urea nanufacturing

7/28/2019 Urea Nanufacturing

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Clean Waterfrom CHP Plant

Prilled Urea (99.3%)

Product

BFD of Urea & Prill Plant

"Dirty Water"

Rich in NH3, CO2 & Impurities

Cleaned Air Out

Urea Solution(72%)

Condensate Water

Solid Urea (99.3%)

Output NH3 Purge & Urea Solution

To Amm. Nitrate & UAN Plants

UreaProduction

Plant Waste WaterTreatmentPlant

EvaporatorUnit

Inlet NH3 & CO2

from NH3 PlantCO2 & NH3 Recycled Gas

Air In

PrillingTower


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Urea Production Plant PFD

1

2

3

4

5

6

78 9

10

11

12

13

14

DECOMPOSER

water

Urea (72%)Solution

Un-reacted Gases


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Urea Production Plant Calculations

Assumptions:

Stream 1 2 3 4 5NH3 Feed Gas Exit from Strip. Solution from Scrub Solution from Pool Gas Recy. to Scrub

TonMoles Tons TonMoles Tons TonMoles Tons TonMoles Tons TonMoles TonsTotals 77.31 1314.33 77.59 2441.84 140.00 3565.00 151.47 4430.96 10.50 234.30CompoundsCO2 41.59 1829.84 10 440.00 18.57 817.14 2.06 90.79NH3 77.31 1314.33 36.00 612.00 100 1700.00 75.97 1291.52 8.44 143.50AC 15 1155.00 10.98 845.16Urea 15.48 928.57Water 15 270.00 30.48 548.57

PropertiesTemperature 185oC 185oC 185oC 185oC 60oCPressure 140 Bar 140 Bar 140 Bar 140 Bar 1 Bar

Calculations:

Input VariablesCO2 input (tons) 1153.15NH3 / CO2 Input Mole Ratio 2.95Input CO2 Split into Reactor 0.90ReactorExtent of Reaction 1 Based on CO2 0.60Extent of Reaction 2 Based on CO2 0.50Fraction of CO2 that gets converted 1.00


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Compound Mass Flow

Rate IN(TPD)

Mass Flow

Rate OUT(TPD)

Mole Flow

Rate IN (tonmole/day)

Mole Flow

Rate OUT(tonmole/day)

AC 506.7 12.5 6.5 0.13

Urea 1513.8 1893.5 25.2 31.6Water 99.54 214.2 5.53 11.9

NH3 2.21 2.21 0.13 0.13

CO2 5.72 5.72 0.13 0.13

TOTAL 2128 2128 37.53 43.9

Q = 177 BTU/ton

Material & Energy Balance for Decomposer Unit

Basis:

1893 TPD of Urea produced

Composition of Urea 72%


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Waste Water Treatment Plant PFD

13

31

32

33


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Waste Water Treatment Plant Calculations

Assumptions: Basis of 50,000kg of

effluent sewer water

10 NH3 ppm specificationfrom EPA

Assumed same PPM forCO2

Inlet Water compositionfrom existing Indian UreaPlant

1% of recycle is vented toair

Calculations:

Stream 13 31 32 33Total 532,066.00 477,245.34 50,000.00 4,820.66

Mass (kg) BalanceComponentsCO2 38,084.00 37,703.11 0.05 380.84NH3 45,332.00 44,878.63 0.05 453.32Urea 4,985.00 4,935.15 0.00 49.85Water 443,665.00 389,728.45 49,999.90 3,936.65

Mole (kmol) BalanceComponentCO2 865.55 865.54 0.00 216.39NH3 2,666.59 2,666.59 0.00 666.65Urea 83.08 83.08 0.00 20.77Water 24,648.06 21,870.28 2,777.77 5,467.57Total 28,263.27 25,485.50 2,777.78 6,371.37

PropertiesTemperature

25

o

C

25o

C

25o

C

25o

C

Pressure 1 bar 1 bar 1 bar 1 bar


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Evaporator Unit PFD

15

16

26

25

24 17

2321

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


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Evaporator Unit Calculations

Assumptions:Input Urea 1572.48 TonsInput Water 611.52 Tonswt% Water Evaporated 1 95%wt% Water Evaporated 2 85%wt% Water Condenses 65%Input Steam 3 Tons

Calculations:Stream # 15 16 17 18 19

Urea (72%) to Tank Urea 72% Solution Water from Evap 1 Urea from Evap1 Steam from Evap 2Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons

Totals 60.18 2184.00 60.18 2184.00 32.27 580.94 27.91 1603.06 32.27 580.94

CompoundsUrea 26.21 1572.48 26.21 1572.48 26.21 1572.48Water 33.97 611.52 33.97 611.52 32.27 580.94 1.70 30.58 32.27 580.94H.P. Steam

PropertiesTemperature

80

o

C

80o

C

110o

C

95o

C

80o

C

Pressure 5 Bar 5 Bar 0.8 Bar 0.8 Bar 1 Bar


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Cyclone

Screen

Bag House

Pump

Melting Furnace

Dehumidifier

Prilled Urea (99.8%)

Urea Melt (99.8%)

PrillingTower

27

30

29

Air from Atm

Cleaned Air

28

Prilling Tower PFD


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Prilling Tower Calculations

Assumptions: Mass flow rate of Prilled

Urea is 738.22 TPD

According to the EPA theallowed urea dust is 3.8lb/ton of Prilled Urea. Forammonia dust theallowed emission is 0.87lb/ton of Prilled Urea.

Stream 27 28 29 30Urea Melt(99.8%) Air FromAtm Prilled Urea(99.8%) Cleaned Air

Tons Tons Tons TonsTotals 739.94 500 738.22 501.724

ComponentUrea Melt 739.94 --- --- ---Ammonia Dust --- --- --- 0.32Urea Dust --- --- --- 1.40Prilled Urea

---

---

738.22

---

Air --- 500 --- 500

PropertiesTemperature 185oC 25oC 25oC 25oCPressure 1 bar 1 bar 1 bar 1 bar

Calculations:


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Estimated Economics

Materials Cost (Money We Spend) Amount Overall CostNH3 $521.00 Per Ton 891.07 Tons Per Day $464,247.47 Per DayCO2 $15.00 Per Ton 1153 Tons Per Day $17,295 Per Day

Product Price (Money We Get) Overall PriceUrea to UAN $230.00 Per Ton 694.48 Tons Per Day $159,730.40 Per DayPrilled $570.50 Per Ton 739.7 Tons Per Day $421,998.85 Per Day

Profit: $100,186.78 Per Day

Profit: $36,568,174.70 Per Year


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Estimated Total Cost

2009- Qatar 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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