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Presented to: Training & ISO Department Presented by: Kashif Yasin

Punjab University

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Continued Brief Overview of Urea Formation

Synthesis Decomposition Recovery Finishing

Comparison of UTIC & SNAMPROGETTI

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UREA

Urea is a white crystalline solid containing 46% nitrogen and is used as a fertilizer widely. It is available in the form of prills and granules It provides required nitrogen to the plant for its growth Commercial manufacture of urea started in 1932 in Germany.
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Once Through Process

Once through process is simplest and less expensive Even though the process is simplest, it is least flexible It must be used in conjunction with the coproduction of some other materials, e.g. ammonium sulfate

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Partial Recycle Process

In this case partial ammonia is recycled to the urea reactor
The remaining ammonia is to be used for some other material Lesser ammonia is available for co-production (15%less)

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Total Recycle Process

In this process all the unconverted ammonia and carbon dioxide mixture is recycled to urea reactor No co-production is necessary This is the most flexible process

It is most expensive in investment & operating costs

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Brief Overview of Urea Formation

Types of Urea production process
By Wohler reaction(never tried for industrial use) NH3 + HCNO NH4OCN NH4OCN NH2CONH2

By Hydrolysis of Calcium Cyanamid CaCN2 + 3H2O NH2CONH2 + Ca (OH)2

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Two Steps Chemical Reaction

a) Carbamate Formation

CO2

2NH3

NH2COONH4

b) Dehydration

NH2COONH4
c) Overall

NH2CONH2 + H2O

CO2

2NH3

NH2CONH2 + H2O

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All Urea Processes have 4 steps

1) Urea Synthesis
CO2 + 2NH3 NH2CONH2 + H2O

2) Product Separation(Decomposition)
NH2-COO-NH4 2NH3 + CO2
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3) Non reacted gases utilization(Recovery)

Off gases used in heat recovery Formation of Carbamate Sent back to urea Reactor

4) Finishing
Prilling Bagging & Shipping
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Vendors of Total Recycle Processes

Ivo Mavrovic UTIC Heat Recycle Process Mitsui Toatsu Total Recycle(Now Toyo Aces Process)

Stamicarbon Stripping Process

Snamprogetti Stripping Process

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Comparison of UTIC & Snamprogetti

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Parameters studied to compare UTIC & SNAMPROGETTI?

Reaction Parameters
Reactor Performance Decomposition Energy Consumption
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Reaction Parameters
Pressure

Temperature
NH3/CO2 Ratio H2O/CO2 Ratio Powerpoint Templates

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Reaction Parameters
UTIC P=3200psig
SNAMPROGETTI P=2275 psig

T=380F
NH3/CO2=4.5:1 H2O/CO2=0.8

T=370F
NH3/CO2=3.6:1 H2O/CO2=0.7
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Reactor Performance
Reactor performance is measured by the Conversion of CO2 in reactor
UTIC SNAMPROGETTI

74% 65%
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Decomposition
It is the main point of difference between UTIC & SNAMPROGETTI

UTIC
HP Decomposition LP Decomposition

SNAMPROGETTI
HP Stripping MP Decomposition LP Decomposition

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UTIC
Decomposition
HP Decomposition (280-320psig) LP Decomposition (20-30psig) Degasser & Vacuum Concentrator (20 inHg)

CO2 is used as a stripping agent High steam consumption

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SNAMPROGETTI
Decomposition
HP Stripper (2130psig) MP Decomposer (270psig) LP Decomposer (70psig) Vacuum Concentrator (0.35-0.03 kg/cm2)

NH3 is used as self stripping agent Less steam consumption

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Energy Consumption
Energy consumption in Snamprogetti is less than UTIC

REASONS
UTIC
More Steam Consumption No arbamate Ejector No HP Stripper Electricity Motors

SNAMPROGETTI
Less Steam Consumption Carbamate Ejector HP Stripper Steam Turbines

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REASONS
HP Stripper pressure is 2130psig Less pressure is required in reactor in Snamprogetti than Utic Steam turbines are used in Snamprogetti Steam consumption is large in Utic
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Comparison
Vendors Pressure Temperature NH3/CO2 Ratio Reactor Efficiency NH3 Consumption/ton urea UTIC 3200 psig 380F 4.5 74% 0.58 ton SNAMPROGETTI 2275 psig 370F 3.6 65% 0.566 ton

CO2 Consumption/ton urea

Steam Consumption/ton urea Power Consumption/ton

0.75 ton
1.2 ton 148 KWh

0.735 ton
0.9 ton 120 KWh

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