My Duration Time at Urea-2 was from 11 th July To 1st August, During this I gone through general equipment details

according to giving schedule and these are as follows CO2 COMPRESSOR

Multistage Centrifugal Compressor Two compressor are installed with different dia of impeller One is L.p and 2nd is HP Driven by steam driven condensable turbine Which gives 7110 rpm to compressor Compressor has Lubricants Which are cooled by cooling water Steam of turbine is condensed in condensate tank CO2 compressed gas is then passed through inter cooler to make the process isothermal Passivation air is given to inhabitate the corrosion process Compressors Are Used For Gases Pressure gauges and temperature indicators are also installed Surging of compressor that is due to back pressure may happen H.P having vertical casing while LP has horizontal casing After compression T=117 c and pressure 159 kg/cm

Urea reactor
Reactor is made of carbon steel with internal lining of carbon ,nickel, molybedim 43 m height NH3 is introduced at high pressure which passed through ejector and also take carbamate solution Where it react with CO2 coming from compressor In reactor 15 trays are employed which increases contact area In reactor residence time is 45 mint There are 500 holes per tray with 8 mm hole Trays are employed to prevent carbamate not to come below and to prevent the escape of CO2 At start up it is heated with steam at temperature 160c which is required to meet the operating conditions. First ammonium carbamate is formed. 2nd decomposition of ammonium carbamate to urea.

 Ammonium carbamate formation is exothermic reaction While decomposition reaction is endothermic reaction. The Reaction is as follow:

2NH3 + CO2 37.6 KCal NH2 COO NH4 6.KCal.

NH2 CO2 NH4

H=-

CO (NH2)2 + H2O H = +

The efficiency of reactor can be enhanced by By increasing pressure and removal of water. Rate of urea formation also depends on Rate of formation of ammonium carbamate which is favorable at high pressure and low temperature Temperature and pressure Residense time By increasing resedense time biuret formation will be increased Conversion of carbamate to urea which is favorable at high temperature NH3 is taken in excess to facilitate the stripping of CO2 and to reduce the formation of biuret. While weep holes are provide to detect leackage of reactor.

Stripper
The removal of gases at the reactor pressure and the boiling point of solution is called stripping. Stripper is made of carbon steel vessel It operate at slightly low pressure than reactor and high temperature The solution is allowed to fall through ferrule in to tubes. which are like falling film type heat exchanger where the partial pressure of carbamate is reduced while solution comes down in falling film tubes. The required heat is supplied in the shell side of stripper by hs steam which is at 219c. There are 2585 tubes and 2582 ferrules.

Carbamate condenser

The effluent high pressure vapors from stripper are absorbed in carbonate solution in carbamate condenser. The condensation reaction is exothermic heat is which is used to generate steam at 4.5atm. The solution inlet ,outlet ,condensate inlet ,outlet are employed Psv connection and temperature indicators are also employed. There are 1483 tubes and weir ring are used to control water level it has also vapour collector .

Carbamate ejector
Ejector work on the principle of venture. Two fluid are necessary one is driving fluid known as driving fluid and second is moving fluid. Liquid ammonia under high pressure is used as driving fluid while carbamate is moving fluid. The suction capacity is controlled by varying the motive fluid flow through a nozzle needle which is moved by pneumatic actuator.

MP SECTION DECOMPOSER
It consist of a vessel and shell and tube heat exchanger Solution enter in the top of mp at 17kg/cm2 Vessel is for the expension of fluid to minimize the pressure Pressure of complete loop is controlled by blow down valve. The purpose of heat exchanger is to decompose the solution into NH3,CO2. The vapour of composer are mixed with aquas carbonate solution coming from lp section. There is also Ls and HS circuit. There is another decomposer in the mp section which is buble cap tray type.

LP SECTION
In This Section There Is One Decomposer At low pressure the remaining CO2 and NH3 are removed. The vapor at the top of vessel are mixed with the vapor coming from pct.

Vacuum section

To achieve the required concentration of urea solution vacuum section is installed. There are two vacuum vessel are installed which are at maximum height to provide the required head. To pump. By centrifugal pump the solution is sent to the 1st vacuum concentrator. The solution from v-4107 to v-4108 is sent with the help of gravity. While the vacuum is generated by ejector principle. In which LH steam is passed at very high speed as driving fluid and suck the vapors from the top of vacuum vessel and vacuum is generated. There is complete control system of vacuum. In winter the efficiency of cooling tower is increased so water at low temperature more vacuum. And it is controlled by giving air.

Prilling tower
Urea solution 99% from vacuum vessel is sent to prilling tower with the help of centrifugal pump. The pipe leading the urea solution from vacuum vessel is steam jacketed.. The solution is showered by means of revolving bucket which is revolving at particular speed controlled by motor. Prilling tower is working on the principle of natural daft . The size of prills is controlled by the speed of bucket ,sieve size, and height of prilling tower At the bottom there is scrapper and conveyor belt arrangement. From here urea prills are sent to the bagging section.

Types Of Airs
Instrument air Passivation air. N2 to plant. Air compressor. For air compression air is compressed in 4 stage centrifugal compressor . At suction of compressor filter are used. At 3rd stage compressor air is taken at temperature of 98 c. It passed through heat exchanger and outlet temp is 40 c and entered in tank. Where it is devided in three section one for passivation and other for N2 to plant and instrument air.

Instrument air
Instruement air is passed through filter to remove dust particles and moisture. Then it passed to two activated alumina filled bed. And this dry air is send to plant.

N2 genaration plant
Air at 35 c is passed through refrigeration unit cooled by chilled water . It comes out at 14c and passed through knock out drum. Molecular sieves unit also installed . where 10 Ao sieve size made of sodium aluminum silicate as absorbate Here co2 and hydro carbon are absorbed and N2 goes out. Adsorption conditions are low temperature and high pressure. Then it passes through cold box N2 is separated under cryogenic process and sent to ammonia section.

PCT SECTION
Vapor from vacuum section along with NH3 and CO2 is condensed in T-4107 Then this solution is passed through heat exchanger with the help of pump. In pct there is fractionating column there are 55 trays and where chimney trays are at 35 positioned . Solution is showered from the top and passed through trays and co2 and NH3 is stripped out while the solution from upper section is passed through hydrolyser where further gases are removed and again send to lower of chimney trays. At chimney trays solution level is maintained and gase from lower solution s stripped out through chimney.

Absorption chiller
Absorber Absorption chiller has four parts Concentrator Condenser Evaporator Absorber And there are also absorber pump, refrigerant pump and concentrated pump. In absorption chiller lithium bromide solution is used.