Limitations:

1) Carbamate decomposition and recycle:

There are many processes that can be used for the manufacture of urea. Main
difference in competing processes is in the recycle design. Since, conversion is
only 40-50 % per pass, the unreacted off gases must be recirculated or used
economically elsewhere. Recompression of off gases is virtually impossible
because of corrosion and formation of solid carbamate in compressors.
2) Corrosion:
Ammonium carbamate solutions are notoriously corrosive to metallic
construction materials, even more resistant forms of stainless steel--especially
in the hottest parts of the plant such as the stripper. Traditionally corrosion has
been minimized (although not eliminated) by continuously injecting a small
amount of oxygen (as air) into the plant to establish and maintain a passive
oxide layer on exposed stainless steel surfaces. Because the carbon dioxide
feed is recovered from ammonia synthesis gas, it contains traces of hydrogen
that can mingle with passivation air to form an explosive mixture if allowed to
accumulate.
3) Production of granular urea:
Biuret formation is another problem. Vacuum evaporation of urea from 80% to
about 99% ,spraying to air cool and solidification must be done just above the
melting point of urea and with a minimum residence time in the range of several
seconds.
4). Clinical market price of feedstock and urea require plants to adjust throughput
5). Comprehensive measurement capabilities of entire process is challenging so
automation is required.
6) Heat dissipation in the autoclave:
The exothermic heat of reaction can be removed by coils or wall cooling.