6200 Area - Urea Plant

Process Overview

The urea plant uses liquid ammonia (NH3) and gaseous carbon dioxide (CO2) from the existing
anhydrous ammonia unit (4400 Area) at the Synfuels Plant. The plant produces 1100 STPD of
granular urea fertilizer with the ability to also produce Diesel Exhaust Fluid (DEF, also known as
AdBlue and AUS 32) as well as pure liquid carbon dioxide.
Urea Synthesis
The urea synthesis section includes three vessels operating at high pressures around 2,100
psig. Liquid ammonia and high pressure carbon dioxide react inside the pool reactor where urea
is produced in two steps. First, carbon dioxide and ammonia react forming an ammonium
carbamate intermediate. Then the carbamate intermediate is partially converted to urea. The
pool reactor liquid outlet is distributed across the tubes of the High Pressure Stripper where the
carbon dioxide feed from the 4300 Area decomposes remaining carbamate and removes non-
reacted carbon dioxide and ammonia. After the urea solution leaves the High Pressure Stripper,
the pressure is reduced and further purified in the Low Pressure (LP) Recirculation Section.
The stripped gasses from the High Pressure Stripper are sparged into the pool reactor where
they are condensed, and the carbon dioxide reacts with ammonia to form carbamate. The inert
gases introduced to the reactor with the carbon dioxide and part of the non-reacted ammonia
and carbon dioxide are collected at the top of the pool reactor and flow to the high pressure
scrubber. In the High Pressure Scrubber, recycled carbamate from the LP Recirculation section
scrubs a majority of the carbon dioxide and ammonia from the inert gases leaving a stream of
primarily nitrogen. The liquid effluent from the HP scrubber is returned to the pool reactor.
Remaining ammonia in the scrubber off gas is further removed in the Medium Pressure
Absorber by an ammonia water wash. Vapor from the Medium Pressure Absorber is sent to the
Acidic Scrubber in the LP Recirculation Section, and the liquid effluent is used in the
Atmospheric Absorber.
Low Pressure (LP) Recirculation Section
The purpose of the LP Recirculation Section is to recover all non-converted ammonia and
carbon dioxide from the urea-carbamate solution leaving the HP Stripper. The stream is fed to
the Rectifying Column where the solution is expanded and heated to decompose the remaining
carbamate and evaporate ammonia, carbon dioxide, and water from the solution. The vapors
leaving the Rectifying Column are condensed in the Low Pressure Carbamate Condenser
(LPCC). The liquid carbamate solution from the LPCC is recycled back to the HP scrubber.
Vapor not condensed in the LPCC flows to the Atmospheric Flash Condenser where remaining
ammonia and carbon dioxide are condensed. Part of this lean carbamate solution is recycled
back to the LPCC, and the rest is sent to the Reflux Condenser in the Water Treatment Section.
Non-condensable gases, primarily nitrogen, from the Atmospheric Flash Condenser are sent to
the Atmospheric Absorber. The Atmospheric Absorber removes almost all the ammonia present
in the uncondensed gases from the Atmospheric Flash Condenser and the First Stage
Evaporator Condenser by contact with an ammonia water spray in the packed column. Any
remaining ammonia in the vent from the Atmospheric Absorber, along with the Medium
Pressure Absorber vent gas, is removed by the Acidic Scrubber. A dilute sulfuric acid solution
removes the ammonia by a reaction forming an ammonium sulfate solution. The scrubbed
overhead gases from the Acidic Scrubber are vented to the atmosphere.
The 66 wt% urea solution leaves the bottom of the Rectifying Column and is flashed to near
atmospheric pressure in the Atmospheric Flash Separator. The solution is then heated and
flashed again at a slight vacuum in the Pre-Evaporator Separator. Here, part of the water and
most of the ammonia, carbon dioxide, and inert gases are freed from the liquid to increase the
urea concentration to 74%. The vapors from the Pre-Evaporator Separator are condensed in the
First Stage Evaporator Condenser. The 74% urea solution is then sent to the Urea Solution
Storage Tank or sent to the DEF Production Section.
Urea Concentration Section
Almost all the water is evaporated from the urea solution in the Urea Concentration Section in
