MATTU UNIVERSITY

College of Engineering and Technology

Department of chemical engineering

Course tittle Chemical Engineering Project design

Project Title: - Production of urea from ammonia and carbon dioxide

Project proposal

Group-1

Name Id

1. Edlawit Regasa 2010

2. Elshaday Gebru 0300
3. Yimer Mohammed 5601
Executive Summary
The process of production of urea from ammonia and carbon dioxide plant is to be designed
for the production of 300,000 kg/day of urea at elevated temperature and pressure, using a
total-recycle process in which the mixture leaving the reactor is stripped by the carbon
dioxide feed. The feed pure liquid ammonia is at 20 o c and 9 bar and pure gaseous carbon
dioxide also 20 o c and atmospheric pressure. This reaction takes place in two stages, in the
first, ammonium carbamate is formed in exothermic and the second the carbamate is
dehydrated in endothermic both reaction are reversible and goes to 40 to 70% completion.
The waste produce are water, ammonia and carbon dioxide but ammonia and carbon dioxide
are directly stored into the storage tank to be used as raw material. Only water flows out. The
removal of water is formed to produce granule of urea. The overall equipment used are
reactor, separator, condenser, compressor, dryer, stripper, prilling tower, and compressor and
storage tank. These flow processes will produce 0.985 of purity. 11.2.
Table of Contents
Executive Summary...................................................................................................................2
 1. Introduction
Urea is being discovered in the urine by H.M Rouelle in 1773. It was synthesized in 1828 by
Friedrich Wohler and urea is the first organic compound that has being synthesized from
inorganic starting materials. It was found when Wohler attempt to synthesis ammonia
cyanate. When he react silver cyanate with ammonium chloride, the reaction produce white
crystalline materials which is quite identical with the urea in the urine. In the year 1870, urea
had being produced by heating in ammonium carbonate in a sealed vessel.

Urea (NH2CONH2) is an organic compound and it is also known as carbamide. Ammonia is

usually used in agriculture sector especially to make fertilizers. Urea is made from ammonia
(NH3) and carbon dioxide (CO2). The production of ammonia and urea are being done
separately. Urea is a nitrogen-containing chemical product which is produced in excess of
140,000,000 tonnes per year worldwide, of which more than 90% of world production is
destined for used as fertilizer. Ammonia is being produce from the reaction of ammonia and
carbon dioxide and it is also being produced commercially. Urea can be produced as prills,
granules, flakes, pellets, crystals and also solutions. In the urea containing the highest
nitrogen in all solids nitrogenous fertilizers in common used (46.4%N). It also containing the
highest concentration dries nitrogen fertilizer available. So it has the lowest transportation
costs per unit of nitrogen nutrient. Urea also suitable for liquid fertilizer because it is soluble
in the water. The solid ureas are being market as prills or granules. Prills are cheaper compare
to granules since prills has the narrower size particles. Narrow size of particles has the
advantage if it is applied mechanically to soil.

Chemical and physical Properties of urea

Chemical properties: - is an organic compound and it is also known as Carbamide. IUPAC
name Diaminomethanal
Chemical formula: - (NH2)2CO.
Molecular mass: - 60.07 g/mol
Dipole moment: - 4.56 p/D
Melting point 132 oF Solubility Highly water soluble

Physical properties:-Solid urea will melt at 135 oc. Due to extensive hydrogen bonding with
water urea is very soluble. 1.33 x 103 kg/m3, solid Density 132.7 o c decomposes

Melting point Colorless Color odorless Odor

Solubility in water 108g/100ml (20oc)
167g/100ml (40oc)
251g/100ml (60oc)
400g/100ml (80oc)
733/100ml (100oc)
Vapour pressure < 10 Pa

Bulk density 0.8 kg.mg -3

Application of urea

In Agriculture: Urea is being used as fertilizers and animals feed. As known urea is
containing nitrogen and the nitrogen in it can help to promote growth for both animals and
plants. Ureas are also used in much multicomponent solid fertilizer formulation. There are
some advantages by using urea as fertilizers which are urea are more safer to ship and handle,
it also not corrosive to equipment compare if using nitrogen fertilizers, urea is high solubility
in water so it is easy to move in the soils and the last one is by using urea as fertilizers it can
be applied in many ways such as using equipment or by spreading it by using hand.

