Urea Project Report 2q5w2

UREA PROJECT REPORT

PREPARED BY: MUKESH M. CHAUHAN BE – IV CHEMICAL M. S. UNIVERSITY BARODA

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CONTENTS

Page No

Chapter 01 1.0 Literature Survey.…………………………………………….…………………………..08 1.1 Urea …………………………………………………………….………………………..08 1.1.1 Synthetic urea ...….……………………………………….……….……………….08 1.1.2 Commercial production of urea ………………...………….……………..………..08 1.1.3 Chemical characteristics of urea.…………………………….………………..……09 1.1.4 Physical characteristics of urea …………………………….……………………...10 1.1.5 Raw materials of urea manufacturing ……………………….……………….……10 1.1.5.1 Ammonia ….……………………………………………………………….10 1.1.5.1.1 Ammonia Production ….……………………………...…………11 1.1.5.1.2 Ammonia storage ……….……………………………………….12 1.1.5.2 Carbon Dioxide …………………….………………………………….......12 1.1.6 Applications of urea……………………….………………………..……………..12 1.1.6.1 Agricultural use …………………….………………………...……………12 1.1.6.1.1 Advantages of Fertilizer Urea…….……………………………...13 1.1.6.1.2 Soil Application and Placement of Urea….………………….…..13 1.1.6.1.3 Spreading of Urea………………………….…………………..…14 1.1.6.2 Industrial use………………………………………….……………………14 1.1.6.3 Further commercial uses……………………………….…………………..14 1.1.6.4 Laboratory use…………………………………………..………………….16 1.1.6.5 Medical use…………………………………………….…………….…….16 1.1.6.5.1 Drug use …………………………………….……………….…..16 1.1.6.5.2 Diagnostic use ……………………………….………………..…16 1.1.6.6 Textile use…………………………………………………………….……17 1.2 Global production and consumption of Urea………………………….……..…………..17 1.2.1 Range of global uses of urea…………………………………….…………..……..20 1.3 Urea Prices…………………………………………………………….………..………..21 1.4 Urea Price in India & Industries Producing Urea in World…………….……………..…22 Chapter 02 2.0 Process Selection & Economic Aspects……………………………..……….…………..24 2.1 Feasibility Study……………………………………………………..……….…………..24 2.1.1 Introduction…………………………………………………….…………..………24 2|P a g e

2.1.2 Technical & Economic Feasibility…………………………….…………...………24 2.1.2.1 Plant Capacity……………………………………………………..……….25 2.1.3 Social & Environmental Feasibility…………………………….……….…………25 2.1.4 Plant Components…………………………………………………………...……..25 2.2 Process Selection…………………..………………………………….………………….26 2.2.1 Conventional Processes………………..………………………..………………….26 2.2.1.1 Once through Process………………...………………..…..………………..26 2.2.1.2 Conventional Recycle Process …………………......………………………26 2.2.2 Stamicarbon CO2 – stripping process………………………………………………27 2.2.3 Snamprogetti Ammonia and self stripping processes………………………………29 2.2.4 Isobaric double recycle process ………………………………...……….…………30 2.2.5 ACES process………………………………….………………...…………………31 2.2.5.1 Process comparison……………………………………..….………………31 2.2.5.2 Basic concept of process …………………………………..………………32 2.2.5.3 Features of Process ……………………………….………..………………33 2.2.5.4 Advantages of ACES Process……………………………..……………….35 Chapter 3 3.0 Process Description and flow sheet…………………………………………...………….37 3.1 Process Description – ACES Process………………………………………...…………..37 3.2 Main component of the process…………………………………………………………..40 3.2.1 Reactor……………………………………………………………………...……...40 3.2.2 Stripper……………………………………………………………………..……...40 3.2.3 Carbamate Condenser…………………………………………….……….……….40 3.2.4 Scrubber………………………………………………………………………...….41 3.2.5 Medium Pressure Decomposer…….………………………………………….…...41 3.2.6 Low Pressure Decomposer………………….………………………………….….41 3.2.7 Medium Pressure Absorber……………….………………………………….…....41 3.2.8 Low Pressure Absorber…………………….………….……………………….….42 3.2.9 Flash Separator………………………….……………………………….…….…..42 3.2.10 Lower Separator……………………….……………………………….…….…..42 3.2.11Upper Separator……………………….…….……………………………...……..42 3.2.12Granulation Plant…………………….……….………………………….………..42 3.3Typical product quality…………………….………….……………………..…………...43 3|P a g e

Chapter 4 4.0 Mass Balance Calculation..…………………………..……………………………..……45 4.1 Material Balance……………………………………..…………………………...………45 4.1.1 Reactor………………………………………..………………………………....…46 4.1.2 Stripper……………………………………….……………………………………47 4.1.3 Carbamate condenser………………………………………….…………………..48 4.1.4 High pressure decomposer……………………….…………..……………………49 4.1.5 Low Pressure Decomposer………………………..……….………………………50 4.1.6 Low pressure absorber……………………………..…………………………...….51 4.1.7 High pressure absorber …………………………….……………………….......…51 4.1.8. Evaporators…………………………………………………………………..……52 4.1.9 Prilling Tower……………………………………………………….……….….…53

Chapter 5 5.0 Heat balance calculation …………………………………………………………………55 5.1 Heat balance…………………………………………………………………………..….55 5.1.1 Reactor ……………..……...………………………………………………….…..55 5.1.2 Stripper……………..……………………………………………….………….….57 5.1.3.Carbamate condenser….…………………………………………………………..58 5.1.4 High pressure decomposer….……..………………………………………………59 5.1.5 Low pressure decomposer….…………………………...…………………………60 5.1.6 Low pressure absorber……….………………………………….…………………61 5.1.7 High pressure absorber……….…………………………………..………………..62 5.1.8 Evaporators…………………..…………………………………………………….63 5.1.9 Prilling Tower……………….……………………………………………………..63

Chapter 6 6.0 Deg of equipment…………………………………………………….....………....65 6.1 Reactor design…………………….………………………………..……………………65 6.1.1 Process Design ……………………………………………………..……………..65 6.1.2.Mechanical design……………………………………………….………………..67 6.2.Prilling Tower Design……………….…………………………………………………..70

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Chapter 7 7.0 Cost Estimation………………………..…………………………………………………76

Chapter 8 8.0 Site Selection & Plant Layout ………….………………………………………………..85 8.1 Site selection………………………….………………………………………..…………85 8.2.Plant layout…………………………..……………………………………………….…..88 8.2.1.Importance……………………..……………………………..……………………89 8.3 Environmental Impact Assessment…..………………………………………..…………90 Chapter 9 9.0 Safety aspects ……………………………………………………………………………97 9.1 Introduction…………………………...…………………………………………...…….97 9.2 List of safety equipments……………………………………………………...…………98 9.3 Fire hazards………………………………..…………………………………………….99 9.4 Principal of fire extinguishing………………………………………………………….100 9.5 Principal of protection and prevention…………...…………………………………….100 9.6 Hazards…………………………………………………………………………………101

References ………………………………………………………... 109 List of Figures Figure 1.1 Chemical structures of urea molecules Figure 1.2 (a) The change in world consumption Figure 1.3: Global distribution of the consumption of urea fertilizer Figure 2.1 Basic of steam system of ACES Figure 2.2 ACES steam system that uses turbine Figure 3.1 Functional block diagram of the ACES Figure 3.2 Process Flow Sheet Figure 3.3 Various sizes of granules Figure 6.1 Cw vs Re 5|P a g e

Figure 6.2 Correction factor for solidification time Figure 8.1 Plant layout

List of Tables Table 1.1 chemical characteristics of urea Table 1.2 Physical Characteristics of Urea Table 1.3 Urea Prices Table 4.1 Compound in urea manufacturing Table 5.1 Component molecular weight Table 5.2 Specific heat constant Table 8.1 Ammonia releases from urea plants

Appendix Flow sheet of different processes

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CHAPTER 1 LITERATURE SURVEY

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1.0 Literature Survey 1.1 Urea Urea is an oraganic compound with the chemical formula (NH2)2CO. Urea is also known by the International Nonproprietary Name (INN) carbamide, as established by the World Health Organization. Other names include carbamide resin, isourea, carbonyl diamide, and carbonyldiamine.

1.1.1 Synthetic urea It was the first organic compound to be artificially synthesized from inorganic starting materials, in 1828 by Friedrich Wöhler, who prepared it by the reaction of potassium cyanate with ammonium sulfate. Although Wöhler was attempting to prepare ammonium cyanate, by forming urea, he inadvertently discredited vitalism, the theory that the chemicals of living organisms are fundamentally different from inanimate matter, thus starting the discipline of organic chemistry. This artificial urea synthesis was mainly relevant to human health because of urea cycle in human beings. Urea was discovered; synthesis in human liver in order to expel excess nitrogen from the body. So in past urea was not considered as a chemical for agricultural and industrial use. Within the 20th century it was found to be a by far the best nitrogenic fertilizer for the plants and became widely used as a fertilizer. Urea was the leading nitrogen fertilizer worldwide in the 1990s.Apart from that urea is being utilized in many other industries. Urea is produced on a scale of some 100,000,000 tons per year worldwide. For use in industry, urea is produced from synthetic ammonia and carbon dioxide. Urea can be produced as prills, granules, flakes, pellets, crystals, and solutions.More than 90% of world production is destined for use as a fertilizer. Urea has the highest nitrogen content of all solid nitrogenous fertilizers in common use (46.7%). Therefore, it has the lowest transportation costs per unit of nitrogen nutrient. Urea is highly soluble in water and is, therefore, also very suitable for use in fertilizer solutions (in combination with ammonium nitrate).

1.1.2 Commercial production of urea Urea is commercially produced from two raw materials, ammonia, and carbon dioxide. Large quantities of carbon dioxide are produced during the manufacture of ammonia from coal or from hydrocarbons such as natural gas and petroleum-derived raw materials. 8|P a g e

This allows direct synthesis of urea from these raw materials. The production of urea from ammonia and carbon dioxide takes place in an equilibrium reaction, with incomplete conversion of the reactants. The various urea processes are characterized by the conditions under which urea formation takes place and the way in which unconverted reactants are further processed. Unconverted reactants can be used for the manufacture of other products, for example ammonium nitrate or sulfate, or they can be recycled for complete conversion to urea in a total- recycle process. Two principal reactions take place in the formation of urea from ammonia and carbon dioxide. The first reaction is exothermic: 2 NH3 + CO2 ↔ H2N-COONH4 (ammonium carbamate) Whereas the second reaction is endothermic: H2N-COONH4 ↔ (NH2)2CO + H2O Both reactions combined are exothermic.

1.1.3 Chemical characteristics of urea

Figure 1.1 Chemical structures of urea molecules The urea molecule is planar and retains its full molecular point symmetry, due to conjugation of one of each nitrogen's P orbital to the carbonyl double bond. Each carbonyl oxygen atom accepts four N-H-O hydrogen bonds, a very unusual feature for such a bond type. This dense (and energetically favorable) hydrogen bond network is probably established at the cost of efficient molecular packing: The structure is quite open, the ribbons forming tunnels with square cross-section. Urea is stable under normal conditions.

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IUPAC name

Diaminomethanal

Chemical formula

(NH2)2CO

Molecular mass

60.07 g/mol (approximate)

Dipole moment

4.56 p/D

Table1.1 chemical characteristics of urea

1.1.4 Physical characteristics of urea Urea is a white odourless solid. Due to extensive hydrogen bonding with water (up to six hydrogen bonds may form - two from the oxygen atom and one from each hydrogen) urea is very soluble. Density

1.33·10³ kg/m³, solid

Melting point

132.7 °C (406 K) decomposes

Boiling point

NA

Solubility in water

108 g/100 ml (20 °C) 167 g/100 ml (40 °C) 251 g/100 ml (60 °C) 400 g/100 ml (80 °C) 733 g/100 ml (100 °C)

Vapour pressure

<10 Pa

Bulk density

0.8 kg.m-3

Table 1.2 Physical Characteristics of Urea

1.1.5 Raw materials of urea manufacturing 1.1.5.1 Ammonia Ammonia, NH3, is a comparatively stable, colourless gas at ordinary temperatures, with a boiling point of –33 C. Ammonia gas is lighter than air, with a density of approximately 0.6 times that of air at the same temperature. The characteristic pungent odors of ammonia can be detected as low as 1-5ppm. Ammonia can be highly toxic to a wide range of organisms. In humans, the greatest risk is from inhalation of ammonia vapour, with effects including irritation and corrosive damage to skin, eyes and respiratory tracts. At very high levels, inhalation of ammonia vapour can be fatal. When dissolved in water, elevated levels of ammonia are also toxic to a wide range of aquatic organisms. Ammonia is highly soluble 10 | P a g e

in water, although solubility decreases rapidly with increased temperature. Ammonia reacts with water in a reversible reaction to produce ammonium (NH4)+ and hydroxide (OH) - ions, as shown in equation. Ammonia is a weak base, and at room temperature only about 1 in 200 molecules are present in the ammonium form (NH4)+. The formation of hydroxide ions in this reaction increases the pH of the water, forming an alkaline solution. If the hydroxide or ammonium ions react further with other compounds in the water, more ammonia with react to reestablish the equilibrium.

While ammonia-air mixtures are flammable when the ammonia content is 16-25% by volume, these mixtures are quite difficult to ignite. About 85% of the ammonia produced worldwide is used for nitrogen fertilizers. The remainder is used in various industrial products including fibers, animal feed, and explosives. 1.1.5.1.1 Ammonia Production Essentially all the processes employed for ammonia synthesis are variations of the Haber-Bosch process, developed in from 1904-1913. This process involves the reaction of hydrogen and nitrogen under high temperatures and pressures with an iron based catalyst. This process also requires large energy consumption. Ammonia is generally produced at a few large plants with stream capacities of 1000 tonnes/day or greater. The formation of ammonia from hydrogen and nitrogen is a reversible reaction, as shown in equation [2]. The fraction of ammonia in the final gas mixture is dependent on the conditions employed. Unreacted hydrogen and nitrogen gases separated from the ammonia and are usually recycled. In almost all modern plants, the ammonia produced is recovered by condensation to give liquid ammonia. H2 + 3N2

2NH3

The source of nitrogen is always air. Hydrogen can be derived from a number of raw materials including water, hydrocarbons from crude oil refining, coal, and most commonly natural gas. Hydrogen rich reformer off-gases from oil refineries have also been used as a source of hydrogen. Steam reforming is generally employed for the production of hydrogen from these raw materials. This process also generates carbon dioxide, which can then be used as a raw material in the production of urea. 11 | P a g e

Trace impurities in the feed gases, such as sulphur compounds and chlorides, can have a detrimental effect on the production of ammonia by poisoning the catalysts employed.The feed gases, therefore, need to be purified prior to use. 1.1.5.1.2 Ammonia storage Anhydrous ammonia is usually stored as a liquid in refrigerated tanks at –33.3 C and atmospheric pressure, often in doubled-walled tanks with the capacity for hundreds or thousands of tonnes. The low temperature is usually maintained by the venting of ammonia gas. The vented gas is reliquefied for recycling, or absorbed in water to make aqueous ammonia. Relatively small quantities of anhydrous ammonia are sometimes stored under pressure in spherical vessel at ambient temperature. Ammonia is corrosive to alloys of copper and zinc and these materials must never be used in ammonia service. Iron and steel are usually the only metals used in ammonia storage tanks, piping and fittings. 1.1.5.2 Carbon Dioxide CO2 is a odourless and colourless gas which contain 0.03% in the atmosphere. It is emitted as a pollutant from number of industries. CO2 can be obtained from ammonia production process as a by product.

