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

Inlet NH3 & CO2

from NH3 Plant

Urea Production Plant

CO2 & NH3 Recycled Gas

"Dirty Water" Rich in NH3, CO2 & Impurities

Waste Water Treatment Plant

Urea Solution (72%)

Clean Water from CHP Plant

Cleaned Air Out Condensate Water

Evaporator Unit

Solid Urea (99.3%)

Prilling Tower

Prilled Urea (99.3%)

Product

Air In

Urea Production Plant PFD

6 5
water

14 13
Un-reacted Gases

1 2 10

11
DECOMPOSER

4 8 7 9

12

Urea (72%)Solution

Urea Production Plant Calculations

Input Variables

Assumptions:

CO2 input (tons) NH3 / CO2 Input Mole Ratio Input CO2 Split into Reactor Reactor Extent of Reaction 1 Based on CO2 Extent of Reaction 2 Based on CO2

1153.15 2.95 0.90

0.60 0.50 1.00

Stream

Calculations:
1 2

Fraction of CO2 that gets converted

NH3 Feed
TonMoles Totals Compounds CO2 NH3 AC Urea Water Properties Temperature Pressure 185oC 140 Bar 77.31 1314.33 77.31 Tons 1314.33

Gas Exit from Strip.

TonMoles 77.59 Tons 2441.84

Solution from Scrub

TonMoles 140.00 Tons 3565.00

Solution from Pool

TonMoles 151.47 Tons 4430.96

Gas Recy. to Scrub

TonMoles 10.50 Tons 234.30

41.59 36.00

1829.84 612.00

10 100 15

440.00 1700.00 1155.00

18.57 75.97 10.98 15.48

817.14 1291.52 845.16 928.57 548.57

2.06 8.44

90.79 143.50

15

270.00

30.48

185oC 140 Bar

185oC 140 Bar

185oC 140 Bar

60oC 1 Bar

Material & Energy Balance for Decomposer Unit

Compound Mass Flow Rate IN (TPD) 506.7 1513.8 99.54 2.21 5.72 2128 Mass Flow Rate OUT (TPD) 12.5 1893.5 214.2 2.21 5.72 2128 Mole Flow Mole Flow Rate IN (ton Rate OUT mole/day) (ton mole/day) 6.5 25.2 5.53 0.13 0.13 37.53 0.13 31.6 11.9 0.13 0.13 43.9

AC Urea Water NH3 CO2 TOTAL

Basis:

1893 TPD of Urea produced Composition of Urea 72%

Q = 177 BTU/ton

Waste Water Treatment Plant PFD

33

31

13

32

Waste Water Treatment Plant Calculations

Calculations:
Stream
Total

13
532,066.00

31
477,245.34

32
50,000.00

33
4,820.66

Assumptions:

Basis of 50,000kg of effluent sewer water 10 NH3 ppm specification from EPA Assumed same PPM for CO2 Inlet Water composition from existing Indian Urea Plant 1% of recycle is vented to air

Mass (kg) Balance Components CO2 38,084.00 37,703.11 0.05 380.84

NH3
Urea Water

45,332.00
4,985.00 443,665.00

44,878.63
4,935.15 389,728.45

0.05
0.00 49,999.90

453.32
49.85 3,936.65

Mole (kmol) Balance Component

CO2
NH3 Urea Water Total

865.55
2,666.59 83.08 24,648.06 28,263.27

865.54
2,666.59 83.08 21,870.28 25,485.50

0.00
0.00 0.00 2,777.77 2,777.78

216.39
666.65 20.77 5,467.57 6,371.37

Properties
Temperature Pressure 25oC 1 bar 25oC 1 bar 25oC 1 bar 25oC 1 bar

Evaporator Unit PFD

23 Condenser 21 Streams 21, 26, 19: To Waste Water Treatment 22 H.P. Steam 24 Evap1 Eductor Evap2 17

25

27 26 Urea Solution (72%) 15 18 20 19

Product Urea (99.8%)

16

Storage Tank

Evaporator Unit Calculations

Assumptions:

Input Urea Input Water wt% Water Evaporated 1 wt% Water Evaporated 2 wt% Water Condenses Input Steam

1572.48 611.52

Tons Tons

95% 85% 65% 3 Tons

Stream #

Calculations:
15 Urea (72%) to Tank Ton Moles Tons 2184.00 16 Urea 72% Solution Ton Moles 60.18 Tons 2184.00 17 Water from Evap 1 Ton Moles 32.27 Tons 580.94 18 Urea from Evap1 Ton Moles 27.91 Tons 1603.06 19 Steam from Evap 2 Ton Moles 32.27 Tons 580.94

Totals

60.18

Compounds Urea Water H.P. Steam 26.21 33.97 1572.48 611.52 26.21 33.97 1572.48 611.52 32.27 580.94 26.21 1.70 1572.48 30.58 32.27 580.94

Properties
Temperature Pressure 80oC 5 Bar 80oC 5 Bar 110oC 0.8 Bar 95oC 0.8 Bar 80oC 1 Bar

Prilling Tower PFD

Cleaned Air 30 Cyclone Prilling Tower Bag House

27

Urea Melt (99.8%) Pump

Melting Furnace

Air from Atm

Dehumidifier Screen

28

29

Prilled Urea (99.8%)

Prilling Tower Calculations

Calculations: Assumptions:

Stream

27
Urea Melt (99.8%) Tons

28
Air From Atm Tons 500

29
Prilled Urea (99.8%) Tons 738.22

30

Mass flow rate of Prilled Urea is 738.22 TPD According to the EPA the allowed urea dust is 3.8 lb/ton of Prilled Urea. For ammonia dust the allowed emission is 0.87 lb/ton of Prilled Urea.

Cleaned Air Tons 501.724

Totals

739.94

Component Urea Melt Ammonia Dust Urea Dust Prilled Urea Air 739.94 ----------------500 ------738.22 ----0.32 1.40 --500

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

Estimated Economics
Materials Cost (Money We Spend) NH3 CO2 $521.00 $15.00 Per Ton Per Ton 891.07 1153 Amount Tons Per Day Tons Per Day Overall Cost $464,247.47 $17,295 Per Day Per Day

Product Price (Money We Get) Urea to UAN Prilled $230.00 $570.50 Per Ton Per Ton 694.48 739.7 Tons Per Day Tons Per Day

Overall Price $159,730.40 $421,998.85 Per Day Per Day

Profit:

$100,186.78

Per Day

Profit:

$36,568,174.70

Per Year

Estimated Total Cost

2009- Qatar 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?