TRAINER INTRODUCTION

Presented By:

Zohaib Ali Butt

Section Head Urea Plant
 WHY I AM HERE ???

Urea Plant Process Description

 WHAT IS FERTILIZER

• Fertilizers: Chemicals that are used to improve growth

and productivity of crops.

Types of Fertilizer:

Benefits of Fertilizer:
 WHAT IS UREA FERTILIZER

Urea is a concentrated straight nitrogenous fertilizer that

contains 46% nitrogen. It provides nitrogen to promote
green leafy growth and make the plants look lush.
• Properties of urea
• Urea is colorless, crystalline solid.
• It is highly soluble in water.

Molecular Weight/ Molar Mass 60.06 g/mol

Density 1.32 g/cm3
Appears White solid
Melting Point 133 °C
 Production Status

• Initial design ---------- 280 MTPD

• Up graded ----------- 300 MTPD

• Current condition ----- 380 MTPD (max.) in

winter and 350 MTPD (max.) in summer.
 CHARACTERISTICS OF RAW MATERIAL

Ammonia

Ammonia content (% min) 99.5 wt / wt

Appearance clear colorless liquid

Oil content (max.) 5 ppm wt.

Pressure (min.) 16 ATA.

Temperature (min.) -33 Centigrade

(Max.) +30 Centigrade
Carbon Dioxide

CO2 (% min. By vol.) 97.5

(% max. By vol.) 98.5

H2 content (% min. By vol.) 0.7

(% max. By vol.) 1.1
Oxygen 6 - 50 ppm
Nitrogen + Argon (% min. By vol.) 0.8
(% max. By vol.) 1.4
Temperature (min/max) 25/ 55 Centigrade
Humidity saturated
Pressure (min.) 0.06 Kg/cm2g
Steam
High Pressure Steam
Pressure kg/cm2g 39
Temperature 399 Centigrade

Intermediate Pressure Steam

Pressure kg/cm2g 15
Temperature saturated

Low Pressure Steam

operating Pressure kg/cm2g 3.5
operating Temperature saturated
Pressure (min.) 0.06
Kg/cm2g
ELECTRIC POWER
6000 Volts 3 phase, 3 wire, 50 c.p.s. AC
400 Volts 3 phase, 4 wire, 50 c.p.s. AC
230 Volts 3 phase, 4 wire, 50 c.p.s. AC
Cooling Water
Temperature 34 – 43 Centigrade
Pressure kg/cm2g 3.2
T 9 Centigrade
AIR
For instruments
Pressure kg/cm2 6
Temperature 40 Centigrade
Dew point -20 Centigrade
Oil and dust free air
Demineralized water

Pressure kg/cm2g 7/8

Temperature 34 Centigrade

Fresh tube well water

Pressure kg/cm2g 3 - 3.5

Temperature 25 Centigrade
 Sections of Urea Plant

CO2 Compressor Section High Pressure Section MP & LP Pressure Sections

Vacuum & Prilling Section Waste water treatment Section Ammonia Storage Section
 Block Diagram of Urea Plant H2O Vapors to T-2

. .
Vapors recycle to R-1 Vapors recycle to HP Vapors recycle to MP

V-6

R-1 E-1 E-2 E-3 E-14

H2O Vapors to T-2

NH3
V-7

CO2
To Prilling bucket
E-15

Urea melt pump

 Urea synthesis and high pressure
recovery
Urea is produced by synthesis from liquid ammonia and gaseous carbon
dioxide. In the reactor R-1 the ammonia and carbon dioxide react to form
ammonium carbamate

2NH3 + CO2  NH2COONH4

A portion of carbamate solution decomposes to form urea and water.

NH2COONH4 ========== NH2 - CO - NH2 + H2O

At synthesis conditions (T = 188 0C, P = 155 kg/cm2 abs) the first reaction
occurs rapidly and goes to completion. The second reaction occurs slowly
and determines the reactor volume.
 UREA PLANT
4- STAGE RECIPROCATING
CO2 COMPRESSOR

CO2 to R-1 C/W

V-13
OIL SEPARATOR
E-24 INTER COOLER

V-37 C/W
CO2 to Vent DAMPNER
Suc. 13.8 Kg/cm2
Dis. 52.4 Kg/cm2 Suc. 2.4 Kg/cm2 V-35
rd Dis. 13.8 Kg/cm2 DAMPNER
3
2nd
STAGE
V-36 STAGE
DAMPNER
V-34 V-24
DAMPNER
Lube Oil Pump OIL SEPARATOR
PCV-19 P-23