1.1.6 Applications of urea 1.1.6.1 Agricultural use More than 90% of world production is destined for use as a fertilizer. Urea is used as a nitrogen-release fertilizer, as it hydrolyses back to ammonia and carbon dioxide, but its most common impurity, biuret, must be present at less than 2%, as it impairs plant growth. Urea has the highest nitrogen content of all solid nitrogeneous fertilizers in common use (46.4%N.) It therefore has the lowest transportation costs per unit of nitrogen nutrient. In the past decade urea has sured and nearly replaced ammonium nitrate as a fertilizer In the soil, urea is converted into the ammonium ion form of nitrogen. For most floras, the ammonium form of nitrogen is just as effective as the nitrate form. The ammonium form is better retained in the soil by the clay materials than the nitrate form and is therefore less subject to leaching. Urea is highly soluble in water and is therefore also very suitable for use in fertilizer solutions, e.g. in “foliar feed‟ fertilizers.

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Commercially, fertilizer urea can be purchased as prills or as a granulated material. In the past, it was usually produced by dropping liquid urea from a "prilling tower" while drying the product. The prills formed a smaller and softer substance than other materials commonly used in fertilizer blends. Today, though, considerable urea is manufactured as granules. Granules are larger, harder, and more resistant to moisture. As a result, granulated urea has become a more suitable material for fertilizer blends. 1.1.6.1.1 Advantages of Fertilizer Urea 

Urea can be applied to soil as a solid or solution or to certain crops as a foliar spray.

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Urea usage involves little or no fire or explosion hazard.

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Urea's high analysis, 46% N, helps reduce handling, storage and transportation costs over other dry N forms.

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Urea manufacture releases few pollutants to the environment.

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Urea, when properly applied, results in crop yield increases equal to other forms of nitrogen. Nitrogen from urea can be lost to the atmosphere if fertilizer urea remains on the soil

surface for extended periods of time during warm weather. The key to the most efficient use of urea is to incorporate it into the soil during a tillage operation. It may also be blended into the soil with irrigation water. A rainfall of as little as 0.25 inches is sufficient to blend urea into the soil to a depth at which ammonia losses will not occur. Urea breakdown begins as soon as it is applied to the soil. If the soil is totally dry, no reaction happens. But with the enzyme urease, plus any small amount of soil moisture, urea normally hydrolizes and converts to ammonium and carbon dioxide. This can occur in 2 to 4 days and happens quicker on high pH soils. Unless it rains, urea must be incorporated during this time to avoid ammonia loss. Losses might be quite low if the soil temperature is cold. The chemical reaction is as follows: CO(NH2)2 + H2O + urease

2NH3 +CO2

1.1.6.1.2 Soil Application and Placement of Urea The volatility of urea depends to a great extent on soil temperature and soil pH. If properly applied, urea and fertilizers containing urea are excellent sources of nitrogen for crop production. After application to the soil, urea undergoes chemical changes and 13 | P a g e

ammonium (NH

4

+) ions form. Soil moisture determines how rapidly this conversion takes

place. When a urea particle dissolves, the area around it becomes a zone of high pH and ammonia concentration. This zone can be quite toxic for a few hours. Seed and seedling roots within this zone can be killed by the free ammonia that has formed. Fortunately, this toxic zone becomes neutralized in most soils as the ammonia converts to ammonium. Usually it's just a few days before plants can effectively use the nitrogen. Although urea imparts an alkaline reaction when first applied to the soil, the net effect is to produce an acid reaction. Urea or materials containing urea should, in general, be broadcast and immediately incorporated into the soil. Urea-based fertilizer applied in a band should be separated from the seed by at least two inches of soil. 1.1.6.1.3 Spreading of Urea Urea can be bulk-spread, either alone or blended with most other fertilizers. Urea often has a lower density than other fertilizers with which it is blended. This lack of "weight" produces a shorter "distance-of-throw" when the fertilizer is applied with spinner-type equipment. In extreme cases this will result in uneven crop growth and "wavy" or "streaky" fields. Urea and fertilizers containing urea can be blended quite readily with monoammonium phosphate (11-52-0) or diammonium phosphate (18-46-0). Urea should not be blended with superphosphates unless applied shortly after mixing. Urea will react with superphosphates, releasing water molecules and resulting in a damp material which is difficult to store and apply. Urea fertilizer can be coated with certain materials, such as sulfur, to reduce the rate at which the nitrogen becomes available to plants. Under certain conditions these slowrelease materials result in more efficient use by growing plants. Urea in a slow-release form is popular for use on golf courses, parks, and other special lawn situations. 1.1.6.2 Industrial use Urea has the ability to form 'loose compounds', called clathrates, with many organic compounds. The organic compounds are held in channels formed by interpenetrating helices comprising of hydrogen-bonded urea molecules. This behaviour can be used to separate 14 | P a g e

mixtures, and has been used in the production of aviation fuel and lubricating oils. As the helices are interconnected, all helices in a crystal must have the same 'handedness'. This is determined when the crystal is nucleated and can thus be forced by seeding. This property has been used to separate racemic mixtures. 1.1.6.3 Further commercial uses 

A stabilizer in nitrocellulose explosives

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A reactant in the NOx-reducing SNCR and SCR reactions in exhaust gases from Combustion, for example, from power plants and diesel engines

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A component of fertilizer and animal feed, providing a relatively cheap source of nitrogen to promote growth

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A raw material for the manufacture of plastics, to be specific, urea-formaldehyde resin

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A raw material for the manufacture of various glues (urea-formaldehyde or ureamelamine-formaldehyde); the latter is waterproof and is used for marine plywood

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An alternative to rock salt in the de-icing of roadways and runways; it does not promote metal corrosion to the extent that salt does

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An additive ingredient in cigarettes, designed to enhance flavour

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A browning agent in factory-produced pretzels

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An ingredient in some hair conditioners, facial cleansers, bath oils, and lotions

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A reactant in some ready-to-use cold compresses for first-aid use, due to the endothermic reaction it creates when mixed with water

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A cloud seeding agent, along with salts, to expedite the condensation of water in clouds, producing precipitation

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An ingredient used in the past to separate paraffins, due to the ability of urea to form clathrates (also called host-guest complexes, inclusion compounds, and adducts)

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A flame-proofing agent (commonly used in dry chemical fire extinguishers as Ureapotassium bicarbonate)

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An ingredient in many tooth whitening products

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A cream to soften the skin, especially cracked skin on the bottom of one's feet

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An ingredient in dish soap.

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To make potassium cyanate

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A melt agent used in re-surfacing snowboarding halfpipes and terrain park features

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A raw material for melamine production More than 95% of all melamine production 15 | P a g e

is based on urea. Stamicarbon‟s parent company DSM is the largest melamine producer in the world. 

A supplementary substitute protein source in feedstuffs for cattle and other ruminants. Because of the activity of micro-organisms in their cud, ruminants are able to metabolize certain nitrogen containing compounds, including urea, as protein substitutes. In the USA this capability is exploited on a large scale. Western Europe, in contrast, uses little urea in cattle feed.

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Feed for hydrolyzation into ammonia which in turn is used to reduce emissions from power plants and combustion engines.

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Other, miscellaneous products such as de-icing material for airport runways. Although on a smaller scale than as a fertilizer or as raw material for synthetic resins, urea is also used as a raw material or auxiliary material in the pharmaceutical industry, the fermenting and rewing industries and in the petroleum industry.

1.1.6.4 Laboratory use Urea is a powerful protein denaturant. This property can be exploited to increase the solubility of some proteins. For this application, it is used in concentrations up to 10 M. Urea is used to effectively disrupt the noncovalent bonds in proteins. Urea is an ingredient in the synthesis of urea nitrate. Urea nitrate is also a high explosive very similar to ammonium nitrate, however it may even be more powerful because of its complexity.

1.1.6.5 Medical use 1.1.6.5.1 Drug use Urea is used in topical dermatological products to promote rehydration of the skin. If covered by an occlusive dressing, 40% urea preparations may also be used for nonsurgical debridement of nails. This drug is also used as an earwax removal aid. Like saline, urea injection is used to perform abortions. It is also the main component of an alternative medicinal treatment referred to as urine therapy. 1.1.6.5.2 Diagnostic use Isotopically-labeled urea (carbon-14 - radioactive, or carbon-13 - stable isotope) is used in the urea breath test, which is used to detect the presence of the bacteria Helicobacter pylori (H. pylori) in the stomach and duodenum of humans. The test detects the characteristic enzyme urease, produced by H. pylori, by a reaction that produces ammonia from urea. This increases the pH (reduces acidity) of the stomach environment around the bacteria. Similar

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bacteria species to H. pylori can be identified by the same test in animals such as apes, dogs, and cats . 1.1.6.6 Textile use Urea is a raw material for urea-formaldehyde resins production in the adhesives and textile industries. A significant portion of urea production is used in the preparation of ureaformaldehyde resins. These synthetic resins are used in the manufacture of adhesives, moulding powders, varnishes and foams. They are also used for impregnating paper, textiles and leather. In textile laboratories they are frequently used both in dyeing and printing as an important auxiliary, which provides solubility to the bath and retains some moisture required for the dyeing or printing process.

1.2 Global production and consumption of Urea

Figure 1.2 (a) The change in world consumption (million metric tons of N) of total syntheticnitrogen fertilizers (solid line) and urea consumption (solid bars) since 1960. Data for 2005–2020 (shown as the shaded region) are calculated assuming an annual increase of 3% in total consumption and 5% in the fraction that is urea. (b) Same data as in (a) with the fraction that is urea displayed as a percentage of the total nitrogen fertilizer.

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Urea is processed into granules or other forms. Urea production is energy intensive. Most commonly, it is produced using natural gas, so the major producing regions are those where natural gas is abundant. Several leading manufacturing countries for urea are Russia, Canada, and Saudi Arabia, but other Middle East producers, including Iran and Iraq are (or were before the Gulf Wars) significant. In the US, urea production facilities are located mainly in the Gulf of Mexico states. Production of urea has at least doubled every decade since 1980 in the Middle East, increasing from 2 million metric tons per year in 1980 to 10 million metric tons year per in 2000. Further expansion of production is anticipated in the coming years in Kuwait, Qatar, Egypt, Oman and Iran. From the mid-1970s to the early 1990s, Russia (USSR) erected at least 40 new ammonia and urea production facilities. Production of urea in China tripled from 1989 to 1999. Dramatic increases in global production have also occurred in many countries since 2000, with several Latin American countries increasing production by more than 25%. As late as the 1960s, urea represented only about 5% of world nitrogen fertilizer use. However, urea usage escalated in the 1980s, such that it represented about 40% of global nitrogen fertilizer by the early 1990s, and soon thereafter urea sured ammonium nitrate as the most common nitrogen fertilizer. It is now estimated that urea represents >50% of world nitrogen fertilizer (Figure 1b). Assuming urea consumption continues at 5% per year, as projected for many parts of the world, urea consumption may reach 70% of total nitrogen use by the end of the next decade (Figure 1b): this is a dramatic global change in the composition of nitrogen applied to land throughout the globe. Such projections depend on global commodity markets, construction of new plants, and other factors that are difficult to project, but most of this increase is expected to occur in developing countries, particularly in Asia and Latin America. China and India together for about half of the global consumption, and have at least doubled their consumption of urea in the past decade. In India, Bangladesh and Pakistan, urea fertilizer has been heavily subsidized (as much as 50% of the cost of production) leading to its widespread use and overapplication. The US and Canada now represent about 20% of the global urea market, with urea constituting about 30% of US synthetic nitrogen fertilizer usage. Consumption is increasing even in regions where land applications of nitrogen have heretofore been low. The rural Canadian provinces of Manitoba, Saskatchewan and Alberta, for example, are now the regions where over 70% of Canada‟s urea is consumed. Urea is the only form of fertilizer 18 | P a g e

used in British Columbia forests. In Latin America, consumption of urea has fluctuated more than in Asia during the past decade due to various economic crises and unstable political environments, leading to fluctuating incentives and subsidies. This global trend in increased urea consumption represents both a net increase in total nitrogen applied, as well as a shift from the use of nitrate or anhydrous ammonium to urea. These increases parallel the increases in the production of both cereal and meat (associated with increasing human population) that have occurred globally in the past several decades. Urea is used in the production of virtually all crops from corn to Christmas trees, sugar cane to sweet potatoes, and vegetables to vineyards. Urea is preferable to nitrate for growing rice in flooded soils, and thus the Far East and the Mid-East are major consumers of urea. In coated form, urea becomes a slow-release fertilizer and this is one of the most popular forms for applications to lawns, golf courses, and parks, as well as many crops. The global shift toward the use of urea fertilizer stems from several advantages it has over other fertilizer forms. It is less explosive than ammonium and nitrate when stored, it can be applied as a liquid or solid, and it is more stable and cost effective to transport than other forms of reactive nitrogen. The increasing production of „granular‟ urea has contributed to its widespread use, as this is safe and easy to transport. Urea also contains twice the nitrogen of ammonium sulfate, making application rates per unit of fertilizer less costly for individual farmers. With the growth of large, industrial farms, the economics and safety of urea transport and storage are thus major factors in the shift away from ammonium nitrate.

Figure 1.3: Global distribution of the consumption of urea fertilizer, in metric tons per year by country, in 1960 (upper ) and in 1999 (lower ), based on data from the Global Fertilizer Industry data base (FAO 2001),These estimates of urea consumption do not include uses other than fertilizer.

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1.2.1 Range of global uses of urea While more than 75% of manufactured urea is consumed as nitrogen fertilizer, there are other significant uses of urea, which also are increasing globally. One such use is as a feed additive for ruminants, used to stimulate gut microbial flora. This application represents about 10% of non-fertilizer usage. Urea can be added directly to feed, such as in urea-treated wheat or rice straw, or mixed with molasses („urea–molasses licks‟ or „urea multi-nutrient blocks‟) for sheep, cattle, water buffalo, and horses. Urea may also be used as a fertilizer of the grasslands on which cattle or sheep may graze. Another direct application of urea to land is as urea-based herbicides or pesticides (sulfonyl urea pesticides). In this case, urea is chemically synthesized with a poison or inhibitor. Sulfonyl urea is one of the preferred herbicides for broadleaf and grassy weeds. It is also commonly used in non-agricultural situations, such as to control weeds in railroad and electric utility rights of way. Urea-based herbicides potentially have a large impact by both increasing urea inputs and reducing the potential for local uptake. Urea has long been used as a de-icer. Commercial airports and airfields are the largest consumers of these de-icing materials, although recommendations are now in place to reduce its usage in the US and elsewhere because of its recognized contribution to water pollution. Even with such reductions, it is still the de-icer of choice under some weather conditions. It is also used fairly extensively for domestic ice-melting applications (e.g. roads and sidewalks). Urea may also be spread on agricultural crops to prevent frost when temperatures drop to a level that may cause crop damage, and commercial formulations of urea are available for this purpose. Urea is also used in some direct applications to seawater. It is used in the growing world aquaculture industry. In intensive shrimp culture, for example, ponds may be fertilized with urea and superphosphate to initiate an algal bloom that eventually serves as food for the In addition to the direct applications of urea to land and sea, urea is used in many other applications, including manufacture of a wide range of common materials such as urea formaldehyde and plastics. This use represents about 50% of the non-fertilizer urea. Urea is also an additive in fire retardant paints, tobacco products, and in some wines. In the cosmetics industry, urea is an ingredient in moisturizing creams. There are numerous uses of urea in holistic medicine therapies. One application currently being considered which would greatly expand the global use of urea is as a reductant in catalytic and non-catalytic reduction of combustion products in vehicles.commercial resource. A significant proportion of such 20 | P a g e

nutrients are subsequently discharged to local waters with pond effluent, as only a small fraction of added nutrients ultimately winds up in marketable product. Urea may also be spread on coastal oil spills, to stimulate the growth of natural bacteria populations which break down the oil; it was widely used, for example, during the Exxon Valdez spill, and has been used in numerous other spills since. For the Exxon Valdez spill, fertilizer applications continued for years following the initial crisis, and this approach was estimated to have enhanced the degradation of the oil by 2–5-fold. In addition to the direct applications of urea to land and sea, urea is used in many other applications, including manufacture of a wide range of common materials such as urea formaldehyde and plastics. This use represents about 50% of the non-fertilizer urea. Urea is also an additive in fire retardant paints, tobacco products, and in some wines. In the cosmetics industry, urea is an ingredient in moisturizing creams. There are numerous uses of urea in holistic medicine therapies. One application currently being considered which would greatly expand the global use of urea is as a reductant in catalytic and non-catalytic reduction of combustion products in vehicles.

