Slide 24

 For this chapters consist of 5 section which are (from slides

Slide 25
 For our plant process consist of 4 section which are Synthesis, Purifying, Concentration
Finishing section
 For synthesis section its include the Ammonium carbamate and Urea synthesis and Stripper
 This section operate at high pressure at 142 atm and temperature around 170-190 because
to achieve high conversion (theory principle –le chaterlie principle*)
 For purifying section, its operate at moderate temperature and low pressure 4.3 atm the
reversible reaction is favour in the decomposer and low pressure and temperature in
concentration section near to the boiling point is used for easier to evaporate the water and
based on bubble point calculation.
 For prilling tower, low pressure and temperature above the melting is used to solidify the
urea to form of urea prill by using ambient air as a solidifying medium.

Slide 26
 Mass balance is very important parameters in plant design
 The theory of mass balance is based on law of conversation of mass which states that mass
can neither be created nor destroyed.
 The general mass balance equation is …..
 At steady state, the accumulation is equal to 0 because we set a basis of mass per hour
 This equation is used to for reactive process equipment in carbamate condenser.
 If there is no reaction occur in the equipment, the generation and consumption is equal to 0
which lead to the equation states (from slides). Example that using this equation is on the
flash drum.

Slide 27
 Our plant using ammonia, carbon dioxide used as raw material and air as solidifying medium
and output that consist of unreacted ammonia, carbon dioxide, air, water vapour and our
selected product (urea).
 We can see that amount of inlet is equal to amount of outlet. The overall MB is satisfied.

Slide 28 and 29
 Next we proceed to the example of mass balance on the reactive equipment, carbamate
condenser reactor
 Reaction occur in the equipment is synthesis of intermediate product which is ammonium
carbamate by reacting ammonia and carbon dioxide.
 Based in the literature, molar ratio of ammonia to carbon dioxide and conversion of carbon
dioxide, 3:1 is choosen because it is a optimum condition where the high conversion can be
achieve.
 The reaction is almost complete reaction in which low possibilities of reverse reaction will
occur because at high T and P it can achieve a almost complete reaction.
 Our basis is carbon dioxide with the value of 447.78
 This is the mass balance table of reactor (R-101).
  To calculate the amount of ammonium carbamate produced, ammonium carbamate recycle
from stream 9 is added with multiplication of conversion of CO2 (98%) and amount of
carbon dioxide entering the reactor (448.63) give a total of 523.64.
 Because of 98% of co2 has been converted to ammonium carbamate, the remaining 2% is
the unreacted amount of co2 going out from the reactor (8.97)
 Based of stoichiometry, unreacted nh3 can be calculated and the remaining is 1483.61.

Slide 30 and 31
 Next is the example of mass balance for stripper
 Stripper is used to strip out the unreacted ammonia and co2 gas by the decomposition of
intermediate product to the top of the column by using CO2 as a stripping agent
 Based on the literature 83% decomposition of ammonium carbamate is happened in stripper
and higher percentage it can achieve to strip out the gas is 90%
 Intalox saddle is used as a packing because it has good corrosion resistance and can achieve
low pressure drop.
 Calculation (explain based on the slides)

Slide 32
 Energy balance is also important in designing the plant design
 Theory of the energy balance is based on first law of thermodynamics.
 General balance equation is (from slides)
 Assumes no potential and kinetic energy the equation becomes (from slides)
 Because of no mechanical part that used in the process the work shaft is equal to 0
 Delta H is consist of sensible heat, heat of reaction, latent heat, heat of solution and
pressure change
 Reference state for whole process is (from slides)

Slide 33/34
 Explain based on slides

Slide 35
 Utilities used in the plant consist of three types (superheated steam(preheater……),cooling
water (…) and electricity (….)

Slide 36
 Waste can be categorize based on three common types which are (solid,liquid and gas)
 For this it only consist of gas waste
 Gas waste in the plant is consist of 2 types water vapour(…) and air (…)

Slide 37
 The waste is calculated based on ton/year
 For water vapor waste, it can be treat by (from slides) and for water vapour because of only
water and air, it can be release safely to the environment

Slide 38
 In can be conclude that the mass inlet of the plant is equal to the mass outlet of the plant
 Negative value of heat duty release heat while Positive value of heat duty absorb heat to
supply
 Utilities that has been used in the plant is (…)
 And waste produced is (..) and futher treat to reduce environmental impacts.