In Industrial: -With the mixed with many organics compounds urea has the ability to form a
loose compound. The organic compounds are held in channels formed by interpenetrating
helices comprising of hydrogen bonded area molecules. This kind of behavior has been used
to separate mixture. This has been apply in production of lubricating oils. Urea are also use as
raw materials for manufactured plastics (example urea-formaldehyde rasins) and glue
(example ureamelamine-formaldehyde). It also used as additive ingredient in cigarette, some
ingredients for making facial cleanser and also as a reactant in some ready to use cold
compresses for first aid used.

In Medicals: -In medicals urea has been used to produce barbituric acids. Urea is reacting
with the malonic acids to form barbituric acids. Barbituric acids are the parents of barbiturate
drugs. Barbiturate drug is act as central nervous system depressant. Urea also has been used
to produce acylureas and urethanes for use as sedatives and hypnotic. It is being made as
sleeping pills. It is used in the treatment of insomnia and in surgical anesthesia.

1.1.Statement Problem
1.2. Objective

1.2.1. General Objective

 To design a plant for the production of 300,000 kg per day of urea from ammonia and
carbon dioxide.

1.2.2. Specific objectives

 To determine the material and energy balance of the process.
 To simulate the design production process using ASPEN plus software.
 To conduct Cost Estimation and Economic of the designed production process.
 To design basic optimum equipment.

1.3. Significant of project

Understanding the process of synthesizing urea from ammonia and carbon dioxide is essential
for optimizing fertilizer production. Nitrogen is an essential nutrient for plant growth, and
urea is a widely used nitrogen fertilizer due to its high nitrogen content. Urea is a major
source of nitrogen for crops, promoting plant growth and increasing crop yields. By studying
urea production, researchers and agricultural scientists can better understand how to
efficiently supply nitrogen to plants, which is vital for sustainable and productive agriculture.
Urea is a versatile compound used in various industrial applications. It is a key raw material
in the production of plastics, adhesives, and certain types of resins. A thorough understanding
of urea production is crucial for the chemical industry to optimize processes, reduce costs,
and ensure a stable supply of urea for various applications.

1.4. Scope

To prepare a mass balance diagram for the process, on a weight per hour basis, through to the
production of urea prills and energy balance for the reactor–stripper–high-pressure condenser
complex. To prepare a process flow diagram, showing the major items of equipment in the
correct elevation, with an indication of their internal construction. Show all major pipelines
and give a schematic outline of the probable instrumentation of the reactor and its
subsidiaries. Prepare an equipment schedule, listing the main plant items with their size,
throughput, operating conditions, materials of construction, and services required. To prepare
an outline design of the reactor and carry out the chemical engineering design of the stripper,
specifying the interfacial contact area that will need to be provided between the carbon
dioxide stream and the product stream to enable the necessary mass transfer to take place. To
prepare a mechanical design of the stripper, which is a vertical steam-heated tube bundle
rather like a heat exchanger. Show how liquid is to be distributed to the tubes, and how the
shell is to be constructed to resist the high pressure and the corrosive process material. And
also the mechanical design of the reactor in the form of a general arrangement drawing with
supplementary detail drawings to show essential constructional features will be prepared.
 2. Literature Review
This process is one of the simplest methods and also the least expensive (both capital
investment and operating cost). This method is divided into three main type of process.
Before partial recycle process being discovered, liquid ammonia and gaseous carbon dioxide
are pumped into urea reactor at about 200 atm. The reactor temperature is maintain at about
185 Celsius by regulating the amount of excess ammonia about 100% excess NH 3 is
required, and about 35% of the total NH 3 is converted to urea (75% of carbon dioxide is
converted). The reactor effluent solution contains about 80% urea after carbamate stripping.
The unconverted NH 3 and CO2 are driven off at moderate pressure by stream heating the
effluent solution to carbamate strippers. Even though this process is the simplest of a urea
process, there are some limitations regarding ammonia gas. It is the least flexible and cannot
be operate unless some provision is made to utilize the large amount of off gas ammonia.
Thus it must be used in conjunction with the coproduction of some other material. For
example ammonium phosphate (used ammonia). One case in which the system can be used is
the production of urea ammonium nitrate solution; the converted NH 3 is used to make
ammonium nitrate solution. This solution than be mixed with the urea solution.

