PRO/IITM Process Engineering

Urea Plant Casebook

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 PRO/II Process Engineering Urea Plant Casebook

Contents
Contact Information.................................................................................................................. 3
Case 5: Urea Plant ................................................................................................................... 7
ABSTRA CT .............................................................................................................................. 7
Feature Highlights ............................................................................................................... 7
Introduction .............................................................................................................................. 7
What is Urea? ..................................................................................................................... 7
Relevance .......................................................................................................................... 8
Rout es to Urea.................................................................................................................... 8
Process Outline ........................................................................................................................ 9
Process Simulation ................................................................................................................. 10
Simulation Model ............................................................................................................... 10
Thermodynamic Dat a ........................................................................................................ 13
Stream Data ..................................................................................................................... 13
Reaction Dat a ................................................................................................................... 14
Unit Operations ................................................................................................................. 14
Kinetic Data ...................................................................................................................... 17
Technical Results .............................................................................................................. 24
Conclusion ............................................................................................................................. 24
Output Results .................................................................................................................. 24
Referenc es ....................................................................................................................... 25
Appendix A Input Dat a File .................................................................................................... 27
Appendix B Output Report File............................................................................................... 33

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 PRO/II Process Engineering Urea Plant Casebook

Case 5: Urea Plant

ABSTRACT
This case book demonstrat es the use of PRO/ II® in the simulation of a chemic als processing plant
manufacturing 1000 tons per day of urea from ammonia and carbon dioxide. Urea is widely used as a
solid fertilizer, as a prot ein supplement for livestock, as well as a feedstock for the manufacture of
plastics and adhesives. The process plant simulated here includes a reactor, an NH3 recovery distillation
column, and a series of crystallizers. SIMSCISM's NRTL databank, along wi th urea/wat er solubility data,
provide a good
simulation of the system's vapor-liquid and solid-liquid equilibria. Urea growth and nucleation rate
crystallization data obtained from the literature are provided for the crystallizer units.

Feature Highlights
 Solids-Handling Application
 User-supplied Solubility Data
 Stoichiometric Reactor Units
 Filtering Centrifuge Units
 Solids Dryer and Freezer Units
 Crystallizer Units with User-supplied Nucleation and Growth Rates

Introduction
What is Urea?
Urea is a source of fixed nitrogen used primarily as a crop fertilizer and as a protein food supplement for
livestock. Urea is particularly desirable for this use as it is readily soluble in water. A secondary use for
urea is as a feedstock for the manufacture of adhesives, plastics and resins.
Urea is manufactured by the high pressure reaction of ammonia and carbon dioxide to form ammonium
carbamate, followed by the decomposition of the carbamate to yield urea and water. With recycle and a
stoichiometric excess of feed components, about 99% of the CO2 and NH3 is converted to urea. The
major contaminant is a dimer of urea called biuret (NH2CONHCONH2.H2O). The biuret concentration
should not exceed 0. 2-0. 3% when the urea is to be used for feed supplements or as feedstock for
plastics production. For fertilizer us e, the biuret content may be up to 1%.

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

Relevance
Urea has a maximum nitrogen content of 46% and, among major nitrogenous fertilizers, is sec ond only to
ammonia. It also has the highest nitrogen content of any solid fertilizer and can be easily manufactured
as granules. Worldwide, in 2002 a total of about 108 million metric tons (108Mt) of urea were produc ed in
more than 70 countries. This production delivered about 51.4Mt of contained nitrogen. China was the
largest producer with about 28%, and all of asia accounted for about 46% of the total. The United States
produced about 13%, or about 14Mt. Capacity in Nort h America and Western Europe is expected to
decline due to fluctuating natural gas prices. It is expected that production will continue to shift toward
world regions that have abundant natural gas, lower -cost raw materials, and cheaper labor.

Routes to Urea
The production of urea may be divided into two separate parts:
 Synthesis
 Finishing
The synthesis loop produces a concentrated 70 -80% urea solution. The finishing step produces either
granular urea or crystalline urea. Spherical granules or flakes are formed by evaporation followed by
passing the molt en solid product countercurrent to a flow of hot air (known as prilling). Crystallization is
used to produce virtually pure crystalline urea. The type of finishing proc ess determines the final form of
urea required (i. e., the biuret content, grain size, and moisture content).
Once-through urea processes, now rare, were once common. In these plants, unconverted ammonia
would be recovered and undergo downstream conversion to other ammonium compounds. Nowadays,
partial and total recycle processes are used, with total recycle plants being more commonplace.
Two types of urea manufacturing process obtained from the open literature are outlined below.

Table: Types of Urea Manufacturing Proce ss

Process Description Reference

1
Toyo Koatsu Total recycle process using medium operating Chao and
2
conditions (synthesis loop at 3500 psia, high Dent e
pressure decomposer at 325 psia, low pressure
decomposer at 25 psia). Produc es prilled urea
with 0.4 wt% biuret, and 0.3 wt% moisture.
Snamprogetti Total recycle process using mild operating Hydrocarbon
6
conditions (synthesis loop at 2500 psia, high Processing
pressure decomposer at 260 psia, low pressure
decomposer at 65 psia).
In the United States, urea is produc ed mainly in the form of spherical prills or granules between 20 and
50 US. mesh in size, although the use of purer, crystalline urea is increasing rapidly.

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Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

Process Outline
The urea process described in this case book produces a crystalline product, and is based on
information obtained from Chao1 and Dent e2. The urea process pres ented is intended as a generalized
example of a urea flowsheet and does not represent any specific licensed technology. The urea
flowsheet presented here is based on the plant described by Chao1 for the Toyo Koatsu process, which
is a total NH3 recycle process. The urea synthesis plant modeled here is a partial NH3 recycle process.
A schematic of the process is shown in the following figure.
Figure: Urea Plant Schematic

CO2 and NH3 are allowed to react at high temperature and pressure to form ammonium carbamat e urea
and water:

This highly exothermic reaction goes almost to completion under reactor conditions of about 365 F and
3515 psia. The reactor product stream pressure is let down through a pressure cont rol valve on the exit
of the reactor. The reactor exit stream then ent ers the NH3 recovery column where rec overed NH3 is
recycled back to the reactor. The bottoms of the NH3 rec overy column then enter the high pressure
decomposer where a small fraction of the ammonium carbamate is decompose d and excess NH3 is
removed as a vapor stream:

This equilibrium endothermic decomposition reaction does not go to completion under normal reaction
conditions of 302 F and 325 psia. The exiting liquid then enters the low-pressure decomposer
where the majority of ammonium carbamate decomposes at 150 F and 25 psia, and a mixed NH3/ H2O
vapor is removed as a vapor stream. The liquid stream then enters a flash drum followed by an
evaporator where additional NH3/H2O is removed as a vapor. The remaining liquid urea/H2O stream
then enters the crystallization section.

