PROCESS DESCRIPTION OF UREA PLANT

Tata Chemicals owns fertilizer complex at Babrala. It has adopted

Snapgrogetti NH3 stripping process for the production of urea. It has two
identical units (11 and 21) of the same nameplate capacity 1750 MTPD each,
so the total capacity is 3500 MTPD.

RAW MATERIALS REQUIRED FOR UREA PRODUCTION

The raw material condition at the battery limit is as under:

Ammonia:
NH3 min – 99.5% wt
Oil – 10 ppm max
Water – 0.5% wt

Carbon di oxide:
CO2 (dry basis) – 98.7% vol.min
Inerts - 0.5 % vol. min
H2 – 0.3 % vol. min
H2O – saturated

UTILITIES CHARACTERISTICS

Cooling water:
Pressure (norm/degn) – 3.5 / 6.0 kg/cm2g
Inlet temperature – 35 0C
0
Outlet temperature – 45 C
Fouling factor – 0.0004 m2 h 0C/kcal

Electric power:
Alternating current – 11 KV 50Hz 3ph
– 3.3kV 50Hz 3ph
–415 V 50Hz 3ph
Direct current – 115 V 1Ph

Service air:
Moister – saturated
Pressure (norm/degn) – 7 / 11 kg/cm2
Temperature – 40 0C

117
Instrument air:
Pressure – 7 / 11 kg/cm2
Temperature – 40 0C
Type – Oil free
Dew point - -20 0C max at 7 kg/cm2

Polished water:
Conductivity – 0.2 s cm-1
Silica (reactive) – 0.02 s cm-1
Fe – 0.01 ppm
TDS – 0.1 ppm
Oil – 0.5 ppm
pH – 7

Nitrogen:
Nitrogen plus noble gases – 99.6% vol
CO2 – 20 ppm max
Water – 20 ppm max
Oxygen – 200 ppm max
Pressure (min/norm) – 5/7 kg/cm2
Temperature – ambient

UREA PRODUCTION PROCESS

Urea is commercially manufactured by direct synthesis of gaseous carbon

dioxide and liquid ammonia.
The urea production involves following steps:
Urea synthesis and high pressure recovery
Urea purification in medium and low pressure recovery
Urea concentration
Pre vacuum concentration
Vacuum concentration
Urea Prilling & BFC
Waste water treatment

118
1. UREA SYNTHESIS AND HIGH-PRESSURE RECOVERY
For urea production raw materials (liquid ammonia and gaseous carbon
dioxide) are supplied by the ammonia plant.
The liquid ammonia is pumped at high pressure through an ejector into the
reactor. The ejector serves as drive-less pump to recycle back ammonia and
CO2 mixture at high pressure known as carbamate into the synthesis loop.
CO2 mixed with small but measured quantity of air is compressed in a four-
stage compressor up to synthesis pressure. CO2 from the compressor outlet
is fed to the reactor. The NH3 and CO2 react in the reactor to form an
intermediate product, ammonium carbamate (NH4COONH2). This
intermediate product dehydrates to form urea and water. The oxygen in the
air forms a passive oxide layer (chromium oxide) on the inner surface of the
vessel to prevent corrosion by carbamate and urea.
The reaction products from the reactor overflow to the stripper where the
unconverted carbamate is decomposed back into the constituents with the
help of the heat supplied by MP steam. The stripper is basically a falling film
exchanger with urea solution on the tube side and MP steam on the shell
side. The urea solution obtained at the bottom flows to MP section through a
level control valve.
The vapors from the stripper top enter the HP carbamate condenser along
with the carbamate solution from MP section. Here they condense to form
carbamate solution again and in the process releasing a large amount of heat
of condensation, which is utilized to generate the low-pressure steam on the
shell side. Vapors consisting mainly of inert are sent from the carbamate
separator to the bottom of the MP decomposer to passivate the MP section

2. UREA PURIFICATION
Urea purification takes place in two stages. One is known as MP section and
the other is known as LP section.

MEDIUM PRESSURE SECTION

Urea solution from the bottom of the stripper enters into the MP Pre
decomposer & then enters in the MP decomposer, during the expansion most
of the remaining carbamate flashes forming the NH3 and CO2 vapors,
thereby concentrating the urea solution. The vapors from the MP decomposer
top flows to pre vacuum concentrator shell side and from pre vacuum
concentrator to MP condenser shell side. Prior to the entry of the vapors in
the pre vacuum concentrator the vapors get mixed with the low
concentration carbonate solution from the LP section. The partly condensed
gas mixture from MP condenser outlet goes to MP absorber where the CO2 is
absorbed from the NH3 Reflux and the pure NH3 vapors from the MP
absorber flows to the ammonia condenser. The solution at the bottom of the

119
MP absorber provides the suction for the HP carbamate pump. Ammonia
condenser has cooling water on tube side.

From ammonia condenser both vapor and liquid ammonia flow to the
ammonia receiver tank. The receiver tank also receives fresh ammonia from
the ammonia plant. The inert gases saturated leaving the receiver enters the
ammonia recovery tower, where ammonia is further condensed by direct
contact with cold ammonia from the battery limit. The inert with residual
ammonia from the tower are sent to MP inert wash tower via a condenser.
The ammonical solution collected at the bottom is recycled back to the MP
absorber.

LOW PRESSURE RECOVERY

The urea solution from MP decomposer bottom enters the LP decomposer

after expansion through a level controller. Consequently most of the residual
carbamate is decomposed and in the process urea solution gets
concentrated. The remaining carbamate is decomposed in falling film
exchanger, which is a part of LP decomposer.

The vapors from the LP decomposer enter the LP condenser where they get
cooled and liquefied. Prior to entry of LP off gases in LP condenser the vapors
get mixed with aqueous solution from wastewater section. The vapors thus
formed get condensed in LP condenser goes to carbonate solution tank from
where it is sent back to MP condenser. The inert gases in the tank contain
considerable amount of ammonia and thus are absorbed in cooled
condensate before being sent to the vent stack.
The urea solution at the bottom of LP decomposer is sent to pre vacuum
concentrator through a level controller valve.

3. UREA CONCENTRATION

PRE VACUUM CONCENTRATOR

The urea solution from LP decomposer enters the pre vacuum concentrator,
which is an exchanger with urea solution from the LP section on tube side
and MP decomposer off-gases on the shell side. The MP decomposer off-
gases give their heat and the urea solution gets concentrated in the process.
The pre vacuum concentrator operates under vacuum and the vapors from
the top are condensed in the pre vacuum condensers. The vapors condensing
in the pre vacuum condenser are collected at the bottom in vacuum system
tank and the liquid is sent to the waste water section.

The concentrated urea solution from the bottom is sent to the vacuum
concentration section.

120
VACUUM CONCENTRATION

The urea solution from the pre vacuum section bottom gets further
concentrated up to the concentration required for prilling in two vacuum
concentrators in series. The heat for concentrating the urea solution is
supplied by low-pressure steam. The vacuum is maintained in both the
stages with the help of ejectors and condensers. The urea solution from the
outlet of second vacuum concentrator has 99.7 %( w /w) concentrations and
is pumped to prilling section. The vapors from both the stages get condensed
in the condensers and are sent to the waste water section.

4. PROCESS CONDENSATE (WASTE WATER) TREATMENT

The process condensate containing water, urea, NH3 and CO2 from the
process, the condensate from vacuum and pre vacuum concentrator ejector/
condensers are collected in a waste water tank. From here it is transferred to
the distillation tower where it is fed in the upper portion of the distillation
tower. The stripping medium is low-pressure steam fed at the bottom of the
tower. The NH3 stripped liquid is then pumped to the hydrolyser where the
urea is hydrolyzed i.e. converted back into NH3 and CO2. The hydrolysis
takes place with the help of the superheated steam. The wastewater from the
hydrolyser outlet contains only few ppm of urea but still has NH3 in it. So the
wastewater from the hydrolyser outlet is again fed to the lower portion of the
distillation column where the remaining NH3 is stripped off and the
wastewater at the distillation tower at the bottom contains only few ppm of
NH3 and urea. This treated water is sent to O&U plant for reuse. The vapors
from the distillation tower and hydrolyser get condensed in the overhead
condenser and are recycled back to the LP section and a part of it is used as
reflux for distillation column. The distillation column has a modified valve
tray.

