Contents

Acknowledgement.............................................................................................................................................1
INTRODUCTION OF UREA...................................................................................................................................2
PHYSICAL AND CHEMICAL PROPERTIES..............................................................................................................3
USES OF UREA....................................................................................................................................................4
PROCESS TECHNOLOGY......................................................................................................................................5
ONCE THROUGH PROCESS..............................................................................................................................6
PARTIAL RECYCLE............................................................................................................................................6
TOTAL RECYCLE OR LIQUID CARBAMATE SOLUTION RECYCLE PROCESS:-................................................7
STRIPPING PROCESS.......................................................................................................................................8
THEORY OF STRIPPING...............................................................................................................................8
EFFECT OF PROCESS VARIABLES.........................................................................................................................9
EFFECT OF H2O/CO2 RATIO...............................................................................................................................10
EFFECT OF PRESSURE AND TEMPERATURE......................................................................................................10
EFFECT OF RESIDENCE TIME.............................................................................................................................10
BIURET IN UREA................................................................................................................................................11
PROCESS DESCRIPTION FOR UREA SYNTHESIS.................................................................................................11
HIGH PRESSURE SECTION.............................................................................................................................12
CO2 COMPRESSOR........................................................................................................................................12
COMPRESSION DETAILS................................................................................................................................13
AMMONIA RECOVERY......................................................................................................................................13
UREA SYNTHESIS...............................................................................................................................................13
CONSTRUCTION OF UREA REACTOR.................................................................................................................14
OVER FLOW FROM REACTOR.......................................................................................................................15
AMMONIA STRIPPING......................................................................................................................................15
STRIPPING PROCESS.........................................................................................................................................15
CONSTRUCTION OF STRIPPER.......................................................................................................................16
CONDENSATION AND SEPERATION..................................................................................................................16
MEDIUM PRESSURE SECTION...........................................................................................................................17
MEDIUM PRESSURE SEPARATOR......................................................................................................................17
MEDIUM PRESSURE DECOMPOSER..................................................................................................................18
MEDIUM PRESSURE UREA HOLDER..................................................................................................................19
MEDIUM PREESURE CONDENSATION..............................................................................................................19
MEDIUM PRESSURE ABSORBER........................................................................................................................20
ABSORPTION PROCESS.....................................................................................................................................20
DESCRIPSITION OF MEDIUM PRESSURE ABSORBER.........................................................................................22
MEDIUM PRESSURE AMMONIA CONDENSATION............................................................................................22
AMMONIA RECEIVING......................................................................................................................................23
MEDIUM PRESSURE ABSORBER AND INERT WASHING....................................................................................24
LOW PRESSURE SECTION..................................................................................................................................25
LOW PRESSURE SEPARATOR.............................................................................................................................25
LOW PRESSURE DECOMPOSER.........................................................................................................................26
LOW PRESSURE UREA SOLUTION HOLDER.......................................................................................................27
LOW PRESSURE CONDENSATION.....................................................................................................................27
CARBAMATE SOLUTION TANK..........................................................................................................................28
LOW PRESSURE ABSORPTION AND LOW PRESSURE INERT..............................................................................29
WASHING.........................................................................................................................................................29
VACUUM AND EVAPORATION SECTION...........................................................................................................30
FIRST VACUUM CONCENTRATION....................................................................................................................30
FIRST VACUUM SAPARATION...........................................................................................................................31
SECOND VACUUM CONCENTRATOR................................................................................................................31
SECOND VACUUM SEPARATOR........................................................................................................................32
FIRST VACUUM SYSTEM...................................................................................................................................33
SECOND VACUUM SYSTEM...............................................................................................................................33
FINAL CONDENSATION.....................................................................................................................................34
UREA MELT PUMPING......................................................................................................................................34
PRILLING SECTION............................................................................................................................................35
Acknowledgement
Urea production is based on Snam Progetti's self stripping process. CO2 enters the
centrifugal compressor and leaves it at a pressure of about 160 atm. Liquid NH3 from
NH3 plant is collected in Ammonia Receiver Tank. From here it is compressed to 25
atm pressure. Part of this ammonia is sent to Medium Pressure Absorber the
remaining part enters the high pressure synthesis loop after it is compressed to
pressure of 240 atm.
Liquid ammonia and gaseous carbon dioxide react in Reactor at a pressure of 150
kg/cm2 and 188 deg C to form ammonium carbamate, a portion of which dehydrates
to form urea and water. The reaction products leaving the reactor flow to the steam
heated falling film Stripper which operates at the same pressure as the Reactor. The
unreacted carbamate gets stripped off as NH3 and CO2. Urea solution leaving the
bottom of the Stripper still contains some amount of carbamate.
Purification of urea takes place in the medium and low pressure sections operating at
18atm and 4.5atm pressure respectively. Decomposition of carbamate takes place in
medium and low pressure decomposers. The concentration of solution leaving the
low pressure section is 72% of urea. Vacuum concentrators are provided to
concentrate the solution to 99.8% in two stages operating at 0.3 and 0.03atm
pressure respectively. Urea melt from the concentration section is pumped to the top
of the prilling tower and sprayed by means of rotating prill bucket.
The fine droplets, while descending through the tower, come into contact with cold
air and solidify to form prills. Product urea from the bottom of Prilling Tower is sent
to storage or bagging. In the high pressure section gases leaving the Stripper
thoroughly mixed with the recovered carbamate from the medium pressure section
and gets condensed to ammonium carbamate from the medium pressure section and
gets condensed to ammonium carbamate in two carbamate condensers operating in
series. The heat of reaction is utilised to generate 4.5atm steam. The carbamate thus
formed is recycled back to Reactor.
Ammonia and CO2 present in the decomposed gases of medium and low pressure
sections are recovered in a series of condensers and absorbers. Traces of gases
present in the condensate from Vacuum Section are removed in a distillation tower.
Waste water from the distillation tower is sent to effluent system. The recovered
ammonia solution is recycled back to the LP Section and ammonium carbamate from
LP Section is recycled back to the MP Recovery Section.
 INTRODUCTION OF UREA
Urea synthesis is of historical importance, it is being the first organic compound to be
synthesized from inorganic compound in laboratory. WHOLER in 1828 obtained urea
from ammonium carbonate. Previous to this urea had been separated from urine and
experiment from WHOLER showed that organic chemical can be separated from an
inorganic chemical. Commercial production of urea was started in 1920 by I.C.
FORBEN in Germany based on Ammonium carbonate process. Since then
Considerable ingenuity was us to overcome process difficulties such as: corrosion
problems, recovery of off gases and economic process routes which resulted in
present day development.

The various commercial urea manufacturing process of today use reaction between
liquid ammonia and CO2 gas to form carbamate and subsequent dehydration of
carbamate to form urea and water. Ammonia and CO2 are usually available from
same site, as CO2 is a by product of ammonia plant using hydro carbon as feed stock.

Four streams of urea plant having capacity to produce 1320X4mt/day of urea

fertilizer .The technology is based on SNAM PROGETTI, Italy.

Liquid ammonia and gaseous carbon dioxide s made available by ammonia plant and
sent to reactor after compression and pumping .In reactor ammonia and carbon
dioxide react to form carbamate which is further dehydrated to form urea. The
output of the reactor is sent to the stripper where urea is further concentrated by
removing an dehydrated carbamate using ammonia for stripping .Urea solution
leaving the stripper will contain some carbamate which is further purified in medium
pressure section and low pressure sections. Vapour containing ammonia and carbon
dioxide obtained from these vessels are converted to carbamate and recycled to
reactor.