MK-1 Mechanical Oxygen Contents

1700 KW CRANK CASE P
25
Lubricator
O2 = 2000-3200 ppm
370 RPM

HV-2 V-39
Suc. 52.4 Kg/cm2
V-33
DAMPNER Dis. 165 Kg/cm2 DAMPNER
V-23
4th 1st STAGE
STAGE
Suc. 1.05 Kg/cm2(Abs)
OIL SEPARATOR
Dis. 2.4 Kg/cm2
V-38
DAMPNER
V-32
DAMPNER

C/W
PCV-3
CO2 = 97.05 – 98.5 % V-12 Motor Driven
Lube oil Pump Oil filter
E-23 INTER COOLER
N2 + Ar = 0.6- 1.4 % KNOCK
DRUM
OUT
P-24
H2 < 2 % TCV-9
c/w
RAW WATER
C/W

FCV-1 E-25 INTER COOLER

OIL COOLER V-25
SEAL POT c/w OIL SEPARATOR 14
 volume: 0.46 M3

Urea = 30 – 36 %
NH3 = 49 – 52 %
CO2 = 30 – 38 %
H2O = 12 – 22 %
Reactor R-1 volume: 29.6 M3

NH3 = 49 – 52 %
CO2 = 30 – 38 %
H2O = 12 – 22 %

Urea = 43 – 48 %
HV-12 NH3 = 23 – 27 %
NH3 = 49 – 52 % CO2 = 4 – 8 %
CO2 = 30 – 38 % H2O = 14 – 24 %
H2O = 12 – 22 %
15
 Urea synthesis and high pressure
•
recovery
CO2 at 160 Kg/cm2 and NH3 at 230 Kg/cm2 feed to R-
1.
• The reaction products, leaving the reactor, pass to the
steam heated falling film stripper E-1, which operates at
essentially the same pressure as the reactor. The
mixture is heated as it flows down the tubes of the
falling exchanger.
• The carbon dioxide content of the solution is reduced
by the stripping action of the excess ammonia as it
boils out of the solution.
• Gases of Stripper recycled to R-1. Heat of gases is utilized to
produce 4.5 Kg/cm2 steam.
Ammonia to Carbon Dioxide Ratio
N/C = 3.4 - 3.6
Water to Carbon Dioxide Ratio

H/C = 0.5 - 1
Efficiency of Reactor

58 - 60 %
 Benefits of High N/C ratio
1) Product Quality
High N/C ratio has adverse effect on biuret formation

2) Less chocking tendency

3) Easy recovery

4) Le Chatlier's principle
It states that when a system experiences a disturbance (such as
concentration, temperature, or pressure changes), it will respond to restore
a new equilibrium state
For example, if more reactants are added to a system, Le Chatlier's
principle predicts that the reaction will generate more products to offset the
change and restore equilibrium

• 2NH3 + CO2 → NH2CONH2 (Urea) + H2O

 H/C Ratio

• Higher H/C ratio than design will leads less conversion

in urea reactor which will increase load on the down
stream sections.

• Less H/C can result in blockages in the downstream

sections
 1st purification and recovery stage at 18
Ata (Medium Pressure Section)

• The solution with a low residual CO2 content, leaving the

bottom of the stripper is expanded to the pressure of 18
Ata and enters the medium pressure decomposer E-2
(falling film type).
• Here carbamate decomposition and recovery of
excessive ammonia carried out.
• The NH3 and CO2 rich gases leaving the separator V-2
are sent to the medium pressure condenser E-7, where
the CO2 is totally absorbed and the NH3 partially
absorbed in an aqueous carbonate solution coming from
the low pressure recovery section.
 1st purification and recovery stage at 18
Ata (Medium Pressure Section)

The mixture from E-7 flows to the medium pressure absorber C-1, where
the gaseous phase coming from the solution enters the rectification
section.

This column has bubble-cap type trays and performs CO2 absorption and
NH3 rectification. The tray is fed by pure reflux ammonia, which eliminates
residual CO2 and H2O contained in the inert gases.

