ACKNOWTEDGMENT This study was -not my own effort, many hands were contribute for presenting it in this way.

First, I am greatly indebted to my supervisor prof. Hamid Mohammed Mustafa, so my gratitudes and thanks go to him for hi kind help, splendid guidance and close supervision during the course of this study; his help left appreciable remarks through this study, My thanks should be extended to the working group (administration, supervision, engineering,.. .etc.) in the experimental urea plant in southern Khartoum for their concern and help in data collecting. The design group Eltigani. and Ahmed were a tremendous help presenting the first four chapters. My thanks should be extentend to them or their participation. Last, my thanks to all who helped me in anyway. Najm Eldin
I ___________________________

CONTENTS

CHAPTER ONE
LITERATURE SURVEY ON UREA PRODUCTION

11 Introduction . 12 Properties of urea .. 13 Reaction kinetics l4 Raw materials for urea production 15 Uses of urea .
CHAPTER TWO MANUFACTURING PROCESS AND PROCESS DESCRIPTION

21 introduction 22 Solution recycle process 23 Once. through process 24 Total recycle process .. 25 Process description ..
CHAPTER THREE THE MATERIAL BALANCE
2

CHAPTER FOUR THE ENERGY BALANCE

CHAPTER FIVE

1-2DESIGN OF THE REACTOR 51 Introduction . 52 Chemical kinetics & rate equation ... 53 Design equation . 54 Calculations of the reactor size 55 Mechanical design of the reactor

CHAPTER SIX SPECIAL TASK PROCESS CONTROL

61 Introduction 62 Control objectives 63 Typical control systems 64 Reactor control ..

I1FFERENCES

CHAPTER ONE:-

I TERATURF SURVEY ON UREA PRODUCT IOI : 11 Introduction:_

Urea is a crystalline material, soluble in water and in alcohol. it contains 46% nitrogen. The common method of manufacture of urea is to combine ammonia and carbon dioxide under pressure to form ammonium carbamate which is then decomposed into urea and water, the un reacted ammonia are recovered and recycled to the synthesis operation, The reaction is: 2NH3 +C02 z NH4C02 NH 2 NH2C0NH2 + H20 There are other methods for the production of urea such as the ones through operation and partial recycle operation. Capacity of the plant, production facilities and economic considerations must be taken into account. 12 Properties of urea: 12-1 General Properties: Ammonium carbamate is obtained by direct reaction of ammonia (NH3 ) arid carbon dioxide
4

(Co2). The two reactions are carried out simultaneously in high pressure reactor. Recently urea has been used commercially as cattle feed supp1yjnen and other appijcj113 for urea: the manufacture of resins, solvents and some medicines. 1-22 Chemical properties:-. Urea has the formula
NH NHC

NH
O OH

NHC

Urea is a weak base; at atmospheric pressure and at its melting point urea-decomposes to ammonia, biuret cyanuricacid C3 N3 (oH3,ammelide NH2 C(OH)2 and triuret NH2 (CONH)2 COHN2 Biuret is the main and the least desirable by-product in the commercial Synthesized urea.

Urea acts as monobasic substance and forms salts with acids, with nitric acid it forms urea nitrate CO(NH2)11N03. Solid urea is rather stable at room temperature. and atmospheric pressure, heating under vacuum
5

at its melting point urea sublimes. At1801909C urea will sublime under vacuum and be converted to ammonium cyanate NH4OCN, at pressure of 100200 atm. biuret will, revert to urea when heated in pressure of ammonia. Urea reacts with formaldehyde and forms compounds such as monomethylol urea NH2 CONHCH3OH diaethyloL , urea and others depending on mole ratio and PH of the solution. Urea reacts with hydrogen peroxide to give urea peroxide CO(N112 )211202 while crystalline powder, which is known under the trade name of hyperol , and is used as an oxidizing agent.

Urea derivatives are used as medicines, sedatives and hypnotics, the main derivative is barbituric acid obtained from urea and malonic acid (from its ester).

123 Physical properties:

The following tables show the physical. properties of urea. table 131 shows the properties of saturated aqueous solution of urea: Temperature C Solubility in
water gm urea/100 gm solution

Density Viscocity H2O g/cm cp vapour pressure mm Hg 1,120 1.147 1.167

7

0 20 . 40.

41.0 51.6 62.2

2.63 1.96 1.77

4 13 40

60 80 100 120 130

72.2 80.6 88.3 95.5 99.2

1.184 1,198 1.210 1.221 1.226 Table 1-2-i

1.72 1.93 2.35 2.93 3.25

90 160 220 135 7

The following table (122) shows the general properties of urea

Property Melting point

Assigned value 132. 7C

index of refraction nD20 1.484, 1.602

- specific gravity nD20 - crystalline formed and hapit

1,335 Tetrazonal. needle or prisms

 free energy of formation at 25C heat of fusion heat of solution in water - heat of crystallization 70% aguous ureasolution - bulk density

47.12 cal/gmole

60 cal/g,endothermic 58 cal/g

110 cal/g, exothermic

0.74 gm/cm

Table 12-2

Table 123 shows specific heat of ammonium carbonate.

Temperature co 20 60

Specific heat [cal/gc] 0.4 0.46

100 140 180

0.52 0.58 0.62

10

Table 12-4 shows specific heat of urea at different temperatures. Temperature [0C] 0 50 100 150 Specific heat [cal/g0 c] 0. 344 0.397 0.451 0. 504

Table 1-2-4 Table 125 shows the properties of saturated solution of urea in ammonia. Temperature Urea in solution wt% [0C] Vapour pressure of solution [ mmHg] 0 36 4

11

20 49 40 60 80 100 120 68 79 81 90 96

9.4 10.8 13.3 12.5 5

Table 1-2-5 Ammonium carbamate is of a inciting point of about 150C and heat of fusion in the range of 4000 cal/gmol. and it is soluble in water. 1-3 Reaction Kinetics: Ammonia reacts with carbon dioxide to form Ammonium carbamate by the reaction: 2NH3 + CO2 NH2C02NH4 (1)

This 2 is a third order reaction of equilibrium constant Kp = At high temperature and pressure

the reaction is instantaneous. Ammonium carbamate is dehydrated to urea as follows: NH2 CO2 NH4 NH2 CONII2 + H 20 (2) (1 x)(a carbamate urea 2x)
12

Frejacques made investigations of the equilibrium conversion of Ammonium carbamate to urea with excess ammonia and with excess water, in the temperature range from 130 to 210c. He derived the following formula for the equilibrium constant k = x(b + x)(1 +a + b x)

where K = equilibrium constant X= mole fraction of total initial CO2 converted to urea a = mole ratio of NH3 to CO2 in total mixture
13

b mole ratio of H2O to CO2 in the total initial mixture before the urea reaction takes place The overall given below will clarify the terms in the above derivation aNH3 + NH2O + CO2 xNH2CONH2 + (1

x)NH4CONH2 +

(a 2)NH3 3 + (b + x)H2O The equilibrium conversion K can be increased either by increasing the reactor temperature or by dehydrating ammonium carbamate in the presence of excess ammonia. 2NH3 + CO2 NH2CONH2 + H2O

Excess ammonia shifts the reaction to the right side of the overall equation and in the presence of excess water the reaction is shifted to the left. Mavrovic published a monographic presentation of the reaction equilibrium constant (k). He found the actual equilibrium constant at various temperatures given in the table 141.