Concentration of urea solution is important because increase in temperature

encourages biuret formation which in poisonous to crop, Therefore concentrated
under vacuum concentrator. After concentration urea melt is pumped to urea prill
tower where it is sprayed by rotating prill bucket and fine droplets of urea are
solidified by means of natural air draft. At bottom of prill tower, urea prills are
collected and sent to product handling plant by means of scraper and belt conveyor.
 PHYSICAL AND CHEMICAL PROPERTIES
Molecular weight 60.05
Boiling point Decomposes at atmospheric
Pressure before boiling
Density at 200C 1.335
Heat of combustion 2531
Heat of solution in water 578 cal/gm
Critical humidity 70.1
Viscosity at 1500C 2.16 cp
Crystallisation heat 47 Kcal/kg
Fusion heat 59.95 Kcal/kg
Thermal conductivity 0.197 Kcal/kg

Specific heat: cal/ gm/ 0C

At 200C : 0.321
At 98.40C : 0.158
At 120.50C : 0.194
At 160.30C : 0.224
At 2200C : 0.288

Solubility in water by wt %:

Temperatur 0 20 40 60 80 100 120

e

Urea in gm 62 105 163 246 396 725 2244

per 1000 gm
of water

Urea is a white crystalline chemical product with m.p. of 132.60C .It is readily soluble
in water. On heating beyond its m.p. it decomposes giving CO 2, NH3 and other
complex compound of carbon, nitrogen and oxygen. At 1600C it decomposes to yield
ammonia, biuret, and higher condensation product. The longer urea is held above its
m.p. further reaction proceeds. Urea in fact is the diamide of carbonic acid with a
chemical formula represented by:
 USES OF UREA
Main applications of urea are as follows:

(1) As a fertilizer in agriculture.

(2) As cattle feed.
(3) As an industrial raw material for a number of industrial/household
product like urea formaldehyde, melamine and urea furfural. Due to high
nitrogen content of urea the demand for fertilizer grade urea is rising rapidly.
Urea today account for a large percentage of nitrogenous fertilizer.
(4) Urea is used as cattle feed in western countries. Sheep and cattle are capable
of digesting urea up to about 40%.
(5) Urea also finds extensive use in preparation of adhesive, textile, anti shrink
compound in exchange resin and as intermediate in preparation of pigments.
 PROCESS TECHNOLOGY
Urea is produced by synthesis of liquid ammonia and gaseous carbon dioxide.
Ammonia and carbon dioxide react to form carbamate, a portion of which
dehydrates to form urea and water. The fraction of carbamate that dehydrates is
determined by the ratio of various reactions and various reactants, the operating
pressure, temperature and residence time in reactor .The reaction of ammonia and
carbon dioxide to produce urea takes place in two stages at elevated pressure and
temperature.

2NH3 (l) + CO2 (g)  NH2CONH4 + 38.1 Kcal/gm mol oC

Liquid Gaseous Carbamate Heat

Ammonia Carbon dioxide

NH2COONH4  NH2CONH2 + H2O -7.1Kcal/gm

Ammonium Carbamate urea water heat

The first reaction is highly exothermic & therefore heat is liberated as reaction occurs
with excess NH3. The CO2 conversion to carbamate is almost 100%. Provided solution
pressure is greater than the decomposition pressure. The decomposition pressure is
the pressure at which carbamate will decomposes back in to CO2 and NH3.

NH2COONH4  2NH3 + CO2

Urea Ammonia Carbon dioxide

Decomposition pressure is the function of NH3 concentrate in feed and the solution
temperature and increased if either temperature or NH 3 recycle is increased. It is
desirable if operating pressure is quite high enough to prevent carbamate from
decomposition in to NH3 and CO2. This will maximize CO2 conversion to urea and
towards reaction II.
The second reaction is endothermic therefore heat is required for reaction to start.
The heat of this comes from formation of carbamate. This reaction is function of
temperature and concentration in feed, the solution effluent from the reaction being
a mixture of urea solution. Ammonia, water and carbon dioxide is extremely
corrosive in nature. The subsequently stages of process consist of decomposition of
unconverted carbamate recovery of resulting ammonia and carbon dioxide for
recycle concentration and prilling of urea solution.

ONCE THROUGH PROCESS

This reaction is simple in operation, in this process ammonia and CO2 are fed to
autoclave and effluent solution is stripped of unconverted ammonia and carbon
dioxide. The solution is processed further for concentration and for production of
urea plant. The off gases concentrating ammonia and carbon dioxide are neutralised
with acid for production of over ammonia fertilizer, because this process requires an
investment for other plant to use more expensive ammonia. The capital cost of urea
producing unit will go up.

Although the initial cost of urea pant is low and conversion efficiency is high. The
once through process is no longer an economic proposition.

Besides the exceedingly huge demand of high nitrogen fertilizer has pushed the once
through process in back ground.

PARTIAL RECYCLE
In this process the CO2 from off gases is absorbed in mono ethanol amine. Excess
ammonia is recovered by condensation and recycle whereas CO2 is regenerated and
rented. This process gives a better temperature control of reaction. But suffer from
the defect that CO2 is lost MEA used for CO2 absorption get perpetually degraded.
TOTAL RECYCLE OR LIQUID CARBAMATE SOLUTION
RECYCLE PROCESS:-
Today all conventional total recycle process are much the same. All similar reactor
conditions, reactor pressure of about 200kg/cm2 and a temperature of about 185-
190oc. They maintain a NH3/CO2 mole ratio of about 4:1 in synthesis section. A
conversion of about 64% per pass is obtained.

Reactor effluent solution is let down and decomposition of carbamate is carried out
by heating with steam. The off gases are condensed and recycled as solution to
reactor. The excess ammonia used is condensed and fed back to reactor

Major variation however exists in recycle system in temperature and pressure levels.
The various solution recycle processes endeavour-
 To maintain heat recovery

A> To minimize the amount of carbamate recycled and amount of water

recycled back
B> To minimize power requirement
C> To maximize ammonia recovery
D> To minimize investment

Put together such amount to find a balance between consumption, maintenance and
investment.

STRIPPING PROCESS
Efforts to find addition driving force beyond the usual addition of heat. The stripping
is introduced from bottom which travels upwards. Medium pressure steam
condensing on shell side of stripper supplies heat for decomposition of carbamate.
Currently per day consumption does not require injection of ammonia vapours at
stripper bottom. Only higher molal ratio of NH3/CO2 is maintained in reactor.
Liberated in stripper ammonia is adequate to carry out stripping efficiency since the
reactor stripper condenser system operates at nearly same temperature. It is
possible to feed recycle carbamate either by gravity flow which however necessitate
the installation of carbamate condenses at which a much higher elevation so as to
give the require heat or to use a recycle injector using a part of feed reactant as a
motri fluid . Snam Progetti was first to develop the use of such recycle ejector and
locate condenser at ground level. Since a portion of unconverted carbamate is
decomposed and recycle to reactor at synthetic load on down stream decomposition
and recycle section is comparatively much less resulting in lower utility
consumption.Further since the synthetic pressure in stripping process in lower it is
possible to employ, steam drives centrifugal CO2 compressor which has lower
maintenance process. Low in pressure steam is generated in carbamate condenser
which has resulted in lower consumption of steam and cooling water.