5. UREA PRILLING
The urea melt from the second vacuum concentrator is sent to the prilling
bucket. The urea melt comes out from the bucket in the form of liquid drops
and they fall along the prilling tower. The drops get solidified and cooled by
the counter current flow of air from the bottom of prilling tower. The
solidified urea melt drops known as urea prills, fall on the prilling tower
bottom. These prills are collected by a rotating scrapper and are sent to the
bagging plant with the help of belt conveyors. The heated air containing 50
ppm of NH3 is released from the top into the atmosphere.

121
6. UREA BULK FLOW COOLER

After de-bottle neck of urea plant, the urea prills temperature has increase
considerably due to limitation of Prilling tower. Apart from caking, high prills
temperature also causes inconvenience in product packaging plant, where
packaging is done by semi automatic process and workmen are directly
exposed to hot Urea prills. To overcome this problem, urea prills are cooled
by water in plate type heat Exchanger called - Bulk flow cooler is installed.
BFC is kept in line when urea prills temperature are increase by greater than
70 0 C
Cooling by water in Plate type cooler technology for urea prills cooling
system using water as cooling medium is available with only one party i.e.,
M/s Bulk Flow Technologies Inc. Canada and Known as Bulk flow cooler
(BFC). In this type of system, urea prills are cooled by exchanging heat in
vertical plate type of heat exchanger. This system requires less space and
lower operating cost with lower power consumption. The undersize fraction
and moisture content of urea at the outlet of the cooler remain unchanged.
The main equipments are bulk-flow cooler, D.M. water tank, D.M. water
circulation pump, D.M. water-cooler and heater, air heating /cooling unit , air
blower , urea dust separator unit and inlet and outlet conveyors.

STEAM AND CONDENSATE SYSTEM

The steam networks in the urea plant are as:

1. Superheated steam (KS) network at P = 110 kg/cm2g & T = 510°C
2. Superheated steam (HS) network at P = 37 kg/cm2g & T = 381°C
3. Saturated steam (MS) network at P = 22 kg/cm2g & T = 219°C
4. Saturated steam (LS) network at P = 3.5 kg/cm2g & T = 147°C
5. Saturated steam (LMS) network at P = 4.7 kg/cm2g & T = 160°C

KS NETWORK:
The steam is available at urea plant battery limit and is utilized to drive the
CO2 compressor turbine. It may be used to provide the MS steam in case of
failure of turbine extraction steam

HS NETWORK:
This steam is available at the point battery limit and is utilized in hydrolyzer.

MS NETWORK:
This steam is extracted from the CO2 compressor turbine and is de super
heated to make it saturated. This steam is utilized in the stripper and MP
decomposer.

LS NETWORK:
This steam is produced in the HP carbamate condenser shell & is used in the
following equipments / systems:
1. LP decomposer

122
2. First vacuum concentrator
3. Second vacuum concentrator
4. Distillation tower bottom
5. Prevacuum / vacuum system ejectors
6. Steam tracing
7. Steam jackets
8. MP start up lines
9. MP inert gas wash tower vent line
10. Steam condensate collector tank
11. Blow down vents, ME-14, ME-15, ME-21
12. PSV flushing/heating
13. Mech seal/ jacket flushing of P-08, P-09, & P-20
14. Utilities points
15. BFC and NEEM oil system

LMS NETWORK:

This steam is produced by boosting LS pressure with the help of an ejector

with MS as motive fluid. The steam is utilized in the MP decomposer and it’s
pre-heater.

CONDENSATE COLLECTION:
Turbine condensate is exported to O & U for steam generation. MS & HS
condensate known as MC & HC respectively is utilized for LS generation in HP
carbamate condenser shell.

LS condensate known as LC from all the sources in the plant is collected in a

common tank as steam condensate tank. From where it is used for flushing
purpose and the excess condensate is exported to O&U.

FLUSHING NETWORK:

Condensate in the steam condensate tank is utilized to provide flushing water

requirement in all the sections of the plant. There are three types of
network:
KW NETWORK: Flushing water at pressure of about 180 kg/cm²a

HW NETWORK: Flushing water at pressure of about 25 kg/cm²a

LW NETWORK: Flushing water at pressure of about 10 kg/cm²a

123
DETAILED DESCRIPTION OF THE PROCESS
Prior to synthesis in the HP section of the plant the raw materials for urea
production i.e. NH3 & CO2 are not at the required synthesis pressure &
temperature, so they need to be brought to the synthesis condition. Here is
being described first the CO2 compressor section and then the rest of the
plant below.

AMMONIA PUMPING

Liquid ammonia before feed to the reactor R-01 is first boosted from 16.5 ata
to 22.4 ata in by NH3 booster pump P-05 and then pressurized from 22.4 ata
to about 240 ata by HP NH3 feed pump P-01A/B.

Liquid ammonia at B.L. is available at 25 ata & from –33°C to 28°C. It first
enters the top of the ammonia recovery tower C-05, where it absorbs the
NH3 ammonia vapors coming out from the receiver tank (V-01) along with
the inert, and then falls into the receiver tank. The level in the receiver tank
is controlled by a level controller LC106. The flow is recorded by FQ104.
Ammonia recovered from the ammonia condensers E-9A/B is also collected
into V-01. This ammonia receiver tank V-01 provides suction to the ammonia
booster pump P-5A/B.The discharge of this pump provides suction to the HP
ammonia feed pump P-1A/B and part of P-5 discharge is also sent as reflux
to MP absorber C-01.

HIGH PRESSURE AMMONIA PUMP P-1A/B:

Ammonia from P-5A/B discharge forms the suction for the P-1A/B. This is a
triplex plunger-reciprocating pump driven by the HT motor. The pump is
driven by VFD and is equipped with gearbox and crankcase as its main parts.
The VFD motor is used to provide variable speed to the main pump (P-1).The
suction and discharge line each have a dampener. The suction dampener
MV12A/B is jacketed with LS flowing in its jacket. The discharge pressure in
the common discharge header is indicated by PT30 and PT12.

For plunger sealing water is used now and lube oil was used previously. The
condensate outlet from the water sealed pump goes to waste water
treatment section via closed drain system.

In the case of water sealed pump the sealing water comes through a filter
from the discharge of P-22 via E-21. The flow of sealing water is maintained
at 0.15 -0.6 liter per minute per plunger. The pump discharge at about 240
ata is sent to the reactor, after preheating it in ammonia pre heater (E-4).
The pump has recycle line to V-1 and a tapping in common discharge line for
ammoniation of HP loop during cold start up.

124
For the lubrication of crank case two pumps P-29 and P-31 have been
provided and while gear box has internally mounted pump (MOP) for its
lubrication.
P-01 plunger external lubricating oil is collected into a separator. Its
condensate is sent into V-07 and separated oil sent into S-20

UREA SYNTHESIS

1. HIGH-PRESSURE SECTION

Liquid ammonia from HP ammonia feed pump P-1A/B discharge goes to

ammonia pre-heater exchanger (E-4) tube side, where it gets preheated by
LP decomposer MV-03 off gases. The liquid ammonia from E-4 outlet goes to
the reactor via ejector EJ-01. This liquid ammonia coming in EJ-01 is used as
motive fluid to recycle carbamate from E-5 to the reactor. A pressure
controller PV12 guides ejector needle movement. Prior to the ejector a block
Valve, NRV and a motorized valve MHV07 are provided in the ammonia feed
line to the reactor. A thermocouple TE-15 and PG are provided in the
ammonia line in the upstream of the MHV-07.

Gaseous CO2 from compressor at the discharge pressure of 160 ata comes to
the reactor through a separate line having a vent valve PV-03, motorized
valve MHV-08 and ROV (remotely operated isolation valve) HV-01, prior to
the entry in the reactor. Two NRV are also provided in the CO2 feed line to
avoid the back flow of reactor solution.

A drain line u/s of HV-01 is provided in CO2 line to allow the draining of the
reactor during long shut down.

Liquid ammonia and gaseous CO2 enter through separate nozzles in the
reactor and upon entry in the reactor the following reaction takes place:

2 NH3 (liq.) + CO2 (gas) NH2COONH4 (liq.) + 38.1 Kcal/gmol

This is an exothermic reaction and goes to completion instantaneously. This

carbamate then slowly proceeds to form urea and water by dehydration.