Total recycle process. Regarding partial recycle process all part of the off-gas ammonia and
carbon dioxide from the carbonate strippers is recycle to the urea reactor. Recycling is
accomplished by absorbing the stripper urea effluent, in the process steam condense or in
mother liquor from the crystallization finishing process. In this manner the amount of NH 3
in off-gas is reduced. Any proportion of the unreacted ammonia can be recycled. Typically
the amount of ammonia that must use in some other process is reduced to about 15% of that
from a comparable once-through unit. Mitsui Toatsu has made changes to the process and it
be rename as Mitsui Toatsu partial-recycle process as shown in figure 2. Liquid NH3 and
gaseous CO2 are pumped to the urea reactor at 200 atm. The temperature of the reactor is
maintained at about 185 Celsius by proper balance of excess NH 3 and carbonate solution
feed. About 100%-110% excess NH3 is used, about 70% of the NH3 and 87% of the CO2 are
converted to urea. The remaining 30% of the NH3 must be used in some other process. The
reactor effluent contains about 80% urea. Selection of process Total recycle processes one of
the reasons that total recycle process is chosen is the conversion of urea. In this process the
conversion of urea is about 99% (satisfied with the aim to achieve conversion of urea
between (40%-70%). This is because all unconverted ammonia-carbon dioxide mixture is
recycle and no nitrogen co-product is necessary (reducing the cost) (“Fertilizer Manual,
United National Industrial Development Organization (UNIDO), Kluwer Academic
Publishers, and ISBN 0-7923-5032-4 “)
Both processes give out high rate of conversion of urea, but to achieve the aim, the process
with the highest conversion is selected. This is to make sure that when the process is
undergoing, the possibility to get lower conversion of urea will be reduced. Pressure
(average)
The reason that Plug flow reactor is chosen because this reaction involves between two
reactant in gaseous state (ammonia and carbon dioxide). Theoretically plug flow reactor more
familiar with reaction between gaseous states. Other reactor also can be consider, but in order
to achieve production of 300000 kg day of urea, plug flow reactor is more suitable in large
scale. The production of urea also is continuous production. For temperature of 185 Celsius
can be consider last high temperature reaction, thus PFR are the best choice. CSTR, batch,
and semi-batch are more focusing one batch production, that not very suitable for production
of urea. Although in this production, the temperature is between 20-185 Celsius. That is more
easy control by using batch reactor, temperature still in the range of PFR temperature. In
economy aspect, low operation cost, is one of the aspects that have the main role, although it
may be costly when reach time to shout down and cleaning the reactor, it being cover by the
profit generate by the production of urea. (“H. Scott Fogler, Elements of Chemical Reaction
Engineering, Fourth Edition.”)
Generally this process using More equipment than partial less equipment that total recycle
process recycle process The more complex the reaction involving the more complex
equipment that will be used up. The equipment involves include heater, cooler (“Elementary
Principle of Chemical Process, Richard M. Felder, Wiley Publisher, Third Edition, 2005”)
 3. Methodology

3.1. Process Description

Urea is a chemical compound that is commonly used as a nitrogen fertilizer in agriculture.