THEORY OF STRIPPING
The theory of stripping in s based on Henry’s law. The concentration of compound ‘s
of every component in solution which in equilibrium with vapour phase is directly
proportional as l to partial pressure of component in vapour phase .By changing
partial pressure of component , concentration of solution can be changed. This can
be illustrated as follows:
 CA : concentration of component A in solution

CB : concentration of component B in solution

P A & PB : Partial pressure of component A & B vapour phase

P : Total partial pressure

In stripper we introduce excess NH3 along with reactor effluent .This NH3 is released
as vapour by heating in stripper and this increases partial pressure. Pressure of
ammonia over the solution as total pressure remains same. Partial pressure of CO 2
reduces to a lower value. In accordance with Henry’s law carbamate decomposes to
increase partial pressure of CO2 in vapour phase to approach equilibrium
concentration. Stripping action is thus carried out and heat of decomposition is
supplied from an external source by condensation of medium pressure steam. Partial
pressure of either of component can be changed and this will result in decomposition
of carbamate.

EFFECT OF PROCESS VARIABLES

Cabamate formation takes place with liberation of heat and urea formation takes
place with absorption of heat. The former reaction is rapid and later is slow. The
equilibrium conversion to urea will be favoured under following conditions:

(1) Higher NH3 concentration

(2) Less H2O concentration
(3) Higher temperature
(4) Higher pressure
(5) Increased residence time
 EFFECT OF H2O/CO2 RATIO
Water is by product of urea formation. One mole of water is formed when one mole
of urea is produced. In presence of excess water, equilibrium reaction shift in reverse
direction and yield of urea is poor. However has to add for recycling unconverted NH 3
and CO2 back to reactor. Lower the amount of water in the reactor, higher the yield
of urea to low water concentration in low pressure recovery system and result is
higher carbamate concentration and this causes pumping problem and clogging in
piping system. Excess water in reactor also reduces effective volume for urea
formation and additional energy is required to get rid of this. Study shows that
presence of one mole of excess water per mole of carbamate equilibrium yield of
urea to half.

EFFECT OF PRESSURE AND TEMPERATURE

As per Le Chatliers principle higher pressure favours carbamate formation. As the
operating condition of carbamate formation is almost instantaneous and reaction
tends to completion. Provided reaction heat is removed simultaneously. Lower
temperature favours carbamate formation being an exothermic reaction. In case of
urea formation higher temperature is favourable because reaction is endothermic.
The reaction is such that when temperature increases the conversion increases.
Maximum equilibrium conversion is achieved at around 190 to 200 0 C. Reactant are
highly corrosive at higher temperature. Operating pressure is totally dependent on
temperature at which conversion takes place in liquid phase. So equilibrium pressure
increases when temperature rises.

EFFECT OF RESIDENCE TIME

Urea conversion reaction is slow and takes place in 20 min to attain equilibrium
considering slowness of reaction. Urea reactor is so designed that residence time
should be more than 20 min. The higher residence time favours equilibrium
conversion and normally reactor are designed for residence time of 30 min to 1 hour
depending on other operating parameters. 68% urea conversion takes place with
residence time of 30 min at a mole ratio of 4:1 and temperature at 188C whereas to
achieve 60% conversion with a mole ratio of 2.8:1 at 181C, almost a residence time of
55 min is required.
Residence time in urea reactor plays an important part on equilibrium conversion
where operating parameter including mole ratio are not favourable for a good yield.
The higher residence time contribute to some extend to achieve a better yield. But
this is done by providing higher reactor volume which increases capital investment.

BIURET IN UREA
A problem facing by every urea manufactures is formation of biuret. In production
process it is not a desirable substance at is toxic to plant. It should not exceed more
than 1.5% in urea as fertilizer control order. When urea solution is heated in absence
of free ammonia an objectionable ingredient called biuret is formed according to
following reaction:

2NH2CONH2  NH2CONHCONH2 + NH3

The formation of biuret is favoured by higher temperature, higher concentration of
urea solution, lower ammonia content and higher residence time.

PROCESS DESCRIPTION FOR UREA SYNTHESIS

The technology used is urea plant is “SNAM PROGETTI” from Italy. The whole process
has been divided in four main sections:

(1) High pressure section

(2) Medium pressure section
(3) Low pressure section
(4) Prilling section

In high pressure section, reactor, high pressure stripper and carbamate condenser
are main equipments used.

In medium pressure section, medium pressure decomposer, medium pressure

absorber, ammonia absorption tower and inert washing tower are the main
equipments. In low pressure section, low pressure decomposer, low pressure
absorber and carbamate solution tank. In prilling section urea melt is converted in
prills by natural draft in prilling tower.
In prilling section it is prilled from top and granules of urea are obtained which is sent
to bagging plant, water treatment plant which is required for environment reasons.

HIGH PRESSURE SECTION

The liquid ammonia is pumped at high pressure through a ejector which drive the
carbamate from carbamate separator in to reactor. CO2 mixed with small quantity of
air is compressed in a two stage CO2 compressor and is also fed to reactor. The liquid
ammonia and CO2 react together here. The product formed in carbamate which
dehydrates in reactor itself, to form urea and water. The oxygen in air forms a
passive oxide layer on inside of vessel surface to prevent corrosion by carbamate and
urea.

The reaction products from reactor overflow to high pressure stripper where the
unconverted carbamate is decomposed back into ammonia and carbon dioxide. Heat
of decomposition is supplied by medium pressure steam admitted in stripper shell
side. The condensate obtained is sent to high pressure decomposer shell side. Urea
solution thus obtained flows out to medium pressure solution through level control
valve.

The vapour produced on decomposition in high pressure stripper enter high pressure
carbamate condenser through a mixer along with carbamate solution from medium
pressure section. Here they condense to form carbamate again and flow to high
pressure carbamate separator.

CO2 COMPRESSOR
CO2 is compressed in a twin case centrifugal compressor entering reactor. CO2 is
received at battery limit rate of 40601 kg/hr at 1.4 atm and 40 oC. It’s moisture is
recovered by a knock out drum. Air is added to outlet at rate of 382 kg/hr. The gas
then enter compressor. The compressor consists of two casing – low pressure casing
and high pressure casing. Both casing consist of two stage with inter coolers. By
successive compression and inter cooling. The moisture present in CO 2 is removed.
The gas is pressured from 1.4 atm to 160 atm and 130 0C. It then flows to reactor at
rate of 39722Kg/hr of dry CO2.
 COMPRESSION DETAILS
Compression used in ammonia plant is a turbo driven compression. This compression
casing is made of carbon steel. Compressor has two casing:

1. Low pressure casing

2. High pressure casing

Both casing has two stages. Thus it is four stages turbo driven case CO 2 compressor.
After each stage the temperature of casing increases due to compression.

Thus after each stage inter stages cooler are used. These coolers are simply shell and
tube type heat exchanger. The outlet CO2 rate is 39722Kg/hr dry CO2 + air, Pressure
160 atm. and temperature 1300C.

AMMONIA RECOVERY
Ammonia for urea synthesis comes from ammonia plant at 23 atm. within plant
battery limit. Total 30694Kg/hr ammonia first enters in ammonia recovery tower
where its temp raises up to 350C counter current contact with vapour from receiver.
Liquid ammonia is then stored in ammonia receiver. Ammonia from ammonia
receiver is sent to NH3 booster pump at rate of 52058Kg/hr. A small amount of NH 3
4334kg/hr is sent to medium pressure pump, and remaining is sent to succession of
NH3 feed pump, which is a high pressure pump. Thus booster pump work to boost up
succession pressure pump, Because discharge of high pressure ammonia pump is the
only reciprocating pump in the ammonia pump. This pump is motion driven pump.
This increases pressure for liquid ammonia from 25 atm. to 240 atm.

