Process of Urea Plant:

The raw material required for the process of Urea plant is ammonia (NH3) and carbon dioxide (CO2).

Plant Description:
1) Urea synthesis and high pressure recovery. 2) Urea pressure and low pressure recovery. 3) Urea concentration 4) Urea prilling 5) Waste water treatment

1)Urea synthesis and high pressure recovery:

Compressor K-1 compress carbon-di-oxide comming from ammonia plant at 0.65 kg/cm2g to 157 kg/cm2g pressure . Air is added in CO2 before compressor to provide oxygen for passivating the equipment to avoid corrosion. Liquid ammonia is received in receiver and its pressure is boosted up by means of the pump p-5 . part of the ammonia isi sent to medium pressure absorber c-1 and the remaining is pumped by high pressure ammonia pump p-1 to a pressure of 240kg/cm2g . liquid ammonia from p-1 isii used as motive fluid in ejector in which carbomate coming from separator (MV-1) is recycled to reactor.

In reactor R-1 ammonia and carbon-di-oxide reacts to form ammonium carbomate , a portion of which dehydrates to form urea and water. About 65% of the total CO2 entering the reactor is converted into urea. The reaction product goes to steam heaed falling film bimetallic stripper E-1 , where the carbon-di-oxide content of the solution is substantially reduced by the stripping action of ammonia as it boils out of solution . The overhead gases and the solution recovered from medium pressure absorber C-1 , flow to high pressure condenser E-5 where the total mixture except for a few inerts is condensed and recycled via a carbomate seperator MV-1 to the reactor by means of ejector.

L.P steam is generated n the shell side of E-5 and is used to supply the decomposition and concentration heat required in the downstream section . From the top of carbomate separator MV-1 iert gases with small quantity of ammonia and carbon-di-oxide are sent to the bottom of medium pressure docomposer.

2)M.P purification and recovery:

E-1 bottom solution which contain around 23% ammonia 5% carbon-di-oxide and 45% urea is expanded to a pressure of 17kg/cm3g and enters the medium pressure separator where the released flash gases are removed next it enters the falling film exchanger E-2 where most of the residual

carbomate is decomposed . The required heat is supplied by steam condensate coming from the stripper. The ammonia and carbon-di-oxide rich gases leaving the top of the separator are sent to M.P condenser and then liquid/gas mixture from E-7 goes to medium pressure absorber. The upper part of the absorber I fitted with four no. bubble cap trays for CO2 absorber and NH3 rectification . Here a reflux of ammonia drawn from the ammonia receiver eliminates residual carbon-dioxide and H2O . The bottom solution is recycled by pump P-2 to the H.P carbomate condenser . Ammonia vapour leaving the top of absorber are condensed in ammonia condenser before entering ammonia receiver.

The innert gas leaving the receiver are scrubbed with condensate in ammonia absorber . From bottom of the water ammonia solution is recycled back to medium pressure absorber by mean of ammonia solution pump.

3) L.P purification and recovery: The solution which contain around 6.5% NH3 , 1.5% CO2 and 62% urea leaving he bottom of MP decomposer is expanded to a pressure of 3.5 g/cm3g and enters LP separator . The required heat of decomposition is supplied by 3.5 kg/cm2 LP steam which is generated in E-5. The vapours leaving the top of the separator , together with the recoverd solution from waste

water section are condensed in LP condenser (E-8) . Heat of the condensation is recoverd by cooling water. The solution from E-8 is sent to carbomate solution tank V-3 to be recycled to the medium pressure suction by pump P-3

4) Solution concentration and prillilng: Vaccum section is in two stage to get 99.7% wt urea melts for prilling .The 70% wt. solution of urea leaving the bottom of E-3is sent to 1st stage vaccum separator MV-6 through 1st stage vaccum preconcentraror E-14 and E-15 operating at a pressure of 0.3ata. After 1st stage vacccum sepertor 95% wt. urea is sent to second stage vaccum concentrator E-15 and

separator working at 0.03ata. Heat required in E-14 and E-15 are met by L.P section . The vapour leavin the vaccum evaporator are condensed in vaccum system. Urea melt is sent to prilling spinning bucket which distributes the urea melt in small droplets over the crossection of natural draught circulling prilling tower .Cold air entering the bottom of prilling tower causes urea droplets solidify. The solid urea collected at the bottom of the prilling tower and sent to the bagging plant for further activity.

5) Process condensate treatment:

The waste coming from vaccum system containing NH3 5%, CO2 , and urea 1% is collected in buffer waste water tank from where it pumped by P-16 to waste water distillation tower C-2 through distillation tower preheater operating at a pressure of 1.5kg/cm2g column C-2 is divided into two part by chimney tray located at a suitable height. From upper part of chimney tray located at suitable height . From upper part of the chimney tray the solution containing water urea and small amount of NH3 and CO2 is pumped by hydrolyser R-2 through hydrolyser preheater . In R-2 urea is quantitatively decomposed into CO2 and NH3.

i ii