INTRODUCTION Overview of plant Properties of UREA Uses of UREA
UREA MANUFACTURING PLANT
2.1 Description of UREA production process 2.2 Flow sheet of UREA plant 2.3 SYNTHESIS SECTION 2.4 DECOMPOSITION SECTION 2.5 RECOVERY SECTION 2.6 FINISHING SECTION INTRODUCTION OVERVIEW OF PLANT KANPUR FERTILIZERS & CEMENT LTD. a unit of JAYPEE GROUP known as DUNCANS INDUSTRIAL LTD. JAYPEE GROUP is an infrastructure industrial conglamorates of Rs. 18000 crore turnover. KFCL is subsidizing of JAYPEE GROUP. The fertilizer plant of KFCL is based on TOYO TECHNOLOGY OF JAPAN & three units of each plant & capacity of 730 ton per day. The three ammonia production plants are natural gas plant based on ICI TECHNOLOGY, each plant capacity of 415 ton per day. KFCL sell the product by brand name “CHAND CHHAP” UREA. This well known brand still in the memories of satisfied farmers of Northern, Central & Eastern India. UREA produced by “TOTAL RECYCLE CIRCULATION PROCESS”.
The learning opportunities and industrial exposure at
the KFCL made not just possible to relate the book knowledge to field application but also in developing a through understanding of industrial practice and operating concepts. KFCL is a leading manufacturer & supplier of fertilizer from KANPUR, UTTAR PRADESH. From safety point of view, the industry is listed under “MAJOR ACCIDENTAL HAZARD INDUSTRY”. THERE ARE FOUR SECTION IN PLANT OFF SITES (Water treatment, air station, cooling tower, inert gas plant, ammonia storage) AMMONIA PLANT UREA PLANT CPP ( Captive power plant) PROPERTIES OF UREA PHYSICAL PROPERTIES White in color Odorless Non corrosive Crystalline Substance CHEMICAL PROPERTIES Chemical Formula = NH2CONH2 IUPAC Name = UREA Molecular Weight = 60.05 Maximum Nitrogen Content = 46.6% Specific Gravity = 1.335 Solubility in Water = 1080 g/L (20 0C ) Melting Point = 132 0C USES OF UREA UREA is major used as a solid fertilizer. UREA is used to manufacture synthetic RESINS . UREA is used in the production of PHARMACEUTICAL products. RAW MATERIALS BASIS; 1 Ton of urea LIQUID AMMONIA(0.59 ton) Supplied Conditions; Pressure = 18 kg/cm2 Temperature = 15 to 40 0C Composition(mole%) = 99.7% Oil = 50 ppm CARBON DIOXIDE(0.786 ton) Pressure = 0.45 kg/cm2 Temperature = 40 0C Composition(volume%) = 93.37% UTILITIES STEAM(1.53 ton) Pressure = 13kg/cm2 Temperature = Saturated temperature PROCESS DESCRIPTION UREA is synthesised from CO2 gas , liquid ammonia and recycle carbamate solution under high pressure 210 kg/cm2 and temperature 195 degree centigrade. The reaction takes place in two stages, the first stage where CO2 and NH3 to form AMMONIUM CARBAMATE is fast and highly exothermic. Then in second stage AMMONIUM CARBAMATE decomposes into UREA & WATER at slowly and reaction is endothermic but OVERALL REACTION IS EXOTHERMIC. 2 NH3 + CO2 = NH4COONH2 + 117 KJ NH4COONH2 = NH2CONH2 + H2O - 15.5 KJ The plant is designed to produce 730 ton of PRILLED UREA per stream day single unit , using MITSUI TOTAL RECYCLE “C” PROCESS. SYNTHESIS SECTION Equipment in this section are given below- CO2 COMPRESSOR(GB-101) NH3 INJECTOR(GA-101) RECYCLE FEED PUMP OR EBARA(GA-102) NH3 PRE- HEATER(EA-101) REACTOR(DC-101) CO2 gas , liquid NH3 and recycle solutions are compressed and fed separately to the base of the REACTOR which is operates at about at 195 degree centigrade temperature and 210 kg/cm2 pressure. Ammonium carbamate is formed first and then breaks down to give urea and water. The reaction products are UREA , WATER, NH3 and CO2, whether free or combined as carbamate are expanded through a let down valve into HIGH PRESSURE DECOMPOSER(DA-201) in the decomposition section. CO2 COMPRESSOR The compressor is a six crank, five stage enclosed forced lubricated machine. The FIRST, SECOND and THIRD stages are double acting, FOURTH & FIFTH stages are single acting. The compressor is capable of delivering 12,530 M3/Hr of CO2 gas measured dry at 