UREA PLANT

Urea plant has a rated capacity of 1550 Te/day of prilled urea produced in a
single stream plant employing MITSUI TOATSU TOTAL RECYCLE
IMPROVED PROCESS.
Features of the plant as under:
S. No FEATURES MTS-C-IMPROVED
1. Type of process conventional
2. Mol. Ratio
NH3 : CO2 4:1
H2O : CO2 0.544 : 1
3. %Concentration 70%
4. Reactor condition
Pr.kg/cm2 250
Tem.0C 200
5. Reactor Lining Titanium
6. Reactor Features Hollow
7. Excess NH3 Recycle as liq.NH3
8. Decomposition Stages 1st : 17.5 kg/cm2
2nd : 2.5 kg/cm2
(5%CO2 fed to 2nd Decomposer)
3rd : 0.3 kg/cm2
9. Heat recovery in for supplying heat of crystallization
Carbamate Condensor to urea slurry and heating hot water
10. Sp. Cons.
Te NH3/Te urea 0.58
TeCO2/Te urea 0.76
Power/Te urea KWH 86.4
St./Te urea 1.24
11. No. of conc. Stages One
12. Type of prilling tower Induced draft
13. Approx. Prilling Ht.(m) 40
14 Salient Features : a) Power saving as 5%
CO2 is fed to LD
b) P.T. height is less because of
Cooler at bottom.
c) low biuret
d) Because of Ti lining in reactor
corrosion rate is less and thinner
liner.
e) Water recycle is less due to
counter current flow of liq. and
vapour in decomposer.
The plant is divided into four sections:
1. Synthesis section
2. Decomposition section
3. Crystallization and prilling
4. Recovery

The brief description of various sections is given as under:

SYNTHESIS SECTION
In recycled since it is easier to handle but required equipments like
rectification coloumn storage tanks etc. and higher capacity liquid ammonia
pumps.
Recycling of carbamate requires higher capacity carbamate pumps.
CO2 is received form ammonia plant at a pressure of 0.2 kg/cm2 and 200C and
is compressed in a centrifugal booster compressor, UGB-101 to 32 kg/cm2 in a 3
stage unit. The compressor supplied by M/s BHEL has a normal capacity of 25256
NM3/hr and has a 2 barrels 2 M.C.L. 805 and M.C.L. 455. The drive of the
compressor is a extraction and condensing type of steam turbine supplied by M/s
BHEL. The turbine is driven by 40 K super heated steam and has a rated output of
5729KW.

UREA SYNTHESIS
2.NH3 + CO2 = NH2COONH4 H = -37.64 Kcals.........(i)
NH2COONH4 = NH2CONH2 + H2O H = 6.32 Kcals...........(ii)

Where as reaction (i) is exothermic and rapidly goes to completion (ii) is

endothermic and always incomplete. The overall reaction is exothermic. And heat
has to be removed continuously for the equilibrium reaction to proceed. The
conversion of ammonium carbamate to urea depends upon:
i) Reaction temp. and pressure.
ii) Mo ratio of NH3/CO2 H2O/CO2 of the feed reactants.
iii) Residence time.

