Indian Farmers Fertiliser Cooperative Limited

Kalol - unit

Presented by –
NAVEEN KUMAWAT
(13112056)
Urea plant
 The plant was commissioned in Jan,1975. It was first biggest urea
manufacturing unit in India.
 Name of Process : Stami-Carbon Co2 stripping process
 Designed by : DSM, Netherland
 Capacity : 1650 MT/day
 Feed Sock : Ammonia and Carbon Dioxide
 Chemical Formula : NH₂-CO-NH₂
The two main reactions involved are:

CO2 + 2NH3 NH2COONH4 H= -38.086 Kcal/g mol

NH2COONH4 NH2CONH2 + H2O H= +10.33 Kcal/g mol

The process consists following steps:

 CO2 supply and compression
 NH3 supply and pumping
 Reaction/High pressure synthesis
 Low pressure system
 Evaporation and Prilling system
 Prills cooling system
CO2 supply and compression
 CO₂ from NH₃ plant at normal pressure of 0.1 to 0.2 kg/cm2g and temperature of 50-
60°C is supplied to CO₂ spray cooler of urea plant.
 CO₂ is cooled to 40°C and mixed with small quantity of passivation air from anti
corrosion air blower.
 The CO₂ with air is compressed to 157 kg/cm2g by Hitachi CO₂ centrifugal compressor
and supplied to HP synthesis section.

NH3 supply and pumping

 Liquid ammonia is supplied at a pressure of 20 kg/cm2g and temperature of 40°C
from ammonia plant to urea plant.
 Liquid ammonia at -33°C from storage tank is pumped to the LP ammonia preheater,
where it is heated up to 40°C and then pumped to HP system.
 Out of total ammonia discharged by pumps, 90-95% ammonia goes to HP
Carbamate condenser and 5-10% goes to autoclave.
Reaction/High pressure synthesis

 HP stripper
 HP carbamate condenser
 Autoclave (reactor)
 HP scrubber

The complete HP system

consisting of autoclave, HP
carbamate condenser, HP
stripper and HP scrubber
operates at the same pressure
of 150 kg/cm2a, which
facilitates gravity flow
Low pressure system

 Urea solution from HP stripper is let down to about 2.5kg/cm2a and

feed to the rectifying column, where the temperature of solution
drops 120°C.
 Urea solution(62%) from the bottom of the rectifying column through a
control valve where the pressure is let down to 1.15kg/cm2a and then
passes into the flash tank separator.
 Here part of the water of solution is flashed off and the temperature
drops to 104.9°C. The remaining urea solution(70%) flows under
pressure difference to pre evaporator.
Evaporation and Prilling system
 A 2nd flashing of the urea solution takes place at vacuums of about
450 mm hg in the pre evaporator. The urea solution from the pre
evaporator at a concentration of 80 % by weight is collected in the
urea solution tank.
 Urea melt (98.5%) enters in prill bucket at 138.5°C. The bucket
rotating at 240 rpm distributes urea in fine droplets. Air is drawn
from the bottom of prilling tower, via fixed openings by prill tower
induced fans situated at the prilling tower top & flows counter
current to the flow of urea prills.
 The droplets of urea first solidify then cooled to a temp 90 to 100°C.
The hot urea prills fall on the scraper at bottom & there fed to prill
tower conveyer.
Prills cooling system
 Urea prills after discharging from product conveyer flows into the
fluidized bed cooler through inlet nozzle. Atm air is supplied by inlet air
fan for cooling.
 For production of neem coated urea, about 1.1tpd neem oil is
pumped and sprayed through spray nozzles over the urea prills on
product conveyor.
 After neem oil coating, neem coated urea is transferred to silos
bagging plant via plant transferred conveyor.