Reflux NH3 is drawn from the ammonia receiver and sent to the column
by means of the centrifugal pump P-5 A/B.
The bottom solution is re-cycled by the pump P-2A/B to the synthesis
recovery section. An inert gas stream saturated with NH3 plus a CO2
residue (20-100 ppm) passes from the top of the rectification section to
the ammonia condenser E-9 where it is mainly condensed.
 Carbonate solution
UREA PLANT
M.P DECOMPOSER from P-3 Discharge
M.P Section F.D
LV-17 M.P Absorber
NH3 = 97 – 98.8 % Inert Washing Column
C-1
UREA FV-19
Solution from NH3 < 13.3 % B.D
Stripper Steam
V-2 FV-22
Condensate PV-29

FV-20
C/W
Volume of V-2: E-7
2.5 M3 C-3
HV-17
C/W
Cond. To E-5

E-10 C/W

volume: 18 M3 E-9 E-11

LV-12 NH3 Condenser
To V-5

E-2 M.P Condenser E-7

M.S Cond. C/W
From V-10 C-5
Carbamate
Solution to P-2
NH3 = 48 – 54 %
CO2 = 24 – 32 %
Gases from PV-23A

TV-17
I.S Steam

H2O = 14 – 24 %

TV-18
NH3 Reciever V-4
V-4 volume: 14.3 M3
V TV-16
22
L-2
Cond. To E-5

LV-16 Volume To H.P NH3

of L-2 =
UREA Solution

Pumps LV-18
Fresh
0.3 M3
to L.P.D

C/W
LV-15 Fresh NH3
Urea = 62 – 68 % P-31 P-5 P-6 P-7
P-4 from battery
NH3 = 6 – 8.5 % limits
CO2 = 1.0 – 2.5 % 24
NH3 = 99.5 %
H2O = 12 – 22 %
 2nd Purification and Recovery stage at 4.5
Ata (Low Pressure Section)
• The solution leaving the bottom of medium pressure decomposer is
expanded to 4.5 Ata and enters the low pressure decomposer E-3.

• The gas leaving the separator is sent to the low pressure condenser E-8,
where they are absorbed in an aqueous carbonate solution coming from
the waste water treatment section.

• The absorption and condensation heat is removed by cooling water. From

the condenser bottom, the liquid phase, with the remaining inert gases, is
sent to the carbonate solution vessel V-5.
• From here the carbonate solution is recycled back to the medium
pressure condenser E-7 by means of the centrifugal pump P-3A/B...
 Solution
Carbonate
from P-15 Solution to LV-17
Discharge
UREA PLANT P-12 Stripper D.P
LV-33 LP Section & Flushing Condensate LV-9B Cell Flushing
Down Stream Pump
Condensate Flow Diagram

Vapors

UREA NH3 < 99 %

Solution Gases to
from M.P.D B.D
V-3 LS Condensate C/W C/W
PV-33

FV-26
Solution
Volume : 2.5 M 3
from C-1 LV-41A
E-13
L.S C-4
Steam HV-17

TV-21
C/W

C/W
Condensate Tank
E-12
E-3 E-8 V-11

Steam Cond. C/W HW

To V-11

LV-41B
Volume Steam
Condens
C/W
: 0.3 M3 ate to
L-3 Carbonate Solution Tank Utility

LV-22
V-5
PV-55

UREA Solution to LW
1st Concentrator

Urea = 68.5 – 71 %
NH3 = 1.0 – 2.5 % NH3 = 38 – 43 % P-11
CO2 = 0.4 – 1.2 % CO2 = 9 – 17 % pH = 8-10
H2O = 24 – 29 % H2O = 42 – 47 % Conductivity = 50 KW

TH = nil
P-3 SiO2 < 50 PPB
P-10 26
 Biuret
• Biuret is a stable compound which is formed by the reaction and
combination of two urea molecules, with the release of a molecule of
ammonia

NH2CONH2 + NH2CONH2 → C2H5N3O2 (Biuret) + NH3

• It is also known as carbamylurea

• It is a white solid which is soluble in hot water

• Favorable conditions for formation of biuret are

1) High Residence Time
2) Less Ammonia
3) High Urea Concentration
4) High Temperature

• The rate of biuret formation is principally a function of temperature, and

consequently the heating of urea melt is avoided in practical operations
 Biuret

• R-1 outlet 0.18%

• E-1 outlet 0.22%
• E-2 outlet 0.26%
• E-3 outlet 0.32%
• V-6 outlet 0.75%
• V-7 outlet 1.00%
 Benefits of Using Vacuum in
Evaporation & Prilling Section
• Benefits of Using Vacuum
• The boiling point of a substance is the temperature at which the vapor
pressure of the liquid equals the pressure surrounding the liquid and the
liquid changes into a vapor

• A liquid in a partial vacuum has a lower boiling point than when that liquid
is at atmospheric pressure

• A liquid at high pressure has a higher boiling point than when that liquid is
at atmospheric pressure

• For heat sensitive solutions, vacuum is used to lower the boiling point of
the solvents so evaporation occurs with a minimum amount of additional
heat
 Urea Concentration
• To prill urea it is necessary to concentrate the urea solution up to 99.7%
by wt. This is carried out in a vacuum concentration section of two stages.

