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 Urea Production Plant CO2 & NH3 Recycled Gas Inlet NH3 & CO2 from NH3 Plant Waste Water Treatment Plant "Dirty Water" Rich in NH3, CO2 & Impurities Clean Water from CHP Plant Urea Solution (72%) Cleaned Air Out Condensate Water Prilling Tower Evaporator Unit Prilled Urea (99.3%) Product Solid Urea (99.3%) Air In

Urea Production Plant PFD 14 6 water 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 CO2 input (tons) 1153.15 NH3 / CO2 Input Mole Ratio 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 Some Assumptions: 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 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 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 270.00 30.48 548.57 Properties Temperature 185oC 60oC Pressure 140 Bar 1 Bar

Material & Energy Balance for Decomposer Unit Compound Mass Flow Rate IN (TPD) Mass Flow Rate OUT (TPD) Mole Flow Rate IN (ton mole/day) Mole Flow Rate OUT (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 CO2 5.72 TOTAL 2128 37.53 43.9 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 Stream 13 31 32 33 Total 532,066.00 477,245.34 50,000.00 4,820.66 Mass (kg) Balance Components CO2 38,084.00 37,703.11 0.05 380.84 NH3 45,332.00 44,878.63 453.32 Urea 4,985.00 4,935.15 0.00 49.85 Water 443,665.00 389,728.45 49,999.90 3,936.65 Mole (kmol) Balance Component 865.55 865.54 216.39 2,666.59 666.65 83.08 20.77 24,648.06 21,870.28 2,777.77 5,467.57 28,263.27 25,485.50 2,777.78 6,371.37 Properties Temperature 25oC Pressure 1 bar 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

Evaporator Unit PFD 15 16 26 25 24 17 23 21 22 18 19 20 27 Condenser Eductor Evap1 Evap2 Storage Tank Product Urea (99.8%) H.P. Steam Urea Solution (72%) Streams 21, 26, 19: To Waste Water Treatment

Evaporator Unit Calculations Assumptions: Input Urea 1572.48 Tons Input Water 611.52 wt% Water Evaporated 1 95% wt% Water Evaporated 2 85% wt% Water Condenses 65% Input Steam 3 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 Totals 60.18 2184.00 32.27 580.94 27.91 1603.06 Compounds Urea 26.21 1572.48 Water 33.97 611.52 1.70 30.58 H.P. Steam Properties Temperature 80oC 110oC 95oC Pressure 5 Bar 0.8 Bar 1 Bar

Prilling Tower PFD Cyclone Screen Bag House Pump Melting Furnace Dehumidifier Prilled Urea (99.8%) Urea Melt (99.8%) Prilling Tower 27 30 29 Air from Atm Cleaned Air 28

Prilling Tower Calculations Assumptions: 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. Stream 27 28 29 30 Urea Melt (99.8%) Air From Atm Prilled Urea (99.8%) Cleaned Air   Tons Totals 739.94 500 738.22 501.724 Component Urea Melt --- Ammonia Dust 0.32 Urea Dust 1.40 Prilled Urea Air Properties Temperature 185oC 25oC Pressure 1 bar

Estimated Economics Materials Cost (Money We Spend) Amount   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 1153 $17,295 Product Price (Money We Get) Overall Price Urea to UAN $230.00 694.48 $159,730.40 Prilled $570.50 739.7 $421,998.85 Profit: $100,186.78 $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

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