Key points 1.

Background

2. Importance Of The Stamicarbon CO₂ Stripping Process

3. Steps In The Stamicarbon CO₂ Stripping Process

4. Reaction Mechanism Of The Stamicarbon CO₂ Stripping

Process

5. Process Flow Diagram

6. Equipment Used In Process:equipment Used In Process:

7. Process Flow:

8. Major Engineering Challenges In Urea Manufacturing

9. Environmental Considerations & Safety Considerations

10. Conclusion
 BACKGROUND

Urea is a simple organic compound

The Stamicarbon process is a
with the chemical formula CO(NH₂)₂. relatively new technology for
It is a vital component in various producing urea from carbon dioxide
industries, particularly agriculture and ammonia. It offers several
and pharmaceuticals. Its primary use advantages over traditional methods,
is as a nitrogen fertilizer due to its particularly in terms of energy
high nitrogen content and ease of efficiency and environmental impact.
absorption by plants.
 Importance of the Stamicarbon CO₂ Stripping Process
1. Lower Pressure Operation

Energy Efficiency: Operating at lower pressures significantly reduces the energy required for the
urea synthesis process. This translates to lower operational costs and a smaller carbon footprint.

Reduced Equipment Complexity: Lower pressures allow for simpler and less expensive equipment,
further contributing to cost savings.

2. Integrated Ammonia Synthesis

Synergy:Combining ammonia synthesis with urea production in a single process stream enhances
overall efficiency and reduces capital costs.

Reduced Emissions: The integrated approach can minimize emissions associated with both
ammonia and urea production.
Importance of the Stamicarbon CO₂ Stripping Process
3. Utilization of Captured CO₂

Carbon Neutrality: By utilizing captured carbon dioxide from industrial sources, the
Stamicarbon process can contribute to carbon neutrality efforts.

Diversification: The ability to use captured CO₂ makes the process more adaptable to various
industrial settings, including power plants and refineries.

4. Higher Urea Yields

Improved Efficiency: The Stamicarbon process is designed to achieve higher urea yields per
unit of reactants, leading to increased productivity.

Reduced Waste: Higher yields minimize waste generation and improve resource utilization.
Importance of the Stamicarbon CO₂ Stripping Process

5. Flexibility and Adaptability

Diverse CO₂ Sources: The process can accommodate various CO₂ sources, making it
suitable for different industrial applications.

Scalability: The Stamicarbon process can be scaled to meet varying production demands,
from small-scale plants to large-scale industrial facilities.
 Steps in the Stamicarbon CO₂ Stripping Process

CO₂ Capture:

Gas Capture: Carbon dioxide is captured from a flue gas stream, such as that
emitted from power plants or industrial facilities.

Solvent Absorption: The captured CO₂ is absorbed by a suitable solvent, forming a

CO₂ rich solution.

Ammonia Synthesis:

Haber-Bosch Process: Ammonia is synthesized using the traditional Haber-Bosch

process, which involves reacting nitrogen and hydrogen under high pressure and
temperature.
 Steps in the Stamicarbon CO₂ Stripping Process

CO₂ Stripping:
Regeneration: The CO₂ rich solution is regenerated to release the captured CO₂. This is
typically achieved through heating or pressure reduction.

Purification: The released CO₂ is purified to remove impurities before use.

Urea Synthesis:

Reaction: The purified CO₂ is reacted with ammonia in a reactor under controlled
conditions to form urea and water.

Optimization: The reaction conditions are optimized to maximize urea yield and minimize
byproduct formation.
 Steps in the Stamicarbon CO₂ Stripping Process

Purification and Separation:

Separation: The urea-water mixture is separated to isolate the urea.
Purification: The urea is further purified to remove impurities and meet
product specifications.

Granulation (Optional):
Granulation: The purified urea may be granulated to improve its handling
and application properties.
Reaction Mechanism of the Stamicarbon CO₂ Stripping Process

1: CO₂ Capture and Absorption

Reaction: CO₂(g) + Solvent → Solvent-CO₂ complex

Conditions: Temperature and pressure depend on the specific solvent used. Common solvents
include amines and ionic liquids.

2: Ammonia Synthesis (Haber-Bosch Process)

Reaction: N₂(g) + 3H₂(g) → 2NH₃(g)

Conditions: High temperature (around 400-500°C) and high pressure (around 200-300 atm).
Reaction Mechanism of the Stamicarbon CO₂ Stripping Process

3: CO₂ Stripping and Purification

Reaction: Solvent-CO₂ complex → Solvent + CO₂(g)

Conditions: Temperature and pressure depend on the solvent and the desired CO₂ purity.
Typically involves heating or reducing pressure.

Purification: CO₂ may be further purified through processes like adsorption or membrane
separation.

4: Urea Synthesis
Reaction: 2NH₃(g) + CO₂(g) → CO(NH₂)₂(aq) + H₂O(l)

Conditions: Temperature and pressure are typically lower than those used in the Haber-Bosch
process. The specific conditions depend on the reactor design and catalyst used.
Reaction Mechanism of the Stamicarbon CO₂ Stripping Process

5: Cooling and Crystallization

Cooling: The urea-water mixture is cooled to promote the crystallization of urea.

Crystallization: Urea crystals form, while the remaining liquid, primarily water, remains
in solution.

6: Solid-Liquid Separation

Filtration: The urea crystals are separated from the liquid phase using filtration
techniques, such as vacuum filtration or centrifugation.
Reaction Mechanism of the Stamicarbon CO₂ Stripping Process

7: Washing and Drying

Washing: The separated urea crystals are washed to remove any residual impurities.

Drying: The washed urea crystals are dried to remove excess moisture and ensure a dry,
pure product.

