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    Presentation 0f Urea plant

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    Presentation 0f Urea plant

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    Jatin Gupta
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    2 views40 pages

    Presentation 0f Urea plant

    Uploaded by

    Jatin Gupta

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
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    Presentation on

    Urea Manufacturing
    Process
    Presented By:-

    MR. M. L. GUPTA – Dy. G M (UREA)

    Date: 10. 02. 2021


    FERTILIZER

    • ANY MATERIAL ORGANIC OR


    INORGANIC, NATURAL OR SYNTHETIC
    WHICH SUPPLIES ONE OR MORE
    CHEMICAL ELEMENTS REQUIRED FOR
    PLANT GROWTH
    ESSENTIAL ELEMENTS FOR PLANT GROWTH

    • CARBON
    • OXYGEN
    • HYDROGEN
    • NITROGEN
    • PHOSPHORUS PRIMARY NUTRIENT
    • POTASSIUM
    • CALCIUM
    • MAGNECIUM SECONDARY NUTRIENT
    • SULPHUR
    • BORON
    • CHLORINE
    • COPPER MACRO NUTRIENT
    • IRON
    • MANGANESE
    • MOLYBDENUM
    • ZINC
    HISTORY
    • 1828- WOEHLER SYNTHESIZED UREA FROM
    AMMONIA & CYNIC ACID
    • 1920-FIRST COMMERCIAL PLANT IN GERMANY
    • 1906- FIRST FERTILIZER PLANT IN INDIA 20 TPD
    SSP AT RANIPET, CHENNAI
    • 1941- AMMONIA @ 5TPD NEAR MYSORE BY
    ELECTROLYSIS OF WATER
    • 1947- FIRST MAJOR FERTILIZER PLANT AT FACT,
    UDYOGMANDAL
    • 1951- FIRST PLANT OF AMMONIUM SULFATE AT
    SINDRI
    • 1959- FIRST UREA PLANT AT SINDRI (71 TPD)
    PROCESS LICENSORS
    • MONTECATINI- ONCE THROUGH & PARTIAL
    RECYCLE
    • MONTEDISION- TOTAL RECYCLE & IDR
    • STAMICARBON-ONCE THROUGH
    • STAMICARBON- PARTIAL ,TOTAL RECYCLE
    & CO2 STRIPPING
    • TEC-MTC/ MITSUI TOTSUI- ONCE
    THROUGH, PARTIAL, TOTAL RECYCLE &
    ACES
    • SNAM PROGETTI- AMMONIA STRIPPING
    SPECIAL FEATURES OF KSFL UREA
    PLANT
    • BIMETALLIC STRIPPER
    • CENTRIFUGAL HP AMMONIA FEED PUMP
    (EBARA,JAPAN)
    • CENTRIFUGAL HP CARBAMATE PUMP
    (EBARA,JAPAN)
    • CENTRIFUGAL CO2 COMPRESSOR WITH AIR
    SEAL
    • 505E MICROPROCESSOR BASED WOOD WARD
    ELECTRONIC GOVERNOR
    • ANTISURGE CONTROLLER OF CCC, USA
    • DEEP HYDROLYZER
    • PRILLING TOWER WITH 102.4 M HEIGHT
    MILE STONES OF UREA PLANT
    • COMMISSIONING OF 11 STREAM- 21-11-95
    • COMMISSIONING OF 21 STREAM- 12-12-95

    • HIGHEST EVER PRODUCTION:


    • DAY PRODUCTION – 3188.36 MT (05-04-2020)
    • MONTH PRODUCTION –94893.52 MT(MAY’2020)
    • YEAR PRODUCTION -1063913.675 MT (2018-19)
    • LOWEST ENERGY – 5.4622.GCAL/MT (2019-20)
    UREA PROCESS DESCRIPTION

    The total urea manufacturing process can be broadly divided


    into following three steps:

    Urea Synthesis

    Decomposition of Unconverted Carbamate and


    Recycle

    Concentration of Urea Solution and Prilling


    Carbon Dioxide at Battery
    Limit.

    • CO2 : 99.18 % vol. min.


