325486
CO2 reacted in reaction (1) 41507.44 Double chick
CO2 unreacted 2184.60212685369
Flow rate of carbamate 87063.78653
 Kg
1000
day
365
hours
24
Illustration:

Conversion Factor
Cal/gm © To Kj/Kg ©
4.184

Given:
 Material
NH3
CO2

Material

Carbamate

Solving:

Heat Input = Q =𝑴 ∗𝑪𝒑∗∆𝑻

Material

NH3

CO2

Carbamate

Total Heat Input(Kj/hr)

Illustration:

Heat Input

HR
 𝑯𝒆𝒂𝒕 𝑰𝒏𝒑𝒖𝒕+𝑯𝑹 −𝑯𝒆𝒂𝒕 𝑶𝒖𝒕𝒑𝒖𝒕=𝑨𝒄𝒄𝒖𝒎𝒖𝒍𝒂𝒕𝒊𝒐𝒏 𝑹𝒂𝒕𝒆

Given:

Heat Input
HR
Heat Output

Solving:

Accumulation Rate (Kj/hr)

Illustration:

Assume Cooling at 25 ©, 4.5 Bar

Heat gained by cooling water

𝒎 𝑪𝒑 𝚫𝑻+𝒎 𝝀=𝟗𝟐𝟑𝟒𝟒𝟑𝟓𝟕.𝟗

Given:

ƛ of Steam(Kj/kg)
Cp of Steam(Kj/kg.©)

Solving:

m (Kg/hr)
 Material
NH3
CO2
Carbamate
Total

Heat Input Calculation (Inlet Stream)

Heat Input = Q =𝑴 ∗𝑪𝒑∗∆𝑻

Tempeature Condition
NH3
CO2
Carbamate

Specific heat at 40 ©
 (Cal/gm ©)
0.53
0.22

Specific heat at 180 ©

(Cal/gm ©)

0.62

Calculation (Kj/hr)
(33762 Kg/hr)*(2.217Kj/kg.©)*(40 ©)
2994719.33
(43692 Kg/hr)*(0.9205Kj/kg.©)*(40 ©)
1608706.05
(87064 Kg/hr)*(2.5948Kj/kg.©)*(180 ©)
40653076.9263583

(2994719.33)+(1608706.05)+(40653076.93)
45256502.30

Rat of accumulation Calculation

Autoclave Rector

=
 =

𝒆𝒂𝒕 𝑶𝒖𝒕𝒑𝒖𝒕=𝑨𝒄𝒄𝒖𝒎𝒖𝒍𝒂𝒕𝒊𝒐𝒏 𝑹𝒂𝒕𝒆

Kj/hr
45256502.30
122167068.493151
75079212.8523452

Calculation →
( 45256502.30 Kj/hr)+(122167086.5 Kj/hr)-(75079212.85 Kj/hr)

(Ts=147.9 ©)

92344357.9

2120.6
4.187

(4.187 Kj/kg.©)*(147.9-25 ©)*(2120.6 Kj/kg) →

1091223.225/91994255.8 →
 Autoclave Rector
Flow rate (Kg/hr) Concentration

34%
33762.03 20.52%
43692.04 26.56%
87063.79 52.92%
164517.86

40

180

0©
 Calculation (Kj/Kg ©)
0.53*4.184 2.218
0.22*4.184 0.9205 Material
Urea

80 © NH3

Calculation (Kj/Kg ©) CO2

0.62*4.184 2.594 H2O

Biuret

Carbamate

Heat Output

Accumelation Rate
92344357.9

(147.9-25 ©)
122.9 25

1091223.23

84.62
 Unreacted
𝑵𝑯_𝟑
𝑪𝑶_𝟐
Total

Operation Condition
Temperature
Pressure

Material
Urea
Water (H2O)
Biuret
Carbamate
Total

Illustration:
Tempeature Condition
All mixture

Conversion Factor
Cal/gm © To Kj/Kmol ©
4.184*Mw
4.184

Calculation:
 Specific Heat at 180 ©
(KCal/ gm ©)
0.4828

0.55

0.23

0.4246

0.62

Solving:

Cp (Kj/kmol.©)
M (Kmol/hr)
Cp (Kj/kmol.©)
∆𝑇 (©)

Total Heat Output (Kj/hr)

Illustration:

Conversion Factor
Kcal To Kj
4.184

Given:

HR
 HR

Solving:

Urea formed during reaction

(Kmol /hr)

HR (Kj/hr)

147.9
 Flow rate (Kg/hr)
1782.31
2184.60
3966.91

Values
180©
140 bar

Flow rate (Kg/hr)

55936.07
16980.32
570.78
87063.79
160550.95

Heat Output Calculation(Outlet Stram)

Heat Output= Q =𝑴 ∗𝑪𝒑∗∆𝑻

Tempeature Condition
180

Conversion Factor
Kg/hr To Kmol/hr
Flow rate /Mw
 Specific Heat at 180 ©
Calculation →
0.4828*4.184*60 →

0.55*4.184*17 →

0.23*4.184*44 →

1*4.184*18 →

0.4246*4.184*18 →

0.26*4.184*78 →

Cp= Xi*Cpi (Kj/Kmol.©)

132.34
Heat Output= Q =𝑴 ∗𝑪𝒑∗∆𝑻

132.34
3151.85
132.34
180

Calculation of Heat Output (Kj/hr)

(3151.78 Kmol//hr)*(132.33Kj/kmol.©)*(180 ©)
75079212.8523452

HR Calculation

Conversion Factor
Mg To Kg
1000

Kcal/gm.mol
 -31.32

Calculation [Urea flow rate/Mw (Kmol/hr)] →

(55936 Kg/hr) / (60 Kmol)

Calculation →
(130666.32)*(932.27)
Cocentration%
#REF!
#REF!

Concentration
34.84%
10.58%
0.36%
54.23%
180 ©
(Kj/ Kmol ©) Mole Fraction
121.20 0.296

39.12 0.033

42.34 0.016

75.31 0.299

183 0.002

202.34 0.354
Total 1

Calculation → Kj/Kmol
(31.23 Kcal/gm.mol)*(4.184 Kj/kcal)*(1000 gm/ kg) -131042.88

932.27

122167068.493151
Stamicarbon autoclave reactor is a critical component of the urea pr
Its high-pressure it could achiev a high conversion of ammonia and
The reactor is equipped with cooling coils to remove excess heat an
temperature.
The Stamicarbon autoclave reactor is known for its high efficiency
also relatively easy to maintain and repair.
Calculation (flow rate/Mw) → Flow rate (Kmol/hr)

55936.07/60 → 932.268

1782.30/34 → 104.842

2184.60/44 → 49.650

16980.31/18 → 943.351

570.77/103 → 5.542

1116.202
87063.78/78 →
Total 3151.854
 l component of the urea production process. with
onversion of ammonia and carbon dioxide to urea.
s to remove excess heat and maintain the desired

own for its high efficiency and reliability, . It is

r.
 Matireal
Urea
Water
Carbamate
Biuret
Total

Matireal
𝑵𝑯_𝟑
𝑪𝑶_𝟐
Total

Heat Input Calculation (Inlet Stream)

Total Heat Input (Kj/hr)

 Column2 Concentration
55936.0730593607 34.84%
16980.3165314537 10.58%
87063.7865326656 54.23%
570.776255707762 0.36%
160550.952379188 100%

Flow rate (Kg/hr) Column1 Concentration

1782.30743325486 1.11%
2184.60212685369 1.36%
3966.90956010854 100%

t Input Calculation (Inlet Stream)

75079212.85
 Sripper M

Material
Carbamate

Operation Condition
Sripper

Temperature
Pressure

Matireal
Urea
Water
Biuret
NH3
CO2
Total

Illustration:
Tempeature Condition
All mixture

Conversion Factor
KCal/gm ©To Kj/Kmol ©
4.184*Mw
4.184

Calculation:

Outlet Liquid Stram Calculation:

 Material
NH3
CO2
Urea
H2O
Biuret

Cp (Kj/Kmol.©)

Solving:

Heat Output= Q =𝑴 ∗𝑪𝒑∗∆T

M (Kmol/hr)
Cp (Kj/kmol.©)
∆𝑇 ( © )

Calculation of Heat Output (Kj/hr)

Heat Output Carried by Liquid Stream

Outlet Vapor Stram

(Ammonium carbamate) Calculation:

Given:

" Heat Output= Q =" 𝑴 ∗𝑪𝒑∗∆𝑻

Kj/kg
ƛ for Carbamate
Calculation:

Material
Ammonium carbamate

Solving:

𝑯𝒆𝒂𝒕 𝑶𝒖𝒕𝒑𝒖𝒕=𝑸=𝒎𝟐 𝑪𝒑 𝚫𝑻+𝒎𝟏 𝝀

m1 (Kg/hr)
m2 (Kmol/hr)
Cp (Kj/kmol.©)
∆𝑇 ( © )
ƛ for Carbamate (Kj/kg)

Calculation of Heat Output (Kj/hr)

Heat Output Carried by Vapor Stream
(Ammonium carbamate)

Given:

Steam
ƛ for Steam ( Kj/kg)

Solving:

𝑯𝒆𝒂𝒕 𝑺𝒖𝒑𝒑𝒍𝒊𝒆𝒅 𝒃𝒚 𝑺𝒕𝒆𝒂𝒎∗ƛ=𝑯𝒆𝒂𝒕 𝑶𝒖𝒕𝒑𝒖𝒕−𝑯𝒆𝒂𝒕 𝑰𝒏𝒑𝒖𝒕

𝑯𝒆𝒂𝒕 𝑺𝒖𝒑𝒑𝒍𝒊𝒆𝒅 𝒃𝒚 𝑺𝒕𝒆𝒂𝒎∗ƛ=𝑯𝒆𝒂𝒕 𝑶𝒖𝒕𝒑𝒖𝒕−𝑯𝒆𝒂𝒕 𝑰𝒏𝒑𝒖𝒕

Heat Input (Kj/hr)

Heat Output by Liquid (Kj/hr)
Heat Output by Vapor (Kj/hr)
ƛ for Steam (Kj/kg)

m (Kg/hr)
 Sripper Mass / Energy Balance

Flow rate (Kg/hr)

87063.7865326656 Recycle to Reactor

Values
185©
20 bar

Flow rate (Kg/hr) Concentration

55936.0730593607 72.22%
16980.3165314537 21.92%
570.776255707762 0.74%
1782.30743325486 2.30%
2184.60212685369 2.82%
77454.0754066307 100.00%

Heat Output Calculation (Outlet Liqiud Stream)

Heat Output= Q =𝑴 ∗𝑪𝒑∗∆𝑻

Tempeature Condition
185

Conversion Factor
Kg/hr To Kmol/hr
Flow rate /Mw
 Specific Heat at 185 C
(Cal/ gm ©) (Kj/ Kmol ©)
0.24 44.22
0.58 41.31
0.5385 135.30
1 75.37
0.4246 184
Total

Xi*Cpi
100.68

2035.65
100.68
185

alculation of Heat Output (Kj/hr)

(3151.78 Kmol//hr)*(132.33Kj/kmol.©)*(180 ©)
37914246.3094865

Heat Output Calculation (Outlet Vapor Stream)

Kj/kg
210
 Specific Heat at 185 ©
(Cal/ gm ©) (Kj/ Kmol ©)
0.62 202.34

𝒎𝟏 𝝀

87063.79
1116.20239144443
202.34
185
210

(1116.2Kmol//hr)*(202.34Kj/kmol.©)*(185 ©)
+(87063.79 Kg/hr)(210 Kj/kg)
60065724.2350613

Calculation of m

at (25), (Ts=221.8 v)
1855.3

𝒆𝒂𝒕 𝑶𝒖𝒕𝒑𝒖𝒕−𝑯𝒆𝒂𝒕 𝑰𝒏𝒑𝒖𝒕

𝒆𝒂𝒕 𝑶𝒖𝒕𝒑𝒖𝒕−𝑯𝒆𝒂𝒕 𝑰𝒏𝒑𝒖𝒕

75079212.85
37914246.3094865
60065724.24
1855.3

[(60065724.24Kj/hr)+(3791426.31 Kj/hr)]
-[75079212.85 Kj/hr]/1855.3
97939503.1199521
Reactor