8: Additional Purification (Optional)

Recrystallization: If higher purity is required, the urea can be recrystallized by dissolving

it in a suitable solvent and then cooling to promote crystallization.

Ion Exchange: Ion exchange can be used to remove impurities that may have been
introduced during the process.
 Equipment used in process:

Reactor:

The heart of the process, where the synthesis of urea occurs.

Typically a bubble column reactor, providing efficient gas-liquid contact.

Operates at high pressure (140-200 bar) and temperature (180-200°C).

Low-Pressure Carbamate Scrubber

Removes unreacted carbamate from the gas stream, preventing losses.

Uses a liquid solvent to absorb carbamate, which is later recovered and recycled.

High-Pressure Condenser

Condenses gases to recover valuable components like ammonia and carbon dioxide.

Uses cooling water to reduce the temperature of the gas stream, causing it to condense into a liquid.
 Equipment used in process:

Low-Pressure Scrubber

Removes additional impurities like carbon dioxide and inert gases from the gas stream.

Similar to the high-pressure scrubber, but operates at lower pressure.

Ejector

Creates a vacuum or low pressure to facilitate the stripping process.

Uses steam or a compressed gas to create a vacuum, pulling the gas stream through the scrubber.

Boiler Feed Water

Provides water for generating steam used in the process.

Feeds water into the boiler to produce steam for heating and stripping.
 Equipment used in process:

One-Stage Evaporator

Concentrates the urea solution.

Removes water from the urea solution to increase urea concentration.

Vacuum Evaporator

Further concentrates the urea solution under vacuum conditions.

Operates at a lower pressure to remove additional water and achieve a higher urea concentration.

Stripper

Separates ammonia and carbon dioxide from the urea solution.

Uses steam to vaporize the gases, allowing them to be separated from the liquid phase.
 Equipment used in process:

Expansion Valve

Controls the flow of a fluid.

Regulates the flow of urea solution or other fluids within the process.

Rectifying Column

Separates components based on their boiling points.

Used to purify the urea solution by removing impurities.

Prilling Tower

Forms urea into small granules.

Sprays the concentrated urea solution into a tower, where it solidifies into granules.
 Equipment used in process:

Cooling Water

Used for cooling various components in the process.

Reduces the temperature of equipment to maintain optimal operating conditions.

Hot Air

Used for drying the urea prills.

Heats the urea granules to remove moisture and ensure product quality.
Process Flow:
1.Ammonia and carbon dioxide are fed into the reactor.

2.Ammonium carbamate is formed and separated in the carbamate

scrubber.

3.The separated products are further processed in the Rectifying column

and evaporator.

4.Urea is collected in the urea tank.

Major Engineering Challenges
in Urea Manufacturing

• Corrosion: Urea production involves

corrosive substances, such as ammonia and
1. Reactor carbon dioxide. Reactor materials must be
selected to withstand these conditions.
Design and • Heat Transfer: Efficient heat transfer is
crucial for controlling the reaction
Operation temperature and preventing overheating.
• Mixing: Ensuring proper mixing of reactants
is essential for optimal reaction efficiency
and product quality.
Major Engineering Challenges
in Urea Manufacturing

•High Energy Consumption: Urea production is

an energy-intensive process, particularly the
2. Energy Haber-Bosch process for ammonia synthesis.
Reducing energy consumption is a major

Efficiency
challenge.
•Waste Heat Recovery: Capturing and utilizing
waste heat from the process can improve
energy efficiency.
Major Engineering Challenges
in Urea Manufacturing

• Greenhouse Gas Emissions: The production of

urea, especially when using fossil fuels for
energy, contributes to greenhouse gas
3. Environmental emissions.
• Water Pollution: Runoff from agricultural fields
Impact where urea is used can lead to water pollution.
• Air Pollution: Emissions of ammonia and other
volatile compounds can contribute to air
pollution.
Major Engineering Challenges
in Urea Manufacturing

 Impurities: Ensuring the final product

4. Product is free from impurities is essential for
its effectiveness and safety.
Quality • Crystallization Control: Controlling the
crystallization process to obtain urea
and Purity crystals of the desired size and shape
is challenging.
Major Engineering Challenges
in Urea Manufacturing

 Chemical Hazards: Urea production

involves hazardous chemicals, such as
5. Safety ammonia and carbon dioxide, which
require proper handling and storage.
and Hazard  Explosion Risk: Ammonia and carbon
Mitigation dioxide can form explosive mixtures,
necessitating safety measures to
prevent accidents.
Environmental Considerations
Greenhouse Gas Emissions: The production of urea, particularly when using
fossil fuels for energy, can contribute to greenhouse gas emissions, such as
carbon dioxide and nitrous oxide.

Water Pollution: Runoff from agricultural fields where urea is used as a

fertilizer can lead to water pollution, causing eutrophication (excessive algae
growth) and harming aquatic ecosystems.

Air Pollution: The release of ammonia and other volatile compounds during
urea production can contribute to air pollution.
Safety Considerations:
Chemical Hazards: Urea itself is generally considered low-toxicity, but its
production involves the handling of hazardous chemicals, such as ammonia
and carbon dioxide.

Explosion Hazards: Ammonia and carbon dioxide can form explosive

mixtures under certain conditions, posing a risk of explosions.

Equipment Failures: Failures in equipment, such as reactors or storage

tanks, can lead to chemical releases and environmental contamination.
 Conclusion
The Stamicarbon CO₂ stripping process offers a promising alternative to traditional urea production
methods. By effectively utilizing captured carbon dioxide, integrating ammonia synthesis, and operating at
lower pressures, this technology provides several advantages:

 