Urea plant design proposal through Snamprogetti process

Proposal for Urea (Snamprogetti process) plant design

By
Adil Amin
PG-E10-08
XYZ design firm

Institute of Chemical Engineering and Technology, University of the Punjab

Professor Dr.Mahmood Saleem

Assigned: January 17, 2014

Due: January 24, 2014
Submitted: January 24, 2014

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Urea plant design proposal through Snamprogetti process

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Urea plant design proposal through Snamprogetti process

Table of contents

Executive summary. 4
Proposal basis..7
Proposed technology..9
Major equipment data sheet17
Technical and economic assessment..20
Qualification and experience of project
Higher personnel ...21
Project schedule..22-23
Conclusion 23
Contact details..24

Urea plant design proposal through Snamprogetti process

1. Executive summary
This proposal is in the response of the invitations from
Institute of chemical engineering and technology for the design and
installation of urea plant with energy efficient process. We XYZ firm are
willing to do this great project. XYZ firm is well established and
recognized firm. We provide excellent work.
XYZ firm has proposed urea plant design using snamprogetti
process. Snamprogetti process is well known modern technology, which
is meeting modern day demands. Snamprogetti process is energy
efficient and gives good quality urea production with very minimum
energy wastage. Almost many of the worlds urea production
companies have switched to or have installed expansion plants after
inspiring with this technology. Fauji Fertilizer, Goth machhi, Industry is
presently running on this technology. This company is the best urea
producing company of the Pakistan.
Snamprogetti process for urea production is by reacting
liquid ammonia & gaseous carbon dioxide, which was first introduced in
Germany in 1922. The two reactants react in urea reactor under high
temperature & pressure. The reaction proceeds in two steps, 1st step is
formation of an intermediate product ammonium-carbamate. In 2nd
step it dehydrates to form urea & water.
2NH3 + CO2

NH2COONH4

H = - 37.6 KCal

Urea plant design proposal through Snamprogetti process

NH2COONH4

NH2CONH2 + H2O

H = + 6.3 KCal.

(Urea)
First reaction is highly exothermic, fast & immediately goes to
completion. The second reaction is endothermic & is only partially
complete. The unconverted ammonium carbamate is then decomposed
back into ammonia & carbon-dioxide & totally recycled back to urea
reactor. The design efficiency of most urea reactors is between 60 to
65%. Block diagram of the process is given below.

The detailed description of the process, total production, cost of

production and project scheduling detail is present in this proposal.XYZ
firm provides assurance of the project completion on the given time
scale.

Urea plant design proposal through Snamprogetti process

2. Proposal basis

2.1. Statement of proposal

Our firm XYZ has proposed urea production according to
snamprogetti process for your new plant. The purpose of choosing
(Snamprogetti process) plant design is to make use of new efficient
technology, which improves urea quality, and reduce production cost.

2.2. Feed Stocks

The required feedstocks for the urea production are
Carbon dioxide and Liquid Ammonia. The feedstocks, which your
company ABC is producing, are meeting our design requirement. This is
very good sign. For you convenience the feedstocks specifications
along with the required utilities mentioned below.

Ammonia (Liquid)
Battery Limit Conditions:

Pressure

:24 kg/cm2(g)

Temperature

:29C

Ammonia

: 99.8 %wt mm.

Oil

: 5 ppm max.

Water

: 0.2 %wt max

Carbon Dioxide (Gas)

Battery Limit Conditions:

Urea plant design proposal through Snamprogetti process

Pressure

: 0.2 kg/cm2 (g) mm.

Temperature

: 60C

CO2

: 99.7 % vol.

Water

: Saturated

H 2+ N2+ CH4 : 0.23 %vol.

UTILITIES

Steam

Power

Cooling Water

Instrument Air/ Utility Air

Inert Gas (Nitrogen)

2.3. Product specifications by the proposed process (Snamprogetti)

This product specification chart is currently followed in a well known

urea producing company Fauji fertilizer company at Goth Machhi.