    • N2 : 0.22 % vol. max.
    • H2 : 0.60 % vol.
    • Pressure : 1.78 Kg/cm2abs.
    • Temperature : 35°C
    H P Section Flow diagram

    • CO2 : 99.18 % vol. min.


    • N2 : 0.22 % vol. max.
    • H2 : 0.60 % vol.
    • Pressure : 1.78 Kg/cm2abs.
    • Temperature : 35°C
    Ammonia at Battery
    Limit
    • NH3 content : 99.77% wt.
    min.
    • H2O : 0.23 % wt.
    max.
    • Oil : 50 ppm max
    • Temperature : 10°C
    • Pressure : 22
    Kg/cm2abs.
    K.S. Steam

    • Pressure : 109
    Kg/cm2abs.
    • Temperature : 510°C
    • Flow for Both Unit : 120 TPH
    Cooling Water
    Pressure : 3.0
    Kg/cm2g.
    Temp. (supply/return): 36/44.°C
    FLOW RATE : 17000
    M3/HR
    Advantage of Excess Ammonia in Reactor

    Anti Corrosive Agent


    Higher Conversion
    Stripping Agent
    Dehydrating Agent
    Prevent Biuret Formation
    Temperature Controller
    Effect of NH3/CO2 Molar ration on CO2 Conversion
    Effect of Water Recycle

    • Lowers Conversion Efficiency in


    Reactor
    • Lowers Decomposer Performance
    • Higher Steam Consumption
    • Inhibits Carbamate to Urea Reaction
    FACTORS AFFECTING UREA CONVERSION

     Reaction temperature
     Pressure
     Molar ratio of NH3/CO2
     Molar ratio of H2O/CO2
     Retention time
    Temperature in Reactor
     Melting Point of Urea 132.7 0C
     Melting Point of Ammonium Carbamate 145 0C
     Melting Point of Biuret 157 0 C
     Reaction Temperature must be more than
    Melting Point of these Constituents to carry
    Reaction in Liquid Phase and at 190 0C optimum
    Conversion is achieved.
     CO2 remains in gaseous phase and bubbles
    through liquid phase
    Operating Variables of Reactor

    Reactor Temperature : 1880C


    Reactor Pressure : 156 Kg/Cm2g
    Mole Ratio (N/C) : 3.3 – 3.6
    Mole Ratio (H/C) : 0.5 – 0.6
    CO2 Conversion : 64 % per pass
    NH3 Conversion : 36 % per pass
    NH3 % in Effluent : 32 %
    CO2 % in Effluent : 15.5%
    Urea % in Effluent : 33 %
    Operating Variables of
    Stripper
     Operating Temperature
    Range:188- 2050C
     Operating Pressure: 147 Kg/Cm2g
     NH3 % in Effluent : 25 %
     CO2 % in Effluent : 6.2 %
     Urea % in Effluent : 46 %
    HP CONDENSER (E-5)

    • OP. TEMP. IN TUBE SIDE – 180 0C


    • OP. PRESS. IN TUBE SIDE -145
    Kg/Cm2g
    • OP. TEMP. IN SHELL SIDE – 150 0C
    • OP. PRESS. IN SHELL SIDE -3.5
    Kg/Cm2g
    • LP STEAM GENERATION IN SHELL
    SIDE –
    42 TE/HR
    M.P.DECOMPOSER

    • OP. TEMP. - 1580C


    • OP. PRESS. - 16.5 Kg/cm2g
    • NH3 % IN EFFLUENT: 6.55%
    • CO2% IN EFFLUENT : 1.40%
    • UREA % IN EFFLUENT : 63.62
    M.P.Section

    • OP. TEMP. - 1580C


    • OP. PRESS. - 16.5 Kg/cm2g
    • NH3 % IN EFFLUENT: 6.55%
    • CO2% IN EFFLUENT : 1.40%
    • UREA % IN EFFLUENT : 63.62
    MP ABSORBER ( C-1)
    • OP. TEMP. – 80 0C
    • OP. PRESS. – 16.5 Kg/cm2g
    • NH3 RECOVERY FROM TOP- 21 Te/Hr
    • CARBAMATE TO P-2 – 34 M3/Hr