preparation for granulation in the Granulation Section. The 74% urea solution is concentrated up
to 98.5% by two stages of evaporation operating at increasing vacuum pressures. In each
stage, the urea melt solution is heated and then the vapor and liquid phases are separated in
the First and Second Stage Evaporator Separator vessels. UF85 formaldehyde solution is
added to the concentrated urea melt solution from the Second Stage Separator and then
pumped to the Granulation Section.
The vapors from the First and Second Stage Evaporators are condensed in the First and
Second Stage Evaporator Condensers. The First and Second Stage Evaporator Condenser
Ejectors create vacuum on their respective stage of separation. Condensate from the
Evaporator Condensers flows into the Ammonia Water Tank and is treated in the Water
Treatment Section.
Water Treatment Section
In the Water Treatment Section, the Desorber and Hydrolyzer columns remove the ammonia
and carbon dioxide from the ammonia water stream and produce a relatively clean water stream
for export back to the main plant. Ammonia water from the Ammonia Water Tank is preheated
and pumped to the top of the Desorber, which is divided into two sections. In the top section, the
bulk of the ammonia and carbon dioxide are stripped out the ammonia water by rising vapors
from the bottom of the Desorber and the overhead vapor from the Hydrolyzer. The bottom
effluent of the Desorber top section is pumped through a preheater and into the top of the
Hydrolyzer. The water is brought to a boil inside the Hydrolyzer by injecting live steam which
causes urea to decompose into carbon dioxide and ammonia. After cooling, the Hydrolyzer
bottom effluent is fed to the top of the bottom section of the Desorber. Here, any remaining
ammonia and carbon dioxide are stripped out of the water by live steam injection into the bottom
of the Desorber. The purified process condensate leaving the bottom of the Desorber is cooled
and pumped to the existing Synfuels Plant's process condensate system. Additionally, the
process condensate can be used in the DEF Production Unit for diluting the urea solution.
Overhead vapor from the top section of the Desorber is condensed in the Reflux Condenser,
and then recycled to the LPCC. Uncondensed vapors from the Reflux Condenser are sent to the
Atmospheric Absorber via the Atmospheric Flash Condenser.
DEF Production Section
In the DEF Production Section, the 74% urea solution from the Pre-Evaporator is diluted to a
marketable range of 32-50%. First, the 74% urea solution is cooled and sent to the DEF Mixing
Tank. Here the urea solution is diluted to the desirable range with process condensate. After
dilution, product with the desirable concentration is stored in the DEF Storage Tank for sales.
Urea Granulation Section
Equipment in the Urea Granulation Section converts urea melt from the Urea Concentration
section to an on-size high quality urea granular product. Granular urea is produced inside the
fluidized bed Granulator by pressure “film” spraying of liquid urea onto seed material. The
Granulator is divided into two sections, a granulation section and a cooling section. In both
sections, fluidization air from the Fluidization Air Fan is evenly distributed by a perforated plate
to fluidize and cool down the granules. The seed (recycle) material is introduced into the first
chamber of the granulation section, where the urea solution is sprayed. The Sprayer Air Fan
provides the hot air to each spray nozzle necessary to create the film spray of urea melt. As
granules move along through the granulation section, their size steadily increases by layering to
reach the required granule diameter at which the product drops out of the fluidized state and
flows out of the Granulator.
The granulated product flows from the granulation section of the granulator into the cooling
section (without melt spray nozzles) where the granules cool down and harden before further
size classification. The fluidization and sprayer air and some urea dust are exhausted from the
top of the Granulator by means of the induced draft Granulator Scrubber Fan in the downstream
off gas line of the MMV Scrubber.
