Production of

Prilled Urea
Sule Alabi
Jonathan Arana
Elizabeth Moscoso
Oleg Yazvin
Mentor: Dan Rusinak – Middough
 BFD of Urea & Prill Plant
Output NH3 Purge & Urea Solution

To Amm. Nitrate & UAN Plants

CO2 & NH3 Recycled Gas

Inlet NH3 & CO2 Urea
from NH3 Plant Production Waste Water
Plant "Dirty Water"
Treatment
Rich in NH3, CO2 & Impurities
Plant

Clean Water
from CHP Plant
Urea Solution
(72%)

Cleaned Air Out

Condensate Water

Prilling
Prilled Urea (99.3%)
Evaporator Solid Urea (99.3%) Tower
Product
Unit

Air In
Urea Production Plant PFD
water 14
6

5 13
Un-reacted Gases

3 11
1
2 DECOMPOSER

10

12
4
8 7 9
Urea (72%)Solution
 Urea Production Plant Calculations
Input Variables

 Some Assumptions: CO2 input (tons)

NH3 / CO2 Input Mole Ratio
1153.15
2.95
Input CO2 Split into Reactor 0.90
Reactor
Extent of Reaction 1 Based on CO2 0.60
Extent of Reaction 2 Based on CO2 0.50
Fraction of CO2 that gets converted 1.00
 Calculations:
Stream 1 2 3 4 5
NH3 Feed Gas Exit from Stripper Solution from Scrub Solution from Pool Gas Recycle to Scrub
Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons
Totals 77.31 1314.33 77.59 2441.84 140.00 3565.00 151.47 4430.96 10.50 234.30

Compounds
CO2 41.59 1829.84 10 440.00 18.57 817.14 2.06 90.79
NH3 77.31 1314.33 36.00 612.00 100 1700.00 75.97 1291.52 8.44 143.50
AC 15 1155.00 10.98 845.16
Urea 15.48 928.57
Water 15 270.00 30.48 548.57

Properties
Temperature 185oC 185oC 185oC 185oC 60oC
Pressure 140 Bar 140 Bar 140 Bar 140 Bar 1 Bar
Material & Energy Balance for Decomposer Unit

Compound Mass Flow Mass Flow Mole Flow Mole Flow

Rate IN Rate OUT Rate IN (ton Rate OUT
(TPD) (TPD) mole/day) (ton
mole/day)
AC 506.7 12.5 6.5 0.13
Urea 1513.8 1893.5 25.2 31.6
Water 99.54 214.2 5.53 11.9
NH3 2.21 2.21 0.13 0.13
CO2 5.72 5.72 0.13 0.13
TOTAL 2128 2128 37.53 43.9

Basis:
1893 TPD of Urea produced Q = 177 BTU/ton
Composition of Urea 72%
Waste Water Treatment Plant PFD

33

31

13

32
 Waste Water Treatment Plant Calculations
Calculations:
Stream 13 31 32 33
Total 532,066.00 477,245.34 50,000.00 4,820.66

Assumptions:
Mass (kg) Balance
 Basis of 50,000kg of
effluent sewer water Components
 10 NH3 ppm specification CO2 38,084.00 37,703.11 0.05 380.84
from EPA
NH3 45,332.00 44,878.63 0.05 453.32
 Assumed same PPM for
Urea 4,985.00 4,935.15 0.00 49.85
CO2
 Inlet Water composition Water 443,665.00 389,728.45 49,999.90 3,936.65
from existing Indian Urea
Plant Mole (kmol) Balance
 1% of recycle is vented to
Component
air
CO2 865.55 865.54 0.00 216.39
NH3 2,666.59 2,666.59 0.00 666.65
Urea 83.08 83.08 0.00 20.77
Water 24,648.06 21,870.28 2,777.77 5,467.57
Total 28,263.27 25,485.50 2,777.78 6,371.37

Properties
Temperature 25oC 25oC 25oC 25oC
Pressure 1 bar 1 bar 1 bar 1 bar
 Evaporator Unit PFD
23
Condenser 21

Streams 21, 26, 19:

H.P. Steam 24 17 To Waste Water Treatment
22
Evap1

Eductor
Evap2

25

27 Product Urea (99.8%)

26 19

Urea Solution 15
(72%)
18 20

16

Storage Tank
 Evaporator Unit Calculations
 Assumptions: Input Urea
Input Water
1572.48
611.52
Tons
Tons
wt% Water Evaporated 1 95%
wt% Water Evaporated 2 85%
wt% Water Condenses 65%
Input Steam 3 Tons

 Calculations:
Stream # 15 16 17 18 19

Urea (72%) to Tank Urea 72% Solution Water from Evap 1 Urea from Evap1 Steam from Evap 2
Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons

Totals 60.18 2184.00 60.18 2184.00 32.27 580.94 27.91 1603.06 32.27 580.94

Compounds

Urea 26.21 1572.48 26.21 1572.48 26.21 1572.48

Water 33.97 611.52 33.97 611.52 32.27 580.94 1.70 30.58 32.27 580.94

H.P. Steam

Properties

Temperature 80oC 80oC 110oC 95oC 80oC

Pressure 5 Bar 5 Bar 0.8 Bar 0.8 Bar 1 Bar

 Prilling Tower PFD
Cleaned Air

Cyclone 30

Prilling
Tower

Bag House

27 Urea Melt (99.8%)

Pump

Melting Furnace

Air from Atm 28

Dehumidifier

Screen

29
Prilled Urea (99.8%)
Prilling Tower Calculations
Calculations:
Assumptions: Stream 27 28 29 30

 Mass flow rate of Prilled

Urea Melt Air From Prilled Urea
Urea is 738.22 TPD (99.8%) Atm (99.8%) Cleaned Air
 According to the EPA the Tons Tons Tons Tons
allowed urea dust is 3.8
Totals 739.94 500 738.22 501.724
lb/ton of Prilled Urea. For
ammonia dust the
allowed emission is 0.87
Component
lb/ton of Prilled Urea.
Urea Melt 739.94 --- --- ---
Ammonia Dust --- --- --- 0.32
Urea Dust --- --- --- 1.40
Prilled Urea --- --- 738.22 ---
Air --- 500 --- 500

Properties
Temperature 185oC 25oC 25oC 25oC
Pressure 1 bar 1 bar 1 bar 1 bar
Estimated Economics

Materials Cost (Money We Spend) Amount Overall Cost

NH3 $521.00 Per Ton 891.07 Tons Per Day $464,247.47 Per Day
CO2 $15.00 Per Ton 1153 Tons Per Day $17,295 Per Day

Product Price (Money We Get) Overall Price

Urea to UAN $230.00 Per Ton 694.48 Tons Per Day $159,730.40 Per Day
Prilled $570.50 Per Ton 739.7 Tons Per Day $421,998.85 Per Day

Profit: $100,186.78 Per Day

Profit: $36,568,174.70 Per Year

Estimated Total Cost
 2009- Q’atar built a 3,836 TPD Urea Plant
 Plant Cost: $610 Million Dollars.

 Urea Plant Produces 1,384 TPD

 Using 6/10ths rule and 2010 Cost Index
 Plant Cost: $389.4 Million Dollars.

 About 10 years to break even

Questions?