1. Urea- A Cost Effective Way to Feed the World
Elizabeth Moscoso
Oleg Yazvin
Sule Alabi
Jonathan Arana
Mentor: Daniel Rusinak - Middough

2. Table of Contents Williston Basin Fertilizer Plant Design Basis
Block Flow Diagram
Process Flow Diagram
Plant Layout
Environmental Concerns
Economics
Summary
Stage Gate 2 Considerations
Questions

3. Williston Basin Fertilizer Plant
Purpose:
Convert shale gas into a nitrogen-based fertilizer
Plant Location:
Williston Basin
Reason for Location:
Bakken Shale Gas Formation
Agricultural Activities

4. Design Basis Producing: Require: 2,180 TPD of 72% Urea Solution
1155 TPD to the UAN plant
1025 TPD to Prill Block
740 TPD of 99.8wt% Urea Prill
89 TPD water to the CHP plant
Require:
892 TPD NH3 from Back-End Ammonia Plant
1,153 TPD CO2 from Front-End Ammonia Plant

5. Reaction
ΔH = -159 kJ/mole
ΔH = kJ/mole

6. Block Flow Diagram Cleaned Water Water from CHP Plant Condensate Water
Urea Solution (72wt%)
to UAN Plant
Air Out
Inlet
CO2 & NH3
from NH3 Plant
Urea Solution
(72wt%)
Prilled Urea
(99.8wt%) Product
Reactor Block
Evaporator Block
Prilling Block
Urea Melt
(99.8wt%)
Water from CHP Plant
Recycled Gas
Condensate Water
Air In
Wastewater
Treatment Block
Cleaned Water
to CHP Plant
Reactor Block
Cleaned Water
to CHP Plant
Water from CHP Plant
Condensate Water
Recycled Gas
Prilled Urea
(99.8wt%) Product
Air Out
Urea Solution (72wt%)
Urea Melt (99.8wt%)
Waste Water
Treatment Block
Evaporator Block
Prilling Block
Air In
to UAN Plant
Inlet
CO2 & NH3
from NH3 Plant

7. Process Flow Diagram This is a snapshot of our entire plant.
P Steam
Manual
Valve
LIC
FIC FY
AIC T V PT
PIC FO
High Pressure Steam P -
305 F
330
SIC M E 19 C
Controller
TIC
Master Controller
HIC DT AE TT CO 2 in NH 3
O in
To CHP
Legend
Solid Connector –
Pipeline
Dashed Connector
Signal 4 8 9 11
Urea Prill
Product To
UAN L
Steam
PRILLING BLOCK
REACTOR BLOCK
EVAPORATOR BLOCK
This is a snapshot of our entire plant.
We have fully automated the process to account for any fluctuations in production.
There are various points of energy efficiency and optimization. AE
AIC
TIC
LIC
PIC AY
FTC
FIC
LP Steam
To CHP HP
Steam
Vapor To Urea Plant
Wild
Screening
WASTEWATER TREATMENT BLOCK

8. Reactor Block Cleaned Water Water from CHP Plant Condensate Water
Urea Solution (72wt%)
to UAN Plant
Air Out
Inlet
CO2 & NH3
from NH3 Plant
Urea Solution
(72wt%)
Prilled Urea
(99.8wt%) Product
Reactor Block
Evaporator Block
Prilling Block
Urea Melt
(99.8wt%)
Water from CHP Plant
Recycled Gas
Condensate Water
Air In
Wastewater
Treatment Block
Cleaned Water
to CHP Plant 8
Reactor Block
Cleaned Water
to CHP Plant
Water from CHP Plant
Condensate Water
Recycled Gas
Prilled Urea
(99.8wt%) Product
Air Out
Urea Solution (72wt%)
Urea Melt (99.8wt%)
Waste Water
Treatment Block
Evaporator Block
Prilling Block
Air In
to UAN Plant
Inlet
CO2 & NH3
from NH3 Plant

