CH 4202 Comprehensive Design Project

Assignment 1

Design of an Urea Manufacturing Plant

Group Members: -

Wellappili A.Y.G

090556N

Wijesinghe C.D

090577E

Silva G.G.S.N

090488G

Pathiraja P.D.T.P

090361L

Ariyaratne V.T

090029d

Rashara G.A.D.D

090428B

Gamage G.P.S

090147L

Abeywickrama T.D

090010L

Dayananda L.K

090079E

Date of Submission:-

Department of Chemical and Process Engineering

University of Moratuwa

Table of Contents
1) INTRODUCTION.................................................................................................... 4
1.1)

Importance of Nitrogen for plant growth........................................................4

1.2)

Nitrogen sources and fertilizers.....................................................................4

1.3)

About Urea..................................................................................................... 6

1.4)

Importance of Urea as a fertilizer...................................................................7

1.5)

Other applications.......................................................................................... 8

2) PRODUCTION PROCESS OF UREA.......................................................................10

2.1)

Raw materials for manufacturing Urea...................................................................10

2.1.1)

Ammonia............................................................................................... 10

2.1.2)

Carbon dioxide....................................................................................... 11

2.2)

Sources and availability of raw materials..............................................................11

2.2.1) Hydrogen Production..................................................................................... 11

2.2.2) Nitrogen................................................................................................... 12
2.3)

Synthesis of Ammonia..................................................................................... 12

2.3.1) Steam Reforming method.............................................................................. 12

2.4)

Process in general production of Urea.........................................................19

2.5)

Process variation of Urea manufacturing.....................................................22

2.5.1) Once-through processes..........................................................................22

2.5.2) Partial recycle processes..........................................................................23
2.5.3) Total recycle processes............................................................................24
3) ECONOMIC ASPECTS OF UREA PRODUCTION.....................................................33
4) ENVIRONMENTAL AND SAFETY ISSUES...............................................................34
4.1) Health and Safety.......................................................................................... 34
4.1.1) Health...................................................................................................... 34
4.1.2) Safety....................................................................................................... 35
4.2) Safety Procedures.......................................................................................... 37
4.3) Inherent Safe Design...................................................................................... 37
4.4) Layers of Process Safety................................................................................38
4.5) conclusions.................................................................................................... 39
4.6) recommendations.......................................................................................... 39
4.7) Environment................................................................................................... 39
5) GREEN CONCEPTS USED IN PLANT DESIGNING..................................................40

5.1) why should we care about green buildings?...................................................40

5.2) Current methods used in industries...............................................................41
6) HISTORY OF UREA PRODUCTION IN SRI LANKA..................................................44
7) PROCESS SELECTION AND DESIGN DECISIONS..................................................46
REFERENCES............................................................................................................ 58

LIST OF TABLES

LIST OF FIGURES