Temperature [oC] 140 150 160 170 180

Reaction equilibrium constant 0.695 0.850 0.075 1.375 1.8

14

190 200

2.38 3.18

Table 131

1-4 Raw Materials For Urea Production :T he raw materials for the production of urea are ammonia and carbon dioxide. Natural gas is the main source of producing these raw materials. The carbon dioxide is often passed over a catalyst to remove any remaining traces of free oxygen, the main source of corrosion in the urea reaction. Ammonia synthesis gas is prepared by high-pressure catalytic reforming of hydrocarbon feed gas, in the primary reformer with superhealed stream and in the secondary reformer with air to furnish nitrogen. The amount of air is adjusted eventually to supply a H2/N2 molar ratio of 3:1. In the experimental plant in the southern part of Khartoum, Naphtha is the main source of producing the raw materials of urea production, and this require very high cost.

15

1-5 Uses Of Urea; There are many uses of urea in our daily life: 1 The major uses of urea is its importance as a fertilizer which mainly due to its high nitrogen content (about 46%). Also urea solution is converted into ammonium bicarbonate by the action of soil bacteria. Ammonium bicarbonate is quickly changed by soil acid
16

into a form stable against wash away loss. The ease of application and unexistence of any residual matter in the soil are some causes to make urea used as a good fertilizer. 2- Urea is used in the manufacture of thermosetti.ng resins, the most important of which is urea formaldehyde resin. 3 Urea is also used in feeding of animals (cattle), it can replace for up to one third of the total protein intake by cattle. 4 Urea is also used as a softener for various cellulose products, e.g. glassing, cellophane paper and wood. Urea is also used as an additive to reduce the Viscocity of starch and others. It is also used in the manufacture of caffeine , ethyurea hydrazine , and many other chemical industries.

17

CHAPTER TWO
MANUFACTURING PROCESS AND PROCESS DESCRIPTION

18

CHAPTER TWO: 1AMUFACTURING CESS AND PROCESS DESCRIPTION : 2-1 Urea can be produced by hydrolysis of cyammide according to t he equation: CN.NH2 + H2O C O(NH2)

At 33 to 53 atmosphere urea can also be formed by heating ammonium carbamate. Equilibrium is obtained at 130 to 1500C with a 30 to 45% yield. The common method of manufacture is to combine ammonia and carbon dioxide under pressure to form ammonium Carbamate which is then decomposed into urea and water. The un reacted carbon dioxide and ammonia are recovered and recycled to the synthesis operation. Table 211 shows the number of processes available for urea manufacturing: Type of Dupant Pechiner y operatio n carbamt e recycle d Reactor conditio wit NH3 & H2O with oil liquid recycle itrate for NH3 recycled rtial urea n carbamte Montica tini pa aqueous Inventa Chemica l MEA used to abso rb C03H3 Recycle

19

n Recover y

Temperature Pressure [atm] Lining

200 400

180 200

180 200

200 200

185 170

silver

lead

stain undis less closed 2:1:0

Silver

NH3;CO2; H2O; CO conversion in Autoclave

5:1:0.73 2:1:0 3:4:1

6:1:0

70

50

52

50

76

20

Total NH3 conversion in Autoclave Total

70 24

50 50

88 32

50 50

76 25

24

50

72.5

50

73

22 Solution Recycled Process:

The process employs aqueous urea nitrate to recover ammonia without CO current absorption of the carbon dioxide. The ammonia and carbon dioxide are recompress and fed with the makeup carbon dioxide and ammonia to converter.

23 Once Through Process:

In this process, un reacted ammonium can be used by recycling and un reacted carbon dioxide wasted or utilized elsewhere. Recycling un reacted ammonia and carbon dioxide may cause formation of solid ammonium carbamate. The recycling of NH3 and CO2 results in higher NH3/CO2 ratio. Ammonia conversion is 32% and this is the least expensive process.

21

24 Total Recycle Process:

The hot gases from decomposers are re circulated to the reactor, there are different types adopted for total recycle processes which can be briefed into: (i) Hot gas mixture recycle:This method includes compression of the NH3/C02 gas mixture in the five stages with air cooling between stages. The gas mixture compressed to 2700C is very corrosive and the tenPerat1jre control is very difficult. This process is of high capital costs, difficult operation and very high maintenance costs. (ii) Separated gas recycle:This process involves the absorption of either ammonia r carbon dioxide in a selective solvent, e.g. (mono ethanol amine) and urea nitrate, resulting in their sepaation and then re circulating back to the urea synthesis reactor independently. (iii) Carbonate solution recycle :T

his process involves the absorption of ammonia and carbon dioxide gas mixture iii water and recirculation as aquous ammonia carbamate solution. The excess ammonia can be stripped and re circulated
22

separately. (iv) Carbamate slurry recycle: T his process involves the reaction of the ammonia and carbon dioxide to form solid ammonium carbamate in a non aquous medium, such as mineral, oil or liquid ammonia. The carbamate is re circulated back t the urea synthesis reactor. A special purification is required to separate the medium from the urea solution. 25 Process Description:. This description was carried up with reference to the process flow sheet (fig. 21). Liquid ammonia from vessels V101 and V-105 were combined, passed through several pumps, preheated to 165F by E-105 and fed to the bottom of reactor Rl01. Carbon dioxide was cooled to 101 F by El01 and then compressed to greater than 3615 psia 295F by compressors. A liquid recycle stream containing water, ammonia ,urea , ammonium carbamate and some biuret also fed to the reactor. The reactor (Rl01) was operated adiabatically
23

at 3516 psia and 365F. The total N113/C02 mole ratic was 4.6. Half an hour is satisfying to the residence time in the reaction. The percent of the urea CO2 per total CO2 was 68%. The mixture from the reactor was passed through a pressure reduction valve to bring the pressure to .bout 305 psia and the temperature to 250F, the stream was fed near the top of the high pressure C-101. Heat was supplied to a re boiler on the high pressure decomposer C101 and about 85% of the ammonium carbamate was decomposed to ammonia and carbon dioxide which exist with water to the top of the decomposer.

