UREA

MANUFACTURING
PROCESSES

by
Jawad Ullah Khan
Asstt. Technical Manager

History of Urea

Urea was first discovered in Human Urine in 1773 by H.M Rouelle

It was synthesized in 1828 by Friedrich Wohler as a first organic

compound

In 1890 Urea was produced by heating Ammonium Carbamate in a

sealed vessel. This provided the basis of the current industrial
process for its industrial production

Urea
Urea is a nitrogen-containing chemical product which is produced on a
scale of some 100 Million Tons per year worldwide. Urea has the highest
nitrogen content of all solid nitrogeneous fertilizers in common use.
(46.4%N.) It therefore has the lowest transportation costs per unit of
nitrogen nutrient.

Application
More than 90% of world production is destined for use as a fertilizer.
Manufacture of urea-formaldehyde resins. These synthetic resins are
used in the manufacture of adhesives, moulding powders, varnishes and
foams. They are also used for impregnating paper, textiles and leather.
A raw material for melamine production More than 95% of all melamine
production is based on urea.
A supplementary substitute protein source in feedstuffs for cattle etc.

Manufacturing Processes
Once Through Process
Partial Recycle
Total Recycle

Once Through Process

Once through process is simplest and less expensive (in both capital
investment and operating cost) of the three basic type of processes.

Even though the process is simplest, it is least flexible and cannot be

operated unless some provision is made to utilize the large amount of offgas ammonia.

Thus, it must be used in conjunction with the co-production of some other

materials, e.g.
ammonium sulfate, ammonium nitrate, nitric acid or
ammonium phosphate.

Partial Recycle Process

As is clear from the name in this process partial
ammonia is recycled to the urea reactor.
The remaining ammonia is to be used for some other
material as in the case of once through process, but in
this case lesser ammonia is available for coproduction (15% less).

Urea Manufacturing
Synthesis
Section

CO2
NH3

Decomposition
Section

Finishing
Section

Product

Recovery
Section

Reactions:

2 NH3 + CO2

NH4COONH2 (Amm. Carbamate)

NH4COONH2

NH2CONH2 (Urea) + H2O

2 NH2CONH2

NH2CONHCONH2 + NH3
(Biuret)

Process Features

Low Energy Consumption

High CO2 Conversion
Efficient Stripping in Stripper
Efficient Heat Recovery within Process

Easy and Safe Plant Operation

High Operational Flexibility
Maintenance Free Operation

High On-Stream Factor

High Operational Flexibility
Easy Operation

Process Features

No Pollution
Efficient Dust Recovery
Efficient Water Treatment

Low Operation and Maintenance Cost

Less Energy & Raw Material Consumption
Proven Design & Equipment

High Product Quality

High Purity
Sharp Product Size Distribution

Energy Demands in Urea Plant

Pressurization of Raw Materials

Compression of CO2 Gas
Pumping of Ammonia
Pumping of Carbamate Solution

Separation of Unconverted Material

Decomposition of Ammonium Carbamate
Evaporation of Excess Ammonia

Concentration of Urea Solution

Evaporation of Water

Low Energy Consumption

High CO2 Conversion in Reactor

NH3 / CO2 Molar Ratio
H2O / CO2 Molar Ratio
Operating Pressure / Temperature
Reactor Design

Efficient Decomposition

Efficient Heat Recovery within Process

Decomposition by Steam generated in Carbamate Condenser
Evaporation by Condensation Heat in Medium Stage Absorption

Urea Manufacturing Processes

MITSUI TOATSU
STAMICARBON
SNAMPROGETTI
ADVANCED PROCESS FOR COST AND ENERGY SAVINGS (ACES)
UREA TECHNOLOGIES INC. (UTIC)

CO2 Stripping Process

NH3 and CO2 are converted to urea via ammonium carbamate at a

pressure of approximately 140 bar and a temperature of 180-185 oC.

The molar NH3/CO2 ratio applied in the reactor is 2.95.

This results in a CO2 conversion of about 60% and an NH3

conversion of 41%.

The reactor effluent, containing unconverted NH3 and CO2 is

subjected to a stripping operation at essentially reactor pressure,
using CO2 as stripping agent.

CONTD

The stripped-off NH3 and CO2 are then partially condensed and
recycled to the reactor.

The heat evolving from this condensation is utilised to produce 4.5

bar steam some of which can be used for heating purposes in the
downstream sections of the plant.

Surplus 4.5 bar steam is sent to the turbine of the CO 2 compressor.

The NH3 and CO2 in the stripper effluent are vaporised in a 4bar
decomposition stage and subsequently condensed to form a
carbamate solution, which is recycled to the 140bar synthesis
section. Further concentration of the urea solution leaving the 4bar
decomposition stage takes place in the evaporation section, where
a
99.7%
urea
melt
is
produced.

Comparison of Reactor Conditions

ACES

SnamprStamicarbon
UTIC
ogetti

Pressure
psig

2538

2000

2320

3200

Temperature
O
F

374

365

374

380

NH3 / CO2

4.0

2.90

3.6

4.5

CO2 Conv. %

68

58

65

75

Lining
Material

316L
SS

316L SS

316 L
316L SS
SS

Comparison of Utilities Consumption

SnamprACES Stamicarbon
UTIC
ogetti
Steam T/T

0.48

0.70

0.90

0.90

Electric Power
KWH/T

121

115

120

140

Cooling Water
T/T

55

65

75

65

Fertilizer Plants in Pakistan

#

Company

Process

Production
MTPD

Dawood Hercules Chemicals Limited

UTIC

Urea = 1350

Engro Chemicals Limited

MTC Total Recycle

ACES

Urea = 810
Urea = 1810

Fauji Fertilizers Limited

FFC 1 & 2 (Sadiqabad)
FFC 3(Former Pak Saudi)
Fauji Fert. Bin Qasim

Snamprogetti
Snamprogetti
Stamicabon

Urea = 4030
Urea = 1950
Urea = 1670
DAP = 1350
Urea = 280
CAN = 1350
NP = 915

Pak Arab Fertilizer Ltd.

Snamprogetti
Hoest / Uhde
Stamicarbon

Pak China Fertilizer Ltd.

Chinese

Urea = 340

Pak American Fertilizer Ltd.

ACES

Urea = 1050

Thank You