Since, no reaction takes place in the stripper and only carbamate gets recycled bac
reactor. Therefore, the amount of ammonia, carbon-dioxide ,water and biuret in th
stream of stripper will be same as it was in the inlet stream.
Mole Fraction Flow rate (Kmol/hr)
0.05 104.842
0.024 49.650
0.46 932.268
0.463 943.351
0.003 5.542
1 2035.652
Flow rate (Kmol/hr)
1116.20239144443
mate gets recycled back to the
,water and biuret in the outlet
Carbamate Vapor

Liquid Carbamate
87063.79
Kg/hr

𝒎𝒗 ∗ƛ𝒗=𝒎𝒔 𝑪𝒑 (𝑻𝒔−𝟐𝟓)+𝒎𝒔 ∗ƛ𝒔

𝑹𝒂𝒕𝒆 𝒐𝒇 𝑨𝒄𝒄𝒖𝒎𝒆𝒍𝒂𝒕𝒊𝒐𝒏= 𝒎𝒗 ∗ƛ𝒗

given:

𝒎𝒗 (Kg/hr)
ƛ𝒗 (Kj/Kg)
Cp of Steam
Ts (©)
ƛs ( Kj/kg)
T©

Solving:

𝒎𝒗 (Kg/hr)
 Water
Temperutre (©) 25
Carbamate
Condencer Steam at 4.5 bar
Ts (©) 147.9

Calculation of ms

ƛ𝒗=𝒎𝒔 𝑪𝒑 (𝑻𝒔−𝟐𝟓)+𝒎𝒔 ∗ƛ𝒔

𝒐𝒇 𝑨𝒄𝒄𝒖𝒎𝒆𝒍𝒂𝒕𝒊𝒐𝒏= 𝒎𝒗 ∗ƛ𝒗

87063.79
210
4.187
147.9
2120.6
25

(87063.79 Kg/hr)*(210 Kj/hr)

/(4.187 Kj/kg)*(147.9-25 ©)+2120.6
536670204.340522
 M.P Separator

Material flow rate (Kg/hr) Concentration

Urea 55936.073059361 72.22%

M.P Separator
Water 16980.316531454 21.92%
Biuret 570.77625570776 0.74%
𝑵𝑯_𝟑 1782.3074332549 2.30%
𝑪𝑶_𝟐 2184.6021268537 2.82%
Total 77454.075406631 100.00%
 M.P Separator Mass Balance

Material Flow rate (Kg/hr) Concentration

𝑵𝑯_𝟑 891.15371662743 44.93%
𝑪𝑶_𝟐 1092.3010634268 55.07%
Total 1983.4547800543 100%

Stamicarbon medium press

ammonia and carbon dioxid
M.P Separator

Operation Condition Values The MP stripper is a vertica

Temperature 140© the MP stripper and flows d
Pressure 20 bar flows down the trays, it is h
and carbon dioxide to evapo
dioxide are then removed fr
The urea solution exits the b
downstream unit for further

Material Flow rate (Kg/hr) Concentration

Urea 55936.073059361 74%
Water 16980.316531454 22%
Biuret 570.77625570776 0.76%
𝑵𝑯 891.15371662743 1.18%
_𝟑
𝑪𝑶_𝟐 1092.3010634268 1.45%
Total 75470.620626576 100%
Stamicarbon medium pressure (MP) stripper, It is used to remove excess
ammonia and carbon dioxide from the urea.
The MP stripper is a vertical vessel where urea solution is fed into the top of
the MP stripper and flows down through a series of trays. As the solution
flows down the trays, it is heated by steam. The heat causes the ammonia
and carbon dioxide to evaporate. The evaporated ammonia and carbon
dioxide are then removed from the top of the stripper.
The urea solution exits the bottom of the MP stripper and is sent to a
downstream unit for further processing.
 L.P Separator Mass Balance

