Devansh Bhardwaj PDP-II

ASSIGNMENT
2016A1PS0612P
CHE-F343
12/04/2019

Cost Analysis of Urea Production with ASPEN

Summary:

 Urea is an organic compound with the chemical formula CO(NH2)2 consisting of

carbonyl and amide functional groups. Urea serves an important role in the
metabolism of nitrogen-containing compounds by animals and is the main
component of urine of mammals. It is an important component of nitrogen-based
fertilizers and also as a raw material for urea-formaldehyde resin which is an
industrially important polymer
(1) 2NH3 + CO2 => CARBAMATE
(2) CARBAMATE => UREA + H2O
 The first reaction is carried out in a stoichiometric reactor, while the second reaction
which produces urea is carried out in a plug flow reactor where the conversion
increases along the length of the reactor.
 Optimization analysis has been carried out across the plug flow reactor by varying
two parameters the length of the reactor as well as the operating pressure to obtain
maximum profit by increasing the flow rate of the urea stream
 For stoichiometric reactor the pressure and the temperature has been varied, and
the profit has been similarly maximized
 The length of the reactor has to be in the range of 25m- 30m.
 The pressure is kept within 140 kg/sq. cm – 150 kg/sq. cm keeping in consideration
the space provisions and compressor capabilities.
 In PFR It was found that as the pressure increases, we are able to increase the flow
rate of urea, which in turn increases the revenue by product sales from the process.
However, in order to increase the pressure, a greater compression cost is also
incurred. Clearly, this is a trade-off between compressor cost and product revenue
and the revenue is optimised by plotting a graph in excel by varying the pressure
from 140-150 kg/sq.-cm.
 the length of the reactor has been varied which when increased, provides a greater
reactor volume that increases conversion and therefore, the final output of urea. But
increasing the length of the reactor incurs a higher equipment installation cost and
thus there is again a trade-off between urea production and equipment cost.
 For stoichiometric reactor It was found that as the pressure increases, we are able to
increase the flow rate of urea, which in turn increases the revenue by product sales
from the process. However, in order to increase the pressure, a greater compression
cost is also incurred. Clearly, this is a trade-off between compressor cost and product
revenue and the revenue is optimised by plotting a graph in excel by varying the
pressure from 140-150 kg/sq.-cm.
 For stoichiometric reactor’ the temperature of the reactor has been varied which
when increased, increases the conversion of the product, but also the coolant costs
and other heat exchanger costs.
 After performing the sensitivity analysis of the Distillation Columns and plotting the
relevant curves, the following conclusions were arrived at.
 For PFR

 For stoichiometric reactor