NH2COONH4 NH2CONH2 + H2O -7.1 kcal/gmol

This is an endothermic reaction and heat of reaction is supplied by the heat

librated during the first reaction. The net reaction is exothermic.

Both the reactants and the recycled carbamate rise from bottom of the
reactor towards the top and when the reactor is completely filled, the urea
solution containing urea and NH3, CO2, H2O in the form of carbamate comes
out of the reactor through an overflow pipe, and goes to the stripper E-01.

125
High pressure favors the carbamate reaction and the urea formation reaction
is disfavored to a little extent. Synthesis pressure is totally dependent on the
reaction temperature and vice versa. So, the pressure 156 kg/cm2g (PT-05),
which corresponds to an equilibrium temperature of 188°C (TE70) is
maintained in the reactor. Valve HV-03 provided in the reactor outlet is used
to control the reactor pressure.

A mole ratio of (3.3-3.6) :1 is maintained in the reactor for NH3/CO2. A

higher ammonia to carbon dioxide ratio favors the formation of the urea
while a lower water to carbon dioxide ratio favors the urea synthesis. If water
content is too low then crystallization of the solution may take place, which
will result in choking of the pipelines.

The reactor outlet solution composition is as under (on wt % basis):

NH3 32.82%
CO2 13.78%
Urea 33.4%
Water 20.01%

Urea reactor R-01 has 10 number of sieve trays in the upper portion of the
reactor. These have been provided to prevent the escape of gaseous CO2,
which must react with NH3 in the lower portion of the reactor. These trays
also help in preventing the internal recycling of the reaction products with
higher specific gravity products formed in the upper part of the reactor.

Reactor shell is made of CS with a 7mm liner of SS316LM on the inner

surface. Liner of the reactor is cladded to the CS shell and has 14 longitudinal
seams and 15 circumferential seams. For detecting any leakage in the liner a
weep hole monitoring system has been provided. The reactor has 93 weep
holes. In the weep hole monitoring system there are two loops of weep holes
covering the entire reactor. From the top instrument air with a pressure of
0.5 kg/cm2g is provided through the loop and at the bottom terminal of the
reactor one-phenolphthalein solution bottle for each loop has been provided.
So whenever there is any leakage in the liner air along with leaked gases
comes in contact with phenolphthalein solution at the bottom turning its color
immediately to pinkish red due to presence of ammonia in the leaked gases.

AMMONIA STRIPPING:

Unconverted carbamate in the reactor outlet section is decomposed in the HP

stripper E-1. This is basically a falling film exchanger. Its working is based
upon the Henry’s Law. The law states that mole fraction of a component in
liquid phase is directly proportionate to the partial pressure in vapor phase
under the equilibrium conditions.

126
The solution from the reactor coming in a 8” line enters the stripper in the
tube side and the solution enter into the tube as a film facilitated by the
ferrules. Ferrules have three equispaced tangential holes at the bottom
periphery of the ferrules, meant for the solution entry and two holes at the
diametrically opposite ends at the top to provide escape route for
decomposed gases. The urea solution enters the top tube channel and forms
a static liquid head over the ferrules. This head drive the urea solution
through the solution entry holes of the ferrules and into the tubes. Ferrules
also ensure that no tube or any portion of it is starved of the solution thus
causing the overheating of the tubes. To passivate bimetallic stripper a 80 m
3
/ hrs flow is maintained continuously via K-10

The solution with extra ammonia enters the stripper and with the heat from
the medium pressure steam on the shell side a part of the ammonia boils off
causing an increase in the partial pressure of the ammonia in vapor phase
and since the total pressure of the stripper is constant, the partial pressure of
CO2 decreases. Hence the concentration of CO2 must decrease (as per
Henry’s Law). This happens by the decomposition of the carbamate, which
releases the CO2 until equilibrium is reached.

The heat of decomposition is supplied by medium pressure saturated steam

(MS) coming from the CO2 compressor turbine. The steam enters the stripper
through a control valve PV-14 and a vent valve PV-306 with silencer has also
been provided in the steam line. The condensate from the stripper shell flows
out to the condensate separator MV-51. The separated vapors re enter the
stripper shell through a balancing line and the condensate flows out to the
MP decomposer (E-2B) through a level control valve LV-3.

The stripped solution is collected at the bottom of the stripper and flows to
E-10, where it is heated with LMS steam and finally reached into the
separator MV-2 through a level controller LV-2. The level control in stripper is
important because a low level increases the possibility of passing of the
gases into the MP section and thus upsetting the downstream section while a
higher level may result in lower bottom temperature and increased biuret
content of the urea. Stripper bottom temperature (TE-09) is maintained of
around 204 °C for the level transmitter LT-2 to function correctly a DP cell
type of transmitter with condensate from discharge of P-17A /B have been
provided.

A motorized valve MHV-05 has been provided in the downstream of LV-2 for
quick isolation of HP loop during the shutdown. The reactor drain line via HV-
04 joins the stripper outlet in down stream of LV-2 and in upstream of MHV-
05.

127
The vapors from the top of he stripper at 145kg/cm2 g and 190 0C flow to the
HP carbamate condenser E-5. About 80% of carbamate is decomposed in the
stripper.

The stripper outlet solution composition (on wt% basis) is as under:

NH3 – 24.73%
CO2 – 6.66%
Urea – 44.05%
Water – 24.56%

CARBAMATE CONDENSATION, SEPARATION AND RECYCLE:

The vapors from the stripper E-1 are condensed in the HP carbamate
condenser E-5. The carbamate thus formed is recycled back to the reactor R-
1.

The vapors from the stripper along with the recycled carbamate from the HP
carbamate pump P-2A /B are mixed prior to the entry in the E-5 tube side.
The recycled carbamate flow from P-2A /B is controlled by the valve HV-6
and the carbamate from the pump is preheated in the carbamate pre heater
E-6 before entering the E-5.

The carbamate is a cattle type heat exchanger with carbamate in the tube
side and the condensate from the MP decomposer (E-2A /B) in the shell side.
This condensate utilizes the heat of condensation of carbamate to produce
the low-pressure steam (LS) in the shell side. The steam thus produced is
generally enough to meet the LS requirement of the plant. Any significant
drop in steam production may be an indication of the lowered stripper E-1
performance. The carbamate condenser comes under the category of unfired
boiler and the steam is produced at 4.5 kg/cm2g (147 0C). The condenser has
U-type of tube bundle, which are always kept in the immersed in the
condensate. A level controller LV-5A /B has been provided to keep the level
constant in the condenser. This condenser is a split range controller in which
LV-5B exports the excess condensate and LV-5A is for importing the
condensate from the discharge of the pump P-13A /B. At a given time only
LV-5A or LV-5B can be open. The LS line from the top of the condensate has
FT-301, which indicates the amount of LS generated in the condenser.

In E-5 most of the carbamate is condensed but a little amount leftover along
with the liquid is sent to the carbamate separator MV-1. On entering the
separator ammonia and inerts are separated from the liquid phase and the
liquid carbamate is recycled back to the reactor through the ejector EJ-1. The
recycle carbamate is the driven fluid for the ejector its entry is controlled by
the valve HV-2 which is located in upstream of the ejector and HV-2 is a
solenoid operated on/off valve. The separated vapors in the carbamate
separator are sent to MP decomposer holder ME-2 via PV-7A. PV-7A/B is a
split range controller, which controls the HP loop pressure. In normal

128
 operation it is only PV-7A that opens to control the loop pressure however if
the loop pressure remains high even after PV-7A is fully open then PV-7B
opens to the blow down ME-14.

There should be practically no level in the carbamate separator. Its level is

indicated by LT-1. A high level in the separator will increase the pressure of
the HP loop and also there are chances of carbamate carryover.

UREA PURIFICATION AND RECOVERY

First purification and recovery at 18 ata (M.P. section)

Urea solution from the stripper enters into the MP decomposer via E-10,
which consists of three parts. These are:

1.The top most portions are MP separator MV-02.

2. The middle portion consists of the exchangers E-2A/B where carbamate
decomposition takes place.
3. The lowermost portion is urea solution holder ME-03.