1.3 Urea Prices The world price for urea has trended downwards in real since 1975, although it can be volatile. In real (1990s), the price per ton was $438 in 1975; $309 in 1980; $199 in 1985, and $131 in 1990. These prices are on a bulk FOB basis, and freight and bagging charges of about $20 to $25 per ton must be added to arrive at bagged import costs. From 1991 to 2000, the prices of urea ($/ton) are shown in the table below: Year

1991

1992

1993

1994

1995

1996

1997

1998

1999

Urea

$151

$123

$94

$131

$194

$187

$128

$103

$78

2000 $112

Mean $130

($/ton) Source: IMF, International Financial Statistics, Yearbook and July, 2001 issues.

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1.4 Urea Price in India & Industries Producing Urea in World

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CHAPTER 2 PROCESS SELECTION AND ECONOMIC ASPECTS

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2.0 Process Selection & Economic Aspects 2.1 Feasibility Study 2.1.1 Introduction Urea white crystalline solid containing 46% nitrogen is widely used in the agriculture industry as an animal feed additive and fertilizer. Agriculture forms the major sector in the national economy of the majority of the countries in the Southeast Asian region. As these countries try to expand the sector, through diversification of agriculture and extensive multiplecropping programs, the demand for agriculture chemicals growing day by day. Large population countries like China, India, Pakistan, and Bangladesh are largely manufacturing the Urea for Domestic consumption. Due to high cost of the production facility Government incentives are common in 3rd world countries. In Middle East Saudi Arabia developed the large production facility of Urea production as an allied industry of the petroleum product. The surplus amount is being exported to neighboring countries.

2.1.2 Technical & Economic Feasibility When considering economic feasibility, raw material cost could be higher than usual since all most all urea manufacturing plants is being operated along with ammonia plants in order to produce raw materials (Ammonia and carbon dioxide: The carbon is produced as a byeproduct from the ammonia plant) for urea manufacturing process. To establish a urea plant without ammonia plant, raw materials has to be imported. It is not a better option, but under the circumstances Ammonia has to be imported from abroad. Considering the carbon dioxide, it is emitted by number of industries as a waste from which it has to be derived and purify. If it is not viable it is too has to be imported. Transportation cost will quite high (shipping costs, import taxes etc) so imported raw materials will be higher than when produced in ammonia plant. Plant technology is considered as high. Japan, China and North European countries are licensing the technology. Government incentives can be obtained for construction and operation since high costs are involved. The plant can be ordered directly from the manufacturers which basically sell the license of technology. Local fabrication can be carried out. Where as more critical equipments can be imported. Latest technology for confirming the quality and purity of the finished good is very important to complete the existing units. Companies involve in urea manufacturing technology and have license for technology.

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1. Toyo Engineering corporation ( Japan ) 2. Mitsubishi Heavy industries ( Japan ) 3. Stamicarbon 4. Snam progetti

2.1.2.1 Plant Capacity Urea plant capacity is on the rise since its establishment in 1940. In 1969 1800 MT/day plant was the largest. In Nineties 2000 tons urea plants become standardized. Now up to 3500 tons/day plants are under construction and planning. In this project we are planning to establish 1060 t/day plant having overall annual production of 350,000 MT.

2.1.3 Social & Environmental Feasibility Environmental feasibility is discussed under environmental impact assessment (EIA) and in site selection. Social issues are considered under site selection.

2.1.4 Plant Components The components of a urea plant can be divided in to two categories 1. Static Equipment 2. Rotating equipment Static Equipment Reactor:

Reactor is the largest and heaviest key equipment in the urea plant. This is the place where Ammonia and Carbon di-oxide react together. The performance of the reactor influences the performance of the whole urea plant. The size of the shell depends upon the size of plant. For a plant of 2000 tons capacity the height of the shell will be around 30 Meters and Dia around 3 meters.

Stripper Stripper is also a key component where the excess ammonia is separated.

Carbamate Condensers They are relatively smaller in size 25 | P a g e

HP Rotating Machines

CO2 Compressors This is the largest and most critical rotating equipment. Very large compressors are used of approximate capacities of around 30,000 N cubic meter/hour capacity.

HP Ammonia pumps and Carbomate pumps piping Stainless steel 316 L pipes are utilized

HP Control Valves Various control valves are required. The most critical is the solution feed control valve from the reactor to stripper. The material is stainless steel

2.2 Process Selection Several processes are used to urea manufacturing. Some of them are used conventional technologies and others use modern technologies to achieve high efficiency. These processes have several comparable advantages and disadvantages based on capital cost, maintenance cost, energy cost, efficiency and product quality. Some of the widely used urea production processes are 1. Conventional processes 2. Stamicarbon CO2 – stripping process 3. Snamprogetti Ammonia and self stripping processes 4. Isobaric double recycle process 5. ACES process 2.2.1 Conventional Processes 2.2.1.1 Once through Process In this process non converted ammonia was neutralized with acid such as nitric acid to produce ammonium salt such as ammonium nitrate as co products of urea production. In this way, a relatively simple urea process scheme was realized. The main disadvantages of this process are the large quantity of ammonia salt formed as co product and the limited amount of overall carbon dioxide conversion that can be achieved. 2.2.1.2 Conventional Recycle Process Here all of the non converted ammonia and carbon dioxide were recycled to the urea

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reactor. In first generation of this process the recirculation of non converted NH3 and CO2 was performed in two stage. The first recirculation was operated at medium pressure (18-25 bar); the second at low pressure (2-5 bar). The first recirculation comprises at least a decomposition heater, in which carbamate decompose into gaseous NH3 and CO2, and while excess NH3 evaporate simultaneously. The off gas from this first decomposition step was subjected to rectification, from which relatively pure ammonia at the top and a bottom product consisting of an aqueous ammonium carbamate solution were obtained. Both products are recycled separately to the urea reactor. In these processes, all non converted CO2 was recycled as associated water recycle. Because of the detrimental effect of water on reaction conversion, achieving a minimum CO2 recycle so achieve maximum CO2 conversion was more important than achieving a low NH3 recycle. All conventional processes therefore typically operate at high NH3:CO2 ratios (4-5mol/mol) to maximize CO2 conversion per . Although some of these conventional processes partly equipped with ingenious heat exchanging net works have survived until now. Their importance decreased rapidly as the so-called stripping process was developed. 2.2.2 Stamicarbon CO2 – stripping process In this process to achieve maximum urea yield per through the reactor at the stipulated optimum pressure of 140 bar, an NH3:CO2 molar ratio of 3:1 is applied. The greater part of the unconverted carbamate is decomposed in the stripper, where ammonia and carbon dioxide are stripped off. This stripping action is effected by countercurrent between the urea solution and fresh carbon dioxide at synthesis pressure. Low ammonia and carbon dioxide concentration in the stripped urea solution are obtained. Such that the recycle from the low pressure recirculation stage is minimized. These low concentration of both ammonia and carbon dioxide in the stripper effluent can be obtained at relatively low temperatures of the urea solution because carbon dioxide is only sparingly soluble under such conditions. Condensation of ammonia and carbon dioxide gases, leaving the stripper, occurs in the high pressure carbamate condenser as synthesis pressure. As a result, the heat liberated from ammonium carbamate formation is at a high temperature. This heat is used for the production of 4.5bar steam for use in the urea plant itself. The condensation in the high pressure carbamate condenser is not effected completely. Remaining gases are condensed in the reactor and provide the heat required for the dehydration of carbamate, as well as for heating the mixture to its equilibrium temperature. In recent improvement to this process, the condensation of off gas from the stripper is carried out in a pre reactor, where sufficient 27 | P a g e

residence time for the liquid phase is provided. As a result of urea and water formation in condensing zone, the condensation temperature is increased, thus enabling the production of steam at higher pressure level. The feed carbon dioxide, invariably originating from an associated ammonia plant, always contains hydrogen. To avoid the formation of explosive hydrogen-oxygen mixture in the tail gas of the plant, hydrogen is catalytically removed from the CO2 feed. Apart from the air required for this purpose, additional air is supplied to the fresh CO2 input stream. This extra potion of oxygen is needed to maintain a corrosion-resistance layer on the stainless steel in the synthesis section. Before the inert gases, mainly oxygen and nitrogen, are purged from the synthesis section, they are washed with carbamate solution from the low pressure recirculation stage in the high pressure scrubber to obtain a low ammonia concentration in the subsequently purged gas. Further washing of the off gas is performed in a low pressure absorber to obtain a purge gas that is practically ammonia free. Only one low pressure recirculation stage is required due to the low ammonia and carbon dioxide in the stripped urea solution. Because of the ideal ratio between ammonia and carbon dioxide in the recovered gases in this section, water dilution of the resultant ammonium carbamate is at a minimum despite the low pressure (about 4 bar). As a result of efficiency of the stripper, the quantities of ammonium carbamate for recycle to thesynthesis section are also minimized, and no separate ammonia recycle is required. The urea solution coming from the recirculation stage contains about 75 wt% urea. This solution is concentrated in the evaporation section. If the process is combined with a prilling tower for final product shaping, the final moisture content of urea from the evaporation section is 0.25 wt%. If the process is combined with a granular unit, the final moisture content may wary from 1 to 5 wt%, depending on granulation requirements. Higher moisture content can be realized in a single stage evaporator; where as low moisture content are economically achieved in a two stage evaporation section. When urea with an extremely low biuret content is required ( at maximum of 0.3 wt%) pure urea crystals are produced in a crystallization section. These crystals are separated from the mother liquor by combination of sieve bends and centrifuges and are melted prior to final shaping in a prilling tower or granulation unit. The process condensate emanating from water evaporation from the evaporation or crystallization sections contains ammonia and urea. Before this process condensate is purged, urea is hydrolyzed into ammonia and carbon dioxide, which are stripped off with steam and

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return to urea synthesis via the recirculation section. This process condensate treatment section can produce water with high purity, thus transforming this “waste water” treatment into the production unit of a valuable process condensate, suitable for, e.g., cooling tower or boiler feed water makeup. Since the introduction of the Stamicarbon CO2 stripping process, some 125 units have been built according to this process all over the world. 2.2.3 Snamprogetti Ammonia and self stripping processes In the first generation of NH3 and self strip ping processes, ammonia was used as stripping agent. Because of the extreme solubility of ammonia in the urea containing synthesis fluid, the stripper effluent contained rather large amount s of dissolved ammonia, causing ammonia overload in down stream section of the plant. Later versions of the process abandoned the idea of using ammonia as stripping agent; stripping was achieved only by supply of heat. Even without using ammonia as a stripping agent, the NH3:CO2 ratio in the stripper effluent is relatively high. So the recirculation section of the plant requires an ammonia-carbomate separation section The process uses a vertical layout in the synthesis section. Recycle within the synthesis section, from the stripper via the high pressure carbamate condenser, through the carbamate separator back to the reactor, is maintained by using an ammonia-driven liquidliquid ejector. In the reactor, which is operated at 150 bars, NH3:CO2 molar feed ratio of 3.5 is applied. The stripper is of the falling film type. Since stripping is achieved thermally, relatively high temperatures (200-210 0C) are required to obtain a reasonable stripping efficiency. Because of this high temperature, stainless steel is not suitable as a construction material for the stripper from a corrosion point of view; titanium and bimetallic zircornium – stainless steel tubes have been used Off gas from the stripper is condensed in a kettle type boiler. At the tube side of this condenser the off gas is absorbed in recycled liquid carbamate from the medium pressure recovery section. The heat of absorption is removed through the tubes, which are cooled by the production of low pressure steam at the shell side. The steam produced is used effectively in the back end of the process. In the medium pressure decomposition and recirculation section , typically operated at 18 bar, the urea solution from the high pressure stripper is subjected to the decomposition of carbamate and evaporation of ammonia. The off gas from this medium pressure decomposer is rectified. Liquid ammonia reflux is applied to the top of this rectifier; in this way a top product consisting of pure gaseous ammonia and a bottom product of liquid ammonium carbamate are obtained. The pure ammonia off gas is condensed and recycled to 29 | P a g e

the synthesis section. To prevent solidification of ammonium carbamate in the rectifier, some water is added to the bottom section of the column to dilute the ammonium carbamate below its crystallization point. The liquid ammonium carbamate-water mixture obtained in this way is also recycled to the synthesis section. The purge gas of the ammonia condenser is treated in a scrubber prior to being purged to the atmosphere. The urea solution from the medium pressure decomposer is subjected to a second low pressure decomposition step. Here further decomposition of ammonium carbamate is achieved, so that a substantially carbamate –free aqueous urea solution is obtained. Off gas from this low pressure decomposer is condensed and recycled as an aqueous ammonium carbamate solution to the synthesis section via the medium pressure recovery section. Concentrating the urea water mixture obtained from the low pressure decomposer is preformed in a single or double evaporator depending on the requirement of the finishing section. Typically, if prilling is chosen as the final shaping procedure, a two stage evaporator is required, whereas in the case of a fluidized bed granulator a single evaporation step is sufficient to achieve the required final moisture content of the urea melt. In some versions of the process, heat exchange is applied between the off gas from the medium pressure decomposer and the aqueous urea solution to the evaporation section. In this way, the consumption of low pressure steam by the process is reduced. The process condensate obtained from the evaporation section is subjected to a desorption hydrolysis operation to recover the urea and ammonia contained in the process condensate. 2.2.4 Isobaric double recycle process This process is developed by Montedison, is characterized by recycle of most of the un reacted ammonia and ammonium carbamate in two decomposer in series, both operating at the synthesis pressure. A high molar NH3:CO2 ratio (4:1 to 5:1) in the reactor is applied. As a result of this choice ratio, the reactor effluent contains a relatively high amount of non converted ammonia. In the first, steam heated, high pressure decomposer, this large quantity of free ammonia is mainly removed from the urea solution. Most of the residual solution, as well as some ammonium carbamate, is removed in the second high pressure decomposer where steam heating and CO2 stripping are applied. The high pressure synthesis section is followed by two low pressure decomposing stages of traditional design, where heat exchange between the condensing off gas of the medium pressure decomposition stage and the aqueous urea solution to the final concentration section improves the overall energy consumption of the process. Probably because of the complexity of this process, it has not achieved great 30 | P a g e

popularity so far. This process or parts of the process are used in four revamps of older conventional plant. 2.2.5 ACES process ACES (Advanced Process for Cost and Energy Saving) process has been developed by Toyo Engineering Corporation. Its synthesis section consist of the reactor, stripper, two parallel carbamate condensers and a scrubber all operated at 175 bar. The reactor is operated at 1900C and an NH3:CO2 molar feed ratio of 4:1. Liquid ammonia is fed directly to the reactor, whereas gaseous carbon dioxide after compression is introduced into the bottom of the stripper as a stripping aid. The synthesis mixture from the reactor, consisting of urea, unconverted ammonium carbamate, excess ammonia, and water, is fed to the top of the stripper. 2.2.5.1 Process comparison Process Conventional Processes Once through process

Advantages 

Simple process

Disadvantages     

Large quantity of ammonia salt is formed as co product Overall carbon dioxide conversion is low. High production cost High energy cost High environment pollution High production cost High energy cost High environment pollution

Conventional Processes – Conventional recycle process



High CO2 conversion

  

Stamicarbon CO2 – stripping process



Has high urea yield per High purity

 

High production cost High energy cost

Low consumption of low pressure steam

 

High production cost High energy cost



Complex process



High capital cost

 Snamprogetti Ammonia and self stripping processes



Isobaric double recycle process ACES process

   

Low production cost High energy recovery Low environment pollution High efficiency

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Among above urea manufacturing processes, ACES process is selected because of it has following advantages compared to other processes 2.2.5.2 Basic concept of process Most of the energy required for industrial urea production is consumed in the following steps:   

Compression and pumping of raw materials to achieve the required pressure levels for urea synthesis. Separation of unconverted ammonium carbamate and excess ammonia from reaction product. Concentration of aqueous urea solution and finishing of urea product.