It is also used in the production of plastics, adhesives, and animal feed. In addition, urea is
used in the manufacturing of cosmetics, pharmaceuticals, and as a reagent in chemical
laboratories.
This process is known as the Bosch-Meiser urea process and is the most commonly used
method for industrial production of urea it is a highly efficient and cost-effective method for
producing large quantities of urea. Overall urea plays a crucial role in various industries and
is an essential component in the global production of food, consumer products, and industries
goods. Its synthesis from ammonia and carbon dioxide is a key process that enables its
widespread use in diverse application.
First, the raw material, ammonia (NH 3) at 20oc, 9 bar and considered pure is pumped into
mixer thus increase the pressure to 125 bars. For the carbon dioxide (CO 2), raw material
available is at 20oc and 1 bar, also considered pure. The CO2 then is feed to the mixer through
a compressor which increased the pressure to 125 bar. The mixer mix three streams before
been feed to the reactor which is the NH3 and CO2 raw and also the ammonium carbamate
recycle stream. At the reactor, the feed at temperature 86.92 oc is allowed to react thus
produce urea and water. Small amount of biuret is also produce as a side product. NH 3 and
CO2 is first react to produce ammonium carbamate. 95% of equilibrium is achieved at this
rate. The limiting reaction for this process is the conversion of ammonium carbamate to urea
and water where the result fluctuates to 40 – 70 % conversion. For the calculation, 40%
conversion of urea is taken. Then, all the remaining reactant and product that formed in the
reactor enter the stripper. Carbamate is removed in the top stream of stripper and remaining
compound is leaves the stripper at the bottom. Carbamate leaves the stripper in form of
vapor. Since carbamate required in feed stream is in liquid phase, a condenser is put in the
recycle stream. By using steam at 40 bar with 200C of superheat, the temperature of the
stream is reduced from 185 to 170oc and the phase of carbamate is change from vapor to
liquid phase. Carbamate leaves the condenser at temperature 170 oc and pressure of 125 bar
and will fed into the mixer. Before entering the medium pressure separator, MPS and low
pressure stripper, the pressure of components leave the stripper is reduce from 125 bars to 18
bars and 18 bars to 5 bars respectively by using valves. Half of composition of NH 3 and CO2
is removed in the top stream of MPS and the remaining NH 3 and CO2 is removed in the LPS.
All the NH3 and CO2 are transferred to storage tank to be reuse back as feed. Remaining
component of urea, water and Biuret is leave the MPS and then LPS at the bottom stream
with pressure 18 bars, temperature 140oc and pressure 5 bars and temperature 80 oc
respectively. Next step is to reduce composition of water in product stream to 0.5% only.
Vacuum evaporator and prilling tower equipment is used for this process. The pressure of the
product stream leave the evaporator at 0 bar pressure since it operates in vacuum condition.
The temperature also reduces from 80oc to 27.25oc. Then, component that leaves the
evaporator at temperature 27.25oc and pressure 0 bar is entering the prilling tower. Air at
temperature at 25oc is used to remove the remaining water in the product stream. At the end
of the process, the products components leave at the bottom of tower at pressure 1 bar and
temperature 25oc, meanwhile air leave at temperature 26 oc. There is no waste and wastewater
treatment is needed since there no wastes are produced and the water leaves the temperature
in pure composition and at low temperature in this plant.

3.2. Material and Energy Balance

Material and energy balance is critical to ensure conservation of material and energy in
the urea production process. To do this, you can use the following method:
Defining the scope of the process: Clearly identify the part of the process where the
material and energy balance is performed. This includes all necessary input and output
flows, the urea production process involves several stages which include reactor,
separator, condenser, compressor, and storage tank. Material and energy balances can be
performed for each part or for the entire process.
Input and Output Data Collection: Collect detailed information about all input and output
flows. This includes mass flow rates, concentrations, temperatures and pressures. The
ingredients include pure liquid ammonia at 20 degrees Celsius and 9 bar pressure and
pure gaseous carbon dioxide at 20 degrees Celsius and atmospheric pressure.The outputs
include urea, water, ammonia and carbon dioxide.The correct composition and mass flow
rate of each flow is important for accurate balance.
Performing Calculations: Using mass and energy balance equations to calculate unknown
variables. This may involve determining mass flow rates, concentrations, temperatures,
and pressures at various points in the process.
Material balance: Law of Conservation of Mass: The total mass in a closed system
remains constant. This can be explained as follows:
Total Input = Total Output + Accumulation
 Material balance for each class: A material balance equation can be written for each
chemical species. This can be explained as follows:
Input for species i = output for species i + stock for species i
Energy Balance:
Law of Conservation of Energy: Energy cannot be created or destroyed, it can only be
changed from one form to another. This can be explained as follows
Total Energy Input = Total Energy Output + Accumulation
Energy balance for each unit: The energy balance equation can be written for each unit.
This can be explained as follows:
Energy In = Energy Out + Energy Stored

Types of Energy: There are different types of energy to consider, such as heat, work, and
internal energy.