Urea plant design proposal through Snamprogetti process

This company is also using the same proposed Snamprogetti process

for producing urea at minimum cost as compared to other processes.

2.4. Why Snamprogetti process is better than Stamicarbon process

This above comparison concluded that proposed snamprogetti is far

better than stamicarbon process in term of energy efficiency,
production cost and product quality.

Urea plant design proposal through Snamprogetti process

3. Proposed Technology

3.1. Process description

Description of Snamprogetti Urea Process

Main stages of the process are:

a)
b)
c)
d)
e)
f)
g)

CO2 compression
Urea synthesis and high pressure recovery
Medium pressure recovery
Low pressure recovery
Urea solution concentration
Prilling
Waste water treatment

a) CO2 Compression
Urea synthesis takes place at 154 ATA and 175oC. CO2 is available at 0.3 Ata at
battery limit, therefore the CO2 gas available from ammonia plant has to be
compressed to a synthesis pressure for feeding into the urea reactor.
The compression is done in the four stage centrifugal compressor driven by
Extraction steam turbine.
A four stage reciprocating compressor was added in 1993 to meet the additional
requirement under debottlenecking.

Urea plant design proposal through Snamprogetti process

b) Urea Synthesis and High Pressure Recovery

Urea is produced by synthesis from liquid ammonia and gaseous carbon dioxide. In
urea reactor (57 % efficiency), R-101, liquid ammonia and carbon dioxide react to
form ammonium carbamate, a portion of which dehydrates to form urea and water.
The reactions are as follows:

2NH3 + CO2 NH2 COONH4

(H = -100KJ/Mole)

NH2COONH4 NH2 CONH2 + H2O

(H = -100KJ/Mole)

Optimum temperature and pressure for synthesis are 188oC and155 Ata
respectively. The first reaction occurs rapidly and is completed; the second reaction
occurs slowly and determines the reactor volume.
The fraction of ammonium carbamate that dehydrates is determined by the ratio of
the reactants, the operating temperature and the residence time in the reactor.
Optimum range of molar ratio of ammonia to carbon dioxide is 3.2-3.5 to 1 and
molar ratio of water to carbon dioxide is 0.50-0.70 to 1.0.
The liquid ammonia coming directly from the battery limits is collected in the
ammonia receiver, V-101. From where the ammonia is pumped to the high pressure
section using ammonia booster pumps, P-105A/B and high pressure reciprocating
ammonia feed pumps, P-101A/B/C.
High pressure liquid ammonia is used as driving fluid for the carbamate ejector EJ101, which is used to transfer carbamate to the reactor coming from carbamate
separator, MV-101.
From CO2 compressors K-101 & K-101A the carbon dioxide received at 156Ata and
enters into urea reactor R-101. A small quantity of air is introduced in the suction of
K-101 (in future it will be introduced in 1st stage discharge), in order to passivate the
stainless steel surface of the equipments, thus protecting them from corrosion.
The reaction products leaving the reactor enters in falling film stripper, E-101. The
mixture is heated as it flows down the falling film exchanger. The carbon dioxide

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Urea plant design proposal through Snamprogetti process

content of the solution is reduced by the stripping action of the excessive ammonia
as it boils out of the solution and as well as by mass transfer phenomenon. Heat for
the decomposition of carbamate is supplied by saturated steam at 26Ata and 225C.
The overhead gases from the stripper and recovered carbonate solution from the
medium pressure section is routed to the carbamate condenser, E-105A/B where the
total mixture, except for a few inerts, is condensed and recycled to the reactor by
means of carbamate ejector, EJ-101.
Condensing the gases at high pressure and temperature permits the production of
steam at 3.5 kg/cm2g in the shell side of carbamate condenser, E-105A/B.
The incondensable gases from the top of the carbamate separator MV-101 consist
mainly of inert gas, with a small quantity of NH3 and CO2, are passed under pressure
control to the MP decomposer holder, ME-102.

c) Medium Pressure Recovery Section

The solution, with a low residual CO2 content, leaving the bottom of the stripper, E101 is expanded at 17Ata pressure and enters in MP decomposer, E-102A/B through
MP Pre-decomposer E-102C.