UREA SYNTHESIS
Urea synthesis section that is the “UREA SYNTHESIS REACTOR” is the heart of
urea plant, as urea is formed only in reactor. Remaining all section of plant is for
concentration of urea. Liquid ammonia and gaseous CO2 at high pressure enter the
reactor bottom and react to form carbamate which further decomposes to form urea
and water. Ammonia at high pressure serves as motion fluid in ejector and drives
carbamate from high pressure carbamate separator to reactor. Compositions of
carbamate on mixing with NH3 are:

NH3 70.39%
CO2 17.88%
H 2O 11.73%
FLOW RATE 121393Kg/hr

CONSTRUCTION OF UREA REACTOR

Urea reactor in urea plant is a tubular plug flow type reactor .this is a vertical reactor,
made up of carbon steel. It is internal is lined with 7mm thick stainless steel. The feed
inlet is of disperse type so hole are provided for both NH 3 and CO2 inlet.

Total number of holes for NH3 -> 350

Total number of holes for CO2 -> 200

Total 10 number of sieve plates are provided over length of 22.5 m from top .These
plates gives mixing to liquid and gas and avoid the back mixing in the reactor thus
maintaining plug though reactor. Data of the plug reactor are:

Design pressure 170kg/cm2

Operating pressure 160kg/cm2
Height 40m
Shell thickness 67mm
OVER FLOW FROM REACTOR
The over flow from over flow line is taken out from reactor at a length of 2.5m from
top. The over flow stream from reactor is sent to high pressure stripper from where
carbamate is decomposed. The compositions of overflow stream are as follows:

NH3 33.88%
CO2 13.34%
UREA 33.8%
WATER 18.98%
FLOE RATE 161115kg/hr
TEMPERATURE Vary throughout the reactor
PRESSURE 156 atm.

AMMONIA STRIPPING
In stripping process carbamate is decomposed with medium pressure steam. In
presence of excess ammonia in a falling film type stripper, unconverted carbamate
present in reactor outlet solution of urea is decomposed in stripper.

Urea solution from reactor at 156 atm. and 1880C enter the tube side of stripper
operating a 147 atm. The high pressure stripper is of falling film type heat exchanger.
The stripper tubes are provided with liquid dividers are called FERRULES. These
ferrules have three equispaced on their periphery. The urea solution enters at top
tube channel and from a static liquid head over ferrules. This have drive urea solution
through holes and in to tubes where a thin film is created on tube inner surface. The
ferrules not only ensure uniform.

STRIPPING PROCESS
In stripper introduce excess ammonia along with reactor effluent. The ammonia
released as vapour by heating in stripper. This ammonia vapour increases partial
pressure of NH3 over the solution. as total pressure remain same, the partial pressure
of CO2 reduces to the lower value in accordance with the HENRY’S LAW carbamate
decomposes to increase the partial pressure of CO2 in vapour phase to approach
equilibrium concentration. Stripping reaction is thus carried out heat of
decomposition is supplied from an external source by condensation of medium
pressure steam. Condensate from a stripper shall go out to a steam condensate
separator and is send to a medium pressure decomposer shell, through level control
valve. Stripped urea solution is collected in bottom of stripper and goes to medium
pressure decomposer through a level control valve. The valve in stripper is important
because the higher level increases the residence time of urea solution in stripper
thereby increasing biuret content. Compositions of urea solution coming out of the
stripper are as follows:

NH3 24.3% by wt
CO2 5.8% by wt
H 2O 24% by wt
UREA 45.9% by wt
FLOW RATE 118627 kg/hr

The top end of stripper tube is highly susceptible to carbamate corrosion thus to
protect it from exposure to high temperature, nitrogen is periodically injected to
maintain nitrogen blanket in upper shell.

CONSTRUCTION OF STRIPPER
The stripper is a falling film type heat exchanger. It has shell and tube type
arrangements. Falling film is formed by using ferrules. Ferrules not only ensure
uniform arrangement though all tubes but also aids in continuous film on tubes inner
surface. Thus no tube on any of its portion is starved of liquid thereby preventing it
from getting overhead it from getting overhead and subsequent carbamate
corrosion.

CONDENSATION AND SEPERATION

The vapours from stripper are condensed in high pressure condenser. The carbamate
thus formed is recycled back to reactor. Vapours from stripper obtained by
decomposition of unconverted carbamate. These first enter the carbamate mixer at
147 atm. and 1900C. These vapours contain mainly of ammonia and carbon dioxide
mixed with carbamate solution from high pressure carbamate pump (high speed
centrifugal pump). They take suction from medium pressure carbamate pump. It also
maintains a minimum flow through high pressure carbamate pump by flow control
valve in discharge line. If carbamate flow to high pressure section decreases which
maintain pump though put by recycling more carbamate to high pressure condenser.
A very high condensate, flushing connection is provided on line going to kettle. The
Composition is as follows:

NH3 46.9%
CO2 20.1%
H 2O 33.98%
FLOW RATE 35713 kg/hr

MEDIUM PRESSURE SECTION

Urea solution from bottom of high pressure stripper now enters the medium
pressure decomposer after pressure reduction through a level control valve. During
experiment much of remaining cabamate flashes from NH3 and CO2 vapour, there by
concentrating urea in solution. This urea solution is further led down in pressure by
level control valve and enters low pressure section. It consists of three parts- the top
most part is medium pressure separator, the middle is medium pressure decomposer
and bottom is medium pressure urea solution holder.

MEDIUM PRESSURE SEPARATOR

The vapours from high pressure decomposer are condense in an medium pressure
condenser using ammonium carbamate solution from low pressure section with
tempered cooling water on tube side. The cabamate solution overflows from
medium pressure condenser in to medium pressure absorber where excess
ammonia, inert, a little amount of carbon dioxide separates to form vapour. These
vapours are purified in top section absorber with reflux ammonia. Ammonia with
inert gases leaving top of medium pressure absorber are mostly condensed in
ammonia condenser, with cooling water on tube side. From ammonia condenser
both liquid and gases are sent to ammonia receiver, along with incoming liquid
ammonia. The inert gases saturated with ammonia, leaving the receiver enter the
ammonia recovery tower. Here ammonia is further condenses with direct contact
with cold ammonia from battery limit and flow down to ammonia receiver. The inert
with residual ammonia from tower are sent to medium ammonia absorber where
later gets absorbed in cool condensed and recycle to medium pressure absorber as
ammonia water.