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

The crystallization scheme used involves the use of a vacuum, forced recirculation configuration. This
concentrates the solution to supersaturation resulting in urea crystal formation. The first crystallizer
operates at 130 F and 1.5 psia, while the second crystallizer operates at 130 F and 1.335 psia. Following
each crystallization stage is a centrifuge which separates the crystal product from the mother liquor. The
two-stage crystallizer is then followed by a dryer to remove<%0> most of the <% -2>remaining water.
This type of crystallization scheme requires significantly less energy compared to atmospheric
configurations.

Process Simulation
The complete input file for this simulation can be found in Appendix B. Selected portions of the input file
are shown here. For detailed explanations of the keywords used in the input file, please refer to the
PRO/II Keyword Manual, available from SimSci.

n appears beside some examples of keyword input. KWM indicates the PRO/II Key Word
Manual, Thermo indicates the PRO/ II Thermodynamic Data Input Manual, etc. "n" indicates the chapter
that provides detailed explanation of the keyword entries.

Simulation Model
The following figure shows a block diagram of the simulation flowsheet.

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Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

Figure: Urea Plant Simulation Flowsheet

General Data
English units of measure are used throughout the simulation for input and output report data. The density
3
units are changed from the default API gravity units to DENSITY units (lb/ft ). The FLENGTH keyword is
used to specify the fine length units of microns. The MBALA NCE keyword specifies that an overall mass
balance be reported in the final output.
 KWM 5 TITLE PROJECT=CASEBOOK, PROBLEM=UREAPLANT, USER=SIMSCI,
DATE=MAY 95
PRINT STREAM=COMPONENT, RATE=WT, MBALANCE=ON, HISTORY=ON
TOLERANCE DEFAULT=V94
DIMENSION ENGLISH, MDUTY=ON, BASIS=MOLE, FLENGTH=MIC, &
XDENSITY=DENS
SEQUENCE SIMSCI

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

Component Data
All components except the intermediate, ammonium carbamate, are in the SimSci databank. Ammonium
carbamate is specified to be a non-library component (using the NONLIB keyword). The particle size
distribution intervals for urea are given using the A TTRIB UTE statement. The component urea is
specified to exist in the vapor, liquid, and solid phases using the PHASE statement.
 KWM 6 COMPONENT DATA
CURRENT SEARCH = SIMSCI
LIBID 1,UREA/2,WATER/4,AMMONIA/5,CO2/6,N2/7,O2/8,H2, BANK=CURRENT
NONLIB 3,AMCA
PHASE VLS=1,VLS=3
MWAVG 3,78.071
SPGR 3,1.2

1,4
Literature data and the property estimation facilities of the Thermodynamics Dat a Manager (TDM
program) are used to obtain physical property data for the int ermediate compound ammonium
carbamate. A portion of the physical property data input for this compound is shown below.
$ PRO/II physical property insert for:
$ Name: AMMONIUM CARBAMATE
$ Formula: CH6N2O2
$ Created: 05/10/95
$ Source: User File: urea
$
$ Thermo methods available for use:
$ Library
$ EOS Methods
$
ACENTRIC 1,0.59739/3,0.59421
TC 3,726.7
PC 3,977.66
HFUSION(M) 3,29680
NMP 3,271.4
FORMATION(S,M) 3,-277320,-192630
ATTRIBUTE COMP=1, PSD=0,20,50,100,200,500,1000
ASSAY FIT=ALTERNATE, CONVERSION=API94, CURVEFIT=CURRENT, &
FORMATION=CURRENT, KVRECONCILE=TAILS
VISCOSITY(V,K,PAS) CORRELATION=1, DATA=1,500,200,-1.11177e-006, &
2.16478e-008,2.48575e-015,-8.14361e-018,1.3193e-020, &
-8.38278e-024
VISCOSITY(L,K,PAS) CORRELATION=20, DATA=1,500,200,-176.103,12442.1, &
23.1548
CONDUCTIVITY(V,K,W/MK) CORRELATION=1, DATA=1,500,250,-0.0189453, &
7.76855e-005,-8.99174e-012,2.44916e-014,-3.28476e-017, &
1.73399e-020
CONDUCTIVITY(L,K,W/MK) CORRELATION=1, DATA=1,500,200,0.253287, &
-0.00017696,-1.30975e-007
SURFACE(L,K,N/M) CORRELATION=1, DATA=1,500,200,0.156584, &
-0.000268471,1.9517e-008,9.79654e-011,-1.37613e-013, &
1.20688e-016
VP(L,K,PA) CORRELATION=20,LN, DATA=3,426.15,303.15,-29.298,-3908.2, &
9.29569,-1.62079e-005,2,1.16265e-008

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Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

Thermodynamic Data
The NRTL liquid activity coefficient method is used to predict the vapor-liquid equilibria, while the
Soave-Redlich-K wong equation of state is used to calculate the liquid and vapor phase entropies.
Trans port properties are calculated using the LIBRA RY method. User -supplied solubility data are used
to predict solid-liquid solubilities.
 KWM 8 THERMODYNAMIC DATA
TRESET CONSTANT = NOFLASH
METHOD SYSTEM=NRTL, KVAL(SLE)=SOLU, ENTROPY(L)=SRK, ENTROPY(V)=SRK, &
SET=NRTL01, DEFAULT

Solubility Data
With many inorganic systems, ideal solubility does not adequately describe the solution behavior. For
these cases solubility data can be fitted to the following equation:

The above equation provides a good fit to much of the solubility data reported in the literature. For
systems containing more than one solvent, the solubility of the solute in the multi component solvent is
calculated using the following relationship:

where:

The solubility expression and the mixing rule described in the above equations provide a great deal of
flexibility in matching data reported in the literature and obtained in the plant. Solubility data for the
urea/wat er solute/solvent pair are provided as shown below.
Thermo 7 KVAL(SLE)
SOLUTE 1
SOLDATA(K) 1,2, 0., -1310.37, 0.533619

Stream Data
Feed Streams
Data for the ammonia feed stream and the carbon dioxide feed stream are provided as shown below.
KWM 9.1 STREAM DATA
PROPERTY STREAM=1, TEMPERATURE=-28, PRESSURE=320, PHASE=M, &
COMPOSITION(WT,LB/H)=4,105049
PROPERTY STREAM=2, TEMPERATURE=100, PRESSURE=300, PHASE=M, &
COMPOSITION(WT,LB/H)=5,93408

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

Recycle Streams
The composition, temperature, and pressure of the recycle stream from the NH3 recovery column are
estimated initially for the first run through the simulation.