MP decomposer is divided into two parts:

1. MP decomposer separator MV-102; where the released flash gases are removed
before the solution enters the tube bundle of E-102A/B.
2. Decomposition section E-102A/B; where the residual carbamate is decomposed
and the required heat is supplied by means of steam condensate at 20Ata and
215oC (in the upper part of E-102A shell) and saturated steam at 25Ata and 220oC
(in lower part of E-102B shell).
The NH3 and CO2 rich gases leaving the MP decomposer top separator, MV-102 are
sent to the shell side of vacuum Pre-concentrator, E-150 where they are partially
absorbed in the aqueous carbonate solution coming from the LP section. The heat of

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Urea plant design proposal through Snamprogetti process

absorption and condensation is used in evaporating water from urea solution

flowing in the tube side.
The final condensation of the vapors takes place in MP Condenser, E-107 where the
residual heat of absorption and condensation is removed by tempered water. The
mixed phase from E-107 flows to the MP absorber, C-101 where absorption of CO2
and rectification of ammonia takes place. Pure ammonia is used as a reflux which is
drawn from the ammonia booster pump, P-105A/B.
The bottom solution from C-101 is recycled by High pressure carbamate solution
pumps, P-102A/B to the high pressure section.
The ammonia vapors with inert gases coming out from the top of MP absorber, C101 are partially condensed by cooling water in the ammonia condenser, E-110.
From here the liquid and gaseous phases are sent to the ammonia receiver, V-101.
From ammonia receiver, V-101 the inert gases saturated with ammonia enter in the
ammonia pre-heater for heating battery limit ammonia, and then sent to the MP
falling film ammonia absorber, E-111 where ammonia is absorbed in cold steam
condensate coming from the MP inerts washing tower C-103.The heat of absorption
is removed by cooling water in the shell side. From the bottom of
E-111 the
ammonia solution is recycled to the medium pressure absorber, C-101 by means of
the ammonia solution pumps, P-107A/B.
The upper part of the MP Inert washing tower, C-103 inert gases are submitted to a
final washing by means of the cold steam condensate. Inerts sent to the blow down
system under pressure control.

d) Low Pressure Recovery Section

The solution leaving the bottom of MP decomposer holder, ME-102 is expanded at
3.5 kg/cm2g pressure and enters in LP decomposer, E-103 which is divided into two
parts:
1. LP decomposer separator MV-103, where the released flash gases are removed
before the solution enters the tube bundle.

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Urea plant design proposal through Snamprogetti process

2. Decomposition section E-103, where the residual carbamate is decomposed and

the required heat is supplied by mean of saturated steam at 4.5Ata and 147oC.
The gases leaving the top LP decomposer separator, MV-103 jointly with ammonical
solution from the waste water treatment section are sent to the LP condenser, E-108
where the heat of absorption and condensation is removed by cooling water.
The liquid phase, with the remaining inert gases, is sent to the carbonate solution
accumulator, V-103. From here by means of the MP carbonate solution pumps, P103A/B, the carbonate solution is recycled back to MP section
The inert gases are washed in the LP inert washing tower C-104 with cold steam
condensate and then sent to blow down system.

e) Urea Concentration Section

In order to prill urea, vacuum concentration section is provided to concentrate the
urea solution up to 99.7% wt.
The solution leaving the bottom of LP decomposer holder, ME-103 is expanded at
0.45Ata and enters in the vacuum pre-concentrator, E-150 which is divided into two
parts:
1. vacuum pre-concentrator separator, MV-150 where the released flash gases are
removed before the solution enters the tube bundle:
2. Decomposition section E-150, where the last residual carbamate is decomposed.
The gases leaving the top of the pre-concentrator, MV-150 are routed to the vacuum
unit where condensation takes place.
The urea solution collected at the bottom of the vacuum pre-concentrator holder
ME-150 is sent to the 1st vacuum concentrator, E-114 by the urea solution pumps, P150A/B. Operating pressure of E-114 is 0.45 Ata, and heat is supplied by steam at
4.5Ata and 147oC for evaporation of water.
The mixed phase coming out of E-114 enters in 1st vacuum separator, MV-106 where
vapors are extracted by the vacuum system, while the solution concentrated up to
about 95% wt. enters in 2nd vacuum concentrator, E-115. Operating pressure of E-