Therefore, to conserve energy and save on the amount of external energy that must be introduced into the process, the following goals must be achieved: 1. A reduction in the energy needed for compressing and pumping raw materials through a lowering of pressure required for urea synthesis. 2. A minimizing of the energy needed to separate out unconverted material at the end of the process by achieving a high conversion efficiency in the reactor. 3. A minimizing of the heat recovered within the process. Goals 1 and 2 above are incompatible in a single system, as lowering the process pressure reduces the conversion efficiency. This has resulted in the development of two types of urea synthesis processes now in commercial use; the “solution recycle” process and the “stripping” process. * The former involves goals 2 and 3, and was realized first in the Toyo Engineering Corporation – Mitsui Toatsu Chemicals (TEC-MTC) “total recycle” process. The latter involves goals 1 and 3, and aims at the efficient recovery of the heat through lowpressure steam generation in the synthesis loop to compensate for the need to import additional energy for the separation of unconverted materials from urea in cases where the conversion efficiency in the reactor is low. ACES was developed to attain further energy savings in the production of urea without losing either economic feasibility or flexibility. It involves an integral achieving of all three goals listed above through an optimizing of the process conditions and the development of new equipment. And it leads to considerable energy savings compared with the conventional processes.

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Specifically, ACES was developed to:  

Maintain a high one- conversion of CO2 in the reactor under milder synthesis conditions that those found in the solution recycle processes . Achieve a good stripping efficiency with a higher NH3 to CO2 ratio in the feed solution than that found in the conventional stripping processes

To cope with the first demand, baffle plants were installed inside the reactor to avoid back-mixing, which lowers conversion efficiency. Table 3.12-1 compares reactor operating conditions for ACES and TEC-MTC’s conversional process. The second demand was met through the use of a proprietary stripper which has trays above the conversional falling film heater. 2.2.5.3 Features of Process Utility System The basic steam system of ACES is shown in Fig. 3.12-4. However, details of an actual system to be used for a specific project depend on various local conditions. For example, if there is little demand for the export of steam from the urea plant to other facilities in the area, or the price of high-pressure steam is not much higher than that of low-pressure steam, production of export steam will not be very important. On the other hand, in areas where conditions are the reverse, the quantity of export steam should be maximized by as much heat recovery as possible. ACES is flexible enough to meet any of the above requirements, merely by adjusting process conditions. For instance, the installation of a scrubber to recover purged gas from the reactor that would otherwise be fed directly to the high-pressure absorber means additional heat can be recovered to maximize steam export, whereas adjusting the temperature of the return steam condensate can provide a steam balance for plants where no export is needed. The conventional stripping process, on the other hand, is forced to export a rather big quantity of low-pressure steam regardless of local conditions. Figure shows an ACES steam system in which a steam turbine is used to drive the CO2 compressor, as is the case in large-capacity urea plants.

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25-kg/cm2 gauge steam Carbamate condensor

stripper

Steam drum

5 kg/cm2 gauge Lowpressure decomposer

hydrolyser

concentrator evaporator

Fig 2.1 Basic steam system of ACES ejector

NH3 preheater

Condensate stripper Export steam

Return condensat e

40-kg/cm2 gauge steam

co2 compressor turbine 25 kg/cm2 gauge

steam condensate

Desuper heater stripper

hydrolizer

Carbamate condenser

Steam drum

Process use

Fig 2.2ACES steam system that uses a turbine Export steam

NH3 preheater

Return condensate

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2.2.5.4 Advantages of ACES Process      

Less HP piping and construction materials owing to lower elevation layout, fewer HP vessels and simplified synthesis loop Easier erection using commonly available construction equipment and techniques owing to low elevation layout and fewer and smaller HP vessels Easier operation ed by forced circulation by HP ejector, low elevation layout and fewer HP equipment Easier maintenance owing to low elevation layout and fewer HP equipment Less energy consumption owing to optimized synthesis conditions and proprietarily designed reactor and stripper Even though initial capital investment is higher than the other processes, it will overcome by lower production cost per metric ton of urea

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CHAPTER 3 PROCESS DESCRIPTION AND FLOWSHEET

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3.0 Process Description and flow sheet 3.1 Process Description – ACES Process Advanced Process for Cost and Energy process consists of the reactor, stripper, two parallel carbamate condensers and a scrubber. All above equipments are operated at 175 bar.

Figure 3.1 Functional block diagram of the ACES Process 37 | P a g e

The reactor is operated at 1900C and an NH3:CO2 molar feed ratio of 4:1. Liquid ammonia is fed directly to the reactor, whereas gaseous carbon dioxide after compression is introduced into the bottom of the stripper as a stripping aid. The synthesis mixture from the reactor, consisting of urea, unconverted ammonium carbamate, excess ammonia, and water, is fed to the top of the stripper. The stripper has two functions. Its upper part is equipped with trays where excess ammonia is partly separated from the stripper feed by direct countercurrent of the feed solution with the gas coming from the lower part of the stripper. This pre stripping in the top is said to be required to achieve effective CO 2 stripping in the lower part. In the lower part of the stripper (a falling film heater), ammonium carbamate is decomposed and the resulting CO2 and NH3 as well as the excess NH3 are evaporated by CO2 stripping and steam heating. The overhead gaseous mixture from the top of the stripper is introduced into the carbamate condenser. Here the gaseous mixture is condensed and absorbed by the carbamate solution coming from the medium pressure recovery stage. Heat liberated in the high pressure carbamate condenser is used to generate low pressure steam. The gas and liquid from the carbamate condensers are recycled to the reactor by gravity flow. The urea solution from the stripper, with a typical NH3 content of 15 wt%, is purified further in the subsequent medium and low pressure decomposers, operating at 17.5 and 2.5 bars, respectively. Ammonia and carbon dioxide separated from the urea solution here are recovered through stepwise absorption in the low and medium pressure absorbers. Condensation heat in the medium pressure absorber is transferred directly to the aqueous urea solution feed in the final concentration section; the purified urea solution is concentrated further either by two stage evaporation up to 99.7 % for urea prills production or by a single evaporation 98.5 % for urea granule production. Water vapour formed in the final concentrating section is condensed in surface condensers to form process condensate. Part of this condensate is used as an absorbent in the recovery sections, where as remainder is purified in the process condensate treatment section by hydrolysis and steam stripping, before being discharge from the urea plant. The highly concentrated urea solution is finally processed either through the prilling tower or via the urea granulator. Instead of concentration via evaporation, the ACES process can also be combined with a crystallization section to produce urea with low biuret content.

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Fig 3.2 Process Flow Diagram

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3.2 Main component of the process 3.2.1 Reactor The reactor is operated at 190 °C and 175 bar. NH3:CO2 molar feed ratio to the reactor is 4:1. One conversion rate of CO2 to urea is about 68%. NH3 is directly fed to the reactor. Following reaction occurs inside the reactor. NH2COONH4 + heat ↔ NH2CONH2 + H2O

∆H = -117 kJ/mol

2NH3 + CO2 ↔ NH2COONH4 + heat

∆H = +15.5 kJ/mol

3.2.2 Stripper Carbon dioxide is introduced into the bottom of the stripper as a stripping aid. The synthesis mixture from the reactor, consisting of urea, unconverted ammonium carbamate, excess ammonia, and water, is fed to the top of the stripper. Medium pressure steam is supplied to the stripper. The stripper has two functions. Its upper part is equipped with trays where excess ammonia is partly separated from the stripper feed by direct countercurrent of the feed solution with the gas coming from the lower part of the stripper. This pre stripping in the top is said to be required to achieve effective CO2 stripping in the lower part. In the lower part of the stripper (a falling film heater), ammonium carbamate is decomposed and the resulting CO 2 and NH3 as well as the excess NH3 are evaporated by CO2 stripping and steam heating. The overhead gaseous mixture from the top of the stripper is introduced into the carbamate condenser. Following reaction occurs inside the stripper. NH2COONH4 + heat ↔ 2NH3 + CO2

∆H = +117 kJ/mol

NH3(l) → NH3(g)

3.2.3 Carbamate Condenser Carbamate condenser is fed with overhead gaseous mixture from the top of the stripper, In this unit the gaseous mixture is condensed and absorbed by the carbamate solution coming from the medium pressure recovery stage. Heat liberated in the high pressure

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carbamate condenser is used to generate low pressure steam. The gas and liquid from the carbamate condensers are recycled to the reactor by gravity flow. 2NH3 + CO2 ↔ NH2COONH4 + heat

∆H = -117 kJ/mol

NH3(g) → NH3(l)

3.2.4 Scrubber In the scrubber Ammonia and Carbon Dioxide coming from the reactor are absorbed to ammonia and ammonium carbamate solution which is going to Carbamate Condenser.

3.2.5 Medium Pressure Decomposer The urea solution from the stripper, with a typical NH3 content of 15 wt%, is purified further in the medium pressure decomposer operating at 17.5 bars. No external heat supply. NH2COONH4 + heat ↔ 2NH3 + CO2

∆H = +117 kJ/mol

NH3(l) → NH3(g)

3.2.6 Low Pressure Decomposer After the medium pressure decomposer, further purification of urea solution occurs inside the low pressure decomposer which is operating at 2.5 bar. External heat supply is available. All ammonia and ammonium carbamate are removed by the Low Pressure Decomposer. NH2COONH4 + heat ↔ 2NH3 + CO2 NH3(l)

∆H = +117 kJ/mol

→ NH3(g)

3.2.7 Medium Pressure Absorber In medium pressure absorber ammonia and carbon dioxide separated from the urea solution in medium pressure decomposer are recovered. Condensation heat in the medium pressure absorber is transferred directly to the aqueous urea solution feed in the final concentration section. 2NH3 + CO2 ↔ NH2COONH4 + heat

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3.2.8 Low Pressure Absorber In low pressure absorber ammonia and carbon dioxide separated from the urea solution in low pressure decomposer are recovered. Heat release from that reaction is used to produce steam at 2 bar. This steam is used for evaporation process of lower and upper separator. 2NH3 + CO2 ↔ NH2COONH4 + heat

∆H = -117 kJ/mol

3.2.9 Flash Separator This unit is operated at 1.0 bar and 110 °C. Here by reducing the pressure, let water to evaporate and concentrate the urea solution. H2O(l) → H2O(g)

3.2.10 Lower Separator This is a calendria type evaporator. This is operated at 0.55 bar vacuum pressure and at 110 °C Here the purified urea solution is further concentrated and required heat is taken from 2 bar pressure steam produced in low pressure absorber.

3.2.11 Upper Separator This is evaporative type separator. This is operated at 0.55 bar vacuum pressure and at 112 °C Urea solution coming from the lower separator is further concentrated. Output from that unit has 99.2% pure urea. After that urea solution is sent to granulation section. 3.2.12 Granulation Plant The Urea Granulation process consists of following three sections. • granulation section • recycle and product cooling section • dust removal and recovery section Aqueous urea solution from urea plant is fed to the granulator to enlarge recycle particles in the granulator. In the granulator, the granules are dried and cooled simultaneously. The granulator is operated at 110-115oC and at 42 | P a g e

slightly negative pressure. Enlarged urea particles are cooled to about 90ºC in the after-cooler inside the granulator to be transported to the recycle section. The discharged granules are separated into three sizes, product, small and large size by the screen. Product size granules are further cooled below 60ºC in the product cooler to be sent to the urea storage or bagging facility. Large size granules are crushed by the crusher. The rushed particles and smaller size particles from the screen are recycled to the granulator as seed.Urea dust contained in the exhaust air from the granulator and the product cooler is scrubbed in the dust scrubber by ing counter currently with aqueous urea solution. The urea dust content in the exit air of the bag filter is 30 mg/m3 or less. Urea recovered in the bag filter, approximately 2.5-3.5 % of production rate, is recycled to the urea granulator.