 KWM 9.1 $
$ INITIAL GUESS FOR TEAR STREAMS
$
PROPERTY STREAM=7, TEMPERATURE=126, PRESSURE=320, PHASE=M, &
COMPOSITION(WT,LB/H)=2,0.5/4,58667

Reaction Data
The stoichiomet ry of the two reactions—the primary urea reaction and the decomposition
reaction<% -2>—is provided in the Reaction Data category of input.
KWM 10.8 $
$ REACTION DATA
$
RXDATA
$
$ MAIN UREA REACTION
$
RXSET ID=RST1
REACTION ID=RXC1
STOICHIOMETRY 1,3/2,3/3,1/4,-8/5,-4

Unit Operations
Urea Synthesi s
As shown in Figure above, fresh NH3 feed (stream 1) is mixed with recycle NH3 (stream 7) from the NH3
recovery column (COL1). The combined NH3 feed is raised to the operating pressure of reactor RX1 of
3515 psia in pump P1. Fres h CO 2 feed (stream 2) is raised to the operating pressure of reactor RX1,
3516 psia, in compressor COM1. The primary urea reaction occurs in a high pressure, high temperat ure
reactor. Reactor (RX1) is modeled as a conversion reactor unit, with 100% conversion. This reactor uses
the reaction set RS TI previously defined in the Reaction Data category of input.
Note that the heat of reaction may be optionally input for the urea reaction. However, PRO/II can
calculate the heat of reaction from the heat of formation of the components if a value is not input.

KWM 14.2 CONREACTOR UID=RX1

FEED 3,4
PRODUCT L=5
OPERATION ISOTHERMAL, TEMPERATURE=365
RXCALCULATION MODEL=STOIC
RXSTOIC RXSET=RST1
REACTION RXC1
BASE COMPONENT=5
CONVERSION 1

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Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

High pressure reactor effluent is reduced in pressure to 320 psia through a valve (VL1) before entry into
the NH3 recovery column (COL1). The column is simulated with the S HORTCUT column model. The
column product specifications are 65% of the NH3 are recovered in the overhead product (stream 7),
which is 99.995% ammonia. A bubble condenser is used for the overhead product.

KWM 12.8 SHORTCUT UID=COL1

FEED 6
PRODUCT STREAM=7, PERCENT(WT)=23, PHASE=L, PRESSURE=320
PRODUCT STREAM=8, PHASE=L, PRESSURE=325
WATER=9
CONDENSER TYPE=BUBB
EVALUATE MODEL=CONV, TRIAL=50, KEYLIGHT=4, KEYHEAVY=2, &
RRMIN=2.5
FINDEX 2
SPEC STREAM=7,FRACTION(WT), COMP=4,WET, VALUE=0.99995
SPEC STREAM=7, RATE(WT,LB/H), COMP=4,WET, DIVIDE, STREAM=6, &
RATE(WT,LB/H), COMP=4,WET, VALUE=0.65

The bottoms product from column COL1 (stream 8) is then sent to the high pressure and low pressure
decomposers (RX2, RX3) modeled as conversion reactors. Both reactors use reaction set RS T2
previously defined in the Reaction Dat a category of input. In the high pressure (325 psia) reactor, 88% of
the carbamate is decomposed to urea under isothermal conditions at 302 F. An off gas of CO2 and NH3
is generated in streams 9 and 12. In the low pressure (25 psia) reactor, 99. 95% of the remaining
carbamate is converted to urea at 252 F.
KWM 14.2 $
$ HIGH PRESSURE DECOMPOSER
$
CONREACTOR UID=RX2
FEED 8
PRODUCT V=9, L=10
OPERATION ISOTHERMAL, TEMPERATURE=302
RXCALCULATION MODEL=STOIC
RXSTOIC RXSET=RST2
REACTION RXC2
BASE COMPONENT=3
CONVERSION 0.88

KWM 11.1 $
$ HIGH PRESSURE DECOMPOSER BOTTOMS COOLER
$
FLASH UID=FL2
FEED 10
PRODUCT M=11
ISO TEMPERATURE=158, PRESSURE=25

KWM 14.2 $
$ LOW PRESSURE DECOMPOSER
$
CONREACTOR UID=RX3
FEED 11
PRODUCT V=12, L=13
OPERATION ISOTHERMAL, TEMPERATURE=252
RXCALCULATION MODEL=STOIC

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

RXSTOIC RXSET=RST2
REACTION RXC2
BASE COMPONENT=3
CONVERSION 0.9995

The reaction product stream 13 is then sent into a flash drum (FL3) and evaporator (FL4), both modeled
as flash units, where H2O and NH3 are taken off as a vapor in streams 14 and 16.
Finishing
The bulk urea solution from the urea synthesis section is then sent into the first stage (CR1) of a two
stage vac uum evaporative crystallization purification process. The crystallizer is operat ed at 130 F and
1.5 psia, and a design specification is made that 85% of the urea in the feed crystallizes. Growth and
crystal nucleation rate data are provided using information obtained from the literature. See the Kinetic
Data section later in this case book for more information on how these parameters were derived.
Following the first crystallizer unit, the slurry is sent into a centrifuge (CEN1) to separate the crystal
product from the mother liquor. The diameter of the centrifuge is specified to be 3 feet, and operat es at a
speed of 1000 RPM.
KWM 15.6 CRYSTALLIZER UID=CR1, NAME=CSTAGE1
FEED 18
PRODUCTS OVHD=19, BTMS=20
PRINT CSD
OPERATION SOLUTE=1, SOLVENT=2, TEMP=130, PRES=1.5
DESIGN PFRAC=0.85
GROWTH KG=2.952E-8, GEXP=0.
NUCLEATION KB=8.7417, BEXP=-3.87, 0., -1.75, 0.
$
$ PUMP INTO FIRST CENTRIFUGE
$
KWM 11.2 PUMP UID=P3, NAME=PUMP3
FEED 20
PRODUCT L=21
OPERATION PRES=20
$
$ FIRST STAGE CENTRIFUGE
$
KWM 15.3 FCENTRIFUGE UID=CEN1, NAME=CENT1