The conversion increases with the increase of temp. NH3/CO2 ratio and
residence time and decreases with H2O/CO2 ratio since the presence of water tends
to shift reaction (ii) in the backward direction. The pr. employed depends on the
reaction temp. and has to kept higher than the dissociation pressure of ammonium
carbamate at that temp. further since the dehydration of ammonium carbamate to
urea takes place in Liq. Phase only, the Pr. employed must also be higher than the
Vapour Pressure ammonium carbamate which is rather high.
Higher ratio of NH3/CO2 increases conversion and helps to minimize
corrosion. As this increases the load recovery section increases since excess NH 3
over stoichiometric requirement has to be recovered and recycled back to reactor.
This excess ammonia can either be recycle as (a) Liq. Ammonia or (b) carbamate,
in which case it becomes necessary to inject CO2 into carbamate condensers.
The compressed CO2 is washed with a water in a packed bed water called
methanol absorber for removal of entrained methanol in CO2 which is normally
1000 ppm. The washed CO2 is further compressed to a pressure of 260 kg/cm2 in a
two stage compressor, UGB-102 supplied by M/s KOBE STEEL, Japan. This
reciprocating compressor has a normal capacity of 26260 NM3/hr. and is driven by
2.2 Mw synchronized motor. Anti corrosion air at the rate of 65 NM3/hr. is fed to
CO2 at the suction of centrifugal CO2 booster compressor.
Liquid ammonia at 110C and 18 kg/cm2 pressure is receive in the ammonia
receiver, UFA-401 from the Horton sphere. Ammonia booster pump UGA-404 A
& B booster the pressure of the feed pumps UGA-101 A-D. The ammonia feed
pumps are of URACA MAKE driven by 3.3 KV/450 KW and have a capacity of
53.2 M3/hr., 178 RPM and 89% efficiency. The ammonia feed pumps deliver the
liquid ammonia at 260 kg/cm2 to ammonia pre-heater. The pre-heated ammonia at
650C is fed to the urea reactor at bottom.
The recycled carbamate solution of CO2 concentration, 7.5 ltr per 25 ML, at
1050C and 260 kg/cm2 pressure is delivered to the urea reactor at bottom by
recycle carbamate solution pumps UGA-102 A& B. These pumps are centrifugal
type and are driven by back pressure steam turbine, supplied by M/s EBARA of
Japan and have capacity of 81 M3/hr.
The three feeds i.e. CO2 liquid ammonia and recycled pump solution are fed
to a Ti lined multi wall urea reactor. The urea reactor is a multi wall shell having
wall thickness of 37 mm x 4 = 148 mm as thickness. Ti liner thickness is 6 mm
from bottom to 7900 mm, 5mm upto 3950mm, 4mm for next 3950mm and 3mm
for rest height. Top and bottom dish end cladded layer urea reactor. The urea
reactor is a 12 layered C.S vessel with Ti liner thickness of 5mm, 4mm and 3mm
for the 1/6, 1/6 and 2/3rd of total height of the reactor from bottom. The reactor top
temp. is maintained at 2000c maximum. The effuents from urea reactor from top
are let down to 17.5 kg/cm2 pressure through a pressure control valve PCV-101
and fed to the high pressure decompser at 1240C.

DECOMPOSITION SECTION
MITSUI TOATSU TOTAL RECYCLE IMPROVED PROCESS is a conventional
process.
The decomposition reaction, NH4 COONH2 = 2NH3 + CO2 is favoured by
lower pr. of system or by low partial pr. of one of the reaction products i.e. NH3
and CO2 conventional process mean the process where decomposition is effected
by lowering in pressure in successive stages followed by indirect heating whereas
the process where decomposition takes place by lowering the partial pressure of
either NH3 or CO2 followed by indirect heating are called STRIPPING
PROCESSES.
The reactor effluents at 17.5 kg/cm2 and 1240C enters the upper part of high
pressure decomposer UDA-201 having 4 sieve trays at upper and falling film
heater at lower section. The flashed gases go up and liquid flows down through
sieve trays. On the trays the high temp. gas from reboiler, UEA-201 and falling
film heater contacts with the liquid flowing down. The sensible heat of gas and
heat of condensation of water vapours are used evaporate the excess ammonia and
to decompose the carbamate.
This helps in minimizing water evaporation and thus water recycle to reactor.
The reactor further the liquid by 12 kg/cm2 steam to release excess ammonia and
carbamate as gases. The temp at middle is maintained at 1510C by a temp control
valve TCV-201. The temp at bottom is maintained at 1650C through TCV-202.
The falling film heater is used to minimize residence time in order to reduce biuret
formation and hydrolysis of urea.
Anti corrosive air is fed to high pr. decomposer and reboiler through air
compressor UGB-201 @ 2,500 ppm of air. Overhead gases from HD are absorbed
in HAC (high pr. absorber cooler). The bottom liquid flows to L.D. (low pr.
decomposer) at 2.5 K, 1450C upper part, having 4 seive trays. A similar
phenomenon occurs in the low pr. decomposer. The reboiler UEA-202 provides
heat using 7kg/cm2 steam for decomposition and hot steam from H.D. heats up
solution from LD in a exchanger before entering the upper part. The temp. is
maintained at 1300C at the middle by TCV-203. Small amount of CO2 is fed below
packed bed for improved stripping of decomposed gases. The over head gases
from lower pr. decomposer are absorbed in low pr. absorber UEA-402. Bottom
liquid flows to 3rd stage of decomposer called gas separator UDA-203. The upper
part of gas separator operates at 1060C. 0.3 K and lower part with packed bed
operates at 990C and atm. pr. the sensible heat of solution from lower pr.
decomposer is enough for evaporating the over head gases. In the lower part air,
containing trace amount of NH3 and CO2 is blown under the packed bed, by gases
recycle blower UGB-401. The urea solution is concentrated to 70-72% and sent to
crystallization section.