The solution from stripper first enters into E-10, then enters the separator
where the solution flashes due to pressure letdown from 147 kg/cm2g to 18
kg/cm2g and the solution temperature is brought down from 204°C to
around 140°C. This solution is then distributed over a bed of pall rings in the
MV-02. The vapors rising from the E-2A/B just below the separator come in
intimate conduct with the solution and in the process decomposing more
carbonate. These vapors then flow out from the top to the pre vacuum
concentrator shell side. A PSV has been provided on the top of MV-02 to take
care of the over pressurization in the MP decomposer. PT 101 indicates and
records the MP decomposer pressure.

The solution then flows down and gets collected on the tube sheet of E-2A.
The MP decomposer E-2A/B is a falling film type of exchanger. The film
formation takes place with the help tangential holes provided in the ferrules
on the periphery. Ferrules are tight fitted over the tube buds and the solution
entry takes place through these tangential holes. The decomposed gases
passed through the middle portion of the tubes and the ferrules respectively.

The heat for the decomposition is provided by the LMS steam in the shell side
of E-2A and its flow regulated by a valve TV-122 and it takes sensing from
the thermocouple provided in the holder ME-02 at the bottom of the MP
decomposer. The LMS steam is produced by the boosting the LS steam in the
ejector EJ-11, which is placed in upstream of TV-122. For the ejector MS
steam serves as the motive fluid and a controller PV-105 guides ejector
needle movement. The steam transmit its latent heat to the solution and the
condensate is collected in the separator MV-13 whose level is controlled by

129
LV-108 goes to E-05, the carbamate condenser shell side for LS generation.
In case of an upset the condensate can also be sent to the steam condensate
tank V-02 through a separate line in the LV-108 downstream.

The solution from E-2A passes down to the exchanger E-2B that is placed
directly below. Here the heat for decomposition is supplied by MS steam
condensate in the shell side from the stripper E-01 shell side through MV-51.
The level in MV-51 is controlled by the valve LV-03 that is placed in the
carbamate outlet line of E-2B (in the d/s of the condensate outlet from MV-
51). The condensate from the outlet goes to the HP carbamate condenser E-
05 shell side for LS generation.

The carbamate gets decomposed liberating the NH3 and CO2 in the process
and the enriched solution flows to the holder ME-02. The holder receives the
gaseous stream from the downstream of HP loop pressure controller PV-7A
containing mainly ammonia and little amount of CO2 and inert. The inerts
mainly consists of oxygen, which acts as passivating agent in the MP section.
The level in the holder is maintained by LV-101 and it have both capacitance
and a purging type of LT. Previously two no. of level glasses have been
provided in the holder to check the level physically. A 1.5” CD has been
provided in the holder at the bottom most point to drain the vessel whenever
required.

The MP decomposer outlet solution composition (on wt% basis) is as follows:

NH3 – 6.44%
CO2 – 1.38%
Urea – 62.56%
Water – 29.62%

MP CONDENSATION:

The vapors from the top of MV-02 flow to pre vacuum concentrator E-29 shell
side. Prior to the entry in the shell side, these vapors get mixed with a weak
carbamate solution from V-03 through LV102. This solution comes from the
discharge of P-3A/B. As the vapors pass through the shell side of E-29, they
give away their heat to the urea solution in the tube side and in the process
they get partly condensed with the temperature coming down from 140°C to
111°C.

The vapors from the outlet of E-29 shell side flow to the MP condenser E-7
shell side, where the vapors get further condensed. A known quantity of NG
is mixed into solution before entering into E-07 for condensation to avoid
explosive mixture. The E-7 has cooling water on the tube side. This was a
three-pass heat exchanger and now converted a single pass. The cooling
water in the inlet comes from the outlet of the MP ammonia condenser E-
9A/B. The valve HV104 regulates the E-9A/B cooling water outlet flow. The
E-7 cooling water outlet flow is controlled by TV121, provided in the cooling

130
water outlet of the E-7. The controller takes sensing from the E-7 shell side
outlet temperature. This temperature is to be maintained above 80°C, in
order to avoid the carbamate crystallization in the exchanger. The E-7
cooling water inlet has an arrangement for satellite dosing of antiscalant into
the water. Also a fresh cooling water line has been provided in the inlet to be
opened only during the start up of the plant.

The liquid vapor mixture from E-7 flows to MP absorber C-1.

A minimum flow line from the HP carbamate recycle pump P2A/B through FV-
34 is connected in the upstream of E-7 inlet. In case the carbamate recycle
to E-5 is reduced a minimum flow is maintained in the pump through this
valve FV-34.

MEDIUM PRESSURE ABSORPTION

The E-7 outlet liquid vapor mixture flows to MP absorber C-1, where the
rectification and absorption takes place.

The MP absorber consists of two sections. The top section is called the
rectification section. It consists of four bubble cap trays, numbered from
bottom to top. The lower section is called the absorber.
The liquid vapor mixture from E-7 outlet enters the absorber section of the
C-1. Here the liquid part separates out and the vapors consisting of NH3,
CO2, H2O and inert rise, bubbling through the solution to the rectification
section of the C-1. Some gases are absorbed here. As the vapors rise to the
top, they meet liquid ammonia reflux provided on the top tray through the
valve FV102, coming from the discharge of the pump P-5. Vapors also meet
a flow of ammoniacal solution from discharge of the pump P-7A/B through
the valve LV103 and this solution comes on the second tray from the top.
The ammonia and water in the solution helps in absorbing the CO2. By time
the vapors leave the top tray, they are practically free from CO2 and this is
indicated by the top temperature (TE110), which corresponds to saturation
temperature of the pure ammonia vapors at the operating pressure (17.5
ata) of C-1. All the trays have been provided with the thermocouples to
measure and record the individual tray temperatures because increase in the
tray temperature from their normal operating value except for the time when
trays are being flushed with hot condensate, may be an indication of the tray
choking, low solution level in the C-1 or high solution level in C-1. To avoid
tray choking all trays except 3rd from the bottom have provision for flushing
the trays with hot condensate coming from flushing water pump P-22A/B,
through a valve HV103.Individual local isolation valve for the trays flushing
have been provided in the HV103 downstream. A progressively decreasing
temperature from the bottom tray (Ist) to the top tray (4th) is the correct
trend of the temperatures in the trays as it indicated the CO2 being
consumed on each successive tray.

131
The vapors flow from the top to the MP ammonia condenser E-9A /B. A vapor
transmitter PT 112 has been provided on the C-1 top to measure and record
the pressure.

A PSV has also been provided on the C-1 top to safeguard against the over
pressurization. The vapors from the top should not contain any CO2 because
it may choke the E-9A /B and also contaminate the pure ammonia in the
receiver tank V-1 thus may also lead to pumping problems of the feed
ammonia to the reactor.

The C-1 off gas line and MV-02 off gas line are connected with a 2” line called
balance line and it is used during the MP section start up.

It is clear from the above discussion that the level in the C-1 must be
controlled to control the process upsets. The level in C-1 is controlled by the
valve LV-102 and it takes impulse from the level in C-1 and controls the flow
of recycled weak carbamate solution from the discharge of the pump P-3A
/B, which in turn takes suction from the weak carbamate solution tank V-3 at
4.5 ata. A low level in C-1 not only results in the CO2 slippage into the vapors
to the rectification section, but also increases the chances of HP carbamate
recycle pump P-2A/B being tripped on the low current due to low solution
volume. The P-2A/B gets suction through motorized valve MHV105 provided
in the C-1 outlet at the bottom. A high level in the C-1 is also dangerous
because it increases the chances of carbamate carryover into the V-1, which
causes the problem of cavitation in P-5A/B. To safeguard against the high
level in the C-1, a drain line to V-3 has been provided through MHV305 and
HV102 in series. In addition to these there is one manual isolation valve in
the drain line at the V-3 top. Level glasses (12 no initially, now blinded due
to safety concern) have been provided in the C-1 for physical verification of
the level.

The C-1 bottom temperature (TE106) is to be controlled because if the

temperature is too low then P-2A/B, may lose suction due to high ammonia
content and if the bottom temperature is too high then the solution may
have high concentration as a result P-2A/B suction line may get choked and
P-2A/B can cavitate. So bottom temperature should be maintained around
the temperature of greater thane 75°C.