Figure 3.5 Spout-Fluid Bed Granulator

3.3 Typical product quality Total Nitrogen Biuret

46.3wt% 0.7wt%

Moisture

0.25wt%

Formaldehyde

0.45wt%

Size (2-4mm)

95wt%

Hardness

3.5kg at 3mm

Figure 3.3 Various sizes of granules 43 | P a g e

CHAPTER 4 MASS BALANCE CALCULATION

44 | P a g e

4.0 Mass Balance Calculation 4.1 Material Balance Urea production per day = 1060.0 Tons CO2 conversion

= 70.00 %

CO2 requirement per day = 777.3 Tons NH3 requirement per day = 600.7 Tons Compound

Chemical Formula

Molecular Weight (kg/kmol)

Ammonia

NH3

17

Carbon dioxide

CO2

44

Ammonium Carbamate

NH2COONH4

78

Water

H2O

18

Urea

NH2CONH2

60

Table 4.1 Compound in urea manufacturing Input ratio to reactor

NH3 : CO2

Molar ratio

4:1

Weight ratio

68 : 44

Reactions involved in the process 2NH3 + CO2 ↔ NH2COONH4 + heat Sch

2

1

1

Mass

34

44

78

Wt% 0.4359 0.5641

1.000

NH2COONH4 + heat ↔ NH2CONH2 + H2O Sch

1

1

1

Mass

78

60

18

Wt%

1.000

0.7692

0.2308

2NH3 + CO2 ↔ NH2CONH2 + H2O Sch

2

1

1

1

Mass

34

44

60

18

Wt%

0.4359 0.5641

0.7692

0.2308

45 | P a g e

4.1.1 Reactor

Basis: Taking 1060 T/day of urea production per day Carbon dioxide in to ammonium carbamate is complete but, conversion of ammonium carbamate in to urea is 70 % Based on stoichiometry we are getting Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

1086.7768

908.3431

CO2

263.3

32.3859

Ammonium carbamate

1559.663

590.7033

Urea

0.0

1060.237

Water

0.0

318.071

Biuret

0.0

0.0

Total

2909.7398

2909.7403 46 | P a g e

4.1.2 Stripper

The urea solution from the stripper contains 48 % urea & 15 % NH3 content Based onthis information we are getting Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

903.5434

943.5825

CO2

699.9831

751.7983

Ammonium carbamate

590.7033

498.848966

Urea

1060.237

1060.2367

Water

318.071

318.2390

Biuret

0.0

0.0

Total

3572.5378

3527.705

47 | P a g e

4.1.3 Carbamate Condenser

Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

881.3273

486.3369

CO2

774.4911

263.327

Ammonium carbamate

653.0252

1559.18

Urea

0.0

0.0

Water

0.0

0.0

Biuret

0.0

0.0

Total

2308.8436

2308.8439

48 | P a g e

4.1.4 High Pressure Decomposer

Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

331.239

396.6232

CO2

0.0

84.4205

Ammonium carbamate

498.849

349.1943

Urea

1060.237

1059.177

Water

318.071

318.071

Biuret

0.0

0.9100

Total

2208.396

2208.396

49 | P a g e

4.1.5 Low Pressure Decomposer

Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

69.41228

221.9253

CO2

77.27813

274.2595

Ammonium carbamate

349.1943

0.0

Urea

1059.177

1057.058

Water

318.071

318.071

Biuret

.9100

2.72829

Total

1874.042

1874.042

50 | P a g e

4.1.6 Low Pressure Absorber

Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

221.6252

9.69736

CO2

274.2595

0.0

Ammonium carbamate

0.0

486.1873

Urea

0.0

0.0

Water

0.0

0.0

Biuret

0.0

0.0

Total

495.8847

495.8846

4.1.7 High Pressure Absorber

51 | P a g e

Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

338.3079

265.5838

CO2

94.11369

0.0

Ammonium carbamate

486.1873

653.0252

Urea

0.0

0.0

Water

0.0

0.0

Biuret

0.0

0.0

Total

918.6088

918.609

Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

.3001

.3001

CO2

0.0

0.0

Ammonium carbamate

0.0

0.0

Urea

1057.058

1056.53

Water

318.071

318.0710

4.1.8. Evaporators

52 | P a g e

Biuret

2.72829

2.72829

Total

1378.157

1377.629

Component

Inlet ( T / Day)

Outlet (T / Day)

NH3

0.0

0.0

CO2

0.0

0.0

Ammonium carbamate

0.0

0.0

Urea

1056.53

1056.5292

Water

7.9517

7.9517

Biuret

2.72829

2.72829

Total

1067.21

1067.209

4.1.9. Prilling Tower

53 | P a g e

CHAPTER 5 HEAT BALANCE CALCULATION

54 | P a g e

Component

Molecular Weight

Ammonia

17

Carbon Dioxide

44

Urea

60

Water

18

Biuret

103

Ammonium Carbamate

78 Table 5.1 Component Molecular Specific Heat Constant

Component

a

b

c

d

Ammonia(liquid)

1.185

4.98E-02

-2.39E-04

3.89E-07

Ammonia(Gas)

1.5088

1.97E-03

2.70E-08

-1.81E-10

Carbon Dioxide

0.4855

1.46E-03

-9.33E-07

2.23E-10

Urea

2.842

-1.94E-02

1.38E-04

-2.56E-07

Water

2.842

1.18E-02

-3.51E-05

3.60E-08

Ammonium

-4.4838

0.0283

-2.8125E-5

-

carbamate Table5.2 Specific Heat Constant Various Equation used for performing energy balance are as follows :

5.1 Heat balance 5.1.1 Reactor To heat the ammonia from 307K to 443K 130

1.185 + 4.98 10−2 T − 2.39 ∗ 10−4 T 2 + 3.89 ∗ 10−7 T 3 dT

Q1 = 600.681 ∗ 1000 34

Q1=217167.0647MJ/day Q2 = 600.681 ∗ 1000 170

1.185 + 4.98 ∗ 10−2 T − 2.39 ∗ 10−4 T 2 + 3.89 ∗ 10−7 T 3 dT

∗ 130

Q2 = 110089.1495 MJ/day 55 | P a g e

Low pressure steam load at 5 bar pressure and 151.8℃ for ammonia heating S1 ∗ 2117.019 = Q1 = 217167.0647 S1 = 102581.5376kg/day S1 = 102.581 T/day

Medium pressure steam load at 13 bar and 191.6℃ for ammonia heating S1 ∗ 1950.23 = Q2 = 110089.1495 ∗ 103 S2 = 56.4493 T/day Urea formation heat by decomposing Ammonium Carbamate ∆Hf = 1060.256 ∗

15.5 60

∗ 103

∆Hf = 273899.4667 MJ/day Ammonium Carbamate production in the reactor 78

= (263.3 – 32.3859) × 44 = 409.3477 T/day Ammonium Carbamate formation heat ∆Hf = 409.3477 *

(−117) 78

* 103

∆Hf = -614021.5741 MJ/day Heat required for increasing raw materials to 190℃ = (486.095 + 600.681) 190

1.185 + 4.98 ∗ 10−2 T − 2.39 ∗ 10−4 T 2 + 3.89 ∗ 10−7 T 3 dT

∗ 170

+ 1559.7 ∗

463 443

−4.4838 + 2.83 ∗ 10−2 T − 2.81 ∗ 10−5 T 2 dT

190

(0.4855 + 1.46 ∗ 10−3 T − 9.33 ∗ 10−7 T 2 )dT

+263.3 ∗ 170

56 | P a g e

= 185330.5438MJ/day Energy generated in to reactor = 273899.4667 + 185330.5438 – 614021.5841 = -154791.5744MJ/day

5.1.2 Stripper Decomposition energy of Ammonium Carbamate = (590.7140 – 498.8584) *

117 78

∗ 103

= 137783.4MJ/day Heat released from Urea 178

(2.842 − 1.94 ∗ 10−2 T + 1.38 ∗ 10−4 T 2 − 2.56 ∗ 10−7 )dT

= 1060.256 ∗ 190

= -29895.850 MJ/day Heat released from Ammonium Carbamate = 498.8584 ∗

451 (−4.4838 463

+ 2.83 ∗ 10−2 T − 2.8125 ∗ 10−5 T 2 )dT

= -15415.2296MJ/day Heat released from Water = 318.0768∗

178 (2.842 190

+ 1.18 ∗ 10−2 T − 3.51 ∗ 10−5 T 2 + 3.60 ∗ 10−8 )dT

= -15454.4629 MJ/day Heat absorbed by Carbon Dioxide 190

(0.4855 + 1.46 ∗ 10−3 T − 9.33 ∗ 10−7 T 2 )dT

= 700 ∗ 110

= 38293.698 MJ/day Heat absorbed for Ammonium vaporization 57 | P a g e

= 612.4*1000 * 160 = 97984MJ/day Energy required for stripper = 137783.4 – 29895.850 – 15415.2296 – 15454.4 + 38293.698 + 97984 = 213295.55 MJ/day Medium pressure steam load at 13 bar and 191.6℃ for heating S3 ∗ 1950.23 = 213295.55 S3 = 109.3694MT/day 5.1.3 Carbamate Condenser Formation energy of Ammonium Carbamate at 170℃ = (1559.7 – 522.42102 -130.605) *

(−117) 78

∗ 103

= - 1360010.97 MJ/day Heat absorbed by Ammonium Carbamate = 522.42102 * 2.3 * (170 -150) + 130.605 * 2.3 * (170 - 153) = 30039.1969MJ/day Heat absorbed by Carbon Dioxide 170

(0.4855 + 1.46 ∗ 10−3 T − 9.33 ∗ 10−7 T 2 )

= 22.7 ∗ 1000 153

= 269.309 MJ/day Heat absorbed by Ammonia 170

(1.185 + 4.98 ∗ 10−2 T − 2.39 ∗ 10−4 T 2 )dT

= 212.3 ∗ 1000 150

170

1.185 + 4.98 ∗ 10−2 T − 2.39 ∗ 10−4 T 2 dT

+56.5168 ∗ 1000 ∗ 153

58 | P a g e

=24108.082MJ/day Condensation heat and sensible heat released by Ammonia = 612.3438 ∗ 1000 ∗ −160 + 612.4 ∗ 1000 170

(1.185 + 0.048T − 2.39 ∗ 10−4 T 2 )dT

∗ 190

= - 155210.932MJ/day Heat released by Carbon Dioxide 170

(0.4855 + 1.46 ∗ 10−3 T − 9.33 ∗ 10−7 T 2 )dT

= 751.8159 ∗ 1000 ∗ 190

= - 10816.288 MJ/day Heat released from Carbamate condenser = - 1360010.97 + 30039.19 + 269.309 + 24108.082 – 155210.932 – 10816.288 = - 1471621.602MJ/day Production of steam load at 5 bar Assume of water at 145℃ − 150℃ = 4.27 kJ/kg

SLP ∗ 2109 + SLP ∗ 4.72 ∗ 151.8 − 145 = 1471621.602 SLP = 688.305 MT/day

5.1.4 High pressure decomposer Decomposition energy required for Ammonium Carbamate = (498.8584 – 349.230) *

117 78

∗ 103

= 224442.6MJ/day Heat

released

from

Urea

157

(2.842 − 1.94 ∗ 10−2 T + 1.38 ∗ 10−4 T 2 )dT

= 1060.256 ∗ 178

59 | P a g e

= - 77246.025 MJ/day Heat released from Ammonium Carbamate 430 (−4.4838 451

= 498.8584 ∗

+ .0283T − 2.815 ∗ 10−5 T 2 )dT

= - 26440.803 MJ/day Heat released from Water 157 (2.842 178

= 318.0766 *

+ 1.18 ∗ 10−2 T − 3.51 ∗ 10−5 T 2 )dT

= - 26733.66187 MJ/day Heat

released

by

Ammonia

157

(1.185 + .0498T − 2.39 ∗ 10−4 T 2 )dT

= 331.2388 ∗ 178

= - 32328.2994 MJ/day Heat released for Ammonia vaporization = 327.2120*1000 * 200 = 65442.4 MJ/day Energy loss = 224442.6 - 77246.025 - 26440.80 - 26733.66 - 32328.2994 + 65442.4 = 127136.211 MJ/day 5.1.5 Low pressure decomposer Decomposition energy of Ammonium Carbamate = 349.230 *

117 78

∗ 103

= 523845 MJ/day Heat absorbed for Ammonia vaporization =221.5 *210 = 46544.505MJ/day Heat released from Urea 129

2.842 − 1.94 ∗ 10−2 T + 1.38 ∗ 10−4 T 2 dT

= 1059.195 ∗ 157

60 | P a g e

= - 63556.109 MJ/day Heat released from Water = 318.0766 ∗

129 157

2.842 + 1.18 ∗ 10−2 T − 3.51 ∗ 10−5 T 2 dT = - 34873.144 MJ/day

Heat absorbed by Carbon Dioxide 129

0.4855 + 1.46 ∗ 10−3 T − 9.33 ∗ 10−7 T 2 dT

= 77.28 ∗ 80

= 2377.920 MJ/day Heat released by Ammonia 129

(1.5088 + 1.97 ∗ 10−3 T + 2.07 ∗ 10−8 T 2 )dT

= 221.6405 ∗ 157

= -11114.422 MJ/day Heat released by Carbon Dioxide 129

(0.4855 + 1.46 ∗ 10−3 T − 9.33 ∗ 10−6 T 2 )dT

= 274.281 − 77.28 ∗ 157

= - 3727.723 MJ/day Heat released by biuret = 2.7282 * 2.5941 * (129-157) = -198.162 MJ/day Energy required to reactor =

523845 + 46544.505 − 63556.109 − 34873.144 + 2377.920 − 11114.422 − 3727.723 = 459496.027 MJ/day

Medium pressure steam load at 13 bar and 191.8℃ for heating S4 ∗ 1972 = 459496.027 S4 = 233.010 MT/day 5.1.6 Low pressure absorber Formation energy of Ammonium Carbamate at 129℃ 61 | P a g e

= 486.225 *

−117 78

∗ 103

= - 729337.5 MJ/day Condensation heat released by Ammonia = 221.6405 * (-210) = - 46544.505 MJ/day Heat released from LP Absorber = -729337.5 – 46544.505 = - 775882.005 MJ/day Cooling water requirement CW1 ∗ 4.2 ∗ 70 − 30 = 775882.005 CW1 = 4618.345 T/day 5.1.7 High pressure absorber Operating temperature calculation 328.611 * 15 * (157-T) + 94.115 * 0.96 * (157-T) = 9.696 * 15 *(T-129) + 486.225 * 2.3 * (T-129) T = 151.368℃ Formation energy of Ammonium Carbamate at 151℃ = (653.0652 – 486.225) *

(−117) 78

∗ 103

= - 250260.3MJ/day Condensation heat released by Ammonia = (328.611 – 9.696) * (-200) = - 63783 MJ/day Energy released from HP Absorber = - 250260.3 – 63783 = - 314043.3 MJ/day Heat required to heat output from LPD

62 | P a g e

= 1057.076 * 1.96 * (140- 129) + 318.0766 * 4.25 * (140- 129) + 2.728*2.5941*(140-129) = 37738.4833 MJ/day Heat given to cooling water = -314043.3 + 37738.4833 = -276304.8167 MJ/day Cooling water requirement CW2 ∗ 4.2 ∗ 70 − 30 = 276304.8167 CW2 = 1644.671 MT/day

5.1.8 Evaporators Heat absorbed by water vaporization = 310.1193 * 2702.4 = 838066.396 MJ/day Total energy requirement = 838066.396 = 838066.396 MJ/day 5 bar LP steam load S7 ∗ 2109 = 838066.396 S7 = 397.376 MJ/day

5.1.9. Prilling Tower Total production rate = 1063.234 T/day = 44301.420 kg/hr Heat Balance :

J

J

J

44301.420{2098 kg ∗K (135 – 132.6) + 224457 kg + 1748 kg ∗K (132.6-60)} =15,788,893.18

kJ hr

= 15788.89318 MJ/hr

Airflow required Heat gained by air = Heat released by urea 15,788,893.18 = mair ∗ cg ∗ ∆T

15,788,893.18 1.008∗20

= 783,179.225 kg/hr = 783.179 T/hr

63 | P a g e

CHAPTER 6 DEG OF EQUIPMENT

64 | P a g e

6.1 Reactor design 6.1.1 Process design Design parameters Deg

Deg

Operating

Operating

Temperature

Pressure

Temperature

Pressure

250℃

250 kg/cm2

190 ℃

175 kg/cm2

Reaction 2 NH3 + CO2

NH2COONH4

-117 kJ/mol

NH2COONH4

NH2CONH2 + H2O

+15.5 kJ/mol

Volume of reactor Reactor for urea contains number of trays so that each tray behaves like a completely plug flow reactor. Due to number of trays above one another it achieves plug flow reactor. Here second reaction is slow reaction so volume of rector will depend on this rection. So, for Plug flow reactor Performance Equation is given as, 𝑉 = 𝐹𝐴𝑜

𝑋𝐴

𝑜

𝑑𝑋𝐴 −𝑟𝐴

Now, Reaction Kinetics for the urea formation reaction: 𝑟𝑎𝑡𝑒 = 𝑘𝐶𝑐𝑎𝑟𝑏𝑎 Where,

4.2∗105

𝐸

𝑘 = 𝑘𝑜 exp − 𝑅𝑇 = 1.9 ∗ 105 𝑒𝑥𝑝 − 8.314 ∗463 = 3.46921 hr -1 𝑉 = 𝐹𝐴𝑜

𝑋𝐴

𝑜

𝑑𝑋𝐴 𝑘 ∗ 𝐶𝐴𝑜 ∗ (1 − 𝑋𝐴 )