FEED 21
PRODUCT FILTRATE=22, CAKE=23
RATING DIAMETER=3, RPM=1000
The mother liquor (stream 22) is then sent to the second stage crystallizer (CR2) and centrifuge (CE N2).
The second crystallizer operates at the same temperature as the first, 130 F, but at a lower pressure,
1.335 psia.
KWM 15.6 CRYSTALLIZER UID=CR2, NAME=CSTAGE2
FEED 22
PRODUCTS OVHD=24, BTMS=25
PRINT CSD
OPERATION SOLUTE=1, SOLVENT=2, TEMP=130, PRES=1.335
DESIGN PFRAC=0.95
GROWTH KG=2.952E-8, GEXP=0.
NUCLEATION KB=8.7417, BEXP=-3.87, 0., -1.75, 0.
$
$ PUMP INTO SECOND CENTRIFUGE
$
KWM 11.2 PUMP UID=P4, NAME=PUMP4
FEED 25

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Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

PRODUCT L=26
OPERATION PRES=20
$
$ SECOND STAGE CENTRIFUGE
$
KWM 15.3 FCENTRIFUGE UID=CEN2, NAME=CENT2
FEED 26
PRODUCT FILTRATE=27, CAKE=28
RATING DIAMETER=3, RPM=1000
Both crystal product streams 23 and 28 are then s ent to a dryer (DR1) where the final crystal product,
containing 0.1% moisture by weight, is produced (stream 30).
$
$ FINAL DRYING OF SOLID PRODUCT
$
KWM 15.1 DRYER UID=DR1, NAME=DRYER
FEED 23, 28
PRODUCT OVHD=29, BTMS=30
OPERATION PRES=15
DESIGN MOISTURE(W)=0.001, BTMS
Finally, the solid urea crystals from the dryer are cooled to 200 F prior to prilling.
$ENSURE ANY REMAINING UREA IS CONVERTED TO A SOLID
$
KWM 15.7 MELTER UID=FRZ1, NAME=FREEZER
FEED 30
PRODUCT M=31
OPERATION TEMPERATURE=200, DP=0

The prilling section of the urea flowsheet, which converts the urea into a granular product, is not
simulated in this case book.

Kinetic Data
3
It is important to accurately determine growth and nucleation kinetic parameters. The article by Bennett
3 4
is a good source of urea crystallization dat a. The articles by Bennett and Perry provide good
discussions on calculation of crystallization kinetic parameters from crystal size distribution data.
Crystal size distribution data obtained from the Bennett3 article for sample number 192 are used to
demonstrate how to calculate both growth and nucleation rates. First, the crystal size distribution dat a in
Tyler screen size are converted to average particle diam eter.

Table Tyler Screen Sizes

Screen Range Length range (mm) Average Diameter (mm)

14-20 1.168-0.833 1.000

20-28 0.833-0.589 0.711

28-35 0.589-0.417 0.503

35-48 0.417-0.295 0.356

48-65 0.295-0.208 0.251

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

Screen Range Length range (mm) Average Diameter (mm)

65-100 0.208-0.147 0.178

Next the cumulative screen collection data must be converted into actual weight percent for each interval
range.

Table Screen Collection Data

Avg Diameter, Dav (mm) Screen Weight Percent

Accumulation

1.000 4.4 4.4

0.711 18.8 14.4

0.503 43.0 24.2

0.356 74.6 31.6

0.251 90.1 15.5

0.178 97.5 7.4

-0.178 100.0 2.5

The number density (nL) as defined here is the number of crystals in a specified size range up to size L
per liter of volume. The formal definition for n is:

where:
 N = number of crystals retained on the screen in the specified size range
 L = difference between the screen size of the ret aining sieve and its immediate
predecessor.
As an example, the number density for screen size 14-20 (n20) is calculated directly using the following
slurry properties and the above screen data.
Slurry density, MT = 450. g/L
Crystal density, rc = 1.335 g/cm3 = 1.335x10-3 g/mm3
Retention time, t = 3.38 h
 L = 1.168-0.833 = 0.335 mm
Crystal volume, V c = Dav3
Now, nL is given by:

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Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

where:
x wt = weight fraction retained on screen
So for example, the number of crystals / mm L

Similar calculations for the other screen sizes yield the following table.

Table: Crystal Number Density

Avg Diameter, Da v (mm) Number Density (n) ln(n)

0.178 72492960 18.099

0.251 37958350 17.452

0.356 19346070 16.778
0.503 3726570 15.131
0.711 553490 13.224
1.000 44773 10.698

A plot of the natural log of number density versus the average particle diameter is known as a P opulation
Density Plot. An example is shown in) as shown in Figure: Population Density Plot.
0
The intercept of this plot, n , is known as the nuclei population density. When using the following
relationships, both the nucleation and growth rates are calculated.

where:
Dav = average crystal diameter
G= growth rat e over the time interval t
t= crystallizer time interval
0
n = number density of crystal nuclei
B = nucleation rat e

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

Figure: Population Density Plot

From above figure, the intercept is 19.78 and the slope is -9.13. The following calculations then are
performed.
Since Dav = 1 mm and slope = -Dav /Gt
It follows that: Slope = -1/Gt = -9.13
Therefore:
G = 1/(-9.13)(3.38) = 0.0324 mm/h
The growth rate calculated using equation Equation 5 -9 is:
6
B = (0.0324) * exp(19.78) = 12.65x10 crystals / L-h
The nuclei number density is also given by:

where:
Kb = a constant
i, k = exponents (constants)
t3
The following table lists a group of samples reported by Bennett that characterizes observed growt h
and nucleation rates.

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Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

Table : Growth Versus Nucleation Rate

0
Sample No. ln(n ) G ln G

191 18.18 0.0330 -3.41

192 19.71 0.0338 -3-39
193 18.70 0.0317 -3.45
194 20.51 0.0200 -3.91

Using the natural logarithms of growth vs. nuclei number, densities are plotted as shown in Figure 5 -4.
Using the following expression and the resulting slope of the plot, the exponent for the power law
nucleation rate equation is determined. Calculation of the i exponent assumes the slurry density (MT) is
constant.
Figure: Growth vs. Nucleation Rate

The slope (-2.75) of the plot shown in Figure 5-4 yields a value of -1.75 for the exponent i. The
nucleation rat e, B, then is obtained from Equation 5 -11 as:

Similar data at constant growth rate is required to calculate the k exponent in the final form of the
nucleation equation. For urea crystallization, a value of -3.87 is recommended for the k exponent by
Bennett3. In addition, a value of -1.66 is recommended for the i exponent, compared to -1.75 calculated
here. The paper by Garside and Shaw5 is a recommended source of nucleation and growth kinetic data.
The following is the final recommended form of the nucleation equation as reported by Garside and
Shaw5.

The units of the nucleation rate, B, are Number of crystals/L-s. The constants of this equation must be
converted to be consistent with input units (refer to Table 4.1 of the P RO/ II Key word Input Manual for
default dimensional units). The following summarizes the default dimensional units used in the growth
and nucleation expressions.