HP CARBAMATE RECYCLE PUMP P-2A/B

The HP carbamate recycle pump P-2A/B is very high-speed two stage

centrifugal pump designed by Sundstrand. It runs at about 16200 rpm and is
HT motor driven. It takes suction from the C-1 bottom through MHV105,
through a 6” line and discharges through a 4” line. The pump has internal
lube oil pump for lubrication during normal running and an auxiliary lube oil
pump P-35 for providing required lubrication during pump changeover/ start-
up and any upset in lube oil pressure. The mechanical seals of both the
stages are flushed with cold HW coming from P-22 through E-21. This cold

132
HW is filtered and pressurized up to 110 kg/cm²g by pumps P-38/P47, before
being sent for seal flushing. Total seal water requirement is about 1m3/hr.
Carbamate solution is transferred from the first discharge of the pump to the
second stage suction through a crossover pipe. The pump discharges at
about 170 kg/cm²g and the discharge goes to the HP carbamate condenser
shell after being preheated in E-06 shell side. To control the flow of P-2 a
valve HV-06 has been provided in discharge line and also a minimum flow
recycle valve FV34 in the discharge line. In case when the flow of carbamate
to E-5 needs to be reduced, a recycle of carbamate to C-1 through FV34 and
E-7 is established so as the pump does not trips at low load (low current). To
measure the carbamate recycle by P-2 a magnetic flow meter FT34 has been
provided in the common suction of P-2A/B.

MP AMMONIA CONDENSATION:
The ammonia present in the MP absorber off gases is condensed in the
ammonia condensers E-9A/B. The off gases from the C-1 enter the shell side
of E-9A/B, which are the two shell and tube exchangers in the series. They
operate at 17.5 ata pressure and the vapors from the C-1 top are at a
temperature of around 43°C (saturation temperature of NH3 vapors at this
temperature is 42.9°C), so it is possible to liquefy the vapors with cooling
water on the tube side. The vapors thus condensed go to ammonia receiver
tank V-1. But some of the vapors, which do not get condensed, also come
into the V-1 along with the condensed NH3.
The cooling water flow is controlled through HV104.

AMMONIA RECEIVING
Liquid ammonia from the plant battery limit and recovered ammonia from
the ammonia condensers E-9A/B is collected and stored in the ammonia
receiver tank V-1.

Ammonia receiving system consists of a receiver V-1 and an ammonia

recovery tower C-5. The tower is installed on the receiver V-1 as an
integrated part. The tower C-5 is having packing material, pall rings. The
receiver holds ammonia at 17.2 ata and 35°C.

Liquid ammonia from plant battery limits at 25 ata and 28°C passes through
C-5 before entering V-1. In the tower C-5, the incoming ammonia helps in
removal of the ammonia vapors from non-condensing inerts, which go to the
MP inerts-washing tower C-3 from V-1. The ammonia receiving line, before
entering into V-1. a flow meter FT104 has been provided which records and
sends signal to control room for totalizes FQM 104.

Following lines are also find its way into V-1:

1. HP ammonia feed pump P-1A/B recycle line
2. HP ammonia feed pump P-1A/B discharge PSV line.
3. MP start up line from the discharge of P-5A/B (jacketed)
4. P-5A/B recycles line.

133
A PSV has been provided on the V-1 to take care of over pressurization.
PT108 records the pressure of the vessel. V-1 provides suction to the
ammonia booster pump P-5A/B. In the P-5 common suction a ROV, HV24 has
been provided for safety considerations. So in case of heavy ammonia
leakage from P-5, P-1A/B or from P-5/ P-1 suction and discharge lines, the
valve could be immediately closed from control room and NH3 could be hold
up in V-1. The level in V-1 is controlled by the controller LV106. A jump over
has been provided; through which provides enough suction pressure to P-1
whenever P-5 starts cavitating during process upsets/ start up.

MP INERT WASHING

Vapors from the ammonia recovery tower C-5 top are scrubbed in inert wash
tower C-3/E-11. This equipment consists of a heat exchanger E-11 and a
three valve-trayed washing tower C-3 for scrubbing ammonia from the inert.
C-3 is mounted above the exchanger E-11. The part below the E-11 is also
called C-3, where ammoniacal water is collected.

The vapors coming from the C-5 first pass through the lower part (C-3),
where some ammonia from the vapors is removed in the ammonical water,
then the vapors pass through the heat exchanger E-11 with cooling water on
shell side and vapors on the tube side. This is a 1-1 heat exchanger. As
vapors pass through the tubes, some of the ammonia vapors get absorbed in
the weak ammoniacal solution coming from the top section. After this when
the remaining vapors enter the top section (C-3), most of the ammonia gets
scrubbed with cold condendate HW coming from P-22 via E-21.

The tubes of E-11 are fitted with ferrules on the top, which help in the
tangential entry of the solution in the tubes. The heat of absorption is
removed by the cooling water on the shell side of E-11. The weak ammonical
solution moves down to get collected in the lower part (C-3), which provides
suction to the ammoniacal solution pump P-7A/B. The discharge of this goes
to MP absorber through a control valve LV103, which controls the level in the
C-3. The residual vapors from the C-3 top containing inerts and very small
residual quantity of ammonia are sent to either ammonia reformer or the
blow down stack ME15 through a controller PV108A/B. This control valve
controls the MP loop pressure and takes signal from PT108, provided at V-1.
Small amount of LS is kept opened in PV108 B downstream to prevent the
vent gases from forming an explosive mixture into the vent stack.

A PSV has been in the vent gases line, before PV-108 to take care of the
over pressurization of C-3/E-11. A FT105 also has been provided in vent
gases line, to measure the flow of the inerts being vented out.

134
UREA PURIFICATION AND RECOVERY AT 4.5 ATA (L.P. SECTION)

The urea solution from the urea solution holder ME-2 flows to LP decomposer
for further purification and recovery. The urea solution after letdown from 18
ata to 4.5 ata through the control valve LV-101 enters the LP decomposer,
which is again like MP decomposer consists of three parts integrated into one
single unit. The three parts are LP separator MV-3, the heat exchanger E-3
and the holder ME-3.

The reduction in pressure causes some of the un-decomposed carbamate

solution to flash. The heat of vaporization is supplied by the solution itself
whose temperature is brought down from the 158°C to 138°C. The solution
coming from the ME-2 enters the LP separator MV-3 and flashing of solution
takes place. The remaining liquid then moves to the packed bed of pall rings,
where the solution comes in intimate contact of the vapors coming from the
E-3.The heat exchange between the gases and the liquid in further
decomposition of the carbamate. From the packed bed the solution enters
the tubes of E-3 through tangential holes of ferrules, which are tight fitted at
the top of the tubes. The heat for decomposition in E-3 is provided by LP
stream through the valve TV-128 takes place from the ME-3 bottom
temperature. Due to the heat supplied by the LP stream on the shell side, the
residual carbamate decomposition takes place and the decomposed gases
move to the top and from the top they move to ammonia pre-heater E-4
shell side. The concentrated urea solution flows to the bottom and gets
collected in the holder ME-3. The valve LV-131 maintains the level in holder.
Two sight glasses have also been provided in the ME-3 for physical
verification of the level and blinded due to safety reasons. From the ME-3 the
solution flows to pre vacuum separator MV-29.

The LP decomposer outlet solution composition (on wt% basis) is as follows:

NH3 1.75%
CO2 0.77%
Urea 69.82%
Water 27.66%

A PSV has been provided on the LP decomposer top for safeguarding against
over pressurization in the LP decomposer. PT-132 records and transmits the
LP decomposer pressure.

The condensate of the shell side flows to the steam condensate separator
MV-31 steam separated flows back to E-3 through a balancing line and the
condensate level in the separator is maintained by the valve MV-31
condensate from the LV-305 is sent to the steam condensate tank V-2.

135
LP CONDENSATION

The vapors from the MV-3 top flows to ammonia preheater E-4 shell side.
This is a four-pass shell and tube heat exchanger with liquid ammonia from
P-1A/B discharge on the tube shell. The hot gases entering the shell side
transfer their heat to pre heat the liquid for feed in the reactor R-1. In the
process vapors get partially cooled and condensed. Prior to the entry in the
shell side of the E-4 the vapors get mixed with weak carbonate solution from
the P-15A/B discharge through the valve FV-168.