MEDIUM PRESSURE DECOMPOSER

The urea solution coming out of medium pressure stripper and containing 45.9% by
wt urea is further concentrate to 63.28% urea by wt. In medium pressure
decomposer from stripper is led down through it. There is a flushing connection and
a sampling point. The reactor drain lines also meet the stripper outlet line. It is motor
operated valve which act as a quick closing isolation valve of medium pressure
section. The urea solution from stripper at 147 atm. and 120 0C is let down to 18 atm
through level control valve and enter at top of medium pressure separator which has
the following composition by wt.:

NH3 24.3%
CO2 5.8%
UREA 45.9%
H2O 24%
FLOE RATE 118627kg/hr

As a result of pressure let down some solution flashing producing vapour of NH 3, CO2
and H2O. The heat of vaporization is taken from urea solution where the temperature
falls from 2100C down to 1400CS. This solution is taken distributed over bed of
rasching rings in medium pressure separator. The vapours rising from medium
pressure decomposer come in to intimate contact with urea solution on raschig ring
bed. Thus more carbamate decomposed by hot vapours. The vapour from medium
pressure decomposer after imparting heat for carbamate decomposition in medium
pressure separator, flows out at rate of 37113kg/hr at 18 atm. and 145 0C to medium
pressure condenser. The composition of vapour is as follows by wt:

NH3 73.36%
CO2 16.09%
H2Os 10.55%
The solution thus enriched in urea flow down and is collected on top tube sheet of
medium pressure decomposer. The decomposer is falling film type of heat
exchanger. The tubes are tight fitted with ferrules which have four tangential holes
on their periphery of size 4mm. The carbamate enter bottom of medium pressure
decomposer shell and rises to top imparting sensible heat in solution. The carbamate
thus decomposes liberating NH3 and CI2 vapours which rise up to packed bed in
medium pressure separator. The enriched urea solution falls down in medium
pressure urea solution holder at bottom and collected there. 4532kg/hr of vapour
and 473kg/hr inert from medium pressure carbamate separator enter medium
pressure holder. These vapours have following composition by wt.:

NH3 97.97%
CO2 2.03%

MEDIUM PRESSURE UREA HOLDER

These vapours enter the medium pressure urea holder above the liquid level. The
inert in vapour contain oxygen which acts as passivating agent in medium pressure
section. The medium pressure uses holder let out urea solution at 18 atm. and 156 0C
having following compositions by wt.:

NH3 7.02%
CO2 1.16%
UREA 63.28%
H 2O 28.54%

The pressure is then reduced from 18 atm. to 4.5 atm. And Solution then enters the
low pressure decomposer, it then control the level in urea solution holder. Two level
glasses are provided in medium pressure urea solution holder to monitor level
physically.

MEDIUM PREESURE CONDENSATION

The vapours from medium pressure decomposer are condensed in medium pressure
condenser with help of recycle carbonate solution from low pressure section. The
vapour from medium pressure decomposer enter bottom of medium pressure
condenser which operate at 18 atm. Before entering they are mixed with 14160
kg/hr of carbonate solution. This solution contains following composition by wt.:

NH3 61.38%
CO2 13.18%
H 2O 25.44%

Carbonate from carbonate solution pumped by carbonate solution pump and enter
medium pressure condenser at 25atm and 400C through sprayer. The cone sprayer
helps proper mixing of carbonate solution with vapour. The sprayed liquid mixtures
with vapours from medium pressure decomposer and enter condenser shell bottom
at rate of 51273kg/hr at 18atm and 1300C. The composition of mixture by wt is:

NH3 43.79%
CO2 8.52%
H 2O 47.69%
The mixture enters the shell bottom of high pressure condenser. This is a shell and
tube heat exchanger. The vapours condense in liquid carbonate medium and top of
shell.

MEDIUM PRESSURE ABSORBER

Absorption in medium pressure section is carried out in medium pressure absorber.
The vapours of ammonia, carbon dioxide and inert is in medium pressure condenser.
Outlet solution are absorbed and rectified in medium pressure absorber so that
vapours leaving contain only ammonia and inert.

51213kg/hr of liquid and vapour pressure leaving medium pressure condenser at

17.5 atm. and 800C absorber. The medium pressure absorber operates at 17.5atm. It
consists of two sections. The top section is called rectification section. It consists of
four bubble cap Trays numbered from bottom to top. The bottom portion is called
absorber.
ABSORPTION PROCESS
Ammonia reflux is introduced on tray in rectification section. The liquid and vapour
mixture from medium pressure condenser enter the absorber portion of medium
pressure absorber. After entering it flows down to bottom medium pressure
absorber and comes out of a sprayer. A liquid level is also maintained above sprayer.
The vapour pressure of ammonia, carbon dioxide and water comes out of sprayer
and get absorbed in liquid above it. This liquid level is made up of carbamate from
medium pressure condenser. Pure NH3 and NH3 solution from the rectification
section of medium pressure ammonia absorber. Ammonia and water present in
solution help to absorb the CO2 content of vapour and form carbamate. Thus CO2 in
vapour which rise to rectification section of medium pressure absorber is reduced to
minimum. The carbamate solution in medium pressure absorber provides suction to
high pressure carbamate pump at 17.5atm and 720C and has following composition
by wt.:

NH3 46.84%
CO2 20.5%
H 2O 32.66%
FLOW RATE 35013 kg/hr

Level control in medium pressure absorber bottom is very important. Firstly because
of it provide suction to high carbamate pump. Secondly if level is not sufficient,
vapours from sprayer will be absorbed in solution to little extent. This will increase
the load on rectification section and enhance the change of CO2 escaping to medium
pressure absorber over head off gas line. Medium pressure absorber level is
controlled with high pressure condensate purge connection for both tapings. Flow
from medium pressure condenser to medium pressure absorber is regulated and so
in medium pressure absorber level. Five number of sight glasses are provided besides
for physical verification. A high level in medium pressure absorber is dangerous
because this may result in liquid may carry over in medium pressure absorber off gas.
To safe guard against extraordinary high level an absorber drain is provided. This
drain line is equipped with a control valve which let down to solution to carbonate
solution tank in low pressure section. High and low pressure condensate flashing
connections are provided on sides. Medium pressure absorber is also provided with a
drain line to closed drain system with high pressure condensate connection. This is
used for raining the vessel before undertaking any maintenance jib. The vapours
rising above the liquid level, before level medium pressure absorber much have only
ammonia and inert. This is so because ammonia form vapours has to be condensed
and returned to ammonia receiver. Presence of CO2 will choke takes and heat
exchanger in these condensers will reduce. Also ammonia carbamate in the
ammonium condenser will not only corrode them but the ammonia receiver as well.
It will also cause pumping problem in ammonium booster pump by blocking the
section line from ammonia receiver. To remove possibility of CO 2 slip the vapours
pass through the rectification zone. It consists of four bubble cap trays numbered
from bottom to top. The top tray receives pure reflux ammonia at 33c at rate of
4334kg/hr. Tray number 3 receives 2247kg/hr of ammonia solution from medium
pressure ammonia absorber. It has following composition by wt:-

NH3 63.75%
H2O 34.25%
The vapours come in intimate contact with ammonia solution from top. This solution
absorbs the CO2 which react with ammonia to form carbonate. Temperature control
is important in medium pressure absorber. Each tray is provided with a temperature
tapping. Decrease in temperature profile from first tray indicates that all trays are
functioning properly. It implies that CO2 is being progressively consumed to form
carbamate. The overhead gas temperature should be minimum and around 42.5 0C.

DESCRIPSITION OF MEDIUM PRESSURE ABSORBER

The medium pressure absorber consists of four bubble trays. Each tray has 154
number of bubble caps. Vapour liquid mixture enter through an enter pipe which run
down inside column and divided equally in to four perforated arms.

