Sule AlabiJonathan Arana

Elizabeth MoscosoOleg Yazvin

Mentor: Dan Rusinak – Middough

Production of Prilled Urea

Clean Water from 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

Urea Production

PlantWaste Water

Treatment Plant

Evaporator Unit

Inlet NH3 & CO2

from NH3 Plant

CO2 & NH3 Recycled Gas

Air In

Prilling Tower

Urea Production Plant PFD

1

2

3

4

5

6

78 9

10

11

12

13

14

DECOMPOSERDECOMPOSER

water

Urea (72%)Solution

Un-reacted Gases

Urea Production Plant Calculations Some Assumptions:

Stream 1 2 3 4 5  

 

NH3 Feed Gas Exit from Stripper Solution from Scrub Solution from Pool Gas Recycle to Scrub

Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons Ton Moles Tons

Totals 77.31 1314.33 77.59 2441.84 140.00 3565.00 151.47 4430.96 10.50 234.30                   

Compounds                    

CO2     41.59 1829.84 10 440.00 18.57 817.14 2.06 90.79

NH3 77.31 1314.33 36.00 612.00 100 1700.00 75.97 1291.52 8.44 143.50

AC         15 1155.00 10.98 845.16    

Urea             15.48 928.57    

Water         15 270.00 30.48 548.57    

           

Properties            

Temperature 185oC 185oC 185oC 185oC 60oC

Pressure 140 Bar 140 Bar 140 Bar 140 Bar 1 Bar

Calculations:

Input Variables

CO2 input (tons) 1153.15

NH3 / CO2 Input Mole Ratio 2.95

Input CO2 Split into Reactor 0.90

Reactor

Extent of Reaction 1 Based on CO2 0.60

Extent of Reaction 2 Based on CO2 0.50

Fraction of CO2 that gets converted 1.00

Compound Mass Flow Rate IN (TPD)

Mass Flow Rate OUT (TPD)

Mole Flow Rate IN (ton mole/day)

Mole Flow Rate OUT (ton mole/day)

AC 506.7 12.5 6.5 0.13

Urea 1513.8 1893.5 25.2 31.6

Water 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%

Waste Water Treatment Plant PFD

13

31

32

33

Waste Water Treatment Plant Calculations

Assumptions: Basis of 50,000kg of

effluent sewer water 10 NH3 ppm specification

from EPA Assumed same PPM for

CO2 Inlet Water composition

from existing Indian Urea Plant

1% of recycle is vented to air

Calculations:

Stream 13 31 32 33

Total 532,066.00 477,245.34 50,000.00 4,820.66

Mass (kg) Balance

Components

CO2 38,084.00 37,703.11 0.05 380.84

NH3 45,332.00 44,878.63 0.05 453.32

Urea 4,985.00 4,935.15 0.00 49.85

Water 443,665.00 389,728.45 49,999.90 3,936.65

Mole (kmol) Balance

Component

CO2 865.55 865.54 0.00 216.39

NH3 2,666.59 2,666.59 0.00 666.65

Urea 83.08 83.08 0.00 20.77

Water 24,648.06 21,870.28 2,777.77 5,467.57

Total 28,263.27 25,485.50 2,777.78 6,371.37

Properties

Temperature 25oC 25oC 25oC 25oC

Pressure 1 bar 1 bar 1 bar 1 bar

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

Evaporator Unit Calculations Assumptions: Input Urea 1572.48 Tons

Input Water 611.52 Tons

wt% 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 2

Ton 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

               

Compounds                    

Urea 26.21 1572.48 26.21 1572.48     26.21 1572.48    

Water 33.97 611.52 33.97 611.52 32.27 580.94 1.70 30.58 32.27 580.94

H.P. Steam                    

         

Properties            

Temperature 80oC 80oC 110oC 95oC 80oC

Pressure 5 Bar 5 Bar 0.8 Bar 0.8 Bar 1 Bar

Cyclone

Screen

Bag House

Pump

Melting Furnace

Dehumidifier

Prilled Urea (99.8%)

Urea Melt (99.8%)

Prilling Tower

27

30

29

Air from Atm

Cleaned Air

28

Prilling Tower PFD

Prilling Tower Calculations

Assumptions: Mass flow rate of Prilled

Urea is 738.22 TPD According to the EPA the

allowed urea dust is 3.8 lb/ton of Prilled Urea. For ammonia dust the allowed emission is 0.87 lb/ton of Prilled Urea.

Stream 27 28 29 30

Urea Melt (99.8%)

Air From Atm

Prilled Urea (99.8%) Cleaned Air

  Tons Tons Tons Tons

Totals 739.94 500 738.22 501.724

Component        

Urea Melt 739.94 --- --- ---

Ammonia Dust --- --- --- 0.32

Urea Dust --- --- --- 1.40

Prilled Urea --- --- 738.22 ---

Air --- 500 --- 500

Properties        

Temperature 185oC 25oC 25oC 25oC

Pressure 1 bar 1 bar 1 bar 1 bar

Calculations:

Estimated Economics

  Materials Cost (Money We Spend) Amount Overall Cost

NH3 $521.00 Per Ton 891.07 Tons Per Day $464,247.47 Per Day

CO2 $15.00 Per Ton 1153 Tons Per Day $17,295 Per Day

  Product Price (Money We Get)     Overall Price

Urea to UAN $230.00 Per Ton 694.48 Tons Per Day $159,730.40 Per Day

Prilled $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

Estimated Total Cost

2009- Q’atar built a 3,836 TPD Urea PlantPlant 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

Questions?