The Extractor withdraws the product from the Granulator sending it to the Lump Screen where
any lumps and larger agglomerates are removed. The lumps are diverted to the Urea Dissolving
Tank for reprocessing in the Urea Concentration Section while the remaining material is
conveyed via a bucket elevator to the Screening, Crushing, and Cooling Section.
Screening, Crushing, and Cooling Section
Cooled granules from the Lump Screen are conveyed to the Main Screen where the granules
are classified as oversize, on-size, and fines. The final on-size product is then cooled in the
Product Cooler before storage in the Urea Storage and Load-Out Section.
The fine product is recycled to the Granulator as seed material. The oversize material is cooled
in the Crusher Feed Cooler and then crushed. After crushing, oversized product is combined
with the fines to the Granulator.
Scrubbing Section
The fluidization/cooling air from the Granulator, which contains fine dust particles, is combined
with air from the Crusher Feed Cooler, Product Cooler, Dissolving Tank, and various dust
collection points. The combined air stream is cleaned in the Quench Scrubber and Micro Mist
Venturi (MMV) Scrubber.
In the Quench Scrubber, dust laden air is washed with a diluted urea solution. Through water
quenching, the generation of fine droplets and creation of relative droplet/particle motion, the
gas becomes saturated and coarse particulate is removed from the gas stream. Most of the
urea dust is removed in this stage. A portion of the urea scrubbing solution is recirculated to the
scrubber and the rest is recycled to the Urea Concentration Section via the Dissolving Vessel.
The quenched air exhausts to the MMV Scrubber.
The MMV Scrubber consists of two separate sections: a venturi section for sub-micron
particulate removal and an acidic scrubbing section for ammonia removal. The bottom part of
the MMV Scrubber consists of two integral elements: venturi tubes operating in parallel and an
equal number of high pressure liquid MicroMistTM atomizers. The gas and injected micro-fine
droplets travel up through the venturi nozzles. Each venturi tube is also equipped with a “throat
spray” to improve the scrubbing of fine submicron particulate matter. The gas travels through a
chevron mist eliminator into the upper section where an ammonium sulfate solution containing
sulfuric acid removes any ammonia. A chimney hat collection tray separates the upper section
from the lower. Ammonia removal takes place across a dual orifice impingement tray where the
acidic solution contacts the gas. Ammonia in the gas reacts with the sulfuric acid creating an
ammonium sulfate solution. Any remaining particulate is also removed on the trays. The
ammonium sulfate solution is collected on the chimney hat tray and drains into the Ammonium
Sulfate Solution Tank. Sulfuric acid is added to the ammonium sulfate solution before it is
recycled back to the dual orifice trays. A portion of the ammonium sulfate solution is combined
with the ammonium sulfate solution from the Acidic Scrubber in the melt plant and sent to the
Synfuels plant’s existing Flue Gas Desulfurization Unit (Area 5800). Finally, the gas travels
through a mesh style mist eliminator to collect any residual water droplets from the gas stream.
The scrubbed air exhausts through the induced draft Granulator Scrubber Fan and out the
Granulation Vent Stack to the atmosphere.
Storage and Load-Out
The final granular product urea is conveyed to the storage silo where it is stacked by an
overhead tripper conveyor. A portal scrapper reclaims material from the storage pile and
conveys the urea to a screening station to remove any oversized or fine material prior to final
load-out. Oversize material is discharged to a lump breaker and recycled back to the screening
station, and the fines are pneumatically conveyed back to the Dissolving Tank. The on-size
product material is diverted to either a rail load-out silo or truck load-out silo. Trucks and railcars
will be filled automatically by a drag conveyor based on weight of the vehicles.
Product DEF can also be loaded into railcars or trucks from the load out area depending on sale
demands. The Storage and Load-Out area also has facilities for unloading and washing off-spec
DEF railcars and unloading UF-85 Railcars.