24

The exit stream from the bottom of 101 was cooled in E107 and fed near the top of the low pressure decomposer which operated at 43 psia. 85% of the entering carbamate was decomposed and NH ,CO and water was the exit stream. The liquid stream from the bottom was fed to gas separator 0103. The remaining carbamate decomposed in C103 which was operated at 19 psia. Heat was supplied to the liquid in the bottom of the gas separator to increase the water content of the gas stream leaving the top of 0-103. 76.4% by weight was the amount of urea (with 8% of urea was biuret) in the liquid stream from the bottom of C103 The remaining (which was water) was cooled to 176F, and fed to V102 A, and through filter S
25

1O1 A, preparation vessels V103 A & B and S101 B, the impurities were removed. Urea solution was sent to crystallizers E-201 A & B which was operating ,,at, 158F. Heat of crystallization was used to vaporize water in the crystallizers. Urea slurry was fed to centrifuges S201 A & B, dried to 0.3% water by weight in E202. Urea prills exited front the prill tower M-202 at 175F were moved by convertor M203 to elevator M301. Materials were removed by screen 14302 and were melted in 14303 and were recycled to the process. The mother liquor was fed to surge tanks T201 A & B and most of it was recycled to the crystallizers and the other part was recycled to the condenser E116 where it was joined by the gas stream from gas separator. The liquid exit stream from the bottom of condenser E116 (containing ammonium carbamate, ammonia, water, urea and biuret) was fed at the top of low pressure absorber E115. The gas stream from C102 was fed near the bottom of E 115. Inerts were removed from the system and the
26

gas stream from 0101 was fed to the bottom of C-104. In high pressure absorber 0104, ammonia was removed at the top and was condensed. Some of the ammonia was returned to the column as reflux and the other part was passed through surge vessel V105 and was recycle to reactor R10l. The bottom stream from 0104 which contains water, ammonia, and ammonium carbamate was recycled to reactor 11101. A circulating stream in the high pressure absorber was withdrawn from the bottom of C104 and was passed through exchanger E113, to supply heat to the crystallizer. The stream was then passed through cooler E112 where the remaining heat of absorbtion was removed and the stream reenters the column just above the lower packed section.

27

Chapter three
(The material balance)

28

CHAPTER THREES THE MATERIAL BALANCE, To carry out the calculations of material balance, Some information First was used in this calculation, it is necessary to know the

composij1 of recycle carbamate solution, which have 34 mole Z water, mole X urea, 35 mole % ammonium carbamate and mole X of ammonia. Second, the degree of conversion of urea C02/total CO2 i taken as 0.68, and NH3/Co2 ratio is taken as 4.6. Third, the conditions of operation are such that the free CO2 and *l3 in the feed are completely converted t urea. Fourth, the liquid stream from bottom of C103 contains about 76.4% urea and 23.6% water and the product urea contains biuret which is 0.8% of the product urea. Fifth, mother liquor contains 0.35 kg water per kg of urn 5% of the mother liquor is recycled to E116. Sixth , a basis of 3. hour was used for
29

calculation and U product is then 31250 kg urea and 0.8% of product urea is calculated as biuret. Seventh, streams (5), (7) and (9) contain co2, NH3 and water vapour. The amount of CO2 and NH3 were known fro carbamate decomposition and amount of water was determined by trial and error procedure1 using pseudocritical method. Calculations of material balance are shown in this chapter.

The material balance * basis aria hour * Reactions forming urea are CO2 + 2NH3 NH2CO2NH4
30

carbon dioxide + ammonia carbamate NH2CO2NH4

: ammonium

NH2CO NIl2 NH2 +H2O ammonium urea + water

+

carbamate ammonium carbamate 2H2O + CONH2

urea biuret + ammonia

NH2 +CONHCONH2

NH3

molecular weights

: M.W (Kg / kmo1) 60 78 17 44 103 18

Components Urea NH2CONH2 CARBAMATE NH2CO2NH4 Ammonia NH3 Carbon dioxide co2 Biuret nh2conhconh2 Water h2o

Materiab balance around the reactor r 101 :-

31

Conditions : Conversition ( co2 in urea / total co2 ) = 0.68 Mole reaction including co2 STREAM NH3 / co2 = 4.6
&

NH3 IN RECYCLE

Recycle carbonate composition : Component Water Urea Carbonate Ammonia Mole % 34 10 35 21

From equation (1) and (2) production rate mole of co2 = mole of urea = = 520.8 k mole /hr

Kgs of co2 = 520.8 x 44 = 22916.67 kg/hr From equation (1)

32

Mole of NH3 =

= 1041.67 K MOLE/HR

Kgs of NH3 = 1041.67 X 17 = 17708.4 kg/hr Assumption :Recycle carbamate = z K MOLE/HR Recycle ammonia = x K MOLE/HR 0.68 co2 in urea /total co2 0. 68 =

Z = 813.86 kmole /hr NH3 / CO2 ratio = 4.6 4.6 =

Substitution z = 813.86 Given x = 2135.4 kmole /hr = 36301.8 kg /hr Since biuret = 0.7 % of product
33

Biuret =

= 221 kg/hr = 94.7 kg/hr

Weight of H2O IN production =

Weight of H2O in formula from formation of buiret = = 77.24 kg/hr

Weight of C2O required fro forming of buiret = = 188.8 kg/hr

Weight of NH3 required fro forming of buiret = = 145.9 kg/hr = 36.48 kg/hr

Weight of NH3 formed =

C2O required to form 94.7 kg/hr of H2O in product = = 231.5 kg/hr

NH3 required to form 94.7 kg/hr of H2O in product = = 170.88 kg/hr

34

Stream kg/hr

(19) = z = recycle carbamate = 013.86

Stream (19) Component H2O Urea Carbamate ammonia Mole % 34 10 35 21 # of moles 276.710 81.368 284.850 170.920 Wt (kg/hr) 4981 4882 222218 2895

Total weight = 4981 + kg/hr Stream (2) Co2 22916.67 + 188.8 = 23105.5 kg/hr Stream (1) NH3 surge vessel = 17708.3 + 145.9 = kg/hr stream (3) NH3 from (1) + recycle NH3 = 36301.8 + 17854.2 = 54155 kg/hr
35

= 35010.5

17854.2

Stream (18) Recycle ammonia = 36301.8 kg/hr Stream (4) Urea balance Urea in (4) = = recycle carbamate + recycle urea 31250 + 4882 = 36132 kg/hr