Material Flow rate (Kg/hr) Concentration

Urea 55936.073059361 74%

L.P Separotor
Water 16980.316531454 22%
Biuret 570.77625570776 0.76%
𝑵𝑯_𝟑 891.15371662743 1.18%
𝑪𝑶_𝟐 1092.3010634268 1.45%
Total 75470.620626576 100%
Separator Mass Balance

Material Flow rate (Kg/hr) Concentration

𝑵𝑯_𝟑 891.15371662743 44.93%
𝑪𝑶_𝟐 1092.3010634268 55%
Total 1983.4547800543 100%

Stamicarbon medium pressure (LP) strippe

ammonia and carbon dioxide from the urea
Operation Condition Values
The LP stripper is a vertical vessel where u
Temperature 130© the MP stripper and flows down through a s
Pressure 2 bar flows down the trays, it is heated by steam.
and carbon dioxide to evaporate. The evapo
dioxide are then removed from the top of th
The urea solution exits the bottom of the M
downstream unit for further processing.

Material Flow rate (Kg/hr) Concentration

Urea 55936.073059361 76.12%
Water 16980.316531454 23%
Biuret 570.77625570776 0.78%
Total 73487.165846522 100%
 m pressure (LP) stripper, It is used to remove excess
on dioxide from the urea.
vertical vessel where urea solution is fed into the top of
d flows down through a series of trays. As the solution
ys, it is heated by steam. The heat causes the ammonia
to evaporate. The evaporated ammonia and carbon
moved from the top of the stripper.
xits the bottom of the MP stripper and is sent to a
r further processing.
 Evaporator M

Material Flow rate (Kg/hr) Concentration

Urea 55936.073059361 76.12%

Evaporator
Water 16980.316531454 23%
Biuret 570.77625570776 1%
Total 73487.165846522 100%
 Evaporator Mass Balance

Material Flow rate (Kg/hr) Concentration

Water 16344.662857364 96%

The evaporator used to concentrate the urea solution f

76% to 96-97.8% by weight,
Operation Condition Values
120©
The evaporator in the Stamicarbon urea process is typ
Temperature
pass evaporator. In this type of evaporator, the obtaine
Pressure 2 bar
upwards through the tubes of a vertical bundle of tube
The solution is going dowenwards through the tubes o
tubes.

The heat required for the evaporation being supplied b

low-pressure steam .

Material Flow rate (Kg/hr) Concentration

Urea 55936.073059361 97.89%
Water 635.65367408966 1.11%
Biuret 570.77625570776 1.00%
Total 57142.502989158 100%
ntrate the urea solution from approximately

rbon urea process is typically a vertical-one-

f evaporator, the obtained vapour are fed
a vertical bundle of tubes.
wards through the tubes of a vertical bundle of

poration being supplied by condensation of

 Prilling Tower Mass Balance

Material Flow rate (Kg/hr) Concentration

Prilling Tower
Urea 55936.07305936 98%
Water 635.6536740897 1%
Biuret 570.7762557078 1%
Total 57142.50298916 100%
Prilling Tower Mass Balance

Material Flow rate (Kg/hr)

Water 50
The Prilling Tower is a vertical, cylindrical vessel u
into solid prills.
Operation Condition Values The tower is typically made of carbon steel and line
Temperature 110© material, such as stainless steel or titanium.
Air Flow 10-15 m/s
The prilling tower is fed with molten urea from the
The molten urea is then sprayed through a series of
tower. The nozzles break up the molten urea into sm
through the tower and solidify into prills.

As the prills fall through the tower, they are cooled

The prills are collected at the bottom of the tower a

unit for packaging or storage.
Material Flow rate (Kg/hr) Concentration
Urea 55936.073059361 98%
Water 585.65367408966 1%
Biuret 570.77625570776 1%
Total 57092.502989158 100%
ical, cylindrical vessel used to convert molten urea

e of carbon steel and lined with a corrosion-resistant

teel or titanium.

th molten urea from the Stamicarbon urea reactor.

ayed through a series of nozzles at the top of the
p the molten urea into small droplets, which then fall
ify into prills.

e tower, they are cooled by countercurrent air flow.

he bottom of the tower and then sent to a downstream

e.