21
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

PRO/II Growth Rate Expressi on:

Term Units

G velocity
Kg, constant velocity
SSRATIO, supersat uration dimensionless

PRO/II Nucleation Rate Expression

Term Units

B No. / [(time) (liquid volume)]

Kb, constant No. / [(time) (liquid volume)]
MT liquid density
RPM revolutions per minute

The GE XPONENT term in Equation 5 -13 is set to zero. The following are converted growth and
nucleation rat es.

22
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

Next, the Kb constant in the nucleation expression, Equation 5-14, must be converted to be consistent
with input units in the following manner.

Now, using equation (13):

where units of measure are:

3
B (Number of crystals/ft -h)
G (ft/s)Ncx = abbreviation for number of crystals
3
MT (lb/ft )
This newly formulated equation can now be tested to check that it fits the published nucleation rate data
using the reported slurry density of 450 g/L and calculated growth rate of 2.952x10 -8 ft/s.

23
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

There is a large deviation in nucleation rate compared to the value of 3.582x108 number of crystals/ft3-h
calculated from the published data. However, if the calculated growth rate exponent of -1.75 is used in
place of the suggested value of -1.66, the nucleation rate is calculated to be 3.258x108 number of
3
crystals/ft -h. This value compares closely with the value calculat ed from the data. The final form of
growth and nucleation rate equations used in this simulation then are:

Technical Results
The overall mass balance for the partial NH3 recycle urea plant is summarized in the output report of the
simulation:

OVERALL PLANT MASS BALANCE

--------------------------- LB/HR ---------------------------

COMPONENT FEED +REACTION -PRODUCT =DEVI ATION PERCENT DEV

1 UREA 0.00 95598.21 95598.19 0.00 0.00

2 WATER 0.00 28677.21 28677.21 0.00 0.00
3 AMCA 0.00 3542.88 3542.88 0.00 0.00
4 AMMONIA 105049.00 -55765.12 49281.46 2.43 0.00
5 CO2 93408.00 -72053.17 21354.83 0.00 0.00
6 N2 0.00 0.00 0.00 0.00 0.00
7 O2 0.00 0.00 0.00 0.00 0.00
8 H2 0.00 0.00 0.00 0.00 0.00
TOTAL 198457.00 0.01 198454.56 2.44 0.00

Conclusion
The 1000 tons/day urea process discussed in this case book demonstrates the use of many chemicals
and solids capabilities in PRO/ II. This example also highlights those features of PRO/ II that make it easy
to incorporat e available literature data.

Output Results
The keyword input file appears in Appendix A. Appendix B is a listing of selected results. These include
the urea reactor RX1 and the decomposers RX2 and RX3, the filtering centrifuge units CEN1 and CEN2,
the dryer DR1, the crystallizers CR1 and CR2, the solids freezer FRZ1, and stream weight component
rates for selected streams.

24
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

References

1. Chao, George Tsei-Yu, "Urea: Its Properties and Manufacture", Chao's Institute, 1967.
2. Dent e, M., S. Pierucci, A. Sogaro, G. Carloni, E. Rigolli, "Simulation Program For Urea Plants",
Comput. Chem. Eng. Vol 12, No. 5, pp. 389 -400, 1988.
3. Bennett, R.C., M. VanBuren, "Commercial Urea Crystallization", Crystallization From Solutions and
Melts, Chem. Eng. Prog. Symp. Ser., No. 95(7), Vol. 65, 1969.
4. Perry, R.H., D. Green, "Perry's Chemical Engineers' Handbook", Sixth Edition, pp. 19-32 - 19-33,
McGraw Hill, 1984.
5. Garside, J., M.B. Shah, "Crystallization Kinetics From MSMPR Crystallizers", Ind. Eng. Chem.
Process Des. Dev., Vol 19, No 4, pp. 509-514, 1980.
6. Hydrocarbon Processing, Nov. 1985, pp. 172.
7. Austin, G.T., "Shreve's Chemical Process Industries," Fifth Edition, pp.311-13, McGraw-Hill, 1984.
The following are additional sources of information related to using P RO/II with solids and
electrolytes:
8. Goldfarb, S., J. Coon, J. Tanger, K.M. Ng, C.F. Chu, "Crystallization Process Optimization Using
PRO/II", Present ed at: November 1990 AIChE Meeting.
9. Goldfarb, S., J. Coon, J. Tanger, A. Harvey, "Rigorous Simulation of Aqueous Electrolyte Flowsheets
With Special Emphasis on Solids Proc essing Capabilities", Presented at: Fourth International
Symposium on Process Systems Engineering (PSE 91).
10. Goldfarb, S., "Continuous Sugar Crystallization Process With Applications in the Agri -Chemical
Industry," Presented at: August 1993 AIChE Meeting.

25
 PRO/II Process Engineering Urea Plant Casebook

A PPENDIX A
Input Data File
The keyword input file for this example is UreaPlnt.inp. It normally is installed with the PRO/II Cas ebook
manual in the folder:
%ProIIInstall %\Manual\Casebook\Inputs\
where %ProIIInstall% represents the root directory where PRO/ II is installed. The following is a listing of
that keyword input file.

$ UREA PLANT FLOWSHEET

$
TITLE PROJECT=CASEBOOK, PROBLEM=UREAPLANT, USER=SIMSCI, DATE=MAY 95
PRINT STREAM=COMPONENT, RATE=WT, MBALANCE=ON, HISTORY=ON
TOLERANCE DEFAULT=V94
DIMENSION ENGLISH, MDUTY=ON, BASIS=MOLE, FLENGTH=MIC, &
XDENSITY=DENS
SEQUENCE SIMSCI
COMPONENT DATA
CURRENT SEARCH = SIMSCI
LIBID 1,UREA/2,WATER/4,AMMONIA/5,CO2/6,N2/7,O2/8,H2, BANK=CURRENT
NONLIB 3,AMCA
PHASE VLS=1,VLS=3
MWAVG 3,78.071
SPGR 3,1.2
$ Fill in missing data for UREA and AMMONIUM CARBAMATE from the Thermodynamic
$ Data Manager.
$ PRO/II physical property insert for:
$ Name: UREA
$ Formula: CH4N2O
$ Created: 05/10/95
$ Source: User File: urea
$
$
$ PRO/II physical property insert for:
$ Name: AMMONIUM CARBAMATE
$ Formula: CH6N2O2
$ Created: 05/10/95
$ Source: User File: urea
$
$ Thermo methods available for use:
$ Library
$ EOS Methods
$
ACENTRIC 1,0.59739/3,0.59421
TC 3,726.7
PC 3,977.66
HFUSION(M) 3,29680
NMP 3,271.4
FORMATION(S,M) 3,-277320,-192630
ATTRIBUTE COMP=1, PSD=0,20,50,100,200,500,1000