Carbamate in (4) = water from reaction + recycle water + water forming from formation of biuret = = 14433.24 kg/hr Ammonia in (4) = recycle ammonia + ammonia in carbamate solution + ammonia formed from formation of buiret = 36301.8 + 2895 + 36.48 = 39233.3 kg/hr Buiret in (4) = Stream (4) Component Urea NH Water Carbamate Wt (kg/hr) 36132.0 39233.0 14433.0 254.7
36

= 254.7 kg/hr

Wt % 32.2 35.0 12.8 0.2

22218.0 Total 112270.94

19.8 100%

Hint : figure (3 1) show the material balance around the reactor

37

REACTOR R 101

1 3 2

1 9

18

Fig 3 -1 :Material balance Around the reactor

38

Material balance around decomposers C101, C102 & 0103: (see figure 3-2) Overall material balance:stream(4) a stream(6) + stream(s). + stream(9) + stream (7) *Material balance around C101 high pressure decomposer) overall balance stream(4) = stream (6) + stream (5) * In C101, 85Z of carbamate decomposed to kg/hr = 204.85 kmol/hr CO2 in (5) = 0.85 x 294.85 x 44 = 10653.39 kg/hr NH3 in (5) a 0.95 x 294.85 x 2 x 17 = 0232.2 kg/hr To calculate amount of water removed by C101, pseudocritical method was used . Pressure in C101= 305 psia = = 21 bar

Assume amount of water= 25 kmol = 450 kg/hr Mole fraction are as follows : = = = = 0.65 = 0.03 = 0.32

39

Pseudocritical pressure = = 112.8 bar = 73.8 bar H2O = 220.5 bar = 0.32 * 73.8 + 0.65 * 112.8 + 0.03 * 220.5 = 103.55 bar = NH3 = 405.6
0

+ K

+ .

CO2 = 304.2 0K H2O = 647.3 0K Where T is the Temperature . = 0.32 * 304.2 + 0.65 * 405.6 + 0.03 * 647.3 = 380 0K Pseudoreduced pressure P = P/ = 21/103.55 = 0.2

And pseudo reduced temperature = T/ = 438/380.4 = 1.15

From compressability factor chart we find = 0.96 The volume of gas = RT/P
40

= (0.96 * 8.314 *438) = 166.5 m3 /kmo Using Daltons low =

From charts z(CO2) = 0.99 z(NH3) = 0.96 z(H2O) = 0.90 =

( )

= 167.8 m3 /kmol

Repeat this method using other values of amount of water removed and calculate the volume of gass by the two methods above . until the different be minimum and then find the correct amount of water . Then amount of water removed = 30 kmol = 540 kg/hr NH3 in stream (5) = NH3 in (4) + NH3 formed from decomposition of carbamate =39233 + 8232.2 = 47465 kg/hr Composition of stream (5) is Component NH CO2 H2O Total Wt (kg/hr) 47465 10653 540 58658 Wt % 81 18.1 0.09 100

For decomposer C- 102 :

41

Stream (6) Component Urea Biuret Carbamate Water Total Wt (kg/hr) 36132 254.7 3332.7 13893 53612.4 Wt % 67.3 0.48 6.21 26.01 100

Over all material balance around C - 102 STREAM (6) = STREAM (7) + STREAM (8) Also 85% of carbamate were decomposed .

42

5 4

C101 C102

C103

10

Fig3 material balance around decomposer :

43

As in C - 101 , using pseudocritical method we can find the amount of water removed in C - 102 = 50 kmol/hr = 900 kg/hr NH3 in (7) = 0.85 * CO3 in (7) = 0.85 * Stream (7) Component H2O CO2 NH3 Total Stream (8) Urea in stream (8) = 36132 kg/hr Biuret in stream (8) = 0.15 * Water in (8) = water in (6) water in (7) = 13893 900 = 12993 kg/hr = 500 kg Wt (kg/hr) 900 1589 1234.8 3732.8 Wt % 24.1 42.8 33.1 100 = 1234.8 kg/hr = 1598 kg/hr

44

Stream (8) Component Urea Biuret Carbamate Water Total Wt (kg/hr) 36132.0 254.7 500.0 12993.0 49879.7 Wt % 72.94 0.51 1.0 26.0 100

Decomposer C- 103 material balance :Stream (8) = stream (9) + stream (10) Stream (10) contains 76% urea , 23.3 % water and 0.7% Biuret . H2O in (10) = Biuret in (10) = = 11077 kg/hr = 254.7 kg/hr

45

26

E 202

AIR

25

27

Fig 3-3 Material balance Around the dryer E- 202

46

Stream (10) Component Urea Water Biuret Total Wt (kg/hr) 36132 11077 254.7 47463.7 Wt % 76.0 23.3 0.7 100

Sream (9) = stream (b) stream (10) Stream (9) Component CO2 NH3 H2O Total Wt (kg/hr) 282 218 1916 2416 Wt % 11.7 9.0 79.3 100

Material Balance around dryer E- 202:See fig 3-3

47

Since stream (27) contains crystal composed of 0.3% water , then H2O in (27) = = 318 kg/hr Stream (25) Component Urea Water Biuret Total Wt (kg/hr) 31250 318 221 31789 Wt % 98.3 1.0 0.7 100

Material Balance around centrifuges & crystallizers ( E- 201 A& B, T201 A & B , S201 A & B ) : See figure 3 4 Over all material balance Stream (10) = stream (25) str eam (23) Urea balance :Urea in (10) = urea in (25)_ + urea in (22) Urea in (22) = 36250 = 4882 kg/hr Given that stream (22) is 5% of stream (33) + stream (22) +

48

Urea in stream (33) =

= 97640 kg/hr

Given That stream (33) contains 0.35 kgs Of H2O per kg of urea H2O IN (33) = 0.35 * 97640 = 34174 kg/hr and H2O in (22) = 0.35 * 4882 = 1708 .7 kg/hr Biuret in stream (33) = Stream (33) Component Urea Water Biuret Total Wt (kg/hr) 97640 34174 688 132502 Wt % 73.7 25.8 0.5 100 = 688 kg/hr

STREAM (22) WITH IS 5% FROM STREAM (33) Component Urea Water Biuret Total Wt (kg/hr) 4882 1708.7 34.4 6625.1 Wt % 73.7 25.8 0.5 100

Centrifuges A& B material balance :-

49

Over all material balance Stream (24) = stream (33) + stream (25)