Chemical Safety
Most chemicals are potentially hazardous, and if improperly handled, can endanger
personnel and/or property. It is important that all of the hazardous characteristics of any
chemical be fully understood before attempting to handle it, or work in an area where
exposure could occur, due to equipment failure or human error.
The following chemicals and mixtures that are involved in this unit have hazardous
properties:
Ammonia Urea
Carbon Dioxide Diesel Exhaust Fluid (DEF)
Sulfuric Acid Urea Formaldehyde
Ammonium Sulfate
Please refer to the appropriate MSDS for detailed precautions for these materials.
6200 Area - Urea Plant Chemicals
Chemical: AMMONIA
Exposure Limits OSHA PEL 50 ppm 8 hr. (TWA)

Health Hazards Ammonia is extremely destructive to mucous membrane tissue of the

upper respiratory tract. Severe tissue damage to the skin can occur
from exposure to liquids. Contact with liquefied ammonia can cause
severe frost bite burns.
Physical Hazards Difficult to ignite, ignition limits are 16%-25%., vapor density at 32F is
slightly lighter than air.

First Aid Inhalation: Assist conscious victim to uncontaminated area and inhale
fresh air. Remove overcome victim to fresh air safely. If breathing has
stopped administer artificial respiration immediately.
Eyes: Flush immediately with copious amounts of water. Speed is
essential. Irrigate for at least 15 minutes. Seek medical attention.
Skin: Flush area immediately with copious amounts of water.
Ingestion: Flush mouth with cold water and spit out. DO NOT
INDUCE VOMITING. Dilute with milk or water.

Protective Butyl rubber, Neoprene, PVC/Nitrile glove material. Wear impervious

Clothing/Gloves clothing where contact with liquid is possible. Wear goggles or face
shield to protect eyes if respirator is not worn.
Respirator Full face cartridge respirator with green (ammonia) or multi-gas (olive
green) cartridge.
Odor Strong, penetrating, pungent odor. Prolonged exposure can cause
olfactory fatigue or adaptation.

Chemical: CARBON DIOXIDE

Exposure Limits OSHA PEL 5000 ppm 8 hr. (TWA)

Health Hazards Inhalation of gaseous carbon dioxide can adversely affect body
function. Concentrations of 10 percent or more can produce
unconsciousness or death. Lower concentrations may cause
headache, sweating, rapid breathing, increased heartbeat, shortness of
breath.

Physical Hazards It is relatively nonreactive and nontoxic. It will not burn and it will not
support combustion or life. It is heavier than air and may accumulate in
low or confined areas under certain conditions of use or storage.
Discharge of liquid CO2 through a hose will result in static charge
buildup if hose is not grounded.
First Aid Inhalation: If having inhaled large quantities of CO2 and exhibiting
adverse effects remove to fresh air. If breathing has stopped
administer artificial respiration immediately.
 Skin: If skin contact occurs stop the exposure and seek medical
attention. Frost bite may occur, flush skin with tepid water.
Eye Contact: If eye contact occurs patch and cover eye while seeking
medical attention.

Protective Avoid contact of the skin or eyes with solid carbon dioxide or objects
Clothing/Gloves cooled by solid carbon dioxide
Respirator When entering low or confined spaces where a high concentration of
carbon dioxide gas is present wear self-contained air supplied
respirator.

Odor It is felt by some people to have a slightly pungent odor and biting
taste. Essentially odorless.

Chemical: SULFURIC ACID

Exposure Limits OSHA PEL-1 mg/m3 8 hr. (TWA) IDLH-15 mg/m3
Health Hazards A severe eye irritant, extremely irritating, corrosive, and toxic to tissue,
resulting in rapid destruction of tissue, causing severe burns. Repeat
exposures to dilute solutions can cause dermatitis, repeat exposure to
mist can cause inflammation of the respiratory tract leading to
bronchitis. Sensitivity varies by individual. Normally 0.125-0.5 ppm
may be mildly annoying, 1.5-2.0 ppm is unpleasant, 10-20 ppm is
unbearable.

Physical Hazards A very powerful acidic oxidizer than can ignite or explode on contact
with many materials. Will react with water to produce heat.

First Aid Eyes: Flush eyes immediately with water for at least 15 min keeping
eyelids apart.
Skin: Speed in removing material from the skin is imperative. Flush
for at least 15 minutes while removing contaminated clothing.
Inhalation: Move victim to fresh air, perform artificial respiration if
breathing has stopped.
Ingestion: DO NOT INDUCE VOMITING. Dilute with water or milk,
seek medical attention.

Protective PVC/Nitrile, Natural Rubber, Neoprene, Nitrile glove materials. Protect

Clothing/Gloves the skin from all contact with product. Wear chemical goggles and
faceshield.

Respirator Cartridge respirator-full face with yellow, organic vapor/acid gas

cartridge.
Odor Employees exposed to low concentrations may gradually lose their
sensitivity to irritating effects. Product is essentially odorless although
very irritating.
Chemical: AMMONIUM SULFATE
Exposure Limits Exposure limits have not been established.

Health Hazards Causes eye and skin irritation. Routes of exposure are inhalation and
ingestion. If ingested and conscious drink water and induce vomiting.

Physical Hazards Emits toxic vapors when heated or in contact with acids. No flash point-
noncombustible. Avoid acids, oxidizers, ammonium nitrate & chlorine.
Explosion hazard if mixed with potassium or potassium-containing
oxidizers during fire.

First Aid Inhalation: If breathing has stopped administer artificial respiration

immediately. If breathing is difficult administer oxygen.
Eyes: Flush immediately with copious amounts of water. Irrigate for at
least 15 minutes. Seek medical attention.
Skin: Flush area immediately with copious amounts of water. Wash
contaminated clothing before reuse.
Ingestion: Flush mouth with cold water and spit out. INDUCE
VOMITING. Dilute with milk or water.

Protective Protective gloves, neoprene, PVC should be worn to prevent skin

Clothing/Gloves contact.
Wear goggles or faceshield if dusting is severe.
Respirator Use an approved respirator with a P-100 filter.

Odor White, odorless, crystals.

Chemical: UREA
Exposure Limits Exposure limits have not been established.

Health Hazards May cause eye, skin, or respiratory irritation. Routes of exposure are
inhalation and ingestion.

Physical Hazards Hygroscopic and will absorb moisture in air. Avoid oxidizers, nitrates and
chlorine containing compounds which react violently causing fire and
explosion hazards.

First Aid Inhalation: Remove victim from source and allow to rest in well-
ventilated area. If breathing is difficult seek medical attention.
Eyes: Flush immediately with copious amounts of water. Irrigate for at
least 15 minutes. Seek medical attention.
Skin: Flush area immediately with copious amounts of water. Wash
contaminated clothing before reuse.
Ingestion: Flush mouth with cold water and spit out.
Protective Protective gloves, neoprene, PVC should be worn to prevent skin
Clothing/Gloves contact.
Wear goggles or face shield if dusting is severe.
 Respirator Use an approved respirator with a P-100 filter.

Odor White granule with faint ammonia odor.

Chemical: DIESEL EXHAUST FLUID (DEF)

Exposure Limits Exposure limits have not been established.

Health Hazards May cause eye, skin, or respiratory irritation. Routes of exposure are
inhalation and ingestion.

Physical Hazards May react with oxidizers, nitrates and chlorine containing compounds.
Protective Protective gloves, neoprene, PVC should be worn to prevent skin
Clothing/Gloves contact.
Wear safety glasses or chemical goggles if the potential for splashing
exists.
Respirator Not generally required.

Odor Faint ammonia odor.

Chemical: UREA FORMELDEHYDE

Exposure Limits OSHA PEL 0.75 ppm 8 hr. (TWA)

Health Hazards Harmful if inhaled or swallowed. May cause allergic skin reaction. May
be harmful if absorbed through skin. Contains material that may cause
target organ damage. Cancer Hazard - Contains material which can
cause cancer. Causes server respiratory tract irritation. Causes severe
eye and skin irritation.

Physical Hazards Combustible liquid and vapor.

First Aid Inhalation: Remove victim from source and allow to rest in well-
ventilated area. If breathing has stopped administer artificial respiration
immediately and seek medical attention.
Eyes: Flush immediately with copious amounts of water. Irrigate for at
least 15 minutes. Seek medical attention.
Skin: Flush area immediately with copious amounts of water for at least
15 minutes while removing contaminated clothing. Seek medical
attention. Wash contaminated clothing before reuse.
Ingestion: Flush mouth with cold water and spit out, DO NOT INDUCE
VOMITING.

Protective Face shield with safety glasses or chemical safety goggles. Protective
Clothing/Gloves gloves, neoprene, butyl rubber or nitrile rubber, should be worn to
prevent skin contact. Tychem BR suit is necessary if contact to the body
exists. Chemical goggles or face shield if the potential for splashing
exists.
Respirator Use an approved respirator with a multi-gas (olive green) cartridges.

Odor Pungent, irritating.