From the outlet of E-4 shell side the liquid vapor mixture flows to LP
condenser E-8 shell side. This is a three pass shell and tube heat exchanger
with cooling water on the shell side prior to the entry in the E-8 shell side the
vapor liquid mixture get mixed with the weak carbonate solution from the P-
3A/B discharge. The vapors get condensed in the condenser and the solution
flows from the outlet of E-8 to carbonate solution tank V-3.

CARBONATE SOLUTION COLLECTION:\

The carbonate solution from E-8 flows to carbonate solution tank V-3, which
collects all the solution and provides suction to carbonate solution pump P-
3A/B. The pump discharge the carbonate solution at a pressure of 23 ata and
this discharge goes to MP section through LV-102 where it mixes with MV-2
off gases. A part of P-3 discharge also goes to E-8 for recycling. A transfer
line from 11V-3 to 21V-3 has also been provided in the P-3 discharge.
Pressure in V-3 is maintained at 4.5 ata with the help of control valve PV-
133.

LP INERTS WASHING

Inert from the carbonate tank V-3 are scrubbed in LP inerts washing tower C-
4 before being sent to C-02 or vented out to the blow down through PV-
133A/B. C-4 consists of four number of valve trays. C-4 is mounted directly
above the V-3. The inerts and ammonia vapors rise from the bottom of the
C-4 and passes through the trays where they get washed with the cold
condensate HW coming from P-22 via E-21. FT-136 has been provided in the
vent line of C-4, which measures the amount of gases being vented out to
blow down. A PSV has been provided on V-3 to safeguard it against over
pressurization.

136
UREA PURIFICATION IN PRE VACUUM CONCENTRATOR:
The urea solution from urea holder ME-3 flows to pre vacuum concentrator.
It consists of separator MV-29, the heat exchanger E-29 and holder ME-29,
are integrate into a single unit known as pre vacuum concentrator. Urea
solution entering pre vacuum concentrator flashes into the separator MV-29.
There after the remaining urea solution passes through bell distributor and
enters the troops of E-29 through the tangential holes of ferrules fitted at the
top of tubes.

The heat for vaporization of water and decomposition of residual carbamate

is provided by the mixture of carbonate solution and the MV-2 off gases. The
Off gases thus generated flow to the vacuum system of the pre vacuum
concentrator. The vacuum system consists of series of condensers and
ejectors. The condenser use cooling water in the tube side to condense the
vapor in the shell side, where as the ejectors use LS as the motive fluid to
drive the uncondensed vapors and inerts. The non condensable along with
the inerts are vented out to the atmosphere through a vent provided in the
final ejector- condenser. The vapors got condensed in the pre vacuum
condenser E-1 flows to the tank V-30. the ammoniacal solution collected in
the tank V-30 is sent to waste water tank V-6 through the pump P-30A/B.

The pre vacuum condenser is maintained at 0.35-0.4 ata. The urea solution
in the tube side flows down and it gets concentrated by taking heat from the
shell side fluid. The shell side fluid after getting cooled down from 140°C to
111°C moves to E-7 shell side.

The concentrated urea solution gets collected in the solution holder MV-29.
The level in the holder is maintained by LV-134 and the holder provides
suction to the pump P-20A/B. the level indication in the holder MV-29 is
given by LT-134A/B. The pump P-20 discharges the solution to the first stage
vacuum concentrator E-14.The urea solution at the P-20 suction is
maintained at 102°C.

The pre vacuum concentrator outlet solution composition(on wt% basis) is as

follows:
NH3 0.38%
CO2 0.1%
Urea 83.2%
Water 16.32%

137
VACUUM CONCENTRATION

The urea solution from the P-20A/B discharge is further concentrated up to

the concentration required to prill the urea melt in two vacuum stages. First
vacuum stage operates at 0.3 ata and second operates at 0.03 ata. The
vacuum in both the stages is maintained by ejector condenser system.

1ST STAGE VACUUM CONCENTRATOR:

The urea solution from the P-20A/B discharge enters the first vacuum
concentrator E-14 tube side. E-14 is basically a 1-1 shell and exchanger with
low-pressure steam on the shell side and urea solution on the tube side. This
steam flow to the E-14 is controlled by TV-153 in the upstream of the steam
inlet line. TV-153 takes sensing from the urea solution outlet temperature of
E-14. The urea solution in the tube side gets concentrated by absorbing
latent heat of the steam. The urea solution from the outlet of E-14 enters the
1st stage separator MV-6 tangentially. Here water vapors along with the
residual ammonia and CO2 get separated from the urea solution. The urea
solution flows from the bottom of the MV-6 to the 2nd stage concentrator E-
15. Bottom temperature of MV-6 is indicated by TE-137 and three side
glasses have been provided in the MV-6 bottom for physical inspection. In
march 2003 shut down a grating has been provided inside MV-06, to avoid
the entry of polymer from MV-06 to MV-07 and also this eliminate the
problem of lute choking with polymer from MV-06. Inside MV-06, on its dome
a nozzle spray has been provided for the dome flushing.

Just prior to the entry of the urea solution in the E-14, it is joined by the urea
solution recycle line from the P-37A/B discharge through the valve FV-226.

Also the line from the P-9A/B/C/D discharge (which is used to recover the
urea solution from the urea solution storage tank V-5/5A) joins in the
upstream of E-14 inlet.

The 1st vacuum separator outlet solution composition (on wt% basis) is as
follows:

NH3 0.02%
CO2 0.01%
Urea 94.97%
Water 5.0%

The condensate of the shell side is collected in the LP steam condensate

separator MV-14. The valve LV-205 controls its level and the condensate is
sent to the steam condensate tank E-14shell side through a balancing line.

The vapors from the top of the MV-6 are lead to the 1st stage condenser E-
41. Here the vapors get condensed in the shell side by giving their heat to

138
the cooling water on the tube side. E-41 has connections for flushing it with
LW. The condensate is collected in the tank V-9 through the barometric legs
whose open ends are kept immersed in the solution in the tank V-9.

The pressure in the 1st stage is controlled by the valve PV-140A/B. This is a
split range valve with PV-140 opening first to break the vacuum by sucking
the air and if even after full opening of the valve PV-140A vacuum is not
broken then PV-140B opens.

The vacuum is maintained at 0.300 ata in the 1st stage vacuum concentrator.

2ND STAGE VACUUM CONCENTRATOR:

The urea solution from the outlet of MV-6 flows to E-15 through the lute. E-
15 is basically a 1-1 shell and tube exchanger with low-pressure steam (LS)
on the shell side and urea solution on the tube side. The steam flow to the E-
15 is controlled by TV-154 in the upstream of the steam inlet line. TV-154
takes sensing from the urea solution outlet temperature of E-15. The urea
solution in the tube side gets concentrated by absorbing latent heat of LS.
The urea solution from the outlet of E-15 enters the 2nd stage vacuum
separate MV-7 tangentially. Here water vapors along with the residual
ammonia and CO2 get separated from the urea solution. This concentrated
urea solution gets collected in the urea solution holder ME-7. The level in the
holder is maintained by LV-138 and indicated by LT138A/B, both capacitance
types. The temperature of ME-7 bottom is indicated by TE142. The holder
provides suction to the urea melt pump P-8A/B. Its discharge goes to prilling
tower bucket for prilling. The biuret formation in the vacuum sections is most
prominent, so in order to control the biuret content in the prilled urea, the
ME-7 bottom temperature TE142, should be maintained close to design value
and moreover level in the holder ME-7 should be low, because higher the
residence time, higher will be biuret formation.

The 2nd stage vacuum separator outlet solution composition (on wt% basis)
is as follow:

NH3 0.0%
CO2 0.0%
Urea 99.7%
Water 0.3%

Two sight glasses have been provided in the ME-7 for physical inspection of
level. And a grating has been provided inside MV-07, to avoid the entry of
polymer into urea melt which otherwise chokes the holes of prilling bucket
and this causes the overflow of the bucket. Inside MV-07, on its dome a
nozzle spray has been provided for the dome flushing.