Urea in (24) = urea in (33) + urea in (25) = 97640 + 31250 = 128890 kg/hr Stream (24) : Component Urea Water Biuret Total Wt (kg/hr) 128890 34492 909 164291 Wt % 78.45 21.00 0.55 100

Crystallizer A & B material balance Over all material balance

:-

Stream (10) + stream (31) = stream (23) + stream (24) but stream (31) is 95% of stream (33

50

23 22 31
10 03

10 03 E 201 A &B T 201 A&B

33 24

S 201 A&B

25

51

Stream (31) :Component Urea Water Biuret Total Wt (kg/hr) 92758 12767.4 863.55 126388.95 Wt % 73.3 25.9 0.5 100

Water balance : H2O in (23) = H2O in (10) + H2O in (31) H2O in (24)= 11077 + 32767.4 34492 = 9352 kg/hr Stream (23) :Component Water Wt (kg/hr) 9352 Wt % 100

Material balance around condenser (E-116) and high and100 pressure absorber (C- 104 ) & (E 115 ) :See figure (3 5 ) Condenser (E 116 ) Over all material balance Stream (9) + stream (22) Stream (21) : 52

= stream (21)

Component Urea Biuret Water NH3 CO2 Total

Wt (kg/hr) 4882.0 34.4 3624.7 218.0 282.0 9041.0

Wt % 54.0 0.4 40.1 2.4 3.1 100

High pressure absorber ( C 104 ) :Over all material balance :Stream (5)+ stream (20) = stream (18) + stream (19) CO2 balance :CO2 in (20) = CO2 in (19) = 813.80 * co2 in (5)

0.35 * 44 10653 = 1880 kg/hr

NH3 balance :NH3 in (20) = NH3 in (18) + NH3 in (19) - NH3

in (5) = 36301.8 + 813.86 * 0.21 * 17 + (813>83 * 0.35 * 2 * 17 ) 47465 = 1427 kg/hr

Water balance :53

Water in (20) = water in 4981 540 = 4441 kg/hr Stream (20) :Component Urea Water CO2 NH3 Total

(19)

- water in (5) =

Wt (kg/hr) 4882 4441 1880 1427 12630

Wt % 38.6 38.2 14.9 11.3 100

Low pressure absorber E 115 :Over all material balance Stream (7) + stream (21) = inerts + stream (20) NH3 in inerts = 218 + 1234.8 1427 = 25.8 kg/hr CO2 in inerts = 282.1 + 1598 1880 = 0.1 kg/hr Water in inerts = 3624.7 + 900 4441 =83.7 kg/hr

54

Inerts stream :Component Water CO2 NH3 Total Wt (kg/hr) 83.7 0.1 25.8 109.5 Wt % 76.4 0.1 23.5 100

55

7 18 5

22

C - 104

E - 115

E - 116

19

20 21

Fig : 3 5 Material Balance Around Condenser & Absorber :

56

Chapter four

The energy Balance

57

CHAPTER FOUR : -THE ENERGY Balance : The general energy balance equation could be written as: accumulation of energy within the system] =[transfer of energy into system through the boundary]- [energy transfer through system boundary]+[energy generation within the system ] - [energy conception Within the system The enthalpy of each stream was calculated by summing enthalpies of its components with respect to a refer temperature (300c). The enthalpy is given by: H=Mcp where M = mass of stream in kg Cp = mean heat capacity (kcal/kgoc) = temperature difference

58

The Energy balance Reactor R1Ol Energy balance:(see figure 41) Overall enthalpy balance: H2 + + H3 H19 + H4 (heat of solution of urea) + HS. Enthalpy of stream (2) (H2) Generally 11 = mc T = 0.23 kcal/kgoc .. (146 30) = 116c M = 23105.5 kg/hr .. H= 0.23 x 23105.5 x 116 = 616454.74 kcal/hr Enthalpy of stream (3) Cp H 0.525 kcal/kg0c = 54155 x 0.525 x (74 30) = 1250980.5 kcal/hr Enthalpy of stream (19) (1120) = 0.45 kcal/kgoc cp(urea) = 0.472 kcal/kgoc c(carbonate) = 0.55 kcal/ kgoc c(NH) 0.54 kcal/ kgoc Latent heat of vaporization of water = 39.9 kcal/ kgoc
59

H19 = 22218 x 0.55 (120 30) + 0.54 x 895 (120 30) 4882 x 0.472 x (120 -30) + 4891 [ 539.3 + 0.45(120 30)] = 338847.76 kcal/hr Enthalpy of stream (4) Latent heat of solution of urea = 58 kcal/kg Latent heat of fusion of urea 60 kcal/kg .. = 36353 [60 + 0.522(185 30)]+ 22218 x 0.51(185 30) : + 14433[539..g + 0.45(185 30)] + 39233 x 0.54(185 30) = 18,961,714.68 kcal/hr Hs (urea) 58 x 36353 = 2108474 kcal/hr Determination of HR :-

from equations of reactions: .. CO2 + 2NH3 __ NH2CONH4 NII7CONH4 = 67000 Btu/lbmol

NH2CONH2+ NH3 .H = 18000 Btu/lbmol

total heat of reaction = 67000 + 18000 = 49000 Btu/lbmol

= 19056916.56 kcal (urea)-

(carb.) H2 + H3( + H19 N460

= 6113454.74 + 50980.,5 1- 4338847.76 18961714.68 2108474 + 19056916.66 = 3638202 kcal Decomposer C10l energy balance: (see figure 42) Enthalpy of stream (5) 47465 x 0.53 (12130) + 10653 x 0.23 (121 30) + 540(539.9 + 0.45(121 30) = 2795628 kcal H6= 36353(60 +0.422(165 30) +3323.7[51.282 +0.48(165 30)] + 13893[539.9 + 45(165 30)] - = 12982863 kcal * Heat of decomposition of carbamate 477 x 0.85 x 22218 90082863 kcal

61

* Heat of so1utjo of urea = 2108474 kcal. Using overall energy balance H4 +QE106 = H5+ H6+ heat of decomposition of carbamate + heat of solution of urea = 2795628 + 12982863 + 9008288 + 2108478 18961714.68 106 = 7933543 Cooler E107 energy balance: (see fig. 43) Heat loss due to cooling QE106 = 13893 [539.9 + 0.451(165 72)] + 36353 [60 + 0.447(165 72)] + 3323..? [51.282 + 0.5(165 72)] = 12100953.4 kcal .. H5 = H6 - QE106 = 12982863 12100953 881910 keai. C102 Energy balance: (see figure 44) = 0.21 kcal/kgc = 0.7 kcal/kgc =1.0 kcal/kgc H7 = 900 x 1(72 30) + 1234 x 0.21 x 42 + 1598 x 0.7 x 42
62

