Urea is an organic compound with the chemical formula CO(NH2)2 consisting of
carbonyl and amide functional groups. Urea serves an important role in the metabolism of nitrogen-containing compounds by animals and is the main component of urine of mammals. It is an important component of nitrogen-based fertilizers and also as a raw material for urea-formaldehyde resin which is an industrially important polymer (1) 2NH3 + CO2 => CARBAMATE (2) CARBAMATE => UREA + H2O The first reaction is carried out in a stoichiometric reactor, while the second reaction which produces urea is carried out in a plug flow reactor where the conversion increases along the length of the reactor. Optimization analysis has been carried out across the plug flow reactor by varying two parameters the length of the reactor as well as the operating pressure to obtain maximum profit by increasing the flow rate of the urea stream For stoichiometric reactor the pressure and the temperature has been varied, and the profit has been similarly maximized The length of the reactor has to be in the range of 25m- 30m. The pressure is kept within 140 kg/sq. cm – 150 kg/sq. cm keeping in consideration the space provisions and compressor capabilities. In PFR It was found that as the pressure increases, we are able to increase the flow rate of urea, which in turn increases the revenue by product sales from the process. However, in order to increase the pressure, a greater compression cost is also incurred. Clearly, this is a trade-off between compressor cost and product revenue and the revenue is optimised by plotting a graph in excel by varying the pressure from 140-150 kg/sq.-cm. the length of the reactor has been varied which when increased, provides a greater reactor volume that increases conversion and therefore, the final output of urea. But increasing the length of the reactor incurs a higher equipment installation cost and thus there is again a trade-off between urea production and equipment cost. For stoichiometric reactor It was found that as the pressure increases, we are able to increase the flow rate of urea, which in turn increases the revenue by product sales from the process. However, in order to increase the pressure, a greater compression cost is also incurred. Clearly, this is a trade-off between compressor cost and product revenue and the revenue is optimised by plotting a graph in excel by varying the pressure from 140-150 kg/sq.-cm. For stoichiometric reactor’ the temperature of the reactor has been varied which when increased, increases the conversion of the product, but also the coolant costs and other heat exchanger costs. After performing the sensitivity analysis of the Distillation Columns and plotting the relevant curves, the following conclusions were arrived at. For PFR