1.

1 Different processes for the production of urea:

i. Snamprogetti ammonia stripping process

ii. Toyo process (ACES)
iii. Stamicarbon CO2 stripping process
iv. Mitsui Toatsu process

i. Snamprogetti

NH3 and CO2 are converted to urea via ammonium carbamate at a pressure
of 150bar and a temperature of 180°C. A molar ratio of 3.5 is used in the reactor
giving a CO2 conversion of 65%. The reactor effluent enters the stripper where a
large part of the unconverted carbamate is decomposed by the stripping action of the
excess NH3. Residual carbamate and CO2 are recovered downstream of the stripper
in two successive stages operating at 17 and 3.5bar respectively. NH3 and CO2
vapours from the stripper top are mixed with the recovered carbamate solution from
the High Pressure (HP)/Low Pressure (LP) sections, condensed in the HP carbamate
condenser and fed to the reactor. The heat of condensation is used to produce LP
steam. The urea solution leaving the LP decomposition stage is concentrated in the
evaporation section to a urea melt.
 ii. Toyo process (ACES)

Urea is a major nitrogen fertilizer produced from ammonia and carbon

dioxide as raw material. Its application is not only for fertilizer but also for cattle
feed, industrial purpose of resin/plastic/adhesive glue and recently expanded into
reducing agent (“AdBlue®”) for SCR (Selective Catalytic Reduction) to decrease the
emission of NOx from diesel engine vehicles. In addition the increasing of demand
of bio-energy causes more demand of urea fertilizer.In this way, Urea is one of the
most important product to solve the issues of “Food”, “Environment” and “Energy”.

Features

Since its establishment in 1961, Toyo has been a leader in the urea industry.
TOYO has designed, engineered, constructed and commissioned over 100 urea plants
based on our Urea Process including its urea synthesis technologies and urea
granulation technologies.

In early 1980’s, TOYO has established the most energy efficient process of ACES
(Advanced Process for Cost and Energy Saving.). And using its own expertise,
advanced technology and new thinking, TOYO has established the ACES21®, which
achieves energy saving and plant cost reduction with maintaining the excellent
feature of ACES process such as high performance and high efficiency. 　Now, the
production capacity of single train ACES21 reaches 4,000 t/d.

Furthermore, TOYO started the establishment of a Urea Granulation Process based

on a “Spout Bed” type urea granulator and expanded its own Technical range to
provide a variety of urea fertilizer products since late 1970’s in addition to the
conventional Urea Prill Product and Urea Solution Product. In late 1980's, TOYO
further improved its design of the granulator by applying the “Spout Fluid Beds” for
the granulator, which is a combination ofthe spouted beds and fluidizing beds and
reduces energy requirements and improves the quality of the product granules.

TOYO developed High Grade material DP28W™ and other related technologies for
urea production in addition to ACES21 and Urea Granulation Process and supply
them as owner of those technologies.

iii. Stamicarbon Process

NH3 and CO2 are converted to urea via ammonium carbamate at a pressure of
approximately 140 bar and a temperature of 180-185°C. The molar NH3/CO2 ratio
applied in the reactor is 2.95. This results in a CO2 conversion of about 60% and an
NH3 conversion of 41%. The reactor effluent, containing unconverted NH3 and CO2
is subjected to a stripping operation at essentially reactor pressure, using CO2 as
stripping agent. The stripped-off NH3 and CO2 are then partially condensed and
recycled to the reactor. The heat evolving from this condensation is used to produce
4.5 bar steam some of which can be used for heating purposes in the downstream
sections of the plant. Surplus 4.5 bar steam is sent to the turbine of the CO2
compressor. The NH3 and CO2 in the stripper effluent are vaporized in a 4 bar
decomposition stage and subsequently condensed to form a carbamate solution,
which is recycled to the 140 bar synthesis section. Further concentration of the urea
solution leaving the 4 bar decomposition stage takes place in the evaporation section,
where a 99.7% urea melt is produced.i

iv. Mitsui Toatsu process : The process involves three decomposition stages
or less, followed by a crystallisation section of urea melt, the off gases
from the units are absorbed in the mother liquor from the crystaliser and
recycled back to the reactor. The urea melt from subsequent stages is
stripped in next decomposition stage from the vapors. The main focus of
the process is to reduce water content in the reactor recycle stream, this is
 achieved by absorbing the gases in urea mother liquor from the
crystalizer, which is heated and then used for absorbing the gases in high
pressure decomposition sections instead of using low pressure stage
absorbate. The overall conversion of the reactor is thus maintained.
Typical parameters are: N/C = 3 to 5 Reactor temperatu

1.2 Why we select Stamicarbon process?

i. Due to the application of pool condensation in the condensing step in the

synthesis recycle loop. Pool condensation is a technology where, in a
condensing operation, the liquid phase is the continuous phase, whereas the
gases to be condensed are present as bubbles, rising through the liquid phase.
As compared to the technique of falling-film condensation, pool condensation
offers some considerable advantages. Firstly, the turbulence that is introduced
into the liquid phase by the rising bubbles enhances the heat transfer from the
liquid phase to the cooling surfaces. Secondly, the contact area between the
gaseous phase and the liquid phase in pool condensation is considerably
larger than in falling-film condensation. As a result, the mass-transfer
limitations on the condensation of multicomponent mixtures, are largely
eliminated.ii
ii. Reactor volume decreases due to some conversion of urea in pool condenser.
iii. Cost effective due to lower maintenance of equipments.
iv. Number of pressure vessels are less than other processes.
v. Least CO2 emissions to the environment and maximum concentration of
urea.
vi. No drainage of effluent water to the environment. The water produce during
reaction is used for cooling water for condensation.
vii. The overall cost of plant is reduced due to less number of equipments and
less height of reactor for urea conversion.
1.3 PFD and Description

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Figure 2-1
re = 250 OC Reactor pressure = 200 to 400 ATA
iTopham, Susan.Ullmann's Encyclopedia of Industrial Chemistry "Carbon Dioxide". 2000.

iiAmmonia technical Manual "New Urea Process Designs". K. Jonckers, J. Mennen, J. Meessen,
and W. Lemmen. 1997.