UREA PLANT ,NATIONAL FERTILIZERS LIMITED

NANGAL(PUNJAB)

Presented by
Sanjay Godara
13112079

UREA PLANT
Based
Plant

on technimont total recycle process.

was installed in April,1978.

Before

revamping its capacity was 1000 MTPD.

Commercial

production after revamping started

on Feb 1st,2001.

Present

Plant Capacity is 1570 MTPD.

UREA PLANT
CO2

Compressor and H.P. Pumps

Urea

Synthesis

Urea

Saparation

Recovery
Vacuum
Prilling

Section

Section

Section

CO2
11 atm

CA-1

220 atm

Old Urea
Reactor

Ammonia Plant -2
Purification and Rectisol
Section

1.5 atm

CO2

CA-2

220 atm

New Urea
Reactor

CO2 Compressor

There are two motor driven reciprocating compressors

Old Compressor
(CA-1)

New Compressor
(CA-2)

No. of stages

Suction pressure

11 atm

1.5

Dischrge pressure

220 atm

220 atm

Motor Power

2250 KW

2400 KW

RPM

300

350

make

Worthington

Nuovo

Oxygen content maintained

2200ppm

3500ppm

Ammonia Feed Pump

The Liquid Ammonia coming from Ammonia plant is at 0-40
(degree Celsius) temperature.

Suction Pressure

20-30 atm

Discharge pressure 220 atm

After 220 atm pressure Ammonia is heated to around 90

degree Celsius in the steam condensate heater HE-10(A-1
& A-2) and steam heater HE-10(B).

Now Ammonia is fed to old urea reactor and new urea

reactor.

Chemical Reactions in Urea Reactors

NH3 + CO2 = NH4COONH2(Ammonium carbamate) + Heat(38kcal)

NH4COONH2(in liquid phase ) = NH2CONH2(urea) + H2O Heat(7.5kcal)

Urea Synthesis
Old Reactor

New Reactor

Volume

50 M3

33 M3

No. of trays

14

Type of trays

High eff. Casale trays

High eff. Casale trays

Temp. Bott./Top

184/196

184/198

Pressure

220 atm

220 atm

Thickness

12mm

6mm

NH3/CO2

2.9

2.75

H2O/CO2

0.7

New Reactor

Fresh NH3 and CO2 are fed to mixer then to carbmate

condenser.

In carbmate condenser NH4CO2NH2 is formed.

Heat of reaction is taken out in the form of 6.0 atm steam

generation.

The hot carbmate flows to R-2 reactor where residence

time is enough to get 69% conversion.

It is once through reactor , no carbmate solution is fed to

it.

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 & pressure is controlled

by PRC-1 at 220 atm.

Conventional Process
Decomposition
NH4CO2NH2 + heat = 2NH3 + CO2

Urea Saparation and Recovery stages

1st Stage
Pressure
Temperature
Urea conc.

70 atm
185 degree celsius
54.5%

2nd Stage
Pressure
Temperature
Urea conc.

12 atm
150 degree celsius
65%

3rd Stage
Pressure
Temperature
Urea conc.

3 atm
130 degree celsius
72%

Vacuum Section
1st Stage
Pressure

0.35 atm

Temperature

128 degree Celsius

Urea conc.

95%

2nd Stage
Pressure

0.04 atm

Temperature

138 degree Celsius

Urea conc.

99.6%

Prilling Section
Tower
Height

104 .5 mtr

Free fall height

80 mtr

Diameter

22 mtr

Scrapper type

conical

Make

Tuttle/Simco

Number

TX-267,268 & 130

Bucket

Ammonia Recovery Section

Pressure

1.5 atm

Temperature

125 degree Celsius

Outlet Condition
NH3
Urea

0.04%
1.0 %

Salient Features of Urea Plant ,Nangal

S. No.

Discription

Urea Product Quality

Required as per FCO

Urea Product
Quality(Avg.) at
NFL,Nangal

1.

Total N2

46.0%(Min.)

46.4%

2.

Moisture

1.0%(Max.)

0.4-0.5 %

3.

Prill Size

i) Under size(<1mm)=10%

~1.4%

ii) Proper size(1mm to 2.8mm)=80 %

~98.60%

iii) Over size(>2.8mm)

Nil