UREA PLANT

Training Program for Graduate

Trainee Engineers

Showkat Ali khan/Munawar Zaman

Urea Plant Technologies
Percentage

8.5, 9%

20, 20% 45, 45%

26.5, 26%

Stamicarbon 45%
Snamprogetti 26.5%
Market Share Toyo Engineering 20%
Tecnimount 8.5%
CHEMISTERY OF UREA REACTION
UREA SYNTHESIS
 First Reaction:
2NH3 + CO2 ↔ NH2CO2NH4 (Ammonium
Carbamate)
Exothermic, ΔH = -117 KJ / mole
Spontaneous (fast)
 Second Reaction:
NH2CO2NH4 ↔ NH2CONH2 + H2O
Endothermic, ΔH = 15.5 KJ / mole
Slow (rate determining)
UREA REACTION
EFFICIENCY
Factors favorable for higher conversion:

 High Temperature
 High Pressure
 Low H2O:CO2 ratio
 High NH3:CO2 ratio
PROPERTIES OF UREA
Chemical Formula: NH2CONH2
Synonyms: Carbamide,
Carbonyldiamide
Mol weight: 60.056
Physical state: solid at ambient
conditions
Appearance: white, odorless
Boiling point: decomposes before boiling
Melting point: 132.7 ºC
STAMICARBON UREA
TECHNOLOGY
 CO2 Stripping Process
 Pool Reactor Technology
(No Carbamate Condenser)
 Low NH3 to CO2 Reaction
 No MP Section
 Hydrogen Removal from CO2
 Less number of Equipments
 Superior Material (more corrosion resistance)
 Flexibility in Plant Operation
UREA PLANT
It consists of mainly five sections:

CO2 Compressor Section

High Pressure Synthesis Section

Low Pressure Recirculation Section

Vacuum and Prilling Section

Process Condensate Treatment Section

 NH3 NH3, CO2, H2O NH3, CO2, H2O NH3, CO2, H2O

UREA UREA LP FLASH VESSEL

REACTOR STRIPPER DECOMPOSITION

Urea = 33% Urea = 53% Urea = 67% Urea = 72%

CO2

H2O H2O

2ND 1ST
PRILLING
EVAPORATOR EVAPORATOR

Urea = 99.1% Urea = 94.5%

SOLID PRILLS
 CO2 Compressor Section

Hydrogen
Reactor

Passivation
Air Blower

CO2 from
Ammonia Plant

1st Stage 2nd Stage 3rd Stage 4th Stage

LP Casing HP Casing
SYNTHESIS SECTION

o Liquid NH3 and Gaseous CO2 reaction at

elevated temperature and pressure

o High Pressure CO2 Stripping

o High Pressure Scrubbing

SYNTHESIS SECTION
Pressure 145 kg/cm2a
Temperature 185 ºC
NH3/ CO2 Ratio 2.95%

Urea Concentration at Reactor outlet 33%

Urea Concentration at Stripper outlet 54%

 Carbamate Vent to atm

Gases to be vented MP Absorber

HP Scrubber To LP Abs.

Stripper Off Gases

NH3 From
HP
Ammonia Pool Reactor
Pump

Reactor Outlet Solution HP

Stripper

Stripper
Outlet
CO2 from Compressor Solution
Process Flow

Reactor off
Stripper off
Gases to C-203 Liquid Inlet
Gases
from C-203
S.C/Steam
outlet

S.C
Outlet Inlet
Liquid to E-
201
POOL REACTOR TUBE
BUNDLE
REACTOR SHELL
HP SCRUBBER SPHERE
HP SCRUBBER SPHERE
HP STRIPPER
LOW PRESSURE RECIRCULATION
SECTION

Urea Purification

Low Pressure Decomposition

Carbamate Condensation

Carbamate recycling

Absorption of NH3 and CO2 Vapors

DECOMPOSITION
Reaction:

NH2CO2NH4 ↔ 2NH3 + CO2

Endothermic, ΔH = -117 KJ / mole

Favorable Conditions:

High Temperature

Low Pressure
 To LP Abs.
CO2 & Ammonia Gases
LP
Expansion
Carbamate
Vessel
Urea Solution from Condenser
Stripper

To Evaporator
Rectifying Condenser
Flash
Column
Separator

Carbamate
To
Scrubber

Urea
Solution HP carb.
PUMP
Urea Solution
Urea Solution to Evap. Urea Tank
Soln.
Low Pressure Recirculation Section

Pressure 4.2 kg/cm2a

Temperature 135 ºC

Urea Concentration 67%

Urea Concentration after flash vessel 72%

Vacuum and Prilling Section

Purification

Evaporation at very low pressure

Condensation of vapors

Conversion of Urea Melt into Urea Prill

 Molten Urea to Prill Tower
Vacuum & Prilling Section
Ejector & Condenser Section

Evaporation Section

Prill Tower
99.7% Urea

Urea Formaldehyde
Vacuum and Prilling Section
 1st Stage Evaporation
Vacuum 0.34 kg/cm2a
Temperature 130 ºC
Urea Concentration 94.5%

 2nd Stage Evaporation

Vacuum 0.02 kg/cm2a
Temperature 140 ºC
Urea Concentration 99.1%
Urea Soln,
Tank
Prill
Tower
Process Condensate & Treatment
Section
 Purification of Process Condensate Feed
Urea 1.5%, CO2 4%, NH3 8%, H2O 86.5%
◦ Purified Process Condensate
H2O 100%, NH3 1ppm, Urea 1ppm.
 Desorption
NH3 & CO2 are stripped off from process condensate
 Hydrolyzation
Conversion of Urea back into NH3 & CO2
NH2CONH2 + H2O + Heat <====> 2NH3 + CO2
DESORPTION/ HYDROLYSIS
 Desorber

Pressure 4 Kg/cm2a

Temperature 143 ºC

 Hydrolyzer

Pressure 18 Kg/cm2a

Temperature 200 ºC
Process Condensate
Treatment Section
Block diagram of a total recycle
CO2 stripping urea process.
PRODUCT QUALITY

Prill Temperature 50oC

Average Prill Diameter 1 – 2.4 mm

Crushing Strength 15 kg/cm2

Angle of Repose 27o - 30o
Moisture < 0.3%,
Biuret < 0.9%
CO2 Stripping Vs NH3 Stripping

Variable CO2 Stripping NH3 Stripping

Operating Pressure of 145Kg/Cm2 153Kg/Cm2
Stripper.
Operating temp of 185/165C0 190/210C0
Stripper (top/bottom)
Steam Pressure 19.39Kg/Cm2 24.9Kg/Cm2
Outlet Stripper 7-8 25
NH3(Wt%)
Outlet Stripper 10 8
CO2(Wt%)
UTILITIES
Utilities Temperature Pressure

HP Steam 371oC 42.02 kg/cm2

ES Steam 310oC 22.13 kg/cm2
ES Steam (Saturated) 210oC 22.13 kg/cm2
MP Steam 175oC 8.98 kg/cm2
LP Steam 147oC 4.49 kg/cm2
Cooling Water 34oC 5.0 kg/cm2
Demin Water 40oC 6.0 kg/cm2
Materials of Construction

o SAFUREX (Duplex Stainless Steel)

o SS 316L

o SS 304L

o Killed CS

o CS
CORROSION CONTROL
o Corrosive Fluids:
o Ammonium Carbamate
o Urea
o CO2 in presence of moisture
o Factors affecting corrosion:
o Temperature
o Concentration of solution
o NH3:CO2 Ratio
o Oxygen content
CORROSION CONTROL

o Lining with Safurex in Synthesis Section

o Introduction of air with CO2

o Protective Passivation Film

o Weep holes for leakage detection

o NH3 to CO2 Ratio