= 95665 kcal stream (8) cp(urea) = 0.484 kcal/kgc cp(carbonate) 0.57 kcal/kgc H8 = 8353 x 0.484 x (130 30) + 500 x 0.57(130 30) + 12933[539.9 + 0.451(130 30)] = 9352497 kcal Heat of decomposition of carbonate 0.85 x 477 x 3323.7 1347594 kcal Heat of solution of urea 2108474 kcal Overall energy balance: H6 + = H+ h{ + heat of decomposition + heat of solution of urea = 95665 + 9352497 + 1347594 + 2108474 881910 12022320 kcal C-103 Energy balance:(see fig. 45) = 0.2 , = 0,53 = 0.45 kcal/kgoC

= 218 x 3(130 30) + 82 x ).2(130 30) + 1916(539.9 + 0.45(130 - 30)

63

1137862 kcal stream (10) H10 = 11077[539.9 + 0.45(115 30)] + 36353 x 0.47(130 30)

10 = 7856470 kcal

64

65

* Heat of decomposition 500 x 477 238500 kcal/hr Heat of solution of urea 2108474 kcal/hr Over energy balance: H8 + HE109 = H10 + H9 + heat of decomposition

+ heat of solution of urea QE109 =7856470 + 1137862 + 2108474 + 238500 9352497 = 1,988,809 kcal/Hr

total heat added = QE107 + QE108 + QE109 = 121009534 + 1202J2O 1988809 26112082.4 kcal/hr E110 Energy balance: (see fig. 46) H10 = 11077(80 30) + 36353 X 0.431(80 30) 1,337,257 kcal/hr Heat removed by E110 H10 H15 = 7856470 1337257 6519213 kcal/hr Crystallizer (E201 A & B) Energy balance:-

66

(see fig. 47) cp(urea) = 0.397 at-50C = 0.417 at 70cc = 0.431 at 80c H17 = H10 = 1337257 kcal/hr H10= 327674 x 1(50 30) + 93622 X 0.397(50 30) 139870 kcal/hr H23= 9352(70 30) 37408() kcal./hr H24 = 129799 X 0.417(70 30) + 34492(70 30) 3544727 kcal/hr Overall energy balance . H17 + H31 + heat added from C104 H23 = H24 + heat of crystallization of urea * Heat of crystallization of urea 110 x 42003 = 4620330 kcal/hr heat from C104 374080 + 544727 + 4620330 - 13372 1398707 = 5803173 kcal/hr Centrifuges (S201 A & B)energy balance:-

67

. see figure 48 H33 = H31 /0.95 = 1393707/095 = 1472323 kcal/hr H22= 0.05 H33 0.05 X 1472323 73616 kcal/ hr H25 =H24 H33=3544727 1472323 2072404 kcal/hr Condenser E116 Energy balance:_ (see fig. 49) H21 = 218 x 0.53(50 30) + 282 + 4916 X 0.397(50 30) = 44502 kcal/hr Overall energy balance: H9 + H22 = H21 + QE116 QE116 = 44502 + 1137862 + 73616

= 1166976 kcal/hr which is the heat removed by adding water.

LOW PRESSURE DECOMPOSER E116 ENERGY BALANCE : See fig 4 10 H20 = 4441 * 1(50 30 ) + 1427 * 0.525 (50 30 ) + 1880 * 0.2(50 30 ) + 4882 * 0.397 (50 30) = 150229.3 kcal /hr Over all energy balance :
68

H7 + H21 = HINERT + H20 + QE115 H = 0.1 * 0.2 (50 30 ) + 25.8 * 0.525(50 _ 30) + 83 * 1 (50 _30) = 1931 KCAL/hr Q = 44502 + 95665 1931 150229 = 11993 KCAL/hr
NH3 , UREA , WATER , CARBAMATE 4

19

CARBAMATE

120 0 C

69

3 2 1460C

74 0C NH3= 54155 Kg

Fig 4 1 energy balance A round the reactor

5

C 101

70

Fig 4 -2 ENERGY Balance Around Decomposer C 1 :

72 0C

72 0C

E 108

Fig4 4 c 102 energy Balance

130 C0 71

8 130 0 C E - 109

10 116

Fig 4 5 C-103 ENERGY BALANCE

72

72 0 C

E - 107

165 0c

Fig 4 3 Energy balance Around COOLER E 107

10

800C

E - 110

1150C

10

Fig 4 6 E- 110 Energy BALANCE

23

73

17 E 201 A& b

31

70 0 c

24

Fig 4 7 crystallizer energy balance

70 0 C

24 74

S 201 A & B

33 50 0C

25

FIG 4 8 centrifuges energy balance

75

130 0 C

50 0 C

Fig 4- 9 condenser energy balance

INERTS

500C

76

E - 115

21

500C

20

Fig 4- 9 condenser energy balance

77

GHAPTER _ FIVE

THE DESIGN OF THE REACTOR

Chapter five : Reactor design sheet : For the reaction of 23105.5 kg/hr of carbon dioxide and 54155 kg/hr of ammonia to produce 36132 kg/hr of urea, make 32% of the reactor products. Operating Conditions: Temperature = 458K Pressure = 3515 psia Conversion 0.72 Reactor No. : R1Ol Reactor Type : Continuous stirred tank reactor Reactor Size : 3
78

Volume : 38 m Length : 15 m Diameter : 2 m Shell thickness : 80 mm Ends Type : hemispherical shape. Material of construction stainless steel (316 SS)

CHAPTER FIVE: THE DESIGN OF THE REACTOR: 51 Introduction: The aim in designing a reactor is to produce a specific product at a given rate from known reactants. In order to achieve the best design for the reactor, two most important, questions are to be settled: 1 the type of reactor to be used and whether its process is batch or continuous, and will the reactor operate isothermally or adiabatically ? 2- the physical, conditions of the reactants at the inlet of the reactor, such as pressure, temperature and compositions.
79

Many requirements are satisfied by industrial chemical reactors: 1 chemical factors: involve kinetics of the reaction and sufficient residence time. 2 Mass transfer factors: with heterogeneous reactions the reaction rate may be controlled by rate of diffusion of the reacting species. 3 heat transfer factors: removal or addition of heat of reaction. 4 Safety factors: confinement of hazardous reactants and products and control of the reaction and process conditions. The characteristics to classify reactor designs are: 1 mode of operation: whether is batch or continuous. 2 Phases present: which determine whether the reaction is homogenous or heterogeneous 3 Reactor geometry: whether the reactor is tubular, stirred tank, plug flow or backmixed reactor. 5-2 Chemical kinetics & rate equations:The rate of the reaction decreases as the concentrations of the reactants decrease. To calculate the size of the reactor we need to know how the rate of the reactor, at any time or at any point in the reactor, depends on the concentrations of the reactants. The reaction rate also increases rapidly with increasing temperature. Determination of the rate equation is very important to design a reactor. 53 Design equation:
80