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Urea plant design proposal through Snamprogetti process

115 is 0.045 Ata, and heat is supplied by steam at 6Ata and 160 oC for evaporation of
water.
The mixed phase coming out of E-115 under temperature control enters the 2nd
vacuum separator MV-107 from where vapors are extracted by the vacuum system
while the melted urea (99.7% wt) at temperature of about 140 oC reaches the 2nd
vacuum separator holder, ME-107.

f) Prilling
The melted urea leaving the 2nd vacuum separator holder, ME-107 is sent to the
prilling bucket, ME-109A/B by means of the melt urea pump, P-108A/B.
The urea coming out of the bucket in the form of drops falls along the prilling tower
and encounters a cold air flow which causes its solidification.
The solid prills falling at the bottom of the prilling tower are sent to bagging section
for shipment by means of urea conveyor belts.

g) Waste Water Recovery

The waste water collected from vacuum section is treated to hydrolyze urea into
ammonia and CO2 and then recycle back recovered CO2 and ammonia to LP recovery
section.
Waste water is fed into the column, C-102 after preheating with the outgoing waste
water. Low-pressure steam is introduced in the column for stripping. Feed from the
middle of the column is taken and sent to the hydrolyser, R-102 that operates at 36
Ata & 235oC. The hydrolyzed solution is taken back into the column.
Vapors from the hydrolyser are combined with the vapors from the column top and
condensed in the condenser, E-117. The uncondensed gases / inert are vented while
the solution from the condenser is collected in the accumulator and recycled to the
LP recovery section by means of pump, P-115. Treated water sent to evaporation
pond by means of pump, P-114.

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Urea plant design proposal through Snamprogetti process

Process flow diagram for the whole process has been attached in
the proposal documents.

3.2. Reactor selection

The Plug flow reactor containing sieve trays is selected
for the urea production. Carbon dioxide and ammonia comes into the
reactor where they react to form urea. This type of reactor is selected
because it gives maximum conversion of feed into urea solution.
Reactor is equipped with 10 sieve trays in the upper part
of the reactor. Sieve trays holes having diameter of 8mm are equally
spaced on the trays surface. The function of trays is to prevent escape of
gaseous CO2, which must react in the lower part of the reactor with
ammonia and prevent internal recycling of reaction product as higher
density products formed as reactants move upward in the reactor. The
volume and holding time of reactor is designed to allow the carbamate
conversion into urea and water.

3.3. Major Equipments

Equipment List:
Urea Reactor, R-101
HP Ammonia Pumps , P-101A/B/C
High Pressure Carbamate Solution Pumps, P-102A/B
Urea Stripper, E-101
Carbamate Condensers, E-105A/B
Carbamate Separator, MV-101
Carbamate Ejector, EJ-101
Medium Pressure Decomposer, E-102A/B
Medium pressure condenser , E-107
Medium pressure absorber , C-101

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Urea plant design proposal through Snamprogetti process

Overhead ammonia condenser , E-110

Ammonia Receiver , V-101
Ammonia booster pumps, P-105 A/B
Ammonia pre-heater, E-109
Medium pressure ammonia absorber, E-111
MP inert washing tower , C-103
LP decomposer , E-103
LP condenser , E-108
Carbonate solution vessel
LP ammonia absorber , E-112
Inert washing tower , C-104
Medium pressure carbonate solution pump P-103 A/B
Distillation tower feed pump , P-106 A/B
Ammonia solution recycle pumps , P-107 A/B
Prilling tower

Note :
Data sheets for main equipment are given on next pages. The data
sheet detail about other equipments will be provided to you in basic
engineering design report in our first meeting.