760 mmHg and 0 degree centigrade. The suction condition of the CO2 gas is 0.45 kg/cm2 and 40 degree centigrade. The delivery condition of the CO2 gas is 230 kg/cm2 measured at the outlet from the FIFTH stage delivery damper. The compressor is driven by 11 KV (4090 HP), 300 RPM brushless SYNCHRONOUS ELECTRIC MOTOR. LIQUID AMMONIA FEED PUMP These pumps are vertical machines having FIVE SINGLE ACTING RAMS running at a fixed speed of 220 RPM and delivering 34.6 m3/Hr of LIQUID NH3. There are two pumps per stream together with a common spare. Each pump is driven by 3.3 KV (350KW), 50 Hz, 750 RPM electric motor with a gear box to achieve the necessary speed reduction between motor and pump. The suction pressure of pump is at 21 kg/cm2 by ammonia booster pump and delivery pressure is 230 kg/cm2. RECYCLE FEED PUMP OR EBARA This is high speed centrifugal pump and running with 7451 RPM. EBARA PUMP has 8 stages. The suction pressure of EBARA PUMP is 24 kg/cm2 and delivery pressure is 230 kg/cm2. Ebara handles recycle carbamate solution to the reactor. REACTOR In this plant PLUG FLOW TYPE REACTOR are used for reaction. Compressed CO2 gas, Compressed liquid NH3 and compressed recycle solution are fed separately to the base of the REACTOR, Ammonium carbamate is formed first & this then break down to give UREA & water. The operating pressure of reactor is 210 kg/cm2 and temperature is 195 0C The RESIDENCE TIME is 21 minutes and Height of REACTOR is 27 meter. The reaction to form urea takes place in two stages. NH3 & CO2 first react to form ammonium carbamate & reaction is fast , highly exothermic. After that ammonium carbamate undergoes a slower endothermic breakdown to form urea and water.
2NH3 + CO2 ---- NH4COONH2 ----- NH2CONH2 + H2O
DECOMPOSITION SECTION Equipment in this section are given below- HIGH PRESSURE DECOMPOSER with REBOILER LOW PRESSURE DECOMPOSER with REBOILER GAS SEPARATOR & OXIDIZER(upper & bottom)
In this section, the product mixture from the reactor is
processed to remove NH3 and CO2 and leave an aqueous UREA solution. This is achieved by application of heat and stepwise reduction in pressure as solution passes through HPD , LPD ,GAS SEPARATOR & OXIDIZER. RECOVERY SECTION Equipment in this section are given below- High Pressure Absorber Cooler (HPAC) Low Pressure Absorber (LPA) Gas Condenser (GC) Off Gas Condenser (OGC) Off Gas Absorber (OGA) Off Gas Absorber Cooler High Pressure Absorber (HPA) Mist Separator NH3 Reservoir FINISHING SECTION Equipment in this section are given below- FILTER VACUUM EVAPORATER CRYSTALLIZER DRYER (Pneumatic type) CYCLONE MELTER GRANULATORS/DISTRIBUTORS FLUIDISING COOLER TROMMEL & BELT CONVEYER
Urea solution from oxidizer passes through filter into vacuum
evaporator, where water flashes off. The solution than flows down into crystallizer, part of the heat required to evaporator water is obtained from HPAC by means of a slurry circulation from crystallizer through HPAC to vacuum evaporator. Urea crystal are separated from mother liquor by means of centrifuge than dried & moisture content of crystals is reduced up to 0.5%. & conveyed to the top of Prilling tower to a hot air stream. Most of mother liquor returned to crystallizer, a small part is sent to LPA, as a purge to reduce BI-URET content of product. The BI-URET reaction is represented as-
2 NH2CONH2 ---------------- NH2CONHCONH2 + NH3
The biuret in the final product is around 0.5%. At the top of
prilling tower, urea crystals are separated from air stream in cyclones & then melted at 140 0C. Molten urea flows to the prills head/ distributor, from which it forms into spherical drops which solidify and cool as they fall down the tower further cooling is done in a fluidizing cooler sited in the tower base & prills then overflow into a trammel where the oversize material after dissolving is sent back to the process, while the product goes forward to packing plant.