9. Reactor Block

10. Evaporator Block Cleaned Water Water from CHP Plant Condensate Water
Urea Solution (72wt%)
to UAN Plant
Air Out
Inlet
CO2 & NH3
from NH3 Plant
Urea Solution
(72wt%)
Prilled Urea
(99.8wt%) Product
Reactor Block
Evaporator Block
Prilling Block
Urea Melt
(99.8wt%)
Water from CHP Plant
Recycled Gas
Condensate Water
Air In
Wastewater
Treatment Block
Cleaned Water
to CHP Plant 10
Reactor Block
Cleaned Water
to CHP Plant
Water from CHP Plant
Condensate Water
Recycled Gas
Prilled Urea
(99.8wt%) Product
Air Out
Urea Solution (72wt%)
Urea Melt (99.8wt%)
Waste Water
Treatment Block
Evaporator Block
Prilling Block
Air In
to UAN Plant
Inlet
CO2 & NH3
from NH3 Plant

11. Evaporator Block

12. Prilling Block Cleaned Water Water from CHP Plant Condensate Water
Urea Solution (72wt%)
to UAN Plant
Air Out
Inlet
CO2 & NH3
from NH3 Plant
Urea Solution
(72wt%)
Prilled Urea
(99.8wt%) Product
Reactor Block
Evaporator Block
Prilling Block
Urea Melt
(99.8wt%)
Water from CHP Plant
Recycled Gas
Condensate Water
Air In
Wastewater
Treatment Block
Cleaned Water
to CHP Plant 12
Reactor Block
Cleaned Water
to CHP Plant
Water from CHP Plant
Condensate Water
Recycled Gas
Prilled Urea
(99.8wt%) Product
Air Out
Urea Solution (72wt%)
Urea Melt (99.8wt%)
Waste Water
Treatment Block
Evaporator Block
Prilling Block
Air In
to UAN Plant
Inlet
CO2 & NH3
from NH3 Plant

13. Prilling Block

14. Wastewater Treatment Plant
Urea Solution (72wt%)
to UAN Plant
Air Out
Inlet
CO2 & NH3
from NH3 Plant
Urea Solution
(72wt%)
Prilled Urea
(99.8wt%) Product
Reactor Block
Evaporator Block
Prilling Block
Urea Melt
(99.8wt%)
Water from CHP Plant
Recycled Gas
Condensate Water
Air In
Wastewater
Treatment Block
Cleaned Water
to CHP Plant 14
Reactor Block
Cleaned Water
to CHP Plant
Water from CHP Plant
Condensate Water
Recycled Gas
Prilled Urea
(99.8wt%) Product
Air Out
Urea Solution (72wt%)
Urea Melt (99.8wt%)
Waste Water
Treatment Block
Evaporator Block
Prilling Block
Air In
to UAN Plant
Inlet
CO2 & NH3
from NH3 Plant

15. Wastewater Treatment Block

16. Plant Layout

17. Environmental Concerns & Mitigation
Total Recycle – 99.8% Conversion
For every ton of Urea produced 0.3 tons of wastewater formed
Simple discharge is harmful
EPA Standards:
WWTP < 1 ppm Ammonia
Prill Tower < 1.8 ppt of Urea Dust
No Solid Waste
Prill Dust recycled
Use of Scrubbers before venting

18. Raw Material Analysis $175 Million Annually in NH3 & CO2
$250 Million Annually in Prilled Product and solution sold to UAN
$75 Million Annually in revenue

19. Material & Energy Balance
Total Capital Cost
Competing Processes
Process Chosen
Material & Energy Balance
Simulations/Excel
Equipment Sizing
Equipment Cost
Total Capital Cost
$400 Million Installed Cost

20. Bottom Line $31 MM Annually Simple Payback 12.9 Years
[economic potential] = [gross profit]-[raw material per yr] – [utility per yr] –[total capital cost per yr] = $250 MM – $175 MM - $15MM -$29MM
$31 MM Annually
Simple Payback 12.9 Years

21. Summary Energy Efficient Total Recycle – Conversion 99.8%
No Solid Waste
Well below limits required by EPA
Profitable
Projected increase in demand (2030)

22. Considerations for Stage Gate 2
Ammonium Carbamate & Urea Solution
Prill with Formaldehyde
Prill Tower redesign
Rigorous Safety Analysis

23. Questions