139
The condensate of the shell side is collected in the LP steam condensate
separator MV-15. Its level is controlled by the control valve LV-207 and the
condensate is sent to the steam condensate tank V-2. The steam separated
in the separator is sent to the E-15 shell side through a balancing line.

The vapors from the MV-7 are led to the 2nd stage condenser E-42 through
scrubbing separator MV-30. Scrubbing separator is used to scrub the urea
from the vapors of Mv-7. Scrubbing separator has a demister pad, which is
flushed with treated wastewater from the P-18A/B discharge or P21C
discharge through a solenoid, operated valve HV-173 that opens after every
10 minutes for 20 seconds. The solution thus generated is used for recycle.
The solution from the MV-30 is discharged through the pump P-37A/B. A part
of the solution is recycled through FV-224 and the remaining is sent for
concentration in E-14. In case of poor vacuum condition ME-7, a booster
ejector EJ-2 has been provided to suck vapors from MV-7. Booster EJ-2 uses
low-pressure steam (LS) as the motive fluid. In E-42 the vapors get
condensed in the shell side by giving their heat to the cooling water on the
tube side. E-42 has connections for flushing it with LW. The condensate is
collected in the tank V-9 through the barometric legs whose open ends are
kept immersed in the solution in the tank V-9.

The pressure in the 2nd stage is controlled by the valve PV-141A/B. This is a
split range valve with PV-141A opening first to break the vacuum by sucking
the air and if even after full opening of the valve PV-141A vacuum is not
broken then PV-141B opens.

The urea solution has a concentration of 99.7%(w/w) at the P-8A/B

discharge. The P-8A/B discharge line is jacketed its temperature (TE-149) is
controlled by PV-211. The low-pressure steam (LS) is used in the jacket for
heating the urea melt so as to avoid the solidification in the discharge line.

VACUUM SYSTEM OF 1ST AND 2ND VACUUM:

The vacuum systems of the 1st and 2nd stage consist of series of ejectors and
condensers. The vapors from the first stage separator MV-6 get mostly
condensed in E-41 and the remaining non-condensable and inerts are sucked
by EJ-5 to the condenser E-45. And the vapors from the MV-7 get condensed
in E-42 and the remaining non-condensable and inerts are sucked by EJ-3 to
the condenser E-43. The remaining non-condensable of E-43 and E-45 are
sucked by EJ-4 and EJ-6 respectively and discharge to E-44 for final
condensation. And the remaining inerts are vented out to the atmosphere
through a common vent on E-44 via C-8. The condensate from all barometric
legs is collected in the tank V-9 and sent to wastewater buffer tank V-6
through the discharge of the pump P-21A/B. All the condensers have cooling
water on the tube side and for E-41 cooling water inlet is the outlet cooling
water of E-42.

140
UREA PRILLING

The urea melt from the ME-07 is sent to prilling bucket ME-08, by the urea
melt pump P-8A/B through a three way valve HV132. The prilling bucket has
holes of varying size on its outer periphery. As the urea melt enters the
prilling bucket through the distributor, it comes out in the form of tiny
droplets from the bucket holes. As the droplets fall down the prilling tower
ME-06, they come in contact with the air-moving counter currently from the
bottom due to the draft created by the cool air at the bottom and the hot air
being released from the prilling tower top. Due to contact with the air, the
droplets get cooled down and solidify to form solid small round particles,
called prills. These prills fall on the scrapper floor and from there these prills
are collected by the rotating arms of scrapper ME-10 and then pass on the
conveyor belt MT-1 through the scrapper cone.

The valve HV132 is a three way valve which in normal condition remains
lined up towards the prilling bucket, whereas the same valve can be used to
divert the urea melt to the urea melt storage tank V-5/ V-05A. The valve HV-
132 is operated by a hardware switch provided on DCS. When the prilling is
diverted to V-5 steam must go to the bucket side through HV137 to avoid
choking in the line.

The prilling bucket ME-08 is variable frequency motor driven for its speed
control. It is mounted on a rotating platform. The speed of the bucket can be
controlled with the help of hardware switches provided on DCS panel or even
from the local panel. To take the bucket in line, it is lowered into a well with
the help of a lifting device running with the help of motor MME-8A/B and
connected to the urea melt line coming from HV132 with the help of a break
up flange. The bucket overflow condition is indicated by TE150 /TE152 fixed
with the distributor.

The free fall height of the prilling tower is 80 m, ID 26 m and total height
105.6 m. The air enters from the bottom through the movable type of
louvers (upper half of the bottom louvers are of fixed type whereas lower half
are movable type). The movable types of louvers are used to control the
airflow through the prilling tower. The air exit from the prilling tower top is
also through the louvers but these are of fixed type. The free area for the top
louvers is 300m2 whereas the free area for the bottom louvers is 195m2.
The third and fifth floors of the prilling tower have been provided with the
inspection windows.

The urea prills from the belt MT-1 are conveyed to the lump separator
screen. On the lump separator the lumps get separated and the product is
transferred to another conveyor ET-1. From the ET-01, the prills are
transferred to another belt BC-1, which carries the prills to the bagging plant
if temperature of urea prills are <70 °c and if temperature is higher then it is
conveyed for cooling into BFC through ET-02/03.

141
WASTE WATER SECTION

The wastewater generated in the plant from various activities such as

flushing, draining of equipments, condensate generated from the vacuum
system vacuum concentrator and pre vacuum concentrator is collected in the
buffer wastewater tank V-6. The V-06 receives the wastewater
1. From the discharge of 11/21 P-21A/B
2. From the discharge of 11/21 P-30A/B
3. From the discharge of 11 P-18A/B (recycle to V-6)
4. Water from guard tank

The pump P-21A/B receives the suction from the tank V-9 that in turn gets
the solution from the barometric legs of the 1st and 2nd stage vacuum and the
discharge of the pump P-12A/B that in turn receives the suction from the
tank V-7 that receives the solution from all the closed drains of the plant.
The solution from V-9 goes to buffer wastewater tank V-6. V-6 receives
solution from V-30 also through pump P-30A/B. The solution collected in V-6
is called process condensate. The process condensate from the tank V-6,
provides suction to the pump P-16 which provided feed to the distillation
tower C-2. Before being fed to the distillation tower C-2, the process
condensate gets preheated in a plate type heat exchanger E-18 with the hot
treated purified process condensate coming from C-2 bottom.
A 1” line from P-16A/B provides the seal flush water for the hydrolyser
booster feed pump P-50A/B.
The process condensate from the P-16A/B discharge is fed to the 44th or 50th
tray of C-2 and the control valve FV163 controls its flow. The treated process
condensate known as the purified water flows to the O&U for reuse.

In case the wastewater section is under shut down or is not available for
operation for whatsoever reasons, the process condensate collected in V-6
can be directly sent to guard tank (ETP plant) through P-16A/B.

WASTE WATER TREATMENT IN C-2

The process condensate from the P-16A/B discharge is fed to the 44th or 50th
tray of the distillation tower C-2. In the upper part of the tower ammonia
stripping takes place with the help of LS being fed from the bottom part of
the tower through a control valve FV162 and also with EJ50 of V-02 steam
vapour. Ammonia stripped solution but still containing urea flows down to the
chimney tray (just above the 35th tray). The solution collected at the chimney
tray provides the suction to the hydrolyser feed pump P-14A/B through
P50A/B. A cooling water jacket has been provided in the suction line of the
pump P-14A/B to avoid its cavitation. The P-14A/B is a multistage centrifugal
pump.

The level in the chimney tray is controlled by the control valve LV166. In
order to further enhance the ammonia recovery, the tower is fed with a

142
reflux solution from a reflux accumulator drum V-8, through the discharge of
the pump P-15A/B and its flow can be controlled with the control valve
FV161.

Distillation tower is a valve trayed tower. There are 55 trays in total and the
tower is divided into two parts. The upper part has trays from 36th to 55th.
Lower part has 35 trays from tray no 1 to tray no 35. The chimney tray is
provided between the upper and lower part, just above the 35th tray. The
upper part receives the process condensate from the P-16A/B discharge
containing both urea and ammonia as impurities. The lower part receives the
solution from the outlet of hydrolyser R-2.