27
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

ASSAY FIT=ALTERNATE, CONVERSION=API94, CURVEFIT=CURRENT, &

FORMATION=CURRENT, KVRECONCILE=TAILS
VISCOSITY(V,K,PAS) CORRELATION=1, DATA=1,500,200,-1.11177e-006, &
2.16478e-008,2.48575e-015,-8.14361e-018,1.3193e-020, &
-8.38278e-024
VISCOSITY(L,K,PAS) CORRELATION=20, DATA=1,500,200,-176.103,12442.1, &
23.1548
CONDUCTIVITY(V,K,W/MK) CORRELATION=1, DATA=1,500,250,-0.0189453, &
7.76855e-005,-8.99174e-012,2.44916e-014,-3.28476e-017, &
1.73399e-020
CONDUCTIVITY(L,K,W/MK) CORRELATION=1, DATA=1,500,200,0.253287, &
-0.00017696,-1.30975e-007
SURFACE(L,K,N/M) CORRELATION=1, DATA=1,500,200,0.156584, &
-0.000268471,1.9517e-008,9.79654e-011,-1.37613e-013, &
1.20688e-016
VP(L,K,PA) CORRELATION=20,LN, DATA=3,426.15,303.15,-29.298,-3908.2, &
9.29569,-1.62079e-005,2,1.16265e-008
LATENT(K,J/KG,MOLE) CORRELATION=1, DATA=3,600,400,517894000, &
-4814250,20477,-44.0836,0.0474472,-2.05734e-005
ENTHALPY(I,K,J/KG,MOLE) CORRELATION=1, DATA=3,1500,150,91314600, &
23518.1,76.0061,0.00793726,-2.48402e-005,7.27502e-009
ENTHALPY(L,K,J/KG,MOLE) CORRELATION=1, DATA=3,295.5,12.55, &
-17658300,-6685.02,308.557,-0.173574,-1.17478e-009, &
1.79998e-012
CP(S,K,J/KG,MOLE) CORRELATION=1, DATA=3,473.15,293.15,986749, &
-10733.5,47.2555,-0.0875184,5.85683e-005
DENSITY(L,K,KG/M3,MOLE) CORRELATION=1, DATA=3,477.595,366.483, &
23.7594,-0.0455341,0.000167811,-4.52984e-007,6.00457e-010, &
-3.35813e-013
DENSITY(S,K,KG/M3,MOLE) CORRELATION=1, DATA=3,293.15,293.15, &
22.2299
VISCOSITY(V,K,PAS) CORRELATION=1, DATA=3,500,200,-0.191744, &
0.00399355,3.46188e-010,-1.23345e-012,2.12809e-015, &
-1.41668e-018
VISCOSITY(L,K,PAS) CORRELATION=20, DATA=3,500,250,-47.0585,4595.93, &
4.78745
CONDUCTIVITY(V,K,W/MK) CORRELATION=1, DATA=3,500,250,-0.123203, &
0.00141771,-6.67381e-006,1.65359e-008,-2.03913e-011, &
1.0021e-014
CONDUCTIVITY(L,K,W/MK) CORRELATION=1, DATA=3,500,200,0.253287, &
-0.00017696,-1.30975e-007
SURFACE(L,K,N/M) CORRELATION=1, DATA=3,500,200,0.00800654, &
-1.45283e-005,2.24372e-011,9.65258e-012,-1.46223e-014, &
1.19076e-017
THERMODYNAMIC DATA
TRESET CONSTANT = NOFLASH
METHOD SYSTEM=NRTL, KVAL(SLE)=SOLU, ENTROPY(L)=SRK, ENTROPY(V)=SRK, &
SET=NRTL01, DEFAULT
KVAL(SLE)
SOLUTE 1
SOLDATA(K) 1,2,,-1310.37,0.533619
STREAM DATA
PROPERTY STREAM=1, TEMPERATURE=-28, PRESSURE=320, PHASE=M, &
COMPOSITION(WT,LB/H)=4,105049
PROPERTY STREAM=2, TEMPERATURE=100, PRESSURE=300, PHASE=M, &
COMPOSITION(WT,LB/H)=5,93408
$
$ INITIAL GUESS FOR TEAR STREAMS

28
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

$
PROPERTY STREAM=7, TEMPERATURE=126, PRESSURE=320, PHASE=M, &
COMPOSITION(WT,LB/H)=2,0.5/4,58667
NAME 1,NH3FD/2,CO2FD/9,DECGS1/12,DECGS2/14,FLGS1/16,FLGS2/ &
19,CRYGS1/24,CRYGS2/29,DRYGS/31,UREAPROD
$
$ REACTION DATA
$
RXDATA
$
$ MAIN UREA REACTION
$
RXSET ID=RST1
REACTION ID=RXC1
STOICHIOMETRY 1,3/2,3/3,1/4,-8/5,-4
$
$ DECOMPOSITION REACTION
$
RXSET ID=RST2
REACTION ID=RXC2
STOICHIOMETRY 3,-1/4,2/5,1
UNIT OPERATIONS
$
$ CO2 COMPRESSOR
$
COMPRESSOR UID=COM1
FEED 2
PRODUCT V=4
OPERATION CALCULATION=ASME, COPT=SING, PRES=3516, EFF=75
COOLER ACDP=1, ACTEMP=100
$
$ NH3 RECYCLE & FEED PUMP
$
PUMP UID=P1
FEED 1,7
PRODUCT L=3
OPERATION PRESSURE=3515
$
$ HIGH PRESSURE REACTOR
$
CONREACTOR UID=RX1
FEED 3,4
PRODUCT L=5
OPERATION ISOTHERMAL, TEMPERATURE=365
RXCALCULATION MODEL=STOIC
RXSTOIC RXSET=RST1
REACTION RXC1
BASE COMPONENT=5
CONVERSION 1
$
$ PRESSURE REDUCTION VALVE
$
VALVE UID=VL1
FEED 5
PRODUCT M=6
OPERATION PRESSURE=320
$
$ AMMONIA SEPARATOR

