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DESIGN PROJECT 2
(PLANT & PROCESS OPTIMIZATION)
L01-P10
JANUARY 2016
DESIGN A UREA PLANT WITH CAPACITY OF 100, 000
METRIC TONNES / YEAR
SUPERVISOR: MR SYAHIDI FADZLI ALFAN
SHARIFAH ADAWIYAH SYED IDRUS
55201113513
55201113601
55201113660
55201113584
H = 136.23 kJ/mol
H = -17.57 kJ/mol
H = 118.66 kJ/mol
From the above reaction which occurs in the reactor, it can be identified as reversible
process. Whereby, the reaction between 2 mols of liquid NH3 and 1 mol of gaseous CO2 will
produce 1 mol of NH2COONH4 and 1 mol of H2O. This reaction will react reversely forming
back 2 mols of NH3 and 1 mol CO2. This reversible reaction basically evaluated at equilibrium
condition. Following are the kinetics parameter involving in the reaction inside the reactor.
However, this reaction considered as liquid phase reaction due to the outlet flow out from the
reactor in liquid form.
Table 1 Parameter in the reactor
Parameter
Working temperature
Design temperature
Working pressure
Design pressure
Ammonium carbamate conversion
Activation Energy, Ea
Frequency factor, A
Value
190C
250C
175 atm
210 atm
70%
60.93kJ/mol
5
-1
4.259 X 10 min
Ea
RT
60930J /mol
(8.314 J/ molK )(463.15 Kk )
k =0.05719 min
Reactor
4
H = -17.57 kJ/mol
H = 136.23 kJ/mol
1. Total,
=1+2+3
=185330.5438 MJ/day
2. Ammonium Carbamate formation heat, 5
(117)
103
78
H5= 409.34477*
H5 = -614021.5741 MJ/day
3. Urea formation heat by decomposing Ammonium Carbamate, 6
H6 = 1060.256*15.5/60* 10^3
= 273899.4667 MJ/day
4. Energy generated in to reactor
Q==
out
= 273899.5744+185330.5438-614021.5841
= -154791.5744 MJ/day
Reactor Volume
Based on Table 2, inlet each component for the reactor are converted from T/Yr to kg/hr.
The values are as follows.
Table 4 Inlet reactor
Components
NH3
CO2
NH2COONH4
Determination of inlet volumetric flowrate, V0 for each component, density inlet must be
considered.
Table 5 Density Inlet
Components
Density (kg/m3)
NH3 (liquid)
618
( Ref: J H Perry)
277.38
1600
(Ref: http://www.inorganics.basf.com)
Following are the calculation and value of V0 for each components and total.
Table 6 Inlet volumetric flowrate
Components
V0
m3 /hr
NH 3
10617.6 kghr 1
618 kg m 3
17.181
V Bo , CO2
2572.39 kghr 1
277.38 kg m 3
9.274
V Co ,
16796.59 kghr 1
1600 kg m 3
10.498
V Ao ,
NH 2 COO NH 4
Total, V
36.953
V PFR =F Ao
0
dX
r A
r A=k C A
C a=
F A F Ao (1X )
=
=C Ao ( 1X )
V
V0
x
V PFR =F Ao
0
V PFR =F Ao
0
V PFR =F Ao
0
dX
r A
dX
kCA
dX
k C Ao ( 1X )
F Ao x dX
V PFR =
k C Ao 0 (1X )
V PFR =
F Ao
1
ln
k C Ao
1x
V PFR =
Vo
1
ln
k
1x
V PFR =
36.953 m3 /hr
1
ln
1
10.7
3.4314 hr
]
[
]
7
V PFR =12.966 m
Residence time, t
t=
V
V0
t=
12.966 m3
36.953 m3 /hr
t=0.351 hr X
60 min
1hr
t=21.05 min
resistance and relatively low cost. Requirement of huge amount of passivation air by 316L UG in
synthesis and recycle sections restricts its operability.
Type 25Cr-22Ni-2Mo SS is being used due to its better corrosion resistance than 316L
UG and excellent weldability. This type of metal has been used in reactor and strippers but it is
susceptible by chloride to SCC and costly. Duplex SS shows excellent corrosion resistance in
both Weld metal and HAZ. They possess better resistance to Stress Corrosion Cracking, hence
used in chloride environments as well. In oxygen free carbonate solutions, duplex has proved to
be more corrosion resistant than much more costly materials such as Titanium and high nickel
alloys. Various MOC used in urea plants worldwide, their advantages and disadvantages are
depicted in Table 1.
11
12
14
Level Controller
Flow Controller
Output Valve
Reactor Level
Liquid level
Output Flowrate
Liquid Level
Temperature Controller
Flow Controller
Steam Valve
Reactor Temperature
Steam Flowrate
Temperature
Level
Control system measures Jacket Temperature and compare it to set point temperature of the reactor. Then uses the resulting error signal as
the input to a controller for steam makeup.
PRINCIPAL: the 2ndmanipulated variable is located closed to potential disturbance & react quickly
Pressure Controller
Gas Valve
Reactor Pressure
Pressure Level
Gas Flowrate
Reactor Pressure
Heat Exchanger
Gas
Ammonia Ca
FC
Cascade is desired when the single loop performance is unacceptable and a measured
variable is available. Besides that, the secondary variable must indicate the occurrence of an
important disturbancein the system. Furthermore, the secondary variable also must have a
faster response than the primary which is 4 times faster than the primary in order to get a
better control.
opening