Assumptions

 Steady state conditions: This means that the process variables (such as
temperature, pressure, and flow rate) do not change over time. This assumption
simplifies calculations.
 Isothermal Processes: This means that there are no temperature changes during the
process. This assumption is not always correct, but may be an acceptable
assumption in some cases.
 Negligible Heat Losses: This means that heat loss from the system to the
environment is negligible. This assumption is not always correct, but may be an
acceptable assumption in some cases
 Perfect Mixing in the Reactor: This means that the reactants and products in the
reactor are perfectly mixed. This assumption is not always correct, but may be an
acceptable assumption in some cases.

It is important to make correct assumptions as the assumptions made can affect the results
of the calculations.

3.3. Urea production equipment design

The main equipment of the urea production process includes:

Reactor: Used to combine ammonia and carbon dioxide to form urea and ammonium
carbamate. According to the sources, this process takes place under high temperature and
 pressure. The reactor must be designed to withstand high pressure and temperature and
must be given the necessary residence time for the reaction. The sources do not indicate
the exact type of reactor but suggest a continuous production process.

Separation: It is used to separate the urea product from the unreacted ammonia, carbon
dioxide and water. Sources suggest that different types of separation can be used,
including a fan and a high-pressure condenser. The design of the separator will depend on
the required separation efficiency and the process conditions.
Condenser: Used to cool and liquefy unreacted ammonia and carbon dioxide and return
those to the reactor. The size and design of the condenser will depend on the gas flow rate
and the required heat transfer rate.
Compressor: Used to provide the necessary pressure to supply the ammonia and carbon
dioxide to the reactor. The size and design of the compressor will depend on the required
flow rate and pressure rise.
Storage tank: Used to store liquid ammonia and carbon dioxide and store the urea
product. The size and design of storage tanks will depend on the required storage capacity
and safety requirements.
Design criteria
The following approach can be used to determine the main design specifications of urea
production equipment:
Dimensions: The dimensions of the equipment will depend on the requirements of the
process, such as the desired product volume, reaction kinetics and mass and heat transfer
characteristics. For example, the size of the reactor will depend on the required amount of
product and the amount of the reaction.
Material of construction: Materials of construction are selected based on the process
conditions, such as temperature, pressure and severity of the process streams. The sources
indicate that the urea production process involves high pressure and temperature, which
makes it important to choose suitable materials for the reactor and other equipment.
Common construction materials for the reactor include stainless steel or special steel
alloys, which can withstand corrosion and high pressure. Other equipment, such as
separators and condensers, can be made of different materials depending on the specific
conditions of the process.
Operating Limits: Operating limits of temperature, pressure and flow rate are established to
ensure safe and efficient operation. These limits will depend on the design limitations of the
equipment and the chemistry of the process. For example, the reactor may be designed for a
certain temperature and pressure range, and operating beyond these limits may damage the
equipment or create safety hazards.
Design tools
The following tools or software can be used to assist in the design of urea production
equipment:
Engineering Handbooks: Engineering handbooks such as the Perry Chemical Engineers
Handbook provide information on the design of various chemical process equipment.
These books can provide information on design equations, material properties, and design
criteria.
Design software: Computer-aided design (CAD) software, such as Autodesk Inventor or
SolidWorks, can be used to design and model tools. This software can be used to create 3-
D models, run simulations, and create drawings.
Process simulation software: Process simulation software, such as ASPEN Plus or
HYSYS, can be used to model the urea production process and evaluate the effects of
various operating conditions. This software can be used to optimize devices and improve
their performance.
The sources mention the use of ASPEN Plus software specifically for the simulation of
the process. This software can help to understand and predict the process behavior under
various operating conditions.
3.4. Simulate the use of ASPEN Plus:

ASPEN Plus software is a powerful tool used to simulate various processes in the field of
chemical engineering. For the urea production process from ammonia and carbon dioxide,
using ASPEN Plus it is possible to simulate the process, analyze the material and energy
balance and optimize the process conditions.
Setting up ASPEN Plus
Selection of components and thermodynamic models: First of all, the components
involved in the process need to be defined in ASPEN Plus. These components include
ammonia (NH3), carbon dioxide (CO2), urea (NH2CONH2) and water (H2O).
Furthermore, it is important to choose an appropriate thermodynamic model to accurately
predict the properties of these components. For example, the "NRTL" or "UNIQUAC"
models may be suitable for this process.
Building a Process Flow Diagram: It is necessary to build a process flow diagram in
ASPEN Plus. This diagram shows the different stages of the process: mixing of ammonia
and carbon dioxide, sending to the reactor, production of urea, separation of carbamate
and recycling.
Input parameters and operating conditions: According to the sources, urea production is
carried out at high temperature (185 degrees Celsius) and pressure (200 atm).. These data
should be included in ASPEN Plus as input parameters. It is also necessary to specify the
feed rate and amount of ammonia and carbon dioxide.