29
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

$
SHORTCUT UID=COL1
FEED 6
PRODUCT STREAM=7, PERCENT(WT)=23, PHASE=L, PRESSURE=320
PRODUCT STREAM=8, PHASE=L, PRESSURE=325
WATER=9
CONDENSER TYPE=BUBB
EVALUATE MODEL=CONV, TRIAL=50, KEYLIGHT=4, KEYHEAVY=2, &
RRMIN=2.5
FINDEX 2
SPEC STREAM=7,FRACTION(WT), COMP=4,WET, VALUE=0.99995
SPEC STREAM=7, RATE(WT,LB/H), COMP=4,WET, DIVIDE, STREAM=6, &
RATE(WT,LB/H), COMP=4,WET, VALUE=0.65
$
$ HIGH PRESSURE DECOMPOSER
$
CONREACTOR UID=RX2
FEED 8
PRODUCT V=9, L=10
OPERATION ISOTHERMAL, TEMPERATURE=302
RXCALCULATION MODEL=STOIC
RXSTOIC RXSET=RST2
REACTION RXC2
BASE COMPONENT=3
CONVERSION 0.88
$
$ HIGH PRESSURE DECOMPOSER BOTTOMS COOLER
$
FLASH UID=FL2
FEED 10
PRODUCT M=11
ISO TEMPERATURE=158, PRESSURE=25
$
$ LOW PRESSURE DECOMPOSER
$
CONREACTOR UID=RX3
FEED 11
PRODUCT V=12, L=13
OPERATION ISOTHERMAL, TEMPERATURE=252
RXCALCULATION MODEL=STOIC
RXSTOIC RXSET=RST2
REACTION RXC2
BASE COMPONENT=3
CONVERSION 0.9995
$
$ FLASH DRUM
$
FLASH UID=FL3
FEED 13
PRODUCT V=14, L=15
ISO TEMPERATURE=250, PRESSURE=15
$
$ EVAPORATOR
$
FLASH UID=FL4
FEED 15
PRODUCT V=16, L=17
TPSPEC TEMPERATURE=230

30
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

SPEC STREAM=17,FRACTION(WT), COMP=4,WET, VALUE=0.001

$
$ PUMP INTO FIRST CRYSTALLIZER
$
PUMP UID=P2, NAME=PUMP2
FEED 17
PRODUCT L=18
OPERATION PRESSURE=20
$
$ FIRST STAGE CRYSTALLIZER
$
CRYSTALLIZER UID=CR1, NAME=CSTAGE1
FEED 18
PRODUCT OVHD=19, BTMS=20
PRINT CSD
OPERATION SOLUTE=1, SOLVENT=2, TEMPERATURE=130, PRESSURE=1.5
DESIGN PFRACTION=0.85
GROWTH KG=2.952e-008, GEXPONENT=0
NUCLEATION KB=8.7417, BEXPONENTS=-3.87,0,-1.75,0
$
$ PUMP INTO FIRST CENTRIFUGE
$
PUMP UID=P3, NAME=PUMP3
FEED 20
PRODUCT L=21
OPERATION PRESSURE=20
$
$ FIRST STAGE CENTRIFUGE
$
FCENTRIFUGE UID=CEN1, NAME=CENT1
FEED 21
PRODUCT FILTRATE=22, CAKE=23
RATING DIAMETER=3, RPM=1000
$
$ SECOND STAGE CRYSTALLIZER
$
CRYSTALLIZER UID=CR2, NAME=CSTAGE2
FEED 22
PRODUCT OVHD=24, BTMS=25
PRINT CSD
OPERATION SOLUTE=1, SOLVENT=2, TEMPERATURE=130, PRESSURE=1.335
DESIGN PFRACTION=0.95
GROWTH KG=2.952e-008, GEXPONENT=0
NUCLEATION KB=8.7417, BEXPONENTS=-3.87,0,-1.75,0
$
$ PUMP INTO SECOND CENTRIFUGE
$
PUMP UID=P4, NAME=PUMP4
FEED 25
PRODUCT L=26
OPERATION PRESSURE=20
$
$ SECOND STAGE CENTRIFUGE
$
FCENTRIFUGE UID=CEN2, NAME=CENT2
FEED 26
PRODUCT FILTRATE=27, CAKE=28
RATING DIAMETER=3, RPM=1000

31
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

$
$ FINAL DRYING OF SOLID PRODUCT
$
DRYER UID=DR1, NAME=DRYER
FEED 23,28
PRODUCT OVHD=29, BTMS=30
OPERATION PRESSURE=15
DESIGN MOISTURE(WT)=0.001, BTMS
$
$ ENSURE ANY REMAINING UREA IS CONVERTED TO A SOLID
$
MELTER UID=FRZ1, NAME=FREEZER
FEED 30
PRODUCT M=31
OPERATION TEMPERATURE=200, DP=0
$
END

32
 PRO/II Process Engineering Urea Plant Casebook

A PPENDIX B
Output Report File
Selected PRO/II output is shown below. The output selected highlights solids capabilities.

33
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

FILTERING CENTRIFUGE SUMMARY

34
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

DRYER SUMMARY

CRYSTALLI ZER SUMMARY

35
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

MELTER/FREEZER SUMMARY

CONVERSION REACTOR S UMMARY

STREAM W EIGHT COMPONENT RATES

Stream Name 1 10 11 12

36
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

Stream Description NH3FD DECGS2

Phase Liquid Liquid Mixed Vapor

Temperat ure F -28 302 158 252

Pressure PSIA 320 325 25 25
MM
Enthalpy BTU/HR -6.76237 24.05951 13.56366 15.91092
Molecular Weight 17.03056 36.71097 36.71097 18.41471
Vapor Weight Fraction 0 0 0.056472 1
Liquid Weight Fraction 1 1 0.943528 0
Total Mass Rate LB/HR 105049 133543.1 133543.1 21205.85
Total Weight Comp.
Rates LB/HR
UREA 0 95596.12 95596.12 2.458986
WATER 0 24953.62 24953.62 8908.211
AMCA 0 1428.861 1428.861 0.609099
AMMONIA 105049 10548.1 10548.1 10492.4
CO2 0 1016.412 1016.412 1802.172
N2 0 0 0 0
O2 0 0 0 0
H2 0 0 0 0

Stream Name 13 14 15 16
Stream Description FLGS1 FLGS2
Phase Liquid Vapor Liquid Vapor

Temperat ure F 252 250 250 230

Pressure PSIA 25 15 15 8.783429
MM
Enthalpy BTU/HR 13.83514 1.381207 13.35291 0.661921
Molecular Weight 44.5305 17.83289 45.41886 17.83572
Vapor Weight Fraction 0 1 0 1
Liquid Weight Fraction 1 0 1 0
Total Mass Rate LB/HR 112337.3 1448.73 110888.5 641.5908
Total Weight Comp.
Rates LB/HR
UREA 95593.66 0.275736 95593.39 0.097348
WATER 16045.41 989.5765 15055.84 512.6662

