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1. Vishwakarma Institute of Technology, Pune-37 (An Autonomous Institute of Savitribai Phule Pune University)   Guide: Prof. Dr. Hemlata Karne Made by Group 5: Nikhilesh Chauhan (PRN. No 12210230) Kunal Nimkar (PRN. No 12211198) Dnyneshwari Pote (PRN. No. 12210338) Sandip Pawar (PRN. No 12210393) Vishal Purohit (PRN. No 12210408) Manufacturing of Urea

2. Introduction Meeting agricultural demand: Urea plants are crucial in supplying nitrogen fertilizer to support crop growth and address food security needs. Ensuring quality and purity: Production focuses on meeting strict standards to ensure effective fertilization and minimize environmental impact. Maximizing efficiency: Plants aim to optimize processes to reduce costs and enhance competitiveness. Environmental compliance: Adherence to regulations is key to minimizing pollution and greenhouse gas emissions. Sustainable agriculture: Urea production contributes to long-term soil health and supports global food security efforts.

3.   Chemical Reactions:   Conversion of carbon-dioxide (CO2) and Ammonia (NH3) into ammonium carbamate. 2 NH 3​( g )+ CO 2​( g )→ NH 2​ COONH 4​( s )   Production of urea using ammonium carbamate   NH 2​ COONH 4​( s )→ NH 2​ CONH 2​( l )+ H 2​ O ( g )   Side Reaction   2NH2CONH2( l ) →NH2CONHCONH2( l )   Main reaction   2 NH 3​( g )+ CO 2​( g )→NH2CONH2( l )

4. Block flow Diagram of Urea Synthesis    

5. Process flow diagram of urea manufacturing

6. Process description Ammonia Production: Ammonia (NH3) is synthesized from nitrogen (N2) and hydrogen (H2), then purified. Carbon Dioxide Capture: CO2 is captured from various sources, purified to remove impurities. Formation of Ammonium Carbamate: CO2 reacts with ammonia to form ammonium carbamate (NH2COONH4).Thermal Decomposition: Ammonium carbamate undergoes thermal decomposition, yielding urea (NH2CONH2) and water (H2O). Crystallization and Separation: Ammonium carbamate is crystallized, separated from unreacted components. Purification of Urea Solution: Urea solution is purified to remove impurities like biuret, water, and ammonia. Granulation and Solidification: Purified urea is solidified into granules or prills , dried, and packaged for distribution and use in industrial and agricultural applications.

7. Applications of urea Fertilizers Cosmetics and Personal Care Products Pharmaceuticals Chemical Industry Animal Feed Dyeing and Textile Industry

8. Design and material balance   Using Microsoft Excel, we designed a urea manufacturing plant with its material balance. The results are shown in below figure:

9. Conclusion   Urea synthesis optimization requires intricate analysis of reaction kinetics, thermodynamics, and process engineering. Valuable insights have been gained from experiments, like designing a 767.312205 kg/day capacity for a 1000 kg/day feed urea plant. This data is crucial for engineering students and newcomers to fertilizer industries. Designing a new plant demands deep knowledge across engineering disciplines and specific process experience. Engineering companies often have in-house specialists adept at efficiently managing plant reliability issues.     

10. Thank you