NFL NANGAL & BATHINDA

Urea Plant

Presented By
Prem Baboo
Sr. Manager(Prod)
National Fertilizers Ltd, India

R-1 LP R-2

Urea Processes used in NFL units

NANGAL: Technimont Total Recycle
Process.
BATHINDA & PANIPAT: Mitsu toatsu C
Improved Process.
VIJAIPUR: Snamprogetti ammonia stripping
process.

R-1 LP R-2

NANGAL UREA PROCESS

BRIEF DESCRIPTION :

It is a Montedison total recycle process.

Plant is installed in April,1978.
Plant capacity is 1450 Te/day.
Commercial production after revamping started on
Feb 1st,2001.
Before revamping its capacity was 1000 Te/day.

R-1 LP R-2

Plant Description
CO2 Compressor & H.P.Pumps
Urea synthesis.
Urea separation.
Recovery section.
Vacuum section.
Prilling section.
Waste water section.
R-1 LP R-2

Specification Sheet

Ammonia at B/L

NH3
Water

99.5% by weight
0.5% by weight

Carbon Dioxide at B/L

CO2
H2
CH4
H2S
CH3OH
CH3OH

98.99% (Vol.)
0.6 to 1.5% (Vol.)
0.1 to 0.15% (Vol.)
0.65 ppm (Vol.)
6.00 ppm (Vol.) for old compressor
1000 ppm (Vol.) for new compressor

R-1 LP R-2

Specific Consumption
Ammonia
Carbon dioxide
Steam 30ata
Power

0.574Te/Te of urea
0.745 Te/Te of urea
1.23 Te/Te of urea
135 kwh

R-1 LP R-2

CO2 Compressor

There are two motor driven reciprocating compressors

Old Compressor

No. of Stages
3

Capacity
17510 Nm3/hr.

Suction/Discharge press.
11/220 Kg

RPM
300

Motor Power
2250KW

Oxygen content maintained

2200ppm

R-1 LP R-2

 NEW COMPRESSOR:

No.

of Stages
Capacity
Suction/Discharge press.
RPM
Motor Power
Oxygen content

R-1 LP R-2

4
9500 Nm3/hr.
1.5/220 Kg
350
2400KW
3500ppm

Ammonia feed pumps

There are three reciprocating plunger pumps
Make
Peroni
No. of plungers
5
Pulsation dampener
nil
Capacity
53NM3/hr. each
Suction pressure.
30Kg/cm2
Discharge pressure
220 Kg/cm2

R-1 LP R-2

Ammonia feed pump

One no. ammonia pump (New) having less
capacity 25NM3/hr.
Two ammonia pumps run at 100% load.
Ammonia is directly taken from ammonia
plant at 30 kg & fed to reactors at
220kg.Before feeding to reactors it is pre
heated up to 80C.
R-1 LP R-2

10

Carbamate feed pumps

There are four reciprocating plunger pumps
Make
Peroni
No. of plungers
5 in old & 3 in new
Pulsation dampener only in new pump
Capacity
53M3/hr. each
Suction pressure.
70Kg/cm2
Discharge pressure
220 Kg/cm2
Three pump run at 100% load.
R-1 LP R-2

11

Urea Synthesis
Urea reactor {Old}

Volume
No. of trays
Type of trays
Temp. Bott./Top
Pressure
Liner
Thickness

50M3
14
High eff. Casale trays.
184/196OC
220Kg/cm2
SS 316 L
12mm

R-1 LP R-2

12

Urea Synthesis
Urea reactor {New}

Volume
No. of trays
Type of trays
Temp. Bott./Top
Pressure
Liner
Thickness

33M3
9
High eff. Casale trays.
184/198OC
220Kg/cm2
2RE69
6mm
R-1 LP R-2

13

New Reactor
Fresh ammonia & carbon dioxide are fed to
mixer, then to carbamate condenser, where
ammonium carbamate is formed. Heat of
reaction is taken out in the form of 6 .0 ata
steam generation. The hot carbamate flows to
reactor R-2 where residence time is enough
to get 69% conversion.It is once through
reactor, no carbamate solution is fed to it.
R-1 LP R-2

14

Old Reactor
The rest of CO2 & NH3 are fed to old
reactor. All the carbamate sol. of the plant
fed to old reactor.
Both reactor outlet joins & pr. Is controlled
by PRC-1 at 220kg.