37
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

AMCA 0.105331 0.042172 0.063159 0.015285

AMMONIA 678.7775 441.1207 237.6568 127.4101
CO2 19.30808 17.71488 1.593199 1.401901
N2 0 0 0 0
O2 0 0 0 0
H2 0 0 0 0

Stream Name 17 18 19 2
Stream Description CRY GS1 CO2FD
Phase Liquid Liquid Vapor Vapor

Temperat ure F 230 230.0511 130 100

Pressure PSIA 8.783429 20 1.5 300
MM
Enthalpy BTU/HR 11.98528 11.98839 0.747804 4.715396
Molecular Weight 45.83134 45.83134 17.90394 44.0098
Vapor Weight Fraction 0 0 1 1
Liquid Weight Fraction 1 1 0 0
Total Mass Rate LB/HR 110246.9 110246.9 708.3282 93408
Total Weight Comp.
Rates LB/HR
UREA 95593.29 95593.29 0.0036 0
WATER 14543.17 14543.17 629.8848 0
AMCA 0.047874 0.047874 0.009087 0
AMMONIA 110.2467 110.2467 78.24459 0
CO2 0.191298 0.191298 0.186037 93408
N2 0 0 0 0
O2 0 0 0 0
H2 0 0 0 0

Stream Name 20 21 22 23
Stream Description
Wet Wet
Phase Liquid Liquid Liquid Wet Liquid

Temperat ure F 130 130.0609 130.0609 130.0609

Pressure PSIA 1.5 20 20 20

38
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

MM
Enthalpy BTU/HR -0.67668 -0.67333 2.637574 -3.3109
Molecular Weight 46.29834 46.29834 34.92819 58.06219
Vapor Weight Fraction 0 2.22E-16 0 -1.11E -16
Liquid Weight Fraction 0.413043 0.413043 1 0.047724
Total Mass Rate LB/HR 109538.6 109538.6 42021.99 67516.62
Total Weight Comp.
Rates LB/HR
UREA 95593.29 95593.29 29069.82 66523.47
WATER 13913.28 13913.28 12922.41 990.8733
AMCA 0.038787 0.038787 0.036025 0.002762
AMMONIA 32.0021 32.0021 29.72298 2.279118
CO2 0.005261 0.005261 0.004886 0.000375
N2 0 0 0 0
O2 0 0 0 0
H2 0 0 0 0

Stream Name 24 25 26 27
Stream Description CRY GS2
Wet Wet
Phase Vapor Liquid Liquid Liquid

Temperat ure F 130 130 130.0768 130.0768

Pressure PSIA 1.335 1.335 20 20
MM
Enthalpy BTU/HR 7.848498 0.344065 0.345499 1.152559
Molecular Weight 18.01109 43.0554 43.0554 34.94677
Vapor Weight Fraction 1 2.78E-16 2.78E-16 0
Liquid Weight Fraction 0 0.54955 0.54955 1
Total Mass Rate LB/HR 7031.9 34990.09 34990.09 18367.31
Total Weight Comp.
Rates LB/HR
UREA 0.039901 29069.78 29069.78 12712.24
WATER 7002.561 5919.85 5919.85 5654.624
AMCA 0.030956 0.005069 0.005069 0.004842
AMMONIA 29.26297 0.460007 0.460007 0.439397
CO2 0.004881 5.29E-06 5.29E-06 5.06E-06
N2 0 0 0 0

39
PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

O2 0 0 0 0
H2 0 0 0 0

Stream Name 28 29 3 30
Stream Description DRY GS
Wet Wet
Phase Liquid Vapor Liquid Liquid

Temperat ure F 130.0768 369.5332 44.75271 369.5332

Pressure PSIA 20 15 3515 15
MM
Enthalpy BTU/HR -0.80706 1.421346 2.295408 5.018192
Molecular Weight 57.89963 18.16974 17.03123 59.92067
Vapor Weight Fraction 2.22E-16 1 0 0
Liquid Weight Fraction 0.051827 0 1 0.03485
Total Mass Rate LB/HR 16622.78 1193.012 165754.2 82946.39
Total Weight Comp.
Rates LB/HR
UREA 16357.53 14.6735 0 82866.33
WATER 265.226 1176.044 2.53E-07 80.05562
AMCA 0.000227 0.002979 8.362629 1.08E-05
AMMONIA 0.02061 2.291751 165745.8 0.007977
CO2 2.37E-07 0.000374 0 4.14E-07
N2 0 0 0 0
O2 0 0 0 0
H2 0 0 0 0

Stream Name 31 4 5 6
Stream Description UREAP ROD
Phase Wet Liquid Liquid Liquid Mixed

Temperat ure F 200 100 365 292.5616

Pressure PSIA 15 3515 3515 320
MM
Enthalpy BTU/HR -2.04306 4.715396 77.59765 77.59765
Molecular Weight 59.92067 44.0098 28.16443 28.16443
40
Case 5: Urea Plant PRO/II Process Engineering Urea Plant Casebook

Vapor Weight Fraction -1.11E -16 0 0 0.459152

Liquid Weight Fraction 0.000965 1 1 0.540848
Total Mass Rate LB/HR 82946.39 93408 259162.3 259162.3
Total Weight Comp.
Rates LB/HR
UREA 82866.33 0 95598.21 95598.21
WATER 80.05562 0 28677.21 28677.21
AMCA 1.08E-05 0 41433.54 41433.54
AMMONIA 0.007977 0 93453.29 93453.29
CO2 4.14E-07 93408 0 0
N2 0 0 0 0
O2 0 0 0 0
H2 0 0 0 0

Stream Name 7 8 9
Stream Description DECGS1
Phase Liquid Liquid Vapor

Temperat ure F 127.9331 233.0433 302

Pressure PSIA 320 325 325
MM
Enthalpy BTU/HR 6.599876 26.98021 25.08839
Molecular Weight 17.03239 35.20251 22.12617
Vapor Weight Fraction 0 0 1
Liquid Weight Fraction 1 1 0
Total Mass Rate LB/HR 60707.64 198454.6 64911.45
Total Weight Comp.
Rates LB/HR
UREA 0 95598.19 2.071979
WATER 2.53E-07 28677.21 3723.586
AMCA 8.356898 41425.18 3542.161
AMMONIA 60699.28 32754.02 38110.28
CO2 0 0 19533.35
N2 0 0 0
O2 0 0 0
H2 0 0 0

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PRO/II Process Engineering Urea Plant Casebook Case 5: Urea Plant

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