1 Reactor Operating Conditions

- Temp. ºC 188 183 185 190 220 200 196

- Pressure Ata 155 140 175 200 190 250 218
NH3 :CO2: H2O: Mole ratio 3.6 : 1 : 0.6 2.5 : 1 : 0.39 4 : 1 : 0.42 4 : 1 : 0.42 3.5 : 1 : 0.687 3.7 : 1 : 0.563 4.2 : 1
- CO2 Conv. Effcy. % 65 60.4 71.7 71.7 60 70 75
- NH3 Conv. Effcy. % 36.1 41 35.6 35.8 - - --

2 Stripper Operating Conditions 1st 2nd Stripper

- Temp. Top/Bottom ºC 188/210 187/160 188/175 195/205 210/180 - - --
- Pressure Ata 146 140 175 200 200 - - --
- Outlet Composition NH3 24.3 7.5 12.2 36 -- - - --
( wt %)
- CO2 5.8 10.3 14 7 - - --

3 Pressure Letdown Stages

- 1st stage ata 17 -- 20 20 70 18 21

- Last stage ata 3.5 4 3 6 3 1.3 Atmosphere

Urea (%) 72 74 67 -- 73 72 --

4 Evaporation Stages
- 1st Stage Ata 0.3 0.3 0.18 -- 0.3 Crystalization route --
- 2nd Stage Ata 0.03 0.035 -- -- 0.03 is adopted --
- Urea % 99.7 99.5 99.7 -- 99.5 99.5 99.7

5 Matl. of construction
- Reactor Liner 316L 316L -- 316L SS Type 'A' Titanium 25 : 22 : 2
- Stripper 25:22:2/Titanium 25 : 22 : 2 SS 25 : 22 : 2 - - --

6 Product Quality
- Nitrogen (wt%) 46.4 46.4 46.5 46.3 46 46.3 46.3
- Moisture 0.3 0.3 0.3 0.2 0.5 0.3
- Biuret 0.9 0.8 0.8 0.8 0.6 0.3
7 Heat Recovery System Ammonia and Amm. preheating Amm.preheating Ammonia preheating Generation of LS steam by Preheating of Amm.
carbamate pre- with return hot cool- with CW from MP with LP flash steam recovery of heat of cond. of carbamate & Urea
heating by con- ing water from carb- condenser & LP heater. 1st evapora- vapors of 2nd & 3rd stage solution by heat of
densate and amate condenser & flash steam. MP tor with off gas from deccomposers. carbamate forma-
provision of with LP flash steam. decomposer with MP decomposer. Amm to reactor is pre- tion. Urea solution
preconcentrator LP decomposer with shall side of HP Perforated trays. heated by condensate conc. 85%. Use of
with MP decom- CW from HP scrub- carbamate cond- Reactor in 2 parts. counter current
poser vapour. ber heater 1st eva- enser heater. 1st reactor with internal
porator with off gas evaporator with open ended coil
from LP decomposer. off gas from HP improves conv. of
decomposer CO2 to urea.

8 Consumption per tonne Urea

- Ammonia Kg. 570 570 570 570 580 570 573
- CO2 Kg. 740 740 740 740 760 750 740
- Steam Kg. 798 660 494 316 920 ( 32 ata) 1060 ( 41 ata) 470
- Steam export Kg. 155 -- -- -- - - --
- Electricity Kwh 20 15 18.1 20 95 160 116
(Process pump)
- Prilling 1 -- 10 70 (CO2 compr.) - - --
- Cooling water M3 80 75 55 80 100 58 at 14 ° C 83

9 Other design. features Amm. stripping. CO2 stripping Isob- Two stage CO2 Reactor in 2 sections. Isothermal Adiaba-
Isobaric loop. aric loop. Perfora- stripping and Perforated trays & tic reactor with Heat
Perforated ted trays internals isobaric loop. down comers as exchange circula-
trays internal for for reactor. Gravity internals; 2 stage tion.
reactor.Horizon- circulation & vertical stripping with NH3
tal layout of syn- layout of synthesis & CO2.
thesis section. section.

to urea. Amount of steam

 --
180-230
4-5 : 1
77
38

--
--
NH3-35% (from
Decomposer)
8

Prevailing stages in
stripping plant
mentioned.
--
--

--
--
--

25 : 22 : 2
--

--
--
--
 Two reaction zones.
2nd reaction zone
is at 30-50 bar higher
pressure conv. of
carbamate to Urea=
72-75%. Supplemen-
tary reaction and
decomposition.

570
740
600
--
9.6 extra for Urea
solution pump.
--
85

Specially developed
for revamp of stripping
plant. Reaction effluent
from stripping plant to
SRR side section &
outlet sent back to exis-
ting plant to achieve
72-75% conv. of carb.
to urea. Amount of steam
reqd. for both decomp-
oser of existing stripper
is 30-40% lower.