Validation Process
Although verification is optional for this case, it is generally possible to verify material
and energy balances and optimize process conditions using ASPEN Plus simulation
results.
Validation of material and energy balance: The accuracy of the simulation can be verified
by comparing the mass and energy flow data generated by the ASPEN Plus simulation
with real plant data or other validated sources. If there are differences, it may be
necessary to adjust the parameters and models used in ASPEN Plus.
Optimizing process conditions: The ASPEN Plus simulation allows for the analysis of
various operating conditions and the identification of conditions that can improve urea
production. For example, by changing temperature, pressure and feed rates, it can be
evaluated whether it is possible to increase production and reduce energy consumption.
ASPEN Plus simulation analysis can focus on the following key variables and results.
Temperature and pressure: It is important to evaluate the temperature and pressure in
the reactor and other process stages. This helps ensure the safety and efficiency of the
process.
Energy consumption: The ASPEN Plus simulation can be used to estimate the energy
consumption of the process. This information helps in developing energy efficient
strategies.
Urea yield and quality: The ASPEN Plus simulation helps predict expected urea yield
and identify ways to improve yield quality.
Waste products: Sources indicate that urea production produces water as a waste
product. The ASPEN Plus simulation can be used to estimate wastewater volume and
composition. This information helps in developing appropriate waste management
strategies.
 ASPEN Plus software is a powerful tool for simulating and optimizing urea production
process from ammonia and carbon dioxide. The software helps to evaluate the impact of
different operating conditions, increase production volume, reduce energy consumption
and develop appropriate waste management strategies.
3.5. Data collection and analysis for calculation, equipment design and simulation

In order to effectively design and simulate a urea production process, it is necessary to

collect and analyze various data. This information is critical to the calculation, equipment
design, and simulation processes.
Laboratory tests: Experiments in the laboratory make it possible to measure the rate of
reaction of ammonia and carbon dioxide, the rate of production of urea, and the reaction
conditions. This information helps to understand the chemical kinetics of the process and
determine the size and design of the reactor.
Pilot Plant Information: By constructing and operating a small-scale pilot plant, the
performance of the process can be practically evaluated. This information helps to refine
material and energy balances, optimize operating conditions, and evaluate the
performance of various equipment.

Industry Information: Information from other urea production plants is helpful in

obtaining design parameters, operating practices, and performance data. This information
helps to ensure reliability and efficiency in the design process.

Calculations: The data collected is used to calculate material and energy balances,
determine reactor sizing, and analyze various process parameters.

Equipment Design: The analysis of the data allows for the design of the reactor,
separation tower, compressor and other necessary equipment. The information helps
identify the equipment's size, material type, and operating conditions.

Simulation: The collected data can be used to simulate the operation of the process using
ASPEN Plus or other simulation software. This simulation allows for evaluating process
performance, optimizing operating conditions, and comparing different design options.

In general, information from laboratory experiments, pilot plants, and industrial data is
critical to the successful design, construction, and operation of a urea production process.
This information allows for accurate calculations, effective equipment design, and the
development of reliable simulation models.
References
Cook.L.H. Hydrocarbon processing, Feb , 1966 , pp, 129 136.

Elementary Principle of Chemical Process, Richard M. Felder, Wiley Publisher, Third

Edition, 2005

Fertilizer Manual, United National Industrial Development Organization (UNIDO), Kluwer

Academic Publishers, and ISBN 0-7923-5032-4 “)

Frejacques. M.chimieet industries ,July 1948 ,pp.22 35

“H. Scott Fogler, Elements of Chemical Reaction Engineering, Fourth Edition.”

Kaasenbrood . J.C . and Logemann ,J.D. Hydrocarbon processing, April 1969, pp.117 121.

Kucheryavyy , V .I.and Gorlovskly, D.M. Soviet chemical industries nov , 17th 1969, p. 17.