R-1 LP R-2

15

Reactor feeds
The expected best operating condition are:
New sec.
Old sec.
Capacity (TPD) 600
1050
Pr.
(ata)
220
220
Temp. (c)
196
196
N/C
2.9
2.75
H/C
0
0.7
Conversion (%)
69
55
R-1 LP R-2

16

Conventional Process
Decomposition:

NH4COONH2 +Heat = 2NH3 + CO2

R-1 LP R-2

17

Urea Separation.
1st stage

70 Kg/cm2
185OC
54.5%

Pressure
Temperature
Urea conc.

2nd stage

12 Kg/cm2
150OC
65%

Pressure
Temperature
Urea conc.

3rd stage

3 Kg/cm2
130OC
72%

Pressure
Temperature
Urea conc.
R-1 LP R-2

18

Recovery Section
Pressure
Temperature
Outlet conditions

1.5 Kg/cm2
125OC

NH3
Urea

0.04%
1.0%

R-1 LP R-2

19

Vacuum Section
1st stage vacuum system
Pressure
Temperature
Urea conc.

0.35 ata
128OC
95%

2nd stage vacuum system

Pressure
Temperature
Urea conc.

0.04 ata
138OC
99.6%

R-1 LP R-2

20

Prilling Section
Tower

Height
Free fall ht.
Diameter
Air flow
Urea in emission
Scrapper type

104.5mtr
80mtr
22mtr
8,00,000 nm3/hr
40mg/nm3.
conical

Bucket

Make
Number

Tuttle/Simco
TX-267, 268 & 130
R-1 LP R-2

21

Product Quality

Total Nitrogen
Moisture
Biuret
Mean prill dia
Sieve analysis

Over size
Proper size
Under size

46.5%
0.35%
0.8-0.9%
1.75mm
nil
98.5%
1.5%

R-1 LP R-2

22

Waste Water Section

Feed at 100% load
Feed water analysis

NH3
UREA

35m3/hr
3.00%
1.2%

Hydrolyser pr.
Hydrolyser temp.

20Kg/cm2
1980C

R-1 LP R-2

23

Waste Water Section

Distillation tower

4.5Kg/cm2
5.5 Kg/cm2
33+12

Pressure top
Pressure bottom
No. of trays

Outlet water analysis

NH3
Urea

40 ppm
35 ppm
R-1 LP R-2

24

Plant Start up
Reactor is filled with dilute solution.
In case of empty reactor, it is to be filled with
start up solution.
In case of cold start up, reactor solution is
first heated up to 125 OC .
First stage{70ata} remain by passed.

R-1 LP R-2

27

Plant Start up
Plant is started in once through operation.
Once through operation means the solution is
send to urea solution tank and Carbamate is
send to start up solution tank from 2nd stage.
Ammonia feed to reactor and pressure is
maintained at 150ata for 5 minutes and then
CO2 is send to reactor.
R-1 LP R-2

28

Plant Start up
Reactor pressure will increase according to the
temperature and feed ratio.
As the temperature and pressure reaches to the
desired condition then the Carbamate from 2nd stage
is diverted to the 1st stage.
As the level of 1st stage condenser increases, start
the Carbamate pump and feed Carbamate to the
reactor.{known as total recycle}.
R-1 LP R-2

29

Plant Start up
After total recycle, temperature and pressure
of each stage are maintained.
The urea solution is sent to vacuum section.
After normalizing vacuum section, melt urea
diverted towards bucket.

R-1 LP R-2

30

Objective of revamping

Optimum utilization of ammonia plant capacity.

Increase in urea plant capacity by 450 MTPD.
Improvement in urea prills quality.
Reduction in specific energy consumption for urea
from 10.26 G cal. To 9.4G cal. Per MT of urea.
Reduction in dust emission.

R-1 LP R-2

31

Revamping
Project Cost;
Project executed by;

R-1 LP R-2

Rs.161Crores
M/s. Urea Casale
Switzerland.

32

Major equipment added:

CO2 compressor.
NH3 pump.
Carbamate pump.
Urea reactor.
Methanol scrubber.
Urea melt pump
New vacuum distiller {HE9}
R-1 LP R-2

33

Major equipment added:

Additional vacuum condenser.
New circular Prilling tower.
High efficiency trays in old urea reactor.

R-1 LP R-2

34

Urea Quality After Revamping

Over size reduced to nil.
Temperature in summer reduced from 90OC
to 55OC.
Crushing strength increases from 350
gm/prill to 650 gm/ prill.
Urea dust emission reduced . Now it is
< 50mg/nm.
R-1 LP R-2

36

Urea casales high efficiency tray

R-1 LP R-2

R-1 LP R-2