NH3 losses in the plant:

Ammonia balance
In put ammonia to plant-out put ammonia in product-losses=0 for steady state operation
In put ammonia to plant= output ammonia in product (theoretical) + losses
Basis 1200 Ton urea per day
Theoretical ammonia required for 1200 MT urea output=680.40MT

1. Losses of ammonia
1. Prilling Tower Emission:- Actual air flow 6.6 lac NM3/Hr. Avg. dust conc. 60 mg/m3 (actual 45 - 55
mg/m3)
=6.6*100000*60*0.000001*24/1000*.589=.5597MT
2. Vent from first stage:-Ammonia conc. 0.8%. Gas flow ~ 700 m3/Hr (actual 0.48 - 0.80 %)
=700*0.008*24*17/(22.4*1000)=.102MT
3. Plant drain:- Flow rate 5 m3/Hr, Ammonia/Urea conc. 300/300 ppm max (actual 150 - 300 ppm)
=5*0.0003*24+5*0.0003*24*.589=.057MT
4. Hydrolyser Effluent:- Flow rate 40 m3/Hr., Ammonia/Urea conc. 5 ppm. Each (actual 2 - 4 ppm)
=40*0.000005*24+40*0.000005*24*.589=.007627
5. Prill Cooler ID fan:- Air flow 2.1 lac NM3/Hr. Avg. dust conc. 75 mg/m3 (actual 55 - 90 mg/m3)
=210000*75*24/1000000000*.589=.222MT
6. Biuret formation:- Biuret in final product 0.6 Wt%. Each mole of Biuret formed results in
releases of one mole of ammonia (assuming total loss)
=1250*0.006*17/103=1.238
Total losses=.5597+.102+.057+.007627+.222+1.238=2.186MT
Input=680.40+2.186=682.58MT
Efficiency=output ammonia/input=680.4/682.58=.996MT/MT
Efficiency=682.58/1200=.5688MT/MT of Urea