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## Production of Prilled Urea

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**Production of Prilled Urea**Sule Alabi Jonathan Arana Elizabeth Moscoso Oleg Yazvin Mentor: Dan Rusinak – Middough**BFD of Urea & Prill Plant**Output NH3 Purge & Urea SolutionTo Amm. Nitrate & UAN Plants Urea Production Plant CO2 & NH3 Recycled Gas Inlet NH3 & CO2from NH3 Plant Waste Water Treatment Plant "Dirty Water" Rich in NH3, CO2 & Impurities Clean Water from CHP Plant Urea Solution (72%) Cleaned Air Out Condensate Water Prilling Tower Evaporator Unit Prilled Urea (99.3%)Product Solid Urea (99.3%) Air In**Urea Production Plant PFD**14 water 6 13 5 Un-reacted Gases 3 11 1 2 DECOMPOSER 10 12 4 8 7 9 Urea (72%)Solution**Urea Production Plant Calculations**• Some Assumptions: • Calculations:**Material & Energy Balance for Decomposer Unit**Basis: 1893 TPD of Urea produced Composition of Urea 72% Q = 177 BTU/ton**Waste Water Treatment Plant PFD**33 31 13 32**Waste Water Treatment Plant Calculations**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**23**21 Condenser Streams 21, 26, 19: To Waste Water Treatment 24 17 H.P. Steam 22 Evap1 Eductor Evap2 25 Product Urea (99.8%) 27 19 26 15 Urea Solution (72%) 18 20 16 Storage Tank Evaporator Unit PFD**Evaporator Unit Calculations**• Assumptions: • Calculations:**Cleaned Air**Cyclone 30 Prilling Tower Bag House 27 Urea Melt (99.8%) Pump Melting Furnace Dehumidifier 28 Air from Atm Screen 29 Prilled Urea (99.8%) Prilling Tower PFD**Prilling Tower Calculations**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.**Estimated Total Cost**• 2009- Q’atar built a 3,836 TPD Urea Plant • Plant 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