CRYSTALLIZATION AND PRILLING SECTION

The urea solution obtained from the last decomposition stage i.e. gas
separator contains 27% H2O is formed. Urea has to be concentrated to 99.5%
before prilling.
MTC-C IMPROVED PROCESS employees crystallization – remelt prilling
route and uses spray nozzles for prilling. The prilling tower is of induced draft
type.
The solution from gas separator enters lower part of crystallizer, U-FA-201.
The upper part is vacuum concentrator with two stage injectors and barometric
condenser.
In vaccum concentrator, operating at 75mm Hg and 600C, water is evaporated
and supersaturated urea solution comes down through barometric low into the
crystallizer, where urea crystals grow. The heat required for water evaporation
comes from:
i) Sensible heat of feed urea solution.
ii) The heat of urea crystallization.
iii) Heat recovered by urea slurry circulated through high pressure absorber.

The crystallizer is operated at 600C and atmospheric pressure, so that slurry

leaving the bottom contains about 30-35% urea crystal by weight.
Hot water from hot water um is used in jackets of crystallizer and pipe to
avoid crystal build up on vessel walls, which may cause choking otherwise.
The urea slurry is pumped from crystallizer bottom to centrifuges U-CF-201
A-E (1000 rpm, 43 Te/hr of slurry) maintaining minimum recirculation to
crystallizer to prevent choking of lines.
 Biuret remains with mother liquor, whish after separation from the urea
crystals in the centrifuges is recycled back to back to the system. Because of
excess ammonia in reactor biuret, thus recycled is converted back to urea.
NH2 CONHCONH2 + NH3 = 2NH2CONH2
(biuret)
Urea crystals separated from slurry with 2-4% moisture are discharged to
fluidizing dryer UFF-301 at 1100C. The mother liquor flows down to mother liquor
tank, provided with steam coils. Mother liquid is pumped back to crystallizer via
LCV-207. A part of mother liquor going to low pressure absorber has been cut off
and instead dust chamber overflow solution has been lined up.
Air is blown from blower U-GB-301 (82360 NM3/hr) and heated to 1100C in
heater. This hot air dries the crystal to 0.1 to 0.3% moisture content. Dried crystals
are conveyed by a pneumatic duct to cyclones at the prilling tower top. The
collected crystals are melted in melter (1370C) and urea melt is sprayed through 12
Nos. acoustic granulators. Prills are cooled in fluidizing bed called CFD, installed
at the prilling tower bottom. Air/cyclone is scrubbed for urea dust in dust
separators (2 Nos.). air containing urea dust from P.T. Coloumn is scrubbed with
water and passed through 144 sets of olyurethane filters before exhaust to
atmosphere to reduce air pollution.

RECOVERY SECTION
The gases from gas separator are condensed in off gas condenser UEA-406 to
62%C and enter the bottom of off gas absorber DA-402(OGA). Condensed liquid
flows down to 360C, liquid is sent to top portion of OGA as absorbent. OGA
bottom fluid is recycled as absorbent at OGA middle position (2nd bed).
Air from top of OGA is blown to gas separator by GB-401 blower.
The gases from low pr. decomposer are absorbed in low pr. absorber (Ea-
402) bubbling a sparger. Dust chamber overflow solution (10-15% urea) is used as
absorbent. Low pr. absorber temp. is controlled at 450C and CO2 concentration 2.2
Lit/25ml.
 Solution from L. a is pumped by GA-402 A/B to high pr. absorber (DA-401)
middle through mixing cooler where liquid ammonia is mixed and serves as
medium in the absorber.
The gases from HD top are bubbled through a sparger in high pr. absorber
cooler EA-401, where 65% of CO2 is absorbed. Remaining gases from HAC go tot
HA and are cooled down to 800C max. in middle cooler at the bottom of H.A. 35%
CO2 is absorbed in packed bed by a mixture of lean carbamate from low pr.
absorber through FCV-401 and liquid ammonia from GA-404 A/B (temp. 60 0C
max.) through FCV-402. The scrubbed gas then passes through 5Nos. of buubble
cap trays in order to absorb residual CO2 by a mixture of aqueous ammonia (GA-
405 A/B) and liquid ammonia (GA-404 A/B) through FCV-403. Ammoonia gas
from high pr. absorber, temp. 500C is pure and condensed in five Nos. of
condensers (EA-404 A-E) and purge condenser EA-403. Liquid ammonia flows
down to ammonia reservoir FE-401. Non-condensible gases (inserts mostly) flows
to ammonia recovery absorber (EA-405 i to iv). Recovery loop pr. is controlled by
PCV-405 (16.5-17.5K) at top of EA-405 iv. Cold steam condensate is fed (FCV-
408) for absorption. Aqueous ammonia is with drawn from recovery absorber
bottom by GA-405 A/B.

