CONTENTS

INTRODUCTION
 Overview of plant
 Properties of UREA
 Uses of UREA

UREA MANUFACTURING PLANT

2.1 Description of UREA production process
2.2 Flow sheet of UREA plant
2.3 SYNTHESIS SECTION
2.4 DECOMPOSITION SECTION
2.5 RECOVERY SECTION
2.6 FINISHING SECTION
INTRODUCTION
OVERVIEW OF PLANT
 KANPUR FERTILIZERS & CEMENT LTD. a unit of JAYPEE
GROUP known as DUNCANS INDUSTRIAL LTD. JAYPEE
GROUP is an infrastructure industrial conglamorates of Rs.
18000 crore turnover.
 KFCL is subsidizing of JAYPEE GROUP. The fertilizer plant
of KFCL is based on TOYO TECHNOLOGY OF JAPAN &
three units of each plant & capacity of 730 ton per day.
 The three ammonia production plants are natural gas
plant based on ICI TECHNOLOGY, each plant capacity of
415 ton per day.
 KFCL sell the product by brand name “CHAND
CHHAP” UREA. This well known brand still in the
memories of satisfied farmers of Northern, Central &
Eastern India. UREA produced by “TOTAL RECYCLE
CIRCULATION PROCESS”.

 The learning opportunities and industrial exposure at

the KFCL made not just possible to relate the book
knowledge to field application but also in developing a
through understanding of industrial practice and
operating concepts.
KFCL is a leading manufacturer & supplier of fertilizer
from KANPUR, UTTAR PRADESH. From safety point
of view, the industry is listed under “MAJOR
ACCIDENTAL HAZARD INDUSTRY”.
THERE ARE FOUR SECTION IN PLANT
OFF SITES (Water treatment, air station, cooling
tower, inert gas plant, ammonia storage)
AMMONIA PLANT
UREA PLANT
CPP ( Captive power plant)
PROPERTIES OF UREA
PHYSICAL PROPERTIES
 White in color
 Odorless
 Non corrosive
 Crystalline Substance
CHEMICAL PROPERTIES
 Chemical Formula = NH2CONH2
 IUPAC Name = UREA
 Molecular Weight = 60.05
 Maximum Nitrogen Content = 46.6%
 Specific Gravity = 1.335
 Solubility in Water = 1080 g/L (20 0C )
 Melting Point = 132 0C
USES OF UREA
 UREA is major used as a solid fertilizer.
 UREA is used to manufacture synthetic RESINS .
 UREA is used in the production of PHARMACEUTICAL products.
RAW MATERIALS
 BASIS; 1 Ton of urea
LIQUID AMMONIA(0.59 ton)
 Supplied Conditions;
 Pressure = 18 kg/cm2
 Temperature = 15 to 40 0C
 Composition(mole%) = 99.7%
 Oil = 50 ppm
CARBON DIOXIDE(0.786 ton)
 Pressure = 0.45 kg/cm2
 Temperature = 40 0C
 Composition(volume%) = 93.37%
 UTILITIES
STEAM(1.53 ton)
 Pressure = 13kg/cm2
 Temperature = Saturated temperature
PROCESS DESCRIPTION
 UREA is synthesised from CO2 gas , liquid ammonia and
recycle carbamate solution under high pressure 210 kg/cm2
and temperature 195 degree centigrade.
 The reaction takes place in two stages, the first stage where
CO2 and NH3 to form AMMONIUM CARBAMATE is fast
and highly exothermic. Then in second stage AMMONIUM
CARBAMATE decomposes into UREA & WATER at slowly
and reaction is endothermic but OVERALL REACTION IS
EXOTHERMIC.
2 NH3 + CO2 = NH4COONH2 + 117 KJ
NH4COONH2 = NH2CONH2 + H2O - 15.5 KJ
 The plant is designed to produce 730 ton of PRILLED
UREA per stream day single unit , using MITSUI TOTAL
RECYCLE “C” PROCESS.
SYNTHESIS SECTION
Equipment in this section are given below-
 CO2 COMPRESSOR(GB-101)
 NH3 INJECTOR(GA-101)
 RECYCLE FEED PUMP OR EBARA(GA-102)
 NH3 PRE- HEATER(EA-101)
 REACTOR(DC-101)
CO2 gas , liquid NH3 and recycle solutions are compressed
and fed separately to the base of the REACTOR which is
operates at about at 195 degree centigrade temperature and
210 kg/cm2 pressure. Ammonium carbamate is formed first
and then breaks down to give urea and water. The reaction
products are UREA , WATER, NH3 and CO2, whether free or
combined as carbamate are expanded through a let down
valve into HIGH PRESSURE DECOMPOSER(DA-201) in the
decomposition section.
 CO2 COMPRESSOR
 The compressor is a six crank, five stage enclosed forced
lubricated machine. The FIRST, SECOND and THIRD
stages are double acting, FOURTH & FIFTH stages are
single acting.
 The compressor is capable of delivering 12,530 M3/Hr of
CO2 gas measured dry at 760 mmHg and 0 degree
centigrade.
 The suction condition of the CO2 gas is 0.45 kg/cm2 and 40
degree centigrade.
 The delivery condition of the CO2 gas is 230 kg/cm2
measured at the outlet from the FIFTH stage delivery
damper.
 The compressor is driven by 11 KV (4090 HP), 300 RPM
brushless SYNCHRONOUS ELECTRIC MOTOR.
 LIQUID AMMONIA FEED PUMP
 These pumps are vertical machines having FIVE
SINGLE ACTING RAMS running at a fixed speed of
220 RPM and delivering 34.6 m3/Hr of LIQUID NH3.
There are two pumps per stream together with a
common spare.
 Each pump is driven by 3.3 KV (350KW), 50 Hz, 750
RPM electric motor with a gear box to achieve the
necessary speed reduction between motor and pump.
 The suction pressure of pump is at 21 kg/cm2 by
ammonia booster pump and delivery pressure is 230
kg/cm2.
 RECYCLE FEED PUMP OR EBARA
 This is high speed centrifugal pump and running with
7451 RPM.
 EBARA PUMP has 8 stages.
 The suction pressure of EBARA PUMP is 24 kg/cm2
and delivery pressure is 230 kg/cm2.
 Ebara handles recycle carbamate solution to the
reactor.
REACTOR
 In this plant PLUG FLOW TYPE REACTOR are used for
reaction.
 Compressed CO2 gas, Compressed liquid NH3 and
compressed recycle solution are fed separately to the base
of the REACTOR, Ammonium carbamate is formed first &
this then break down to give UREA & water.
 The operating pressure of reactor is 210 kg/cm2 and
temperature is 195 0C
 The RESIDENCE TIME is 21 minutes and Height of
REACTOR is 27 meter.
 The reaction to form urea takes place in two stages. NH3 &
CO2 first react to form ammonium carbamate & reaction is
fast , highly exothermic. After that ammonium carbamate
undergoes a slower endothermic breakdown to form urea
and water.

