1.

Background, Objective and Process relevance

Urea is an organic compound with the chemical formula CO(NH2)2 consisting of carbonyl and amide
functional groups. Urea serves an important role in the metabolism of nitrogen-containing compounds
by animals and is the main component of urine of mammals. It is an important component of nitrogen-
based fertilizers and also as a raw material for urea-formaldehyde resin which is an industrially
important polymer,
Urea is made of from ammonia and carbon di-oxide. The process takes place via the following
reactions at high temperature, and the urea is formed in a 2-stage process.

(1) 2NH3 + CO2 => CARBAMATE

(2) CARBAMATE => UREA + H2O

The first reaction is carried out in a stoichiometric reactor, while the second reaction which produces
urea is carried out in a plug flow reactor where the conversion increases along the length of the
reactor. The urea stream from the second reactor also contains unreacted NH3 and CO2 and
ammonium carbamate. The pressure is therefore reduced via a third reactor and application of heat
results in decomposition of the carbamate to NH3 and CO2. The ammonia and carbon di-oxide are
recycled back and liquid urea is obtained after purification
Since, urea is such a key component in various fertilizers, Optimization of Urea manufacture process
is necessary in order to obtain the maximum yield of Urea production. We know that as we increase
the pressure or the dimensions of the reactors, we are able to obtain greater output from the process,
but at the same time incurring a greater compression or equipment cost. The objective of this study
is to therefore find the optimum operating conditions for the reactors involved that can maximize
profit and implement the same in our process system.
The process flowsheet is as follows:
 2. Optimization

Optimization analysis has been carried out across the plug flow reactor (carbamate formation) as well
as the A02 (urea formation reactor) by varying two parameters each for the respective towers. For the
plug flow reactor, the length of the reactor as well as the operating pressure has been varied to obtain
maximum profit by increasing the flow rate of the urea stream (S-12). For the R-stoic reactor (labelled
as A02), the pressure and the temperature has been varied since no particular variation was observed
against the length of the reactor, and the profit has been similarly maximized.
The Method that has been used for optimization is sensitivity analysis. From sensitivity analysis, flow
rates of products are obtained and are multiplied by their cost for obtaining the revenue. From this
revenue, cost incurred to obtain the desired yield is subtracted in order to obtain the profit. This profit
is optimized to maximum value and the optimum operating conditions are thereby obtained which
may be used in the experimental set-up of the plant.

2.1 Plug flow reactor

In the plug flow reactor, the ammonia and carbon di-oxide feed mixtures react together to form
carbamate, which is then further decomposed to yield the urea product from a subsequent reactor.
The ammonia and carbon di-oxide recycle streams are generated by the same reactor and sent to the
urea stripper.

2.1.1 Objective:
To determine optimum pressure conditions and length of the reactor in order to generate maximum
profit.

2.1.2 Constraints:
The length of the reactor has to be in the range of 25m- 30m.
The pressure is kept within 140 kg/sq cm – 150 kg/sq cm keeping in consideration the space
provisions and compressor capabilities.

2.1.3 Procedure:
Sensitivity analysis was carried out in terms of the pressure of the reactor and the urea flow rate. It
was found that as the pressure increases, we are able to increase the flow rate of urea, which in turn
increases the revenue by product sales from the process. However, in order to increase the pressure,
a greater compression cost is also incurred. Clearly, this is a trade-off between compressor cost and
product revenue and the revenue is optimised by plotting a graph in excel by varying the pressure
from 140-150 kg/sq-cm.
In step 2, the length of the reactor has been varied which when increased, provides a greater reactor
volume that increases conversion and therefore, the final output of urea. But increasing the length of
the reactor incurs a higher equipment installation cost and thus there is again a trade-off between urea
production and equipment cost.
The results of the optimization analysis are as follows:
R-01 Plug flow reactor - Profit as a function of pressure

Clearly from the above results it is clear that a pressure of 147 Kg/sq-cm produces the
maximum profit keeping compression costs under consideration.

R-01 Plug flow reactor – Profit as a function of reactor length

Clearly from the above results it is clear that a reactor length of 27.5 m is optimal for generating
maximum revenue, keeping equipment cost under consideration.
 2.2 R-stoic reactor
This reactor is basically responsible for generating urea from the carbamate. Feed stream to this
reactor is the outlet of the urea stripper.

2.2.1 Objective:
To determine optimum pressure and temperature conditions of the reactor in order to generate
maximum profit.

2.2.2 Constraints:
The temperature is kept within a range of 65-80 degree Celsius since the forward reaction is favoured
at low temperature due to a negative enthalpy of reaction.
The pressure is kept within 140 kg/sq cm – 150 kg/sq cm keeping in consideration the space
provisions and compressor capabilities.

2.2.3 Procedure:
Sensitivity analysis was carried out in terms of the pressure of the reactor and the urea flowrate. It
was found that as the pressure increases, we are able to increase the flow rate of urea, which
in turn increases the revenue by product sales from the process. However, in order to increase the
pressure, a greater compression cost is also incurred. Clearly, this is a trade-off between compressor
cost and product revenue and the revenue is optimised by plotting a graph in excel by varying the
pressure from 140-150 kg/sq-cm.
In step 2, the temperature of the reactor has been varied which when increased, increases the
conversion of the product, but also the coolant costs and other heat exchanger costs.

A-02 R-Stoichiometry reactor – Profit as a function of pressure.

A-02 R-Stoichiometry reactor – Profit as a function of temperature.

 3. Conclusions
After performing the sensitivity analysis of the Distillation Columns and plotting the relevant curves,
the following conclusions were arrived at.

A-02 R-Stoic Reactor