IMPROVEMENTS CARRIED OUT FOR AUGMENTATION OF PLANT

CAPACITY
Urea plant has a rated capacity of 1550 Te/day. With retro fittings and
innovative operational practices, the plant is being run at 105-110% on consistent
basis. The retro fittings carried out are listed as below:
1) CO2 BOOSTER COMPRESSOR
i) The capacity was increased by 3200 NM3/hr. by increasing the suction pr. from
0.08 kg/cm2.
ii) The suction header from ammonia plant has been provided with insulation so as
the deliver the CO2 gas to booster suction at a temp. approx. 60C lower than the
normal value.
2) AMMONIA BOOSTER PUMPS
 Impeller dia. of the booster pump was increased from 284 mm to 310 mm and
the motor rating exchanged from 52 KW to 72.5 KW, the delivery flow of the
booster pumps increased by 10%.
3) AMMONIA RECOVERY SYSTEM
i) The capacity of ammonia pump UGA-405 was increased from 8.0 M3/hr. to
18 M3/hr.
ii) The material of construction of recovery absorbers tubes changed from
carbon steel to stainless steel.
4) PRILLING SECTION
i) The conventional spray nozzles for molten urea changed to acoustic
granulators. This has improved the product quality considerably.
ii) Secondary air flow increased by removing obstruction on air path.
iii) Water spray system provided for cooling ambient air during summer months
at the inlet of CFD blower.

The innovative operational practices introduced is:

Utilization of dust chamber over flow solution
The process route of utilization of dust chamber over flow solution via gas
separator has been changed to via low-pressure absorber. This has contributed in
increase in production of about 9Te/day.
WATER AND AIR POLLUTION
AIR POLLUTION
The sources of air pollution in urea plant is the air from prilling tower which
is the process of cooling of molten urea being sprayed from the top of the tower
gets entertained with urea dust. In order to contain the urea dust emissions in the
exit air, the air is scrubbed with water ab=nd subsequently passes through 144
polyurethane filters before being discharged to atmosphere. The normal emission
level in the exit air is 30-40 mg/NM3 against the prescribed norms of 50mg/NM3.
LIQUID POLLUTANTS
The sources of liquid pollutants in urea plant are:-
i) Dust chamber over-flow solution
 The over-flow dust chamber is being completely utilized after
introduction of innovative operational practice mentioned above.
ii) Dilute urea solution during start-up and shut down of plant
To take care of the dilute urea solution during start-up and shut down of
the plant 3 ss tanks of 100 M3, 100 M3, 200 M3 capacity have been
provided. The three tanks are equipped with steam coils for
concentration of the urea solution. The solution, thus stored, is
reprocessed after the plant conditions are normalized.
iii) C.F.D. Washing
The frequency of CFD washing is 1-1/2 months during summer months
and three months during winter months. The washed water from CFD
containing urea is stored in a pacca solution pit of 250 M3 capacity. This
pit has been provided with a pump and the stored solution is reprocessed
during normal operation of the plant.
iv) Leaks from pumps and effluents generated during flushing of
strainers:
The pollutants generated are delivered to a effluent pet.
The effluent is subsequently sent to the bio Urea hydrolyser in the
effluent treatment plant for hydrolysis of the urea.
HYDROLYSIS OF UREA
In aqueous solution, urea is sufficiently stable upto 800C. Above that
temp it changes into ammonium isocyonate and subsequently into ammonium
carbonate.
CO (NH2)2 = NH4NCO
NH4NCO + 2H2O = (NH4)2CO3
Which changes into ammonium hydra-carbonate and this ultimately
dissociates into ammonia and carbon-dioxide.
(NH4)2CO3 = NH4HCO3 + NH3
NH4HCO3 = CO2+H2O+NH3
The over all hydrolysis reaction is shown by the equation:
(NH4)2CO3 + H2O = (1800C) 2NH3 + CO2
 ACKNOWLEDGEMENT

It gives me immense pleasure to present my Project Report before you. I

thankfully acknowledge the staff of National Fertilizer, Bathinda for giving me so

much co-operation and taught lots of new things to me which I am sure will help

me in my war future.