This equation gives the relationship between the volume of the reactor, reaction rate and flow rate of the limited reactant. Its determination depends on the type of the reactor used. 54Calculations of the reactor size: The calculations of the diameter and high of the reactor are shown in the following paragraphs:

541 Design and rate equation. The reactor Used in this project was continuous stirred tank reactor with design equation given by (5-1) =

where V = volume of reactants contained in the reactor [m] = flow rate of the limited reactant [kmol/sec]
81

= conversion of limited reactant (A) to product = rate of reaction [kmol/n1 .sec] Our reaction is a third order reaction which has a rate equation given by: A-r = k * C3AP
( ( ) )
(5 _ 2)

where K is the equilibrium reaction constant = and CAO initial concentration of the limited reaction [kmol/m I 5-4-2 Given data: a. The residence time for forming urea = 30 min = 30 x 60 1800 sec b. The conversion of limited reactant (carbon dioxide) to product (urea) was given as 0.72 = 0.72 c. Flow rate of CO2 23105.5 kg/hr = 23105.5 0.146 kmol/sec 44 x 3600 d. Reactor temperature = 185c e. Reactor pressure 3515 psia 5-43 Calculation of q & E. : From our reactions: 2NH3 + CO2 NH4CO2NH2 2NH3 + CO2 NH2 NH4CO2NH2 NH2CONH2 + H2O NH2CONH2
82

H2O

2 moles 1 mole 1 mole 1 mole Number of moles of reactants = 3 Number of moles of products = 2 EA To PV P = 2 3 = calculate C we have: nRT = = Crt

C = = 3515 PSIA = * 101.3 = 24222.4 KN /M2

T = 146c = 419K R = 8.314 kmol/K 3 CAO = 24222.415 = 6.95 kmol/m 419 x 8.314 5-44 Calculation of reaction constant (k):T o calculate the reaction constant (k) we need the residence time (t) and then the calculation was carried out according to the equation t = CAO X (53) rA (1 +EA XA) from equation (52) 3

83

A-r = k cAO

( (

) )

substitute equation (2) in equation (3) to give t = OR K =

( ( ( ( ) )( ) )

= 0.72(1 0.24)2 1800 * (6.95)2

(1 0.72)3

Then from equation (51) we can calculate the volume as follows: V = =

( ( ) )

= 0.146 * 0.72 (1 0.24)3 0.00022 * [6.95(1- 0.72)]3

= 28.5 m3

Assume the reactor is 75% full V = 28.5 = 38 m3 0.75 54-5 Determination of diameter and height:For our reactor, a closed cylindrical tank with formed heads on both sides were used. For high pressure vessels a hemispherical end was used. Hence the total volume of the tank is given by the combination of shell volume with the volume of the equivalent Cylinder for the ends ,i.e. v = Di3 l + Di3 (5 4) where V = total volume of he vessel = 38 m3 D = internal diameter of the vessel
84

L = hight of the vessel Assume the value of L/D ratio = 8 V = x * 8Di3 + Di3 4 6 = 13 Di3 (55) 6 Di = (6V/13 7c ) = (6 x 38/13 7c ) = 1.77 L = 1.77 x 8 = 14.2 m take Di = 2 m and L = 15 m

R - 101

19 85

NH3

CO2 = 231055 KG/HR

FIG 5 1 MATERIAL & ENERGY BALANCE AROUND REACTOR R 101

86

hi

ho

FIG 5 2 HEMISPHERICAL HEAD OF THE REACTOR R 101

55 Mechanical Design of The Reactor: 551 Introduction:_ The basic data for mechanical design of a vessel are: 1. vessel function 2. process materials and services 3. operating and design temperature and pressure 4. material of construction 5. vessel dimensions and orientation 6. type of vessel heads to be used 7. openings and connections required 8. specification of heating & cooling jackets or coils 9. type of agitator
87

10. specification of internal fittings. 552 Pressure, temperature & stress for design: For vessels under internal pressure, the design pressure is taken as 510% above the working pressure, The working pressure P = 3515 Psia Design pressure = 1.1 x 3515 = 3-367 Psia A suitable margin for fluctuation was added to the temperature to get the design temperature. Working temperature = 185c take design temperature = 200 The design stress f was given, by the relation f 1/s x minimum tensile strength at working temperature where s is a safety factor. 55-3 Material of construction:_ The important characteristics to be considered when selecting the material of construction are: 1. mechanical properties 2. the effect of the physical properties on the mechanical properties 3. corrosion resistance 4. availability in standard sizes 5. ease of fabrication 6. cost. To prevent corrosion by ammonium carbamate, stainless steel is used as a material of construction (304se) is used below 130C (316SS) is used above 130c Since our reactor was operated at 185 C, stainless steel (316) was used for its design. 554 Shell wall thickness calculations:_ The following relations were used to calculate
88

the minimum thickness needed for the shell wall: z7 = (( )PD2 - W t(DI + t ) Z = Z p(Di + t) /2t = ( z2 z z7 +z7)

where f = design stress [ psia ] P = pressure [ psia ] t = shell thickness [in.] Di= internal diameter of. shell. [in.] w=total weight of vessel [ lb I z= longitudinal stress [ psia ] z = hoop stress [ psia ] -4]- = equivalent stress [ psia j For design the equivalent stress (n.) must not be greater than the design stress (f) f = 1/S x tensile strength S= safety factor taken as 1.4 The tensile strength for (316 stainless steel) is
89

520 N/mm 75459 Psia. f = x 75459 = 53899 psia 1.4 The total equivalent weight of the reactor and its contents was given by W = Wv + Wf where Wv = weight of vessel Wf weight of fluid inside the reactor Wf = V vessel ,is the density of mixture based on the outlet stream (i.e. stream 4). According to the table below-we can calculate the density of the mixture in stream (4), (see chapter 2). Component Co2 NH3 Urea H2O Carbonate [kgmole/m] 17.66 37.59 22.25 55.40 21.05 xi 0.00 0.35 0.32 0.13 0.20

Tale (5-1): Analysj8 of Components in stream (4) Molar e = 31.69 kgmol/ average molecular weig1t of mixture = 43.09 kg/kmol fmix = 31.6s X 43.09 = 1305 kg/kmol = 0.049