    • NH3 % IN CARBAMATE – 48 %
    • CO2 % IN CARBAMATE – 17 %
    L.P.DECOMPOSER

    • OP. TEMP. - 1380C


    • OP. PRESS. - 3.5 Kg/cm2g
    • NH3 %IN EFFLUENT : 1.78%
    • CO2 % IN EFFLUENT : 0.78 %
    • UREA% IN EFFLUENT: 71.15%
    L.P.SECTION

    • OP. TEMP. - 1380C


    • OP. PRESS. - 3.5 Kg/cm2g
    • NH3 %IN EFFLUENT : 1.78%
    • CO2 % IN EFFLUENT : 0.78 %
    • UREA% IN EFFLUENT: 71.15%
    LP CONDENSER (E-8)
    • OP. TEMP. – 40 0C
    • OP. PRESS. – 3.5 Kg/cm2g
    • NH3 RECOVERY FROM TOP- 21 Te/Hr
    • CARBONATE TO V-3 – 13 Te/Hr

    • NH3 % IN CARBONATE – 43 %
    • CO2 % IN CARBONATE – 10 %
    VACUUM SECTION
    • OP. TEMP. – 40 deg
    • OP. PRESS. – 3.5 Kg/cm2g
    • NH3 RECOVERY FROM TOP- 21 Te/Hr
    • CARBONATE TO V-3 – 13 Te/Hr

    • NH3 % IN CARBONATE – 43 %
    • CO2 % IN CARBONATE – 10 %
    Favourable Factors for Biuret
    High Concentration Of Urea
    High Temperature
    High Residence Time
    Low Ammonia Content
    Waste Water Treatment
    Section

    High Concentration Of Urea


    High Temperature
    High Residence Time
    Low Ammonia Content
    Favourable Factors for Urea Hydrolysis
    • High Temperature
    • High Residence Time
    • High Pressure
    • Sufficient Quantity of Water
    • Low Concentration of NH3 and
    CO2
    UREA HYDROLYSER (R-2)

    • OP. TEMP. – 2350C


    • OP. PRESS. - 34 Kg/cm2
    • H.S.STEAM - 4.5 TPH
    • RESIDENCE TIME- 55 min
    DISTILLATION TOWER (C-2)
    • TOP TEMP/PRESS- 1070C/1.6Kg/cm2
    • BOTTOM TEMP/PRESS-
    1350C/3.0Kg/cm2
    • L.P.STEAM FLOW – 8.5 TPH
    • FEED RATE- 58 M3/HR
    • NO. OF TRAYS - 55
    UPC QUALITY
    • NH3 IN EFFLUENT - > 5 ppm
    • UREA IN EFFLUENT - >5 ppm
    • UPC QUANTITY – 65 M3/HR
    Prills Quality

    • Moisture Content 0.4 to 0.6%


    • Biuret Content <1%
    • Free Ammonia 150 ppm
    • Nitrogen Content 46 %
    • Prills Temperature 65 0C
    • Crushing Strength 28 Kg/Cm2g
    • Particle Size 96% (+1 to 2.36 mm)
    4% (-1 & + 2.8 mm)
    DUST EMISSION FROM
    PRILLING TOWER TOP

    • Free NH3 from P.T. Top : 50 ppm


    Max
    • S.P.M from P.T. Top : 50 mg/ NM3 air
    Max
    Specific Consumption Per Te of
    Urea

    Raw Material Design Actual


     Ammonia 0.566 Te 0.575
     CO2 0.733 Te 0.74
     KS Steam 0.84 Te 1.20
     Cooling Water 95 M3 136
     Electricity 23 KWH 52
     Energy 5.8 GCal 5.65
    Physical Properties of Urea
    Molecular Weight :60.05
    Melting Point : 32.7 °C at 1 atm
    Boiling Point :Decomposes at
    atmospheric pressure before boiling
    Density :1.335 g/cc at 20
    °C
    Bulk density :0.65 MT/M3
    Angle of repose :30°
    Critical humidity :72%
    Chemical Properties of Urea
    • white crystalline chemical
    • soluble in water and alcohol
    • diamide of carbonic acid
    • At 160 °C it decomposes to NH3, biuret
    • Its chemical formula is
    / NH2
    O=C
    \ NH2

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