I specially thanks to Mr. D. K. Bora (H.R.D. Head) for their support

during my industrial training. I pay my sincere regards to him, without their

support i wasn’t able to accomplish my project. I also thanks t all engineers who

helps me.
 COOLING WATER SYSTEMS
The cooling water systems provided at NFL bathinda are closed
recirculating type supplying cooling water to various consumers in the plant. There
are total three systems supplying cooling water to different sections as mentioned
in Table-1

S. No SYSTEM CONSUMER
1. CT-1 Ammonia Plant,
2. CT-2 Urea plant,
Boilers, instrument, service air
compressors, caustic
3. CT-3 Facility & sulphur recovery plant.
Crystallization section of urea plant.
4. Emergency pumps Ammonia storage area.
Instrument Air compressors
emergency diesel set.

Emergency cooling water pump is in continuous service for ammonia

storage area. It takes suction normally from CT-2, however, provision is three so
that it can take suction from CT-1.
DESIGN BASIC

Barometric pr. = 971 milli bars

Dry bulb temp. = 390C
Wet bulb temp. = 280C
Degree of approach = 50C
Relative humidity = 81.1% at 31.40C
 Various other condition for all the three cooling water systems are given in
Table-2
COOLING WATER TREATMENT
Cooling water treatment is to avoid following problems;
1. Corrosion 2. Scaling 3. Fouling 4. Microbiological growth

1. CORROSION
Corrosion in basically an electrochemical reaction by which metal tend to
return to its more stable natural state of oxide. The main factors responsible for
this in cooling water systems are low ph, dissolved gasses, conductivity of water,
presence of certain corrosive ions such as chlorides and sulphates.
2. SCALING
Scaling is the deposition of sparingly soluble salts. The most common
scalants in systems are carbonates and sulphates of calcium and magnesium and
phosphates of calcium, magnesium, zinc and iron. The carbonates and sulphates of
calcium has inverse solubility with resect to temp. and PH when the solubility of
these salts exceed, they tend to precipitate out of solution and deposit on metal
surface.
Scale inhibitors are used which keep the scaling salts in dispersed state and
do not allow them to deposit.
3. FOULING
Fouling is the deposition of suspended matter. The most common foulants in
cooling water systems are dust, silt, clay organics like oil and hydrocarbons and
the micro logical slime. These foulants are air borne and water borne. Fouling does
not merely results in drop in heat transfer efficiency but also give rise to under
deposit corrosive leading severe pitting. Fouling is normally enhanced due to
lower water velocity. Lower molecular weight polyanoinie compounds are used as
anti-foulants. These components get absorbed on the surface of the foulest articles
and increase the negative charge. Thus when all particles are sufficiently
negatively charged they repel each other and thus dispersion is achieved.
4. MICROBIOLOGICAL GROWTH
 Following three types of micro organisms are responsible for this type of
problem:
A) ALGAE: It is normally observed on the area of cooling tower as it
requires sunlight for growth.
B) FUNGUS : fungus is found on the wooden surface as itrequires surface
and carbon source.
C) BACRERIA : Three important type of bacteria are;
i) NITRIFYING BACTEIA : These bacteria oxidize ammonia to nitrates
and nitrites which when dissolved in water reduce the PH of circulating
water and cause general corrosion. It is most severe problem at NFL
bathinda.
ii) SULHASE REDUCING BACTEIA : These anaerobic bacteria , s reduce
sulphate ions to H2S.
This cause local PH drop . The hydrogen sulphide thus formed reacts
with metal sulphide . These deposits are very hard to remove and lead to serve
pitting .
iii) IRON BACTRIA :iron bacteria directly oxidize the metal causing server
pitting .in the general most of the species of bacteria present in cooling
water secrete slime. This slime acts as a binding medium for the susended
matter and leads to fouling. The fouling deposits in give turn shelter to an
aerobic bacteria which causes direct corrosion.
In addition to chlorine and bromine use of non oxidizing type of
biocides is most various types of non oxidizing types of biocides are
methylene bis thiocyanate quaternary ammonium compounds, isothiazoline,
dichlorophenes etc. These biocides are normally blended with effective
surface active and penetrating agents. Thereby they can penetrate into the
deposit layers and can kill anaerobic bacteria.
TREATMENT PROGRAMS AT NFL BATHINDA
In the early stages of operation at NFL, a lot of problems were
experienced due to poor quality of cooling water. This led to leakages In heat
exchangers and untimely production interruptions. Over the years cooling water
treatment has been improved upon a lot. Presently treatment programmes supplied
by M/s aquapharm chemicals Co. Ltd, Pune are used CT-1 and CT-2. Sailent
features of these programmes have been highlighted in Table-3.
iv)
5.