 2NH3 + CO2 ---- NH4COONH2 ----- NH2CONH2 + H2O

DECOMPOSITION SECTION
Equipment in this section are given below-
 HIGH PRESSURE DECOMPOSER with REBOILER
 LOW PRESSURE DECOMPOSER with REBOILER
 GAS SEPARATOR & OXIDIZER(upper & bottom)

 In this section, the product mixture from the reactor is

processed to remove NH3 and CO2 and leave an
aqueous UREA solution. This is achieved by
application of heat and stepwise reduction in pressure
as solution passes through HPD , LPD ,GAS
SEPARATOR & OXIDIZER.
RECOVERY SECTION
Equipment in this section are given below-
 High Pressure Absorber Cooler (HPAC)
 Low Pressure Absorber (LPA)
 Gas Condenser (GC)
 Off Gas Condenser (OGC)
 Off Gas Absorber (OGA)
 Off Gas Absorber Cooler
 High Pressure Absorber (HPA)
 Mist Separator
 NH3 Reservoir
FINISHING SECTION
Equipment in this section are given below-
 FILTER
 VACUUM EVAPORATER
 CRYSTALLIZER
 DRYER (Pneumatic type)
 CYCLONE
 MELTER
 GRANULATORS/DISTRIBUTORS
 FLUIDISING COOLER
 TROMMEL & BELT CONVEYER

 Urea solution from oxidizer passes through filter into vacuum

evaporator, where water flashes off. The solution than flows
down into crystallizer, part of the heat required to evaporator
water is obtained from HPAC by means of a slurry circulation
from crystallizer through HPAC to vacuum evaporator.
 Urea crystal are separated from mother liquor by means of
centrifuge than dried & moisture content of crystals is reduced
up to 0.5%. & conveyed to the top of Prilling tower to a hot air
stream. Most of mother liquor returned to crystallizer, a small
part is sent to LPA, as a purge to reduce BI-URET content of
product. The BI-URET reaction is represented as-

2 NH2CONH2 ---------------- NH2CONHCONH2 + NH3

 The biuret in the final product is around 0.5%. At the top of

prilling tower, urea crystals are separated from air stream in
cyclones & then melted at 140 0C. Molten urea flows to the prills
head/ distributor, from which it forms into spherical drops
which solidify and cool as they fall down the tower further
cooling is done in a fluidizing cooler sited in the tower base &
prills then overflow into a trammel where the oversize material
after dissolving is sent back to the process, while the product
goes forward to packing plant.