• The (70% wt. urea) solution leaving the low pressure decomposer is sent
to the first vacuum concentration E-14 operating at a pressure of 0.3 Ata.
Where solution concentrated about 96.5%, then it is sent to second
vacuum concentrator E-15 operating at a pressure of 0.03 Ata. It
concentrated solution to 99.7% where it is pumped to rotating prilling
bucket.

• Overheads vapors are condensed in vacuum condensers and resulting

liquor drains to 01-T-2 & incondensable go to atmosphere.
 UREA PLANT
PROCESS FLOW DIAGRAM
EVAPORATION & PRILLING
SECTION HV-21B
HV-21A
HV-22
L.S
PV-36 Steam

Vent E-33 C/W

Capacity:

Urea Melt Divert Line To “T-1” Tank

Vent

V-6 P

Diameter:14m. Free falling height: 51.25m

L-19A R
20.1 m3. I.S
L-19 B
STEAM
I
L
I.S L
I.S
STEAM
STEAM I
N
E-14 J-703 G
LS V-7
Steam Vent PV-37
TV-24

E 34
T
O
E 35 W
Ist Stage Evaporator
E

Urea = 99.50 – 99.70 %

(E-14/V-6)
J-705 J704 R
LS
Steam E-15 Moisture = 0.5 %
TV-25
or less (objective)
I.S Steam Biuret = 1.2 %
Steam
I.S Steam or less (objective)
Cond. C/W C/W Ammonia < 300 ppm
C/W
C/W
Urea Prill Size
+ 2.3 mm = 2 – 5 %
UREA Solution from Steam
L.P Decomposer Cond. + 1.0 mm = 90 – 96 %
UREA Melt Pump
(P-8 A/B)
- 1.0 mm = 1 – 3 %
-0.5 mm = 0. 1 – 0.4 %
Divert
APS = 1.8-2 mm
2nd Stage Evaporator
(E-15/V-7)

Capacity:16 m3 Urea = 1.44 %

Urea = 50 –70 % NH3 = 4.65 %
H2O = 30 – 50 % CO2 = 2.08 %
To Waste Water Treatment UREA PRODUCT TO
H2O = 91.83 % Plant BAGGING SECTION
Capacity: 7.4 m . 3

Urea Melt Recovery Pump

31
Process
(P-9 A/B) PROCESS CONDENSATE TANK Condensate Pump
UREA MELT TANK (T-!) (T-2) P-14 A/B
PRILLING SECTION

PRILL
TOWER

Urea Soln,
Tank
PRODUCT QUALITY

Moisture < 0.5%

Biuret < 1.2%

Average Prill Size 1.8 – 2 mm

Free Ammonia < 300 ppm

Crushing 0.7 – 0.8 kg/prill

Strength

33
 Waste Water Treatment
• The water, containing NH3 and CO2 and also some urea from the first and
second vacuum system as well as the drain liquors accumulated in the tank T-4
are collected in the process condensate tank T-2.

• From T-2 it is pumped to distillation tower C-2.

• Re-boiler at bottom of distillation tower desorbed the ammonia and CO2
content.
• Hydrolyzer R-2 decomposed the urea is into CO2 and NH3.
• The treated water containing 30 ppm of ammonia, 10 ppm of carbon dioxide and
100 ppm of urea cooled to meet NEQs and drained.
 UREA PLANT
PROCESS CONDENSATE
TREATMENT SECTION

DISTILLATION TOWER (C-2)

DISTILLATION TOWER
OVERHEAD PV-46
CONDENSER (E-17)
HYDROLYZER (R-2)
REFLUX 45

44 FV-42
C/W 41

38
I.S STEAM

32

31
E-19 (B)

TO BLOW DOWN
VESSEL
HYDROLYZER
PV-44 LV-36 PREHEATER
C/W 30
E-19 (A) E-19 (C)
29

REFLUX
ACCUMULATOR
V-8
1
SOLUTION TO FV-44
L.P DECOMPOSER
OFF GASES
FV-37
LV-33 LS PASSIVATION DISTILLATION TOWER
STEAM AIR PREHEATER

LV-35
REBOILER FV-39
E-16
E-18(A) E-18(C)

CONDENSATE

E-18(B) E-18(D)
PROCESS CONDENSATE
FROM T-2
(P-14 Discharge)

FV-40
C/W

E-20
PROCESS CONDENSATE
COOLER

P-15 P-16 NH3 < 30 ppm C/W

REFLUX PUMP HYDROLYZER FEED PUMP
CO2 < 10 ppm
LV-34
35
Urea < 100 ppm
Questions