90

Vvessel = (

L) +

Di

Di = 2 m = 80 in, L = 15 in = 600 in. Vvessel = [ (80)2 x 600] + (8)3 = 3284011,5 in3 4 6 WF = 3284011.5 X 0.049 = 160916.56 lb WV = V * fsteel 489 lb/ft3 0.283 lb/in3 Vesteel = 7 L(D4 + t) = X 600(80 + t) W = V4 = 600(80 + t) x 0.283 = 533.44(80 + t) lb total weight W = 160916.56 + 33.44(80 + t)

..

from equations (5.6), (5.7) and (5.8)

z= [ /4)x3867 X 802 -160916.56 533.44(80 + t) t(80 + t)

= [6135978.7 169.8(80 + t)] / [t(80 + t)] z = 3867(80 + t)/2t = 1933.5(80 + t)/t ze = (a n.. + n. ) The thickness (t) was calculated by trial and error method to obtain the suitable amount of the equivalent stress (
91

Trials: Trail No. 1 2 3 4

t[in.] 2.00 2..50 2.75 3.00

z [psia] 68691.623 55299.356 50433.68 46377.09

minimum thickness required 2.75 in. 6.875 cm take reactor thickness 8 cm 555 Ends specjfjajo8: 9 Since the reactor wits operated at high pressure, hemispherical shape was used for designing the ends. It is the strongest shape, capable o resisting about twice the pressure of a torispherical head of the same thickness. The only disadvantage of the hemispherical heads was its forming cost, which is higher than the other shapes. For equal stress in the cylindrical section and hemispherical head of a vessel the thickness of the head need only be half that of the cylinder. The optimum thickness ratio is normally taken as 0.6. The thickness of the ends was, 8 x 0.6 = 4.8 cm take end thickness as 5 cm 556 Corrosion allowance: Corrosion allowance should be based on experience with the material of construction. Stainless steel is very resistant to corrosion and needs no large allowance, we can take a corrosion allowance of 5mm for the purposes of
92

this project. corrosion allowance = 0.5 cm 557 General observations:_ 1. Stainless steel is a very expensive material and may be economically Unacceptable for design, another material which can be used instead. Generally, carbon steel is the most commonly used engineering material and can be suggested instead of (316ss). Carbon steel need corrosion allowance greater than stainless steel.
55

2. The reaction operates adiabatically and there is no cooling or heating system. 3. For the economical purposes, elliptical dished type can take - place of the hemispherical heads. 4. A scaled representation for the reactor and ends were shown in figure (5-3)&(5-2). 56

93

94

85 * 10-2

Fig 5 3 AVERICAL SECTION FOUR REACTOR R - 101

95

Chapter six

Special task process control

CHAPTER SIX :SPECIAL TASK PROCESS CONTROL :-

61 Introduction: Control is accomplished by measuring the Cor1tIOi1ed variable and comparing this wits the desired value or et point, an adjusting the manipulated variable which has a direct effect on the controlled variable until the desired value is obtained Figure 61 & 62 Show Simple feed back control system.

96

Fig 6 1 simple feeds back control system .

97

Fig 6 2block diagram for the system in fig 6 - 1

* The measured value (B) is compared with the desired value (R) to produce an error ( ) such that R - B. The controller produces an output which a function of the magnitude This is fed to control value in the steam line which make the necessary modif1catbon to satisfy the desired value. 62 Control- objective: We control in order to: 1. keep the process variabe5 within the process limits 2. provide alarms and automatic shutdown systems
98

3. achieve the design product 0utpUt 4. maintain the product composition 0fl within the specified quality standards 5. operate at the lowest production cost, compared with the other objectives. In a typical chemical processing plant, these objectives are achieved by a combiflat0fl of automat control, manual monitoring and laboratory analysis

63 Typical con0j 63-1 Level control:In any equip where an interface exists between two phac05 some means of maintaining the interface at the required level must be provided. This may be incorporated by automatic control of the flow from the equjp011 A typical for level Control is shown in figure. (63). Fig. 63

99

Level control 632 Pressure control 1 : It is necessary for most Systems handling vapour The method of control depends on the nature of the process Figure (64a&b) show typical Sc]1enes f pressure control Fig. 64-b Pressure control of a Condenser by varying the heat transfer area.

100

Fig. 6-4-a Venting of noncondensable after a Condenser

63-3 Flow control:It is usually associated with inventory control in a storage tank or other equipment To provide flow Control at a fixed speed and supplying a near in fig. (65 a&b).

fc

101

(65 a&b). Flow control for a reciprocating pump.

Fig.6_5 b. Alternative scheme for a centrifugal compressor or Pump.

634 Temperature control:102

it is necessary for most chemical system ha significant affect on phy0 and chemical Properties o product, reactor rate pressure, etc. Many devices are used for measuring temperature and each ha its own characteristics and liinitatio115._ a) expansion thermometer b) change of state thermometer c) Instruments exploiting electrical phenomena d) radiation and optical pyrometers * Thermocouple is the most common type of the temperature control see fig. 66. 64 Reactor control:_ The schemes used for reactor control depends on the proc33 and type of the reactor. If the reactor dynamics are suitable the product composjti0 can be monitored continuously and the reactor COfldjj015 and feed flows controlled automatically to maintain the desired product composjtI0 and Yield. Reactor temperature will normally be controlled by regulating the flow of the heating or cooling medium. Material balance will be necessary to maintain the correct flow of reactants to the reactor. reactor and the flow of products un reacted materials from the exit Stream. There are three streams entering into the reactor, and one Stream (2) containing carbon dioxide from it8 source was coztro1led by measuring the pressure in the bottom of the reactor
103

-S and accordingly adjusting the flow of inlet CO to the reactor.

Stream (3) Containing ammonia from its source and from the recycled stream was controlled by regu1atjig globe valve for measuring the flow of ammonia. The exit stream (stream 4) was contro1ed by measuring the temperature in the top of the reactor. Stream (19) which is a recycled stream was controlled in the high pressure absorber and was entered to the reactor as a controllable stream. Fig (67) shows a suggested control system for the reactor.

104

carbamate R 101 From high pressure absorber pc

105

REFERENCES 1. R.K.Sinnott Chemical Vol.6 (1983) 2. Coulson & Richardson Chem Eng Vol.3 (1979) 3. RH.Perry and C.Be1 Chem Eng. Ismail You Design of Urea Synthesis P1a Engineering stu for the degree of .Sc.(l984 5. Ib ElWaleed A1 Design of Urea Plant, year Project for the degree of B.sc.(1984 6. Encyclopedia of chemical Technology vol. 21 John Wiley & Sons (797

106