65 | P a g e

𝑉 ∗ 𝐶𝐴𝑜 1 = 𝐹𝐴𝑜 𝑘

𝑋𝐴

𝑜

𝑑𝑋𝐴 (1 − 𝑋𝐴 )

𝑉 1 = ∗ [−𝐼𝑛 1 − 𝑋𝐴 ] 𝑣0 𝑘 Where , 𝑣𝑜 = 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖d V = volume of reactor Now, 𝑣𝑜 = 40.617 m3/hr (v = FAo/CAo) XA

= 0.70 𝑉 1 = 𝑣0 𝑘

𝑋𝐴

𝑑𝑋𝐴 1 = (1 − 𝑋𝐴 ) 3.46921

𝑜

40.6171 𝑉= 3.46921

0.70

0

0.70

0

𝑑𝑋𝐴 (1 − 0.70)

𝑑𝑋𝐴 = 14.0963 𝑚3 (1 − 0.70)

𝑉 = 14.096 𝑚3 For reactor L/D =10.4 Now,

𝜋

𝜋

V = 4 ∗ 𝑑2 ∗ 𝑕 =

4

∗ 𝐷2 ∗ 10.4 ∗ 𝐷 = 14.096 𝑚3

∴ D = 1.199 m = 1.2 m 𝐿 = 10.4 ∗ 1.2 = 12.48

Residence Time 𝜏 =

𝑉𝑜𝑙𝑢𝑚𝑒 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

=

14.096 = 0.3470 𝑕𝑟 40.617

= 0.3470 ∗ 60 = 20.822 𝑚𝑖𝑛 66 | P a g e

Now the mean residence time 𝜏 is the same in all the equal- size CSTR reactors So, based on residence time 𝜏 the number of stages required in the reactor is given by

1 = (1 + 𝑘𝜏𝑖 )𝑁 (1 − 𝑋𝑁 ) Where 𝜏𝑖 = residence time on each tray =

𝜏 𝑁

=

20.822 𝑁

1 20.822 = 1 + 3.46921 ∗ (1 − .70) 𝑁

𝑁

By solving above equation Number of stages = 14 stages

6.1.2 Mechanical design Design parameter Design Pressure: 250 kg/cm2 = 24.5166 N/mm2 Working Pressure: 175 kg/cm2 Design Temperature: 250℃ Working Temperature: 190℃ Material of Construction: Mild Steel Yield Strength: 40000 psi = 279.7903 N/mm2 Modulus of Elasticity: 2 * 105 N/mm2 Factory of Safety: 2 Poisson’s Ratio: 0.33 ∆ (shrinkage) = 1 mm Yield strength = 240 N/mm2 67 | P a g e

Design of high pressure vessel According to, Maximum Principle Stress Theory 𝑓 𝑦 ,𝑝

𝐾=

𝜆𝑝 𝑖 𝑓 𝑦 ,𝑝 𝜆𝑝 𝑖

+1 −1

=

240 +1 2∗17 .9668 240 −1 2∗17 .9668

K = 1.16283 According to, Maximum Shear Stress Theory 𝐾=

𝑓𝑦 ,𝑝 𝑓𝑦 ,𝑝 − 𝜆𝑝 𝑖 3

=

240 240− 2∗17.9668 3

K = 1.1619 According to, Maximum Strain Theory 𝑓 𝑦 ,𝑝

𝐾=

+ (1− 𝜇 )

𝜆𝑝 𝑖 𝑓 𝑦 ,𝑝 − (1 𝜆𝑝 𝑖

+ 𝜇)

=

6.6789+ (1− .33) 6.6789− (1 + .33)

K = 1.1721 According to, Maximum Strain Energy Theory 𝑓𝑦 ,𝑝 = 𝜆𝑝𝑖 ∗

6 + 10𝐾 4 6 + 10𝐾 4 = 2 ∗ 17.9668 ∗ = 240 2(𝐾 2 − 1) 2(𝐾 2 − 1) K = 1.1719

To be on safer side of deg, we select, K = 1.1719 i.e. maximum value of all the theories. Now, K =

𝑑𝑜 𝑑𝑖

= 1.1719

do = 1.1719 ∗ 1.2 = 1.40628 𝑚 Now, thickness = 1.40628 − 1.2 = 0.20628 m = 206.28 mm = t Since the thickness is very high, we opt for the multi-shell construction. Assuming the 5 layers of shell construction: 68 | P a g e

Hence thickness of each layer is t/5 = 41.256 mm Pressure at every junction is given by:

2 2 2 𝐸∆ 𝑅𝑖+1 − 𝑅𝑖2 (𝑅𝑖+2 − 𝑅𝑖+1 ) 𝑃𝑓𝑖 = 2 2 𝑅2 𝑅𝑖+1 (𝑅𝑖+2 − 𝑅𝑖2 )

i

Di (mm)

Ri(mm)

𝑃𝑓𝑖 (N/mm2)

1

1200

600

-

2

1282.512

641.256

7.6182

3

1365.024

682.512

7.0479

4

1447.536

723.768

6.5397

5

1530.048

765.024

6.0841

6

1612.56

806.280

-

69 | P a g e

6.2 Pilling Tower Design Urea Physical Properties 𝑇𝑜 = 132.6℃ 𝑖 = 224,457 𝐽 ∗ 𝑘𝑔−1 𝜌1= 1230 𝑘𝑔 ∗ 𝑚−3 133℃ 𝜌𝑠 = 1335 𝑘𝑔 ∗ 𝑚−3 (20℃) 𝑐1 = 2,098 J *𝑘𝑔−1 ∗ 𝐾 −1 (132.6℃) 𝑐𝑠 = 1,748 J *𝑘𝑔−1 ∗ 𝐾 −1 (25 − 132℃) 𝜆1 = 0.83 𝑊 ∗ 𝑚−1 ∗ 𝐾 −1 (80℃) 𝜆𝑠 = 1.19 W *𝑚−1 ∗ 𝐾 −1 (𝐵𝑜𝑟𝑒𝑡𝑧𝑘𝑦, 1967) 𝜇1 = 2.16 × 10−3 𝑁 ∗ sec∗ 𝑚−2 (80℃)

Air Physical Properties (36.1℃) 𝜌𝑔 = 1.14 kg *𝑚−3 𝑐𝑔 = 1008 𝐽 ∗ 𝑘𝑔−1 ∗ 𝐾 −1 𝜇𝑔 = 1.90 ∗ 10−5 𝑁 ∗ sec *𝑚−2 𝜆𝑔 = 0.0268 W * 𝑚−1 ∗ 𝐾 −1 1. Heat Balance 𝐽

𝐽

𝐽

44301.420{2098 𝑘𝑔 ∗𝐾 (135 – 132.6) + 224457 𝑘𝑔 + 1748 𝑘𝑔 ∗𝐾 (132.6-60)} =15,788,893.18

𝑘𝐽 𝑕𝑟

=4385.80 kW

2. Airflow required Heat gained by air = Heat released by urea 70 | P a g e

15,788,893.18 = 𝑚𝑎𝑖𝑟 ∗ 𝑐𝑔 ∗ ∆𝑇 15,788,893.18 1.008∗20

= 783,179.225 kg * 𝑕𝑟 −1 = 689,999.32 𝑚3 ∗ 𝑕𝑟 −1

3. Tower diameter An upward air superficial velocity of 1.2 m * 𝑠𝑒𝑐 −1 is taken. D=

686999.32∗4 𝜋∗1.2∗3600

= 14.5 m

Take a tower diameter of 14.5 m leading to an air superficial velocity of 1.156 m * 𝑠𝑒𝑐 −1 . 4. Terminal velocity 𝑑𝑝 = 1.5 * 10−3 𝑚 Assume 𝑣𝑟 = 6.3 m * 𝑠𝑒𝑐 −1 𝑅𝑒 =

1.14 ∗ 6.3 ∗ 1.5 ∗ 10 −3 1.90∗ 10 −5

= 567

𝑐𝑤 = 0.58 (see Fig. )

Fig6.1 𝑪𝒘 𝒗𝒔 𝑹𝒆

71 | P a g e

Terminal velocity of particle 𝜋 6 𝜋 6

𝑑𝑝3 (𝑝𝑠 − 𝑝𝑔 ) g = 𝑐𝑤

𝜋

𝑑𝑝2 ∗

4

1 2

𝑝𝑔 𝑣𝑟2

(1.5 * 10−3 )3 (1335 – 1.14) 9.81 = 2.311 * 10−5 𝜋

0.58 * 4 (1.5 * 10−3 )2

1 2

∗ 1.14 ∗ 6. 32 = 2.317 ∗ 10−5

So, LHS = RHS 𝑣𝑎 = 𝑣𝑟 − 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑟𝑜𝑚 𝑛𝑒𝑤 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑣𝑎 = 4.5 − 0.47 = 4.0 𝑚 ∗ 𝑠𝑒𝑐 −1 5. Heat transfer coefficient 𝑅𝑒 = 567 𝜇 𝑔 𝑐𝑔

𝑃𝑟 =

1.90 ∗ 10 −5 ∗1008

=

𝜆𝑔

0.0268

= 0.7146 1

1

𝑁𝑢 = 2 + 0.552 ∗ 𝑅𝑒 2 ∗ 𝑃𝑟 3 1

1

𝑁𝑢 = 2 + 0.552 ∗ 5672 ∗ 0. 71463 = 13.75 𝑁𝑢 =

𝛼𝑜 𝑑𝑝

=13.75

𝜆𝑔

𝛼𝑜 =

Heat transefer coefficient

𝜆𝑔 𝑑𝑝

∗ 13.75 =

0.0268 1.5∗ 10 −3

∗ 13.75 = 245.68 𝑊/𝑚2 ∗ 𝐾

6. Solidification time 𝑖+ 𝑐 1(𝑇 𝑓 − 𝑇 𝑜 )

Ph =

Bi =

𝑐𝑠 (𝑇𝑜 − 𝑇𝑐 ) 𝛼𝑜 𝑑𝑝 2𝜆 𝑠

Fo = Ph a=𝑐

𝜆𝑠 𝑠 𝑝𝑠

= 1 6

=

=

224457 +2098 (135−132.6) 1748 (132.6−35)

245.68∗1.5∗ 10 −3

+

2∗1.19 1 3𝐵𝑖

= 1.345

1.19 1748 ∗ 1335

= 1.345

= 0.1548 1 6

+

1 3∗0.1548

= 3.1203

= 5.1 ∗ 10−7

72 | P a g e

𝑡𝑠1 =

𝐹𝑜 ∗ 𝑑 𝑝2 4𝑎

=

3.1203 (1.5∗ 10 −3 )2 4 ∗ 5.1∗ 10 −7

= 3.44 𝑠𝑒𝑐

𝜏𝐸 /𝜏𝐸,𝑚𝑖𝑛 = 1.28 𝑠𝑒𝑒 𝐹𝑖𝑔.

Fig6.2 Correction factor for the solidification time. (From VDI, 1993.)

Corrected solidification time 𝑡𝑠2 =

𝜏𝐸 𝜏 𝐸,𝑚𝑖𝑛

∗ 𝑡𝑠1 = 1.14 ∗ 3.44 = 3.9216 𝑠𝑒𝑐 = 4 sec

7. Tower height for solidification = 𝑣𝑎 ∗ 𝑡𝑠2 = 5.144 ∗ 3.9216 = 20.1727 𝑚 8. Prill cooling time 𝑅= 1 𝛼0 𝑅2

𝑑𝑝 2

= 7.5 ∗ 10−4 𝑚

= 7236.151 𝑊 −1 ∗ 𝐾 73 | P a g e

2(𝑅−𝑅/2) 𝜆𝑠

𝑅2

1 𝑘𝑐 𝑅2

=

=

2(7.5 ∗ 10 −4 − 3.75 ∗ 10 −4 )

1 𝛼0 𝑅2

1.19 ∗ 7.52 ∗ 10 −8

+

2(𝑅−𝑅/2) 𝜆𝑠 𝑅2

= 1120.448

= 7236.151 + 1120.448 = 8356.599

1

𝑘𝑐 = 8356 .599 ∗7.52 ∗ 10 −8 = 212.739 𝑊. 𝑚−2 ∗ 𝑘 −1 Cooling time𝑡𝑐 =

𝜌 𝑠 𝑐𝑠 𝑑𝑝 6𝑘 𝑐

70−20

∗ ln 30−20 =

1335 ∗1748 ∗1.5∗10 −3 6∗212.739

∗ ln

132.6−35 60−35

= 3.7350 𝑠𝑒𝑐 = 4 𝑠𝑒𝑐 9. Prill cooling height = 3.7350 * 5.144 = 19.212 m 10. Total tower height = Height required for solidification + Height required for cooling of solidified product = 20.1727 + 19.212 = 39.38554 m, take 40 m

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CHAPTER 7 COST ESTIMATION

75 | P a g e

7.1 EQUIPMENT COST Sr. No.

Equipment

No. Equipment

of Cost Equipment

of Total Cost (Rs.) (Lakhs)

(Rs.) (Lakhs) 1

Autoclave

1

15

15

8

8

4

4

1

1

1

1

1

(Reactor) 2

High

Pressure 1

Decompser 3

Low

Pressure 1

Decompser 4

Gas

Separator 1

+

Oxidizing

Column 5

Vacuum Evaporator

6

Crystallizer

1

1

1

7

Centrifuge

4

2

8

8

Melter

1

1.5

1.5

9

Air Blower for 1

0.1

0.1

5

0.8

4

4

0.25

1

1

1

1

O.C. 10

Ammonia Condensor

11

Conveying System

12

Liquid Ammonia Reservoir

13

Lift

1

1.5

1.5

14

Cooling Tower

2

1.5

3

15

Cooling Tower 6

0.5

3

1

1

1

Pressure 1

2

2

Pump 16

Gas Condensor

17

Low

76 | P a g e

Absorber 18

High

Pressure 1

5

5

7

7

Absorber Cooler 19

High

Pressure 1

Absorber 20

Drain Separator

1

1

1

21

Ammonia

3

0.5

1.5

2

0.5

1

1

0.5

0.5

Water 1

0.5

0.5

Draft 1

1.5

1.5

Draft 1

1.5

1.5

2

2

Recovery Absorber 22

Carbamate Tank

23

Condensate Tank

24

Hot Tank

25

Induced Fan

26

Forced Fan

27

Fluidized

Bed 1

Blower 28

Dryer

1

0.5

0.5

29

Mother Liquor 1

0.4

0.4

2

10

20

3

4

12

3

4

12

1

3

3

Tank 30

CO2 Compressor

31

Ammonia Plunger Pump

32

Recycle Carbamate Pump

33

Emission

77 | P a g e

Control System 34

Prilling Tower

1

20

20

35

Various Pumps

44

0.6

26.4

TOTAL

171.9 Fig .7.1 Equipment cost

Total Capital Investment

(A) Fixed Capital Investment (FCI) (1) Direct Cost Direct Cost Sr. No.