HYDROLYZATION

The solution from the discharge of the pump P-14A/B is fed to the hydrolyser
R-2 in which urea dissociation into its constituents viz ammonia and CO2
takes place. Since the urea formation is highly exothermic and its
dissociation is endothermic, the heat for the dissociation is supplied by the
HS through a control valve FV165. The HS is imported from ammonia plant.
The solution before entering the hydrolyser gets preheated in the E-19A/B/C.
This is a set of two 2-2 shell and tube (U-tube) heat exchangers in series.
The inlet solution of R-2 gets heated from the outlet solution of R-2. The HS
steam is injected directly into the hydrolyser through the five individual
tappings. The HS is at 37 kg/cm2g and 380°C. The urea content of the
process condensate gets hydrolysed as per the following equation:

NH2CONH2 + H20 2NH3 + CO2 - Heat

Factors affecting the hydrolysis reaction:

1. Presence of large quantity of water with the urea. As the water is a
reactant in the hydrolysis, so the reaction is favored by the large quantity
of water.
2. High Temperature: As the overall reaction is endothermic, it is favored by
high temperature.
3. High pressure: As the overall kinetics of the hydrolysis indicates that it
proceeds at the slower rate so high pressure favors the reaction.

The solution entering R-2 travels in the chambers (one by one) through the
baffle plates. These have been provided to increase the residence time in the
hydrolyser. By the time the solution comes out of the hydrolyser, it is almost
free from the urea content (<5ppm). The outlet temperature of the R-2
(TE169) is a critical parameter of the performance of hydrolyser and should
be maintained above 220°C in any case to ensure the quality of the treated
water. The pressure in the R-2 is controlled by PV170 and the level by
LV168. For physical verification of the level a local glass (LG) with HS purging
in the tapings has been provided. A PSV has been provided on the R-2 to

143
take care of over pressurization. The vapors from the R-2 flow through
PV170 and mixes with the C-2 top gases before going to overhead condenser
E-17. The cooled treated water from the outlet of the E-19A/B/C flows to the
lower part of the distillation tower on the 36th tray. The ammonia present in
the treated water gets stripped with the help of LS being fed at the bottom
through the control valve FV162. The stripped vapors along with the steam
move to the top part of the distillation tower passing through chimney tray.
The treated water collects at the bottom and cooled down in plate type heat
exchangers E-18 and E-20 before being pumped to O&U through the pump
P-18A/B. The level at the C-2 bottom is controlled by LV164. In E-18 the
treated water transfers it heat to preheat the feed to the distillation tower
coming from V-6 through P-16A/B and in E-20 the treated water transfers it
heat to the cooling water. The treated water contains ammonia and urea
contents both below 5ppm. The treated water can be recycled back to V-6
through HV162 (hardware switch provided on DCS panel) in case of poor
quality. The export of the treated water can also be stopped fully with the
help of the valve HV163.

A 2” taping from the P-18A/B discharge flows to the vacuum section for the
flushing of the demister pad of the MV30 through a solenoid operated valve
HV173. For on line measurement of conductivity of the treated water a
conductivity analyzer 11AT161A has been provided in the downstream of
P-18A/B, whereas 11AT161B provided at the same point measures urea
content in the treated water.

A ¾” utility air taping has been provided in the C-2 bottom and normally it is
kept slightly open to insulate the C-2 from the pressure swings. The pressure
in the C-2 is controlled with the control valve PV166 and its loop pressure via
PV165 and is maintained at 2.5 /1.5 ata respectively.

The vapors from the C-2 and R-2 top join together and flow to a vertical
overhead shell and tube condenser E-17.The combined flow of the vapors
enter the shell side of the condenser and transfer their heat to the cooling
water on the tube side. The solution thus generated is used as reflux in the
distillation tower, whereas a major part of the solution is recycled back to the
LP section. The solution generated is collected in the reflux accumulator drum
and it provides suction to the pump P-15A/B and the discharge of the pump
is sent to C-2 top as reflux through FV161 and to the LP section through the
control valves 11/21FV168.

Level glasses (LG) have been provided at the chimney tray and C-2 bottom
for the physical verification of the level at the above places.

C-2 has been provided with PSV to protect it against over pressurization and
its PSV has bypass with a isolation valve.

144
BULK FLOW COOLER

The BF cooler plate Bank consists of a series of vertical hollow

stainless steel plates. The plate bank is housed in a rigid casing with
hinged full height doors to provide access for inspection and cleaning.
The heat exchanger plates are made of SS 304L material and fully
welded. Two panels are laser or resistance welded together in a preset
pattern of spot welds; perimeter and pass scams are then welded
followed by installation of the welded inlet and outlet tube connections.
The welded pair of plates is then inflated with hydraulic pressure under
controlled conditions to provide uniform dimples which create
turbulent flow inside the plate for efficient heat transfer.
In this system, urea prills are cooled by exchanging heat with counter-
flowing re-circulating DM water. Hot urea from bottom of Prilling tower
fed to top of cooler through a conveyor and hopper, slides down slowly
through the interspaces between plates banks vertically stacked in
parallel. The BF cooler operates full of product, typically using a simple
level control system and creates sufficient residence time for the
required heat transfer. A discharge device provided at the bottom of
the cooler, controls product level at the top of cooler. The slow
material movement also ensures that there is no additional dust
formation due to attrition and size distribution of urea at inlet and
outlet of cooler remains unchanged.

DESIGN FEATURES OF BULK FLOW COOLER

Thermal duty : 1502.897 kcal/h

Feed Flow rate : 158.5 MT/hr

Product inlet temp : 80 deg C
Product Out let temp : 58 deg C

Cooling medium inlet temperature (PW) : 40 deg C

Cooling medium outlet temp : 58 deg C
Cooling medium flow rate : 83 M3/hr.
Design Pressure : 7 barg
Design Temp : 100 deg C
PSV set pressure : 7.7 barg
PURGE AIR
Dew point : 20 deg C
Flow rate per unit : 2000 M3/hr
Inlet pressure to header : 0.5 bar

145
TEMPERED COOLING WATER SYSTEM

In order to avoid fouling on the water side of BF cooler plates, re-circulating

DM water is used as cooling medium instead of cold water from cooling
tower. DM water circulating pump P-52 takes suction from overhead tank
and discharges cold water to the bottom plate bank manifold. Water flow is
then distributed in parallel to individual plate bank fitted with flexible
connections. A relief valve (set point 7.7 barg) at the outlet of pump
discharge protects the plate banks from over pressurization. The outlet from
bottom plate bank is collected in a main header and fed to the bottom of top
plate bank with the same configuration as bottom plate bank. The hot DM
water from the outlet of top bank enters the tube side of DM water cooler
and cooled with ordinary cooling water fed at the shell side. DM water is then
collected in an atmospheric overhead tank V-54. A low temper water
pressure (PSL-802) alarm protects the pump P-52 from suction starvation.
There are provisions for hot and cold DM water make up in the overhead
tank. In order to avoid condensation of moisture on the plates of top bank,
the temperature of outlet DM water from the BF cooler is controlled by both
TC-802 A/B split range and flow rate is maintain by a variable speed motor.
The level of urea at the top of BF cooler is sensed by a radar type of level
sensor and controlled by LIC-801 by adjusting the opening of the gate
located at the bottom of BF cooler PNG# 2.

AIR HEATING UNIT

The humid air entrapped inside BFC cools down and sticks along with product
urea while passing through the BF cooler. On attaining dew point, moisture
present in the air sends to condense along with surface of plates and
subsequently attracts urea dust and fine prills to form a hard coating on the
surface of BF cooler plates. Thus in course of operation, the passage between
the vertical walls may become narrow and in worst case, block the
flow of urea through the cooler. To overcome the problem, dry air is injected
inside the BF cooler. To dehumidify air an AC unit is installed with
compressors and blowers system, which maintains temperature by automatic
control by thermostat and this cooled air, is heated and fed into BF cooler at
three different places i.e. top of each plate bank and bottom of lower plate
bank with a manual valve for flow adjustment. A solenoid valves/ pressure
switches provided to protect the AC compressors and blower system. The
exhaust air mixed with urea dust is discharged by blower K05 at atmosphere/
dust cyclone separator system.

146