These perforated pipes are submerged in carbamate solution, From where

unabsorbed gas rises. The rising vapours pass through the distributor to the
rectification section. A liquid seal of 50mm is maintined in each bubble tray fourth
and third trays are feed with pure reflux and aqueous NH3. Respectively solution
which eliminated residual CO2 and H2O from NH3 leaving medium pressure absorber.
Flushing water connections are provided on 4th, 2nd and 1st tray for washing
carbamate deposits over the trays.
MEDIUM PRESSURE AMMONIA CONDENSATION
The ammonia in medium pressure absorber off gas is condensed in ammonia
condenser. The ammonia condenser consists of two shells and the heat exchanger in
series. Vapours enter shell side and cooling water enters shell side. Both ammonia
condensers operate at 17.5atm. At this pressure it is possible to condense ammonia
with help of available cooling water at 360C. The vapour from medium pressure
absorber first enter ammonia condenser. Much of ammonia vapours condense here.
The uncondensed vapours along with condensed ammonia flow to second ammonia
condenser. Here further condensation of ammonia takes place. Thus out of a total of
22841 kg/hr of pure ammonia and 473 kg/hr of inert entering ammonia condenser,
18332 kg/hr is condensed. The remaining 4519kg/hr of ammonia stays in vapour
phase along with 473 kg/hr of inert. Both liquid ammonia and vapours from ammonia
condenser enter the ammonia receiver through separator line at 17.2atm and 140 0C.

Ammonia receiver can be isolated from by two isolation valves in liquid line and one
valve in vapour line. Cooling water first enter condenser shell, then goes to ammonia
condenser. Cooling water outlet from is required by control valve. A line is taken
from the cooling water and outlet line. It is connected to cooling water circulation
pump, discharge line of medium pressure condenser to supply cooling water when
necessary. High pressure condenser flushing connection is provided in ammonia
condenser to ammonia receiver.

AMMONIA RECEIVING
Liquid ammonia from plant battery limit and recovered ammonia from ammonia
condenser and medium pressure section is collected and stored in a ammonia
receiver. Ammonia receiving system consists of a receiver portion and an ammonia
recovery tower. The tower is installed on receiver as an integrated part. The receiver
holds ammonia at 17.2 atm and 350C. Liquid ammonia at 23atm pressure and 120C
temperature comes to plant through isolation valves. It enters through a filter. The
filter can be bye passed also. This first filter is connected to vent connections. Then
the incoming liquid passes through flow totaliser. This send impulse to a control
panel, this can be isolated sand bye passed. 30694 kg/hr of liquid ammonia enter the
ammonia receiver through level control valve. A portion of this ammonia, enter the
top of ammonia recovery tower.
The tower is a packed column which operates at 17atm vapour consisting of
ammonia and inert rise from the ammonia receiver and enter bottom of ammonia
recovery tower. The vapour on rising come in intimate contact in packed bed with
fresh liquid ammonia falling from top.

The ammonia vapours thus condense giving away heat of condensation to liquid
ammonia. The liquid ammonia then flows down to ammonia receiver. The vapours
from ammonia recovery tower containing 147kg/hr of inert at 1.7atm and at 35 0C
flow to medium pressure ammonia absorber. The recovered liquid ammonia from
ammonia condenser flows down to ammonia receiver at a value of 18322 kg/hr at
17.2atm and 490C.

MEDIUM PRESSURE ABSORBER AND INERT WASHING

Vapours from top of ammonia recovery tower are scrubbed and washed in medium
pressure ammonia absorber and inert gas washing tower.

This equipment consists of an absorber portion. It is a single pass shell and tube
falling film heat exchanger.An inert washing tower is mounted on its top. This tower
is equipped with three trays. Cooled condensate is introduced on top trays of inert
washing tower. Ammonia vapour and inert enter the bottom tube channel of
medium pressure absorber. Cooling water is circulated on its shell side. The vapours
form ammonia recovery tower enter bottom tube channel of medium pressure
absorber consist of 1477 kg/hr of inert. Cooled condensate introduced in inert
washing tower above comes on top tube. Shell tubes are fitted with ferrules. The cold
condensate comes down through tangential holes of ferrules along the walls of
tubes. It forms weak ammonia solution on absorbing ammonia vapours. This weak
ammonia solution flows down the tubes. In this process it absorbs the ammonia
vapours rising from bottom tube channel to medium pressure ammonia absorber.
The resultant heat of absorption is removed by cooling water on shell side. The
ammonia solution thus form flow out of tubes and is collected in bottom of medium
pressure ammonia absorber at rate of 2247kg/hr. This solution has following
composition:

AMMONIA 65.75%
WATER 34.25%
This is pumped by ammonia solution pump to medium pressure absorber provided in
this line central level in medium pressure ammonia absorber bottom. The vapour
from medium pressure absorber enter the bottom tray of inert washing tower
condensate is cooled by cooling water in steam condensate. Cooler enter top tray of
inert washing tower. The residual ammonia

Vapour come in intimate contact with cool condensate in each of three trays and get
absorbed. Thus ammonia is complete washed from the vapour leaving only trays.

LOW PRESSURE SECTION

The urea solution from medium pressure decomposer bottom enters the low
pressure decomposer, after expansion through a level control valve. As a result of
expansion most of remaining carbamate undergoes decomposition. Thus urea
solution further concentrated and sent to vacuum section through a level control
valve. The vapours enter the low pressure condenser shell and get absorbed in an
aqueous carbmate solution from waste water solution. Low pressure condenser has
cooling water on tube side.

The liquid thus formed goes to carbamate solution tank from where it is recycled
back to medium pressure condenser. The inert gases from tank containing ammonia
is absorbed in cooled condensate in low pressure ammonia absorber, washed in inert
washing tower and sent to vent stack. The liquid flows down to tank. The urea
solution flowing out of medium pressure urea solution holder and having 63.28% by
wt. Urea is further purified by 71.12% by wt. Urea in low pressure decomposer. The
low pressure decomposer consists of three parts:

The top part low pressure separator

The middle is low pressure decomposer and

Bottom is low pressure urea solution holder.

LOW PRESSURE SEPARATOR
The urea solution from medium pressure solution holder at 18atm and 156c has
following compositions:

NH3 7.02%
CO2 1.16%
UREA 63.28%
H 2O 28.54%
FLOW RATE 86040 kg/hr

It is let down to 4.5atm through level control valve and enters at low pressure
separator. The reduction in pressure causes some of unconverted carbamate solution
to flash and generates vapours of NH3, CO2 and H2O. The heat of vaporization is
supplied by solution itself, whose temperature consequently falls from 156 0C to
1280C. The solution is then distributed over a bed of rasching ring in low pressure
separator. The hot vapours from low pressure decomposer come in to intimate
contact with urea solution on rasching ring bed. The heat exchange between rising
vapourS and down going solution results in decomposition of carbamate still present
in solution.

LOW PRESSURE DECOMPOSER

The vapours from low pressure separator flow out to low pressure condenser. The
composition of this vapour steam is as following:

NH3 49.15%
CO2 4.07%
H2O 46.77%
FLOW RATE 9480 kg/hr
INERT 52 kg/hr

The solution thus enriched in urea flow down and is collected on top tube shell of low
pressure decomposer is a falling film type of heat exchanger. The tubes are filled with
ferrules or liquid dividers. These ferrules have tangential holes on their periphery.
The urea solution flow down in test tube of low pressure decomposer and form a
level over ferrules. The liquid head thus formed drives urea solution through holes of
ferrules along inner wall of tubes. In this manner thin film is created on inner surface
of tube. 54kg/hr at 4.5atm saturated steam is supplied to shell side of low pressure
decomposer. The urea solution film on tube inner surface take heat from 4.5atm
steam and remaining carbamate in urea solution decomposes into NH3 and CO2.
These hot vapours then rise to packed bed in low pressure separator and carry on
composition.

LOW PRESSURE UREA SOLUTION HOLDER

The urea solution finally flows out of low pressure decomposer and is collected in low
pressure urea solution holder. The urea solution contain following composition:-

NH3 1.8% by wt
CO2 0.8% by wt
UREA 71.2% by wt
H 2O 26.28% by wt
FLOW RATE 70560 kg/hr

Level in low pressure urea solution holder is controlled and let down the urea
solution at 4.5atm & 1380C to evaporation section which operate under vacuum.

