1. Production of Prilled Urea
Sule Alabi
Jonathan Arana
Elizabeth Moscoso
Oleg Yazvin
Mentor: Dan Rusinak – Middough

2. 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

3. Urea Production Plant PFD14 6
water 5 13
Un-reacted Gases 3 11 1 2
DECOMPOSER 10 12 4 8 7 9
Urea (72%)Solution

4. Urea Production Plant Calculations
Input Variables
CO2 input (tons)
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
77.59
140.00
151.47
10.50
234.30
Compounds
CO2
41.59 10
440.00
18.57
817.14
2.06
90.79
NH3
36.00
612.00
100
75.97
8.44
143.50 AC 15
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

5. 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

6. Waste Water Treatment Plant PFD33 31 13 32

7. 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

8. 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

9. Evaporator Unit Calculations
Assumptions:
Input Urea
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
32.27
580.94
27.91
Compounds
Urea
26.21
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

10. 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

11. Prilling Tower Calculations
Assumptions:
Mass flow rate of Prilled Urea is 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
Component
Urea Melt
---
Ammonia Dust
0.32
Urea Dust
1.40
Prilled Urea
Air
Properties
Temperature
185oC
25oC
Pressure
1 bar

12. 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

13. 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

14. Questions?