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Urea plant design proposal through Snamprogetti process

Urea Reactor, R-101

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Urea plant design proposal through Snamprogetti process

High pressure ammonia pumps P-101 A/B/C

Urea Stripper, E-101

Fluid circulated
No. of passes
No. of tubes
Tube sheet material

Shell Side

Tube Side

Steam
1
-

Urea solution
1
2574
CS+Ti cladding
(Thickness=10mm)
CS+Ti cladding
(Thickness=3mm)
2574
Pall rings

Ferrules material

No. of ferrules
Packing type

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Urea plant design proposal through Snamprogetti process

Carbamate Condenser, E-105A/B

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Urea plant design proposal through Snamprogetti process

Ammonia receiving vessel

4. Technical and economic assessment

This is the cost of sales at FFC. FFC is using the same urea
production process, which is proposed to you by us. You can have
estimation of the raw material consumption. Highlighted column
represents raw material consumption in 2012 and other represents its
consumption in 2011.

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Urea plant design proposal through Snamprogetti process

4.1. Estimated work force requirements (number of operators/shift)

At least 10 operators per shift needed for smooth
operation of the plant.
4.2. Total Production
2,610 tonnes/day

4.3. Estimated Cost of production (cost per bag)

Estimated production cost is B rupee per bag .Sales cost is 1700 rupee per bag at,
FFC goth machhi, which is producing urea through same proposed process. Sales
cost varies according to demand.

4.4. Cost of proposed project

Total project cost

rupees

Project installation

X rupees

Anticipated annual operation cost

Y rupees

Anticipated maintenance cost

Z rupees

5. Qualification and experience of project higher personnel

Member

Experience

Adil amin

B.Sc Chemical engineering

Mr.D

Project designer and chief commissioning engineer

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Urea plant design proposal through Snamprogetti process

Mr.G

Product consultant and project engineer

Other team members

Well experienced (Have designed and

Installed many plant of this process)

6. Project Schedule
Proposed project designing, construction, Permissions, Installations
and performance testing of the completed project are expected to be
completed no later than January 31, 2015
Project stage

Action required

Time and duration

Proposal
submitted Detailed study of January ,2014
for interim agreement different proposals by
I.C.E.T.
Execute
agreement

interim

Proposal
submitted
with
GMP
for
comprehensive
agreements
Funding
purchasing

February,2014
March,2014

and Funding should be April ,2014

from investor ,donors
and sponsors

Site preparation

Facilities provided by May-June 2014

investor

Shipping

Shipping, clearing and July-august ,2014

forwarding
of
equipment to site

Insurance

XYZ firm will initially August , 2014

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Urea plant design proposal through Snamprogetti process

get insured
Fabrication

Fabrication of non- Sep-Oct,2014

shipped equipments

Installation

Safe installation

NovemberJanuary,2015

Running

By the firm XYZ

February,2015

Plant handover

We will hand over the March,2015

plant after providing
operational training to
the personnels of the
Contractor

Project completed

By XYZ firm

Mrach,2015

The required meetings during the project will be conducted either form
you or from us. Any suggestions in the amendment of the schedule are
welcome.
7. Conclusion
Urea production through proposed process is much more
economical than other processes. It has told you already that
Snamprogetti will be the best choice for producing urea as this is a
proven technology and is currently applicable in almost all of the plants
of the world. This technology ensures energy saving and improved
quality of the product. We have passionate team, who love to work.
Project will complete on time. Project will be designed according to the
International standards. XYZ firm will be responsible for any fault in the
equipment designed. We are hopeful to get a positive response from
you. Thank you!

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Urea plant design proposal through Snamprogetti process

Contact details
XYZ firm
123 ABC road, Lahore
+923004149595 , adilamin77@yahoo.com

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