LOW PRESSURE CONDENSATION

Vapours from low pressure separator are condensed in low pressure condenser with
help of recycle carbonate from distillation tower reflux pump. Low pressure
condenser is a shell and tube type heat exchanger. Vapours and recycle carbonate
enter shell side vapours at rate of 9486 kg/hr are mixed at first with recycle
carbonate solution from distillation tower reflux pump. The composition of vapours
by wt is as follows:

NH3 49.15% by wt
CO2 4.07% by wt
H 2O 46.77% by wt
INERT 52 kg/hr

This recycle carbonate line is provided with low pressure condensate flushing
connection. The recycle carbonate has following composition by wt:

NH3 34.87% by wt
CO2 18.55% by wt
H 2O 46.55% by wt

The recycled carbamate is distributed through a sprayer in low pressure separator to

low pressure condenser. This ensures the proper mixing of vapour and liquid.
Mixture then enters the low pressure condenser shell at bottom and rise to top. The
vapours condense in liquid medium while rising. The heat of condensation is carried
away by cooling water on tube side. Most of vapours get condensed in low pressure
condenser. The uncondensed vapours, inert and carbamate together overflow out
low pressure condenser. Air vapours and inert disengage from carbamate solution
and flow out to arbamate solution tank from separator top. The carbamate solution
flows down to carbamate solution tank from separator bottom. The carbamate
solution at outlet of low pressure condenser at 4atm and 400C has following
composition by wt.:

NH3 44.61% by wt
CO2 8.68% By wt
H 2O 46.7 by wt
FLOW RATE 13900 kg/hr
INERT 52 kg/hr
CARBAMATE SOLUTION TANK
The carbamate solution from low pressure condenser is finally collecting carbonate
solution tank at 4atm and 400C. Carbamate solution from low pressure ammonia
absorber and inert washing tower is also connected here. The carbonate solution
tank stores carbonate solution having following composition:

NH3 43.29% by wt
CO2 8.52%by wt
H 2O 37.69%by wt

A steam sprayer is provided at bottom of carbonate solution tank. Low pressure

steam is introduced in sprayer whenever the carbonate solution temperature falls
down especially during long shutdown. In this way carbonate is prevented from
crystallizing. The carbonate solution tank provides suction to medium pressure
carbonate solution pump. The suction line is provided with a low pressure
condensate flushing connection. A cooled condensate connection from steam
condensate cooler is also provided to suction line to build up level in carbonate
solution tank whenever required.

LOW PRESSURE ABSORPTION AND LOW PRESSURE INERT

WASHING
The vapours and inert from carbonate solution tank are absorbed in low pressure
ammonia absorber and subsequently washed in low pressure inert washing tower
before being vented out. Low pressure ammonia absorber is a shell and tube type
Heat exchanger. Low pressure inert washing tower consisting of three trays are
mounted directly mounted on carbonate solution tank. Cooled condensate from
steam cooler flows on top tray of low pressure inert washing tower at following
conditions:-

FLOW RATE 260 kg/hr

PRESSURE 31 atm.
TEMPERATURE 400C
The condensate flow rate is controlled which also reduces the pressure of that
system. This flow rate includes cold condensate flow suction line. Cooling water flows
in a shell side of low pressure ammonia absorber from bottom to top. The vapour
from carbonate solution tank enter bottom of low pressure ammonia absorber.
Cooled condensate entering low pressure inert washing tower flows down to three
trays. The inert rising from carbonate solution tank enter low pressure inert washing
tower. The residual NH3 and CO2 are washed off by the cooled condensate on trays
forming a weak carbonate solution. The inert then go out at rate of 52 kg/hr. The
weak carbonate solution then flow down into tubes of low pressure ammonia
absorber from top through ferrules. The solution flow down in form of a thin film
along walls. It comes in contact with vapour rising from carbonate solution tank. The
NH3 and CO2 vapours are absorbed in weak carbonate solution which then flows out
and is collected in a carbonate solution tank. The heat of absorption is disugrated to
cooling water on shell side of low pressure ammonia absorber.

VACUUM AND EVAPORATION SECTION

Concentration urea solution becomes 70.7% after low pressure decomposition
reaction. This solution is further concentrated in vacuum system with a pressure of 3
atm. and 0.3atm. Concentration is done at vacuum concentration, it may be done
with low temperature of system.

FIRST VACUUM CONCENTRATION

Low pressure solution from low pressure urea holder having 71.10% by wt. Urea is
concentrated at about 9.5% by wt. Urea in vacuum concentrator which operates at
0.3atm.Low pressure urea solution forming out from low pressure urea solution
holder is led down from 1.4atm and 1390C to 0.3atm through level control valve
during this pressure reduction much of water in urea solution flashes. The heat of
vaporisation of water is supplies low pressure urea solution itself, thereby reducing
temperature 1380C to 1000C. The low pressure urea solution them goes to bottom of
1st vacuum concentrator through a three way valve. Low pressure condensate
flushing and drain connection are provide in this line. A three way valve is provided in
low pressure urea solution line from low pressure urea solution urea holder. This may
be used to stop low pressure urea solution flow to first vacuum concentrator and
divert it to urea solution tank in case of shutdown of vacuum evaporation section. A
control valve is provided to regulate the flow of low pressure urea solution to urea
solution tank. Line from 3 way valve is joined by a recovery line measure flow going
in to I vacuum concentrator. It is a climbing film shell and tube type heat exchanger
operating at 0.3atm. Low pressure solution enters the bottom channel of 1 st vacuum
concentrator and travel upward forming a film on inner surface of tubes. The low
pressure saturated steam on shell side supplies heat to low pressure urea solution
film in tubes. The water contained in solution start vaporising taking heat from
steam. Finally urea solution comes out from top of first vacuum. Concentrator and
flashes in to first vacuum separator.

FIRST VACUUM SAPARATION

Urea solution from 1st vacuum concentrator is separated from vapours in 1st vacuum
separator. The urea solution coming out of 1st vacuum concentrator also contains
vapours of water, ammonia and carbon dioxide. Urea solution enters tangentially
into circular hood. This led to separation of vapours containing mostly water and
little ammonia and carbon dioxide from urea solution. The urea solution after
impingement falls down to bottom of 1st vacuum separator by gravity and vapour rise
to top. The urea solution then flows out to 2nd vacuum concentrator at 0.3atm and
1280C. It has following composition:

NH3 7% by wt

CO2 3.11 by wt
UREA 0.49 by wt
H 2O 89.41 by wt
FLOW RATE 19515 kg/hr
Three sight glasses are provided in bottom of 1st vacuum separator for visual
inspection. The vapour contain following composition:

NH3 0.02%by wt
CO2 0.01%by wt
UREA 94.97%by wt
H2O 5%by wt
FLOW RATE 57255 kg/hr

SECOND VACUUM CONCENTRATOR

First vacuum separator from vacuum 1st separator in concentrated from 94.97% by
wt urea to 99.7% by wt in second vacuum concentrator which operates at 0.03atm.
first vacuum urea solution at 0.3atm and 1280C from first separator flows out to
second vacuum concentrator which operate at 0.03atm, thereby creating pressure
gradient. Second vacuum concentrator is a climbing film shell and tube type
exchanger. First vacuum urea solution flows in tube side and low pressure saturated
steam in shell side. First vacuum urea solution enter bottom of second vacuum
concentrator tube channel and climbs up forming a film in tube inner surface. The
remaining water, ammonia and carbon dioxide in first vacuum urea solution vaporize
at this low pressure at 0.03atm. During its upward climb the heat of vaporization is
supplied by low pressure saturated steam on shell side. Thus first vacuum urea
solution get concentrated to 99.7 % by wt Urea and flows out to second vacuum
separator at 1400C. The lines from first vacuum separator to second vacuum
separator form a lute. This lute is provided with a drain connection. Low pressure
condensate and low pressure steam flushing connection are also provided to lute to
clear this line if it gets check with urea.

SECOND VACUUM SEPARATOR

The urea melt from second vacuum concentrator flashes into second vacuum
separator where it is separated from water, ammonia and CO2 vapours. The solution
vapour mixtures the top of separator tangentially which facilitates the separation of
two phases. There is circular hood all around. The urea melt after separation falls
down by gravity into a holder at 0.03atm and 1400C. It has following composition by
wt.:

UREA 99.7%
WATER 0.3%
FLOW RATE 54350 kg/hr

Level control in holder is very important as it provided suction on melt urea pump. As
holder is under a low pressure of 0.03atm at a minimum liquid head must be
maintained above suction pump to provide necessary NPSH. This is ensured by
maintaining level in holder. A high level will increase residence time of urea melt at
1400C and thus more biuret will be formed. The vapour separated from melt urea rise
to top at 0.03atm and 1400C. It has following composition-

NH3 0.41% by wt
CO2 0.2% by wt
UREA 6.51% by wt
H 2O 92.85% by wt

A low pressure flushing condensate is provided to top dome of second vacuum

separator with a spray nozzle for better flushing. The vapour outlet nozzle from
second vacuum separator is provided with a washing tore with holes. Low pressure
condensate is provided to washing tower.

FIRST VACUUM SYSTEM

First vacuum separator controls the vacuum pressure in first vacuum concentrator
and first vacuum separator. Water, ammonia and carbon dioxide vapour from first
vacuum separator at 0.3atm and 1300C flow to shell side of first condenser. This is a
horizontal shell and tube heat exchanger. Cooling water from outlet of first
condenser flows in to tube side of first condenser. Low pressure condensate flushing
connections are provided at several points on shell side of first condenser. The above
maintained vapours get condensed here to quite an extent. The condensate then
flow down to waste water tank. The uncondensed vapours are ejected out to second
condenser. These vapours enter shell side of second condenser where they condense
with the help of cooling water in tube side. The operating pressure in second
condenser is higher than first condenser.

SECOND VACUUM SYSTEM

Second vacuum system controls the vacuum pressure in second concentrator. The
vapour from second vacuum separator at 0.03atm and are first boosted by steam jet
ejector to a higher pressure. It is required to boost the pressure here as it is difficult
to condense the vapour at low pressure of 0.03atm with help of cooling water at
available temperature. Low pressure steam is used as motive fluid in steam jet
ejector. The vapours are discharged to shell side of condenser. Cooling water flows in
tube side and help in condensing the vapour. The condensate flows out of the waste
water tank. Low pressure condensate flushing connections are provided t several
point on shell side along the length of first condenser to remove urea deposits. These
deposits reduce heat transfer. The uncondensed vapours from first condenser are
driven to second condenser by first stage ejector. Low pressure steam acts as motive
fluid. The vapour and steam enter the shell side of second condenser. Cooling water
flowing on tube side condense these vapour. The condensate flows down to waste
water tank. The uncondensed vapours from second condenser are ejected out to
final condenser by second stage ejector.

FINAL CONDENSATION
The uncondensed vapours from first vacuum system and second vacuum system are
finally ejected to final condenser which operates at slightly higher pressure than
atmospheric pressure. The vapour enters the shell side. The cooling water flowing on
tube side condense the vapours. The condensate flows down the waste water tank.
The non condensed vapour flows out to pot where entrained liquid separates and
flows out. The non condensable are verged out to atmosphere from pot’s top.

UREA MELT PUMPING

Urea melt from holder having 99.7% by wt. Urea is pumped by melted urea pump.
Melted urea pumps are centrifugal pump located sufficiently below the holder so as
to provide the required NPSH. Holder collects urea melt from second vacuum
separator and provides suction to urea melt pump. The common suction line from
holder to melted urea pump is steam jacketed so as to any possibility of crystallisation
of urea melt. This line is then divided into branches with separate isolation valves to
provide suction to both melted urea pump. Low pressure steam and connection are
provided to each of suction lines.

UREA 99.7% by wt.

H 2O 0.3 % by wt.

The urea melt is then pumped to a pressure of 15 atm and discharged to the top of
prilling tower. The discharged line from each pump is provided with a pressure
condensate flushing connection. The common discharge line is steam jacketed is
provided in discharged line which controls the level in holder.

PRILLING SECTION
Melt urea from the discharged of melted urea pump is sent to top of prilling tower
where urea prills are made.

Urea melt enter the prilling section from both urea units 11 and 21 through steam
jacketed lines. Before entering the prilling bucket both these urea melt lines join
together. Two three way valves are provided individually on both the lines. These
three way valves will normally allow urea melt to flow to prilling bucket. But in case
when prilling has to be diverted, these ways valve will divert the urea melt to urea
solution tank. Both these three ways valves are operated by manual switches.

As long as prilling is being done the urea melt return lines to urea solution tank.
Which are continuously kept flushed with washing stream. At that time washing
stream to line from prilling bucket stand close. It will open when urea melt is diverted
to urea solution tank.
Prilling tower is natural draft type of tower. Melt urea at rate of 54350kg/hr from
each unit and at about 15 atm and 1490C is pumped into a prilling bucket at the top
of prilling tower. The prilling bucket is housed in the ceiling of prilling tower. Only one
prilling bucket is kept in line and other is kept spare. Prilling bucket is driven by an
electric motor. Speed of prilling bucket can be varied to control prill stze. It is
increased to reduce the size. A high temperature switch is provided at top of prilling
bucket which will sound an alarm at 1300C. This in turn will imply that level in prilling
bucket is going high. Thus its speed must be increased to avoid overflow. Melt urea
comes out of holes of rotating prilling bucket in form of fine droplets. These droplets
are distributed uniformly throughout the cross section of prilling tower by centrifugal
force imparted by rotation of prilling bucket. These droplets then start falling down
the height of prilling tower. Ambient air enters the bottom of prilling tower through
louvers and rise upwards. During its rise the air comes in contact with urea melt
droplets. Thus the urea melt droplets at 1490C first cool down to 132.70C where they
solidify into prills. On travelling down further they are sub cooled to about 60 0C. The
heat generated during urea solidification and cooling is dissipated to incoming
ambient air. In this process the air get heated becomes lighter and thus rises upwards
creating natural draft. The solidified prills falls on rake floor at bottom of prilling
tower. They are then separated by a rotating scrapper though a slit onto prilling
tower belt conveyor. From conveyor the urea prills falls on the lump separator. The
urea lump are separated from prills and conveyed to a urea lump dissolving tank by
urea recycle belt conveyor. The urea prills pass through the lump separation onto the
product belt conveyor.

The heated air along with some urea dust rise upward and enter urea dedusting
system where urea dust is reclaimed. The holes in prilling bucket normally get
clogged by urea melt and other foreign particles after being in constant operation,
this result in improper prill size distribution. Thus the prilling bucket in operation
needs periodic washing and cleaning. For this purpose a prilling bucket cleaning
water tank is provided n prilling tower top.