Item

%

Purchased Total

Equipment

Cost

(Rs.) (Lakhs)

Cost 1

Equipment

100%

171.9

25%

42.975

Cost 2

Installation

3

Instrumentation 10%

17.19

& Control 4

Piping

25%

42.975

5

Electrification

20%

34.38

6

Building

30%

51.57

7

Service

40%

68.76

4%

6.876

Facilities 8

Land Requisition

TOTAL

436.626

78 | P a g e

(2) Indirect Cost Indirect Cost Sr. No.

Item

%

Purchased Total

Equipment

Cost

(Rs.) (Lakhs)

Cost 1

Engineering & 10%

17.19

Supervision 2

Construcution

10%

17.19

3

Contractor

5%

8.595

4

Contigency

5%

8.595

TOTAL

51.57

Fixed Capital Investment (FCI) = DC + IC = 436.626 + 51.57 = 488.196 (B) Working Capital Investment (WCI) = 15% of FCI = 0.15 X 488.196 = 73.2294 Total Capital Investment = FCI + WCI = 488.196+ 73.2294 = 561.4254 (3) Total Product Cost (TPC)

(A) Direct Production Cost

(1) Cost of Raw Material Sr. No.

Raw Material

Kg/Annum

Cost Rs/Kg

Total

Cost

79 | P a g e

Required

(Rs.) (Lakhs)

1

Ammonia

198.322 x 106

10

2

Carbon

513.3333 x 106 0

198.322 0

Dioxide Total

198.322

(2) Operating Labors Cost = 10% T Cost = 0.10 X T = 0.10 T (3) Utility Cost = 20% TPC Cost = 0.20 X TPC = 0.20 TPC (4) Maintenance & Repair Cost = 4% of FCI = 0.04 X 515.75 = 19.5278 (5) Operating & Supply Cost = 15% of Maintenance & Repair Cost = 0.15 X 19.5278 = 2.9292 (6) Laboratory & Testing Cost = 15% Labour Cost = 0.15 X 0.10 TPC = 0.015 TPC (7) Patents & Royalties = 3% TPC = 0.03 X TPC = 0.03 TPC

80 | P a g e

Direct Production Cost =1+2+3+4+5+6+7 DPC = 198.322 + 0.10 TPC + 0.20 TPC + 19.5278+ 2.9292+ 0.015TPC + 0.03TPC DPC = 0.345 TPC + 220.779 (B) Fixed Charges (1) Deprecation = 10% FCI = 0.10 X 488.196 = 48.8196 (2) Local Taxes = 1.5% of FCI = 0.015 X 515.75 = 7.3229

(3) Insurance = 1% of FCI = 0.01 X 515.75 = 4.8819 Fixed Charges = 1 + 2 + 3 = 61.0244 (C) Plant Overhead Cost = 60% of Labor and Maintenance Cost = 0.60 X (0.10TPC + 19.5278) = 0.06TPC + 11.7167 (D) istrative Expenses = 25% of Labor Cost = 0.25 X 0.10TPC = 0.025TPC

(E) Distribution and Market Expenses = 10% of Total Production Cost 81 | P a g e

= 0.10 X TPC = 0.10 TPC

(F) R & D Cost = 5% of FCI = 0.05 X 488.196 = 24.4098

(G) Interest = 8% of FCI = 0.08 X 488.196 = 39.0557 Total Product Cost TPC = A + B + C + D + E + F + G = (0.345 TPC + 220.779) + 61.0244 + (0.06TPC + 11.7167) + 0.025TPC + 0.10 TPC + 24.4098 + 39.0557 TPC = 759.5438 (4) Profitability Analysis (1) Total Income Sr. No.

1

Product

Urea

Cost/Kg

21

Capacity

Total

Income

Kg/Annum

(Rs.) (Lakhs)

386.9 x 106

812.49

(2) Gross Profit = Total Income – Total Product Cost = 812.49 – 759.5438 = 52.9462

(3) Rate of Return (If Taxes are assumed to be 12%) = {(Annual Gross Profit * (1-0.12)) / (FCI/2 + WC)} * 100 = {(52.9462 * 0.88) / (488.196/2 + 73.2294)} * 100 82 | P a g e

= 14.6828 %

(4) Rate of Return (Before Tax) = { (Gross Profit) / (FCI/2 + WC)} X 100 = { (52.9462) / (488.196/2 + 73.2294)} X 100 = 16.685% (5) Pay out Period = FCI / {(Gross Profit/2) + Depreciation} = 488.196 / {(52.9462/2) + 48.8196} = 6.4839 Years ≈ 7 Years

(6) Turnover Ratio = Gross Annual Sales / Fixed Capital Investment = 812.49 / 488.196 = 1.6642

83 | P a g e

CHAPTER 8 SITE SELECTION AND PLANT LAYOUT

84 | P a g e

8.0 Site Selection & Plant Layout 8.1 Site Selection Plant location is however one of the most important part of final planning. Selection of suitable location of the plant is very important because success of the plant is based on this point. The geographical location of the final plant can have a strong influence on the success of an industrial venture. Much care must be exercised in choosing the plant site, and many different factors must be considered. Primarily, the plant should be located where the minimum cost of production and distribution can be obtained, but other factors, such as room for expansion and general living conditions, are also important. An approximate idea as to the plant location should be obtained before a design project reaches the detailed-estimate stage, and a firm location should be established upon completion of the detailed-estimate design. The choice of the final site should first be based on a complete survey of the advantages and disadvantages of various geographical area and, ultimately, on the advantages and disadvantages of available real estate. The following factors should be considered in choosing a plant site: i. Raw materials ii. Markets iii. Power and fuel iv. Climate v. Transportation facilities vi. Water supply vii. Waste disposal viii. Labour supply ix. Taxation and legal restrictions x. Site characteristics xi. Flood and fire protection xii. Community factors

The factors that must be evaluated in a plant-location study indicate the need for a vast amount of information, both quantitative (statistical) and qualitative.

85 | P a g e

1). Raw materials The source of raw materials is one of the most important factors influencing the selection of a plant site. This is particularly true if large volumes of raw materials are consumed, because location near the raw-materials source permits considerable reduction in transportation and storage charges. Attention should be given to the purchased price of the raw materials, distance from the source of supply, freight or transportation expenses, reliability of supply, purity of the available raw materials, and storage requirements.

2). Market The location of markets or intermediate distribution centres affects the cost of product distribution and the time required for shipping. Proximity to the major markets is an important consideration in the selection of a plant site, because the buyer usually finds it advantageous to purchase from nearby sources. It should be noted that markets are needed for by-products as well as for the major final products.

3). Power and fuel Power and steam requirements are high in most industrial plants, and fuel is ordinarily required to supply these utilities. Consequently, power and fuel can be combined as one major factor in the choice of a plant using electrolytic processes are often located near large hydroelectric installations. If the plant requires large quantities of coal or oil, location near a source of fuel supply may be essential for economic operation. The local cost of power can help determine whether power should be purchased or self-generated.

4). Climate If the plant is located in a cold climate, costs may be increase by the necessity for construction of protective shelters around the process equipment, and special cooling towers or air-conditioning equipment may be required if the prevailing temperatures are high. Excessive humidity or extremes of hot or cold weather can have a serious effect on the economic operation of a plant, and these factors should be examined when picking a plant site.

5). Transportation Facilities Water, railroads, and highways are the common means of transportation used by industrial concerns. The kind and amount of products and raw materials determine the most 86 | P a g e

suitable type of transportation facilities. In any case, careful attention should be given to local freight rates and existing railroad lines. The proximity to railroad centres and possibility of canal, river, lake, or ocean transport must be considered. If possible, the plant site should have access to all three types of transportation, and, certainly, at least two types should be available. Effective transportation facilities for the plant workers are necessary.

6). Water supply The process industries use large quantities of water for cooling, washing, steam generation, and as a raw material. The plant, therefore, must be located where a dependable supply of water is available. The temperature, mineral content, silt or sand content, bacteriological content, and cost for supply and purification treatment must also be considered when choosing a water supply.

7). Waste Disposal In recent years, many legal restrictions have been placed on the methods for disposing of waste materials from the process industries. The site selected for a plant should have adequate capacity and facilities for correct waste disposal. Even though a given area has no restrictions on pollution, it should not be assumed that this condition will continue to exist. Waste disposal can be accomplished by water, land, or air dispersal. In choosing a plant site, the permissible tolerance levels for the various methods of waste disposal should be considered, and attention should be given to potential requirements for additional wastetreatment facilities.

8). Labor supply The type and supply of labour available in the vicinity of a proposed plant site must be examined. Consideration should be given to prevailing pay rates, restrictions on number of hours worked per week, competing industries that can cause dissatisfaction or high turnover rates among the workers, racial problems, and variations in the skill and intelligence of the workers.

9).Taxations and legal restrictions State and local tax rates on property, income, unemployment insurance and similar items vary from one location to another. Similarly, local regulations on zoning, building codes, nuisance aspects, and transportation facilities can have a major influence on the final 87 | P a g e

choice of a plant site.

10). Site characteristics The characteristics of the land at a proposed plant site should be examined carefully. The topography of the tract of land and the soil structure must be considered, since they may have a pronounced effect on construction costs. The cost of the land is important as well as local building costs and living conditions. Future changes may make it desirable or necessary to expand the plant facilities. Therefore, even though no immediate expansion is planned, a new plant should be constructed at a location where additional space is available.

11). Flood and fire protection Many industrial plants are located along rivers or near large bodies of water, and there are risks of flood or hurricane damage. Before choosing a plant site, the regional history of natural events of this type should be examined and the consequences of such occurrences considered. Protection from losses by fire is another important factor is picking a plant location. In case of a major fire, assistance from outside fire departments should be available. Fire hazards in the immediate area surrounding the plant site must not be overlooked.

12). Community factor The character and facilities of a community can have quite an effect on the location of the plant. If a certain minimum number of facilities for satisfactory living of plant personnel do not exist, it often becomes a burden for the plant to subsidize such facilities. Cultural facilities of the community are important to sound growth. Churches, libraries, schools, civic theatres, concert associations, and other similar groups, If active an dynamic, do much to make a community progressive. The efficiency, character and history of both state and local government should be evaluated. The existence of low taxes is not in itself a favourable situation unless the community is already well developed and relatively free of debt. 8.2 Plant Layout The efficiency of production depends on how well the various machines; production facilities and employee‟s amenities are located in a plant. Only the properly laid out plant can ensure the smooth and rapid movement of material, from the raw material stage to the end product stage. 88 | P a g e

Plant layout refers to the arrangement of physical facilities such as machinery, equipment, storages, departments etc. with in the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least cost in processing the product from the raw material to the finished product. 8.2.1 Importance Plant layout is an important decision as it represents long-term commitment. An ideal plant layout should provide the optimum relationship among output, floor area and manufacturing process. It facilitates the production process, minimizes material handling, time and cost, and allows flexibility of operations, easy production flow, makes economic use of the building, promotes effective utilization of manpower, and provides for employee‟s convenience, safety, comfort at work, maximum exposure to natural light and ventilation. It is also important because it affects the flow of material and processes, labour efficiency, supervision and control, use of space and expansion possibilities etc. An efficient plant layout is one that can be instrumental in achieving the Following objectives: a) Proper and efficient utilization of available floor space b) To ensure that work proceeds from one point to another point without any delay c) Provide enough production capacity. d) Reduce material handling costs e) Reduce hazards to personnel f) Utilize labour efficiently g) Increase employee morale h) Reduce accidents i) Provide for volume and product flexibility j) Provide ease of supervision and control k) Provide for employee safety and health

89 | P a g e

l) Allow ease of maintenance m) Allow high machine or equipment utilization n) Improve productivity

Fig8.1 Plant Layout

8.3 Environmental Impact Assessment An Environment Impact Assessment is an assessment of the possible positive impact or negative impact which the project may have on the natural environment. The purpose of the assessment is to ensure that decision makers consider environmental impacts used to decide whether to proceed with the project. The International Association for Impact Assessment (IAIA) defines an environmental impact assessment as "the process of identifying, predicting, evaluating and mitigating the biophysical, social, and other relevant effects of development proposals prior to major decisions being taken and commitments made.

90 | P a g e

8.3.1 Objectives of EIA Assessment 

To ensure that proponents take primary responsibility for protection of the environment influenced by their proposals



To ensure that best practicable measures are taken to minimize adverse impacts on the environment, and that proposals meet relevant environmental objectives and standards to protect the environment, and implement the principles of sustainability



To provide opportunities for local community and public participation, as appropriate, during the assessment of proposals



To encourage proponents to implement continuous improvement in environmental performance and the application of best practice environmental management in implementing their proposal



To ensure that independent, reliable advice is provided to the Government before decisions are made

8.3.2 Impact of the Urea Plant on the environment In the early part of previous decade ammonia consumption per ton of final product of 575 kg or even higher used to be acceptable. This figure implies however a loss of some 8 kg per tonne of final product produced (Table 1), which for a 2000 mtd plant would result in a loss of 16 mtpd ammonia either in the form of urea or straight ammonia. Presently ammonia consumptions of some 567 kg per tonne are released in the large single stream plants. Since this figure is very close to the theoretical consumption figure, the conclusion is that losses in steady operation are approaching the zero targets.

Ammonia releases from urea plants Early nineteen eighties = 8 kg NH3/mt final product Presently = 0.7 kg NH3/mt final product Table 8.1 Ammonia releases from urea plants Not only ammonia, carbon dioxide and urea releases from process plants have a negative influence on the environment but also the unnecessary use of energy is negative from an environmental point of view and from the economic point of view as well. Following table shows the present typical energy consumption for urea production

91 | P a g e

8.3.3 Emissions to Air Air emissions may be categorised as either fugitive or point source emissions. 

Fugitive Emissions

These are emissions that are not released through a vent or stack. Examples of fugitive emissions include dust from stockpiles, volatilization of vapour from vats, open vessels, or spills and materials handling. Emissions emanating from ridgeline roof-vents, louvres, and open doors of a building as well as equipment leaks, and leaks from valves and flanges are also examples of fugitive emissions. 

Point Source Emissions

These emissions are exhausted into a vent or stack and emitted through a single point source into the atmosphere. Above table highlights common air emissions from urea manufacturing processes.

8.3.4 Emissions to Water Emissions of substances to water can be categorised as discharges to: 

Surface waters (eg. lakes, rivers, dams, and estuaries);



Coastal or marine waters



Storm water Because of the significant environmental hazards posed by emitting toxic substances

to water, most facilities emitting above listed substances to waterways are required by the relevant environment authority to closely monitor and measure these emissions. The existing sampling data can be used to calculate annual emissions. If no wastewater monitoring data exists, emissions to process water can be calculated based on a mass balance or using emission factors.

8.3.5 Emissions to Land Emissions of substances to land on-site include solid wastes, slurries, and sediments. Emissions arising from spills, leaks, and storage and distribution of materials containing listed substances may also occur to land. These emission sources can be broadly categorised as: 

surface impoundments of liquids and slurries; and



unintentional leaks and spills.

In general, there are four types of emission estimation techniques (EETs) that may be used to estimate emissions from the facility. The four types are: 92 | P a g e



Sampling or direct measurement;



Mass balance;



Fuel analysis or other engineering calculations; and



Emission factors

8.3.6 Elimination Methods Presently plants are equipped with the following features to keep the effluent and emission at extremely low levels: 

N/C ratio meter



Waste water treatment section



Absorbers



Special operational facilities

N/C ratio meter in the Synthesis section Instead of using a gaschromatograph or a mass spectrometer in the gas phase of the synthesis section, Nitrogen/Carbon (N/C) ratio meters are installed in the liquid phase (reactor liquid outlet) of the urea synthesis section The principle of this N/C meter is based on the linear relationship between liquid density and the N/C ratio. The density is measured continuously with a solartron meter, being an instrument in which vibrations are measured in an extremely accurate way whereby the vibrations are a measure of the density of the reactor liquid. This N/C ratio meter allows the process at all times to be operated at the optimum ratio to achieve highest reactor efficiency combined with higher energy efficiency. Special procedures are used to eliminate emissions during start-up.

Urea plant waste water treatment section The process water in urea plants contains ammonia, carbon dioxide and urea. The concentrations of these components vary within a range depending on the operating conditions, On average, the concentrations in the process water are about 6 wt.% ammonia, 4 wt.% carbon dioxide and 1 wt.% urea.

Sources of the ammonia and urea are 

Condensate from the evaporators. 93 | P a g e

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Off-gases from the recirculation section, which are absorbed in the process water.

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Off-gases from the synthesis section, which are absorbed in the process water.

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Flush and purge water for pumps.

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Liquid drains. The purpose of the process water treatment is to remove ammonia, carbon dioxide

and urea from the process condensate. For every tonne of urea produced, approximately 0.3 tonnes of water are formed. This water is usually discharged from the urea concentration and evaporation section of the plant. Removal of ammonia and urea from wastewaters can be a problem as it is difficult to remove one in the presence of the other. One method used to overcome this problem is the hydrolysis of urea to ammonium carbamate, which is decomposed to ammonia and carbon dioxide. These gases can then be stripped from the wastewaters. Urea plants are in operation that produces wastewaters with ammonia and urea levels below 1ppm. This water can then be used for a variety of purposes depending on the required quality suchas cooling water or Boiling Feed Water make-up. The recovered ammonia and carbon dioxide are returned to the process to be subsequently converted into urea.

Absorbers Absorbers are used in urea plant to eliminate emissions to the atmosphere, can be classified as follows:

(1) The vent from the synthesis section of the plant The purge from the urea synthesis section contains inerts, ammonia and carbon dioxide. To avoid ammonia emissions from this purge a low pressure absorber is installed in purge stream. First the ammonia is washed out with a large flow of low concentrated and cooled process water and secondly the remaining ammonia is absorbed in cooled condensate or clean waste water. (2) The vent from the low pressure section of the plant The ammonia and carbon dioxide present in the off gases of the recirculation section, the Process Water Treatment System and the evaporation section are washed out in an atmospheric absorber where large amounts of cooled low concentrated process water are used to absorb all the ammonia present in said off gases.

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Special start-up, shut-down and draining facilities Because of the present low releases during steady state operation in urea manufacturing the consideration regarding environmental issues has changed towards further reducing of effluents and emissions from non-continuous sources during non-steady state conditions such as start-up and shut-down situations. A change in the start-up procedure of the urea synthesis section has reduced the impact on the environment considerably. Presently the ability to measure the feed flows (NH3 and CO2) very accurate in combination with the ability to measure the N/C ratio have enabled us to feed the synthesis section from the very beginning of the start-up with the correct NH3/CO2 ratio, thus eliminating the need, during the initial stage of start-up, to vent excess CO2 accompanied by some NH3 into the atmosphere. Special shut-down and draining facilities assure that non converted NH3 and CO2 are recovered by the process after a shut-down. To achieve this facility to feed clean water to dilute the carbamate formed from non converted NH3 and CO2 from the synthesis section has been introduced. The dilution should be to the extent that no ammonia will escape from the liquid under atmospheric pressure. The water is in principle introduced in the low pressure carbamate condenser and subsequently cooled to increase absorption capacity, and drained in the ammonia water tank. After restart of the plant the NH3 and CO2 in this tank are recovered via the waste water treatment section. The clean water used for the dilution may be an amount of clean waste water stored for such purpose. In case sufficient condensate is available in the complex no such additional storage of clean waste water is required and condensate may be used as well.

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CHAPTER 9 SAFETY ASPECTS

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9.1 Introduction Safety is the state of being „safe‟, the condition of being protected against physical, social, spiritual, financial, political, emotional, occupational, psychological, educational or other types or consequences of failure, damage, error, accidents, harm or any other event which could be considered non-desirable. This can take the form of being protected from the event or from exposure to something that causes health or economic losses. It can include protection of people or of possessions. Scientific minded people have analyzed accidents and developed a separate engineering branch or accident prevention. This analysis was required due to: i. Rising trend of accidents ii. Increased use of machinery iii. Increased material handling iv. Lack of safety standard v. Lack or training vi. Better reporting of accidents

No industry can afford to neglect the fundamentals of safety in design and operation of its plant and machinery. It is important that all the people responsible for management and operation of any industry should have a good knowledge of industrial safety.

9.1.1 Safety Safe use of man, material and machine by safe system method of work is to achieve zero accidents which results in higher productivity.

9.1.2 Accident An accident is unplanned and unexpected events which interfere or interrupts the planned process of work and results in personal injury.

9.1.3 Accident factors i. A personal accident injury occurs as a result of an accident ii. An accident due to unsafe act and/or unsafe condition iii. Unsafe act/unsafe condition exists due to fault of persons iv. Fault of persons are due to negligence.

Thus, if we can remove fault of a person we can prevent 98 % accidents. 97 | P a g e

9.1.4 Principal of Protection and Prevention Industrial accidents are caused by negligence of employer, the worker or the both. Employers‟ efforts to reduce the accidents are generally motivated by four considerations: i. To lessen human suffering ii. To prevent damage to plant and machinery iii. To reduce the amount of time lost as a result iv. To hold the expenses of workman‟s compensation to a minimum

The basic reasons for preventing industrial accidents are human and economic. The most important of these should be to avoid human suffering. Both pain, suffering and wrecked lives are not to be the byproducts of any industry. Accidents are economic losses and this is a challenging reason for accident prevention.

9.1.5 Safety precaution 

When taking sample of anhydrous ammonia and when operating or working on ammonia valves, equipment containing ammonia such as ammonia feed pumps, operators, laboratory and maintenance personnel must wear safety overalls

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Goggles and rubber gloves. If any part of the skin has been exposed to ammonia, wash immediately and thoroughly with water

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Work on the ammonia equipment should be done from the upwind side of the equipment to avoid or minimize with escaping ammonia.

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The location of fire hydrants, safety showers, eyewash fountains ammonia canisters gas mask, emergency air breathing apparatus should be well known to all personnel.

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Instruments containing mercury must not be used if ammonia is likely to come in with the mercury.

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Heavy leakage of ammonia can be dealt by spraying large quantity of water with spray nozzles.

9.2 List of safety equipments A. Respiratory protective equipment i. Self-contained breathing apparatus sets of 30 minutes and 10 minutes ii. Continuous airline masks. iii. Trolley mounted self-contained breathing apparatus set 2.5 hours iv. Canister gas mask 98 | P a g e

v. Dust mask/cloth mask. (Air purifying respirator) B. Non- respiratory protective equipment i. Helmet ii. Ear muff and ear plugs iii. Goggles iv. Face shield v. Hand gloves vi. Aprons vii. Safety Shoes viii. Suits ix. Safety harness C. Warning instrument i. Oxygen, carbon dioxide, chlorine, ammonia indicator with replaceable sensors. ii. Explosive meters for measuring explosive range. iii. Fire fly instrument for confined space entry. D. Gas leak protection system i. Safety Showers ii. Manual water sprinklers iii. Communication systems

9.3 Fire hazards The general types of fire are encountered in the process plants. One involves common combustible material such as wood, rags, paper, etc. (Class „A‟ fires), the next flammable liquids and gases such as lubrication oils and solvents, ammonia vapours etc. (Class „B‟ fires) and the third involve electrical equipment (Class „C‟ fires). In general three things are required to make a fire

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Something which will burn eg., a combustible material

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Oxygen-air

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A source of ignition or existence of a temperature at or above which a material will start burning spontaneously.

9.4 Principal of fire extinguishing 

Fire may be extinguished by withdrawing of flammable contents, interrupting flammable flow, isolating fuel from air, heat removal to below reaction temperature or by dispersal.

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In the event of fire on electrical mains or apparatus, the affected part shall be immediately isolated from its source of supply of electrical energy.

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Carbon tetrachloride extinguishers and Carbon dioxide extinguishers are intended mostly for use on electrical fires and may be used on energized electrical equipment without danger to operator provides. They are properly maintaining no moisture.

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It is dangerous to throw a stream of water, a wet blanket or a stream from an ordinary soda acid or foam type fire extinguishers on line main apparatus. When found necessary to use them, have all neighbouring mains or apparatus made dead.

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In case of fire, it is the duty of the operating personnel to protect life and property and to extinguish the fire as quickly as possible.

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The greatest cause of fire is welding which may be required during plant operation. It should be a stringent rule of the plant that no welding without permission of the supervisor. Fire and safety equipment, under conditions of extreme exertion provide protection only

for a few minutes. Equipment must be cleaned, replenished and inspected for damage before being returned to service. Equipment should be maintained in excellent condition and inspected frequently so that they are available in case of emergency.

9.5 Principal of protection and prevention Industrial accidents are caused by negligence of employer, the worker or the both. Employers‟ efforts to reduce the accidents are generally motivated by four considerations. i. To lessen human suffering ii. To prevent damage to plant and machinery 100 | P a g e

iii. To reduce the amount of time lost as a result iv. To hold the expenses of workman‟s compensation to a minimum. The basic reasons for preventing industrial accidents are human and economic losses. The most important of these should be to avoid human suffering. Pain, suffering and wrecked lives are not intended to be the by-products of any industry.

9.6 Hazards What happens to environment when ammonia enters the environment? 

Because ammonia occurs naturally, it is found throughout the environment in soil, air, and water.

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Ammonia is recycled naturally in the environment as part of the nitrogen cycle. It does not last very long in the environment.

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Plants and bacteria rapidly take up ammonia from soil and water.

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Some ammonia in water and soil is changed to nitrate and nitrite by bacteria.

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Ammonia released to air is rapidly removed by rain or snow or by reactions with other chemicals.

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Ammonia does not build up in the food chain, but serves as a nutrient source for plants and bacteria.

How might I be exposed to ammonia? 

Everybody is regularly exposed to low levels of ammonia in air, food, soil, and water. Ammonia has a strong irritating odour that people can easily smell before it may cause harm.

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If you use ammonia cleaning products at home, you will be exposed to ammonia released to the air and through with your skin.

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If you apply ammonia fertilizers or live near farms where these fertilizers have been applied, you can breathe ammonia released to the air.

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You may be exposed to ammonia from leaks and spills from production plants, storage facilities, pipelines, tank trucks, and rail cars.

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You may be exposed to higher levels if you apply ammonia fertilizers or live near farms where these fertilizers have been applied. 101 | P a g e

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You may be exposed to high levels if you go into enclosed buildings that contains lots of animals (such as on farms).

How can ammonia affect my health? No health effects have found in humans exposed to typical environmental concentrations of ammonia. Exposure to high levels of ammonia in air may be irritating to your skin, eyes, throat, and lungs and cause coughing and burns. Lung damage and death may occur after exposure to very high concentrations of ammonia. Some people with asthma may be more sensitive to breathing ammonia than others. Swallowing concentrated solutions of ammonia can cause burns in your mouth, throat, and stomach. Splashing ammonia into your eyes can cause burns and even blindness.

How likely is ammonia to cause cancer? There is no evidence that ammonia causes cancer. The Department of Health and Human Services (DHHS), the EPA, and the International Agency for Research on Cancer (IARC), have not classified ammonia for carcinogenicity.

How can families reduce risk of exposure to ammonia? The following are the ways by which families can reduce the risk of exposure to Ammonia:      

Keeping products containing ammonia out of the reach of children. Maintaining adequate room ventilation when using cleaners containing ammonia and wear proper clothing and eye protection. Preventing children from entering a room where ammonia is being used. Not storing cleaning solutions in containers that may be attractive to children, such as soda bottles. Avoiding entering fields when ammonia fertilizer is being applied. Minimizing exposure to ammonia in the workplace by wearing proper safety clothes and equipments, and by following safety rules.

Is there a medical test to show whether I’ve been exposed to ammonia? There are tests that can detect ammonia in blood and urine. However, these tests cannot definitely determine if you have been exposed because ammonia is normally found in the body. If you were exposed to harmful amounts of ammonia you would notice it

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immediately because of the strong, unpleasant smell and strong taste. Your skin, yes, nose, and throat would also be irritated.

Has the federal government made recommendations to protect human health? The Occupational Safety and Health istration (OSHA) has set an acceptable eight-hour exposure limit at 25 parts of ammonia per one million parts of air (ppm) and a short-term (15 minutes) exposure level at 25 ppm.

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REFERENCES

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1). MARTYN S. RAY, and DAVID W. JOHNSTON, “ Chemical Engineering Design Project: A Case Study Approach,” 6th ed.,Gordon and Breach Science Publishers, New York 2). Urea manufacturing processes, “ Ullmann's Encyclopedia of Industrial Chemistry,” 5th Edition, Volume A27. 3). The fertiliser Association of india, “ Seminar on fertilizer production and technology,” New Delhi, (December 1969). 4). EIJI SAKATA and TAKAHIRO YANAGAWA, “ Latest Urea Technology for Improving Performance and Product Quality,” TOYO ENGINEERING CORPORATION , TOKYO JAPAN. 5). Perry, R. H., and D. W. Green, Eds., "Physical and chemical data," Chapter 2, in "Perry's Chemical Engineers' Handbook," 8th ed., McGraw-Hill, New York (1984). 6). Urea plant operation manual, Gujarat State Fertilisers and chemicals limited, Gujarat. 7). R.K.Sinnot, “ Coulson & Richardsons Chemical Enginering,” Chapter 8, 6th vol. 8). Mohsen Hamidipour, Navid Mostoufi & Rahmat Sotudeh-Gharebagh., "Modeling the synthesis section of an industrial urea plant," Chemical Engineering Journal, pp. 249-259 (Dec.2004). 9). Xiangping Zhang, Suojiang Zhang Pingjing Yao, Yi Yuan., "Modeling and simulation of high pressure urea synthesis," Computer & Chemical Engineering Journal, pp. 983-992 (Jan.2005). 10). Urea manufacturing processes, “ Kirk & Othmer Encyclopedia of Chemical Engineering,” 23rd vol. 11). Urea reactor calculation - http://www.ureaknowhow.com/urea_j/en/library/412-200909-shen-sric-ureaknowhowcom-urea-synthesis-reactor-its-dynamic-model-part-2.html 12). Urea price list - http://www.indexmundi.com/commodities/?commodity=urea&currency=inr 13). Horacio

A. Irazoqui' and Miguel A. Isla, “Simulation of a Urea Synthesis Reactor. 2. Reactor

Model,” Ind. Eng. Chem. Res. 1993,32, pp- 2671-2680. 14). C. E, REDEMANN, F. C. RIESENFELD, and F. S. LA VIOLA, “ Formation of Biuret

from Urea Research Division,” The Fluor Corp., Ltd., Whittier, Calif. 105 | P a g e

15). Ammonia and Urea Production - http://www.nzic.org.nz/ChemProcesses/production/1A.pdf 16). Urea - www.epa.gov/ttn/chief/ap42/ch08/final/c08s02.pdf 17). Saima Abdul Rasheed, “Revamping Urea Systhesis Reactor using Aspen plus” http://www.ureaknowhow .com

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APPENDIX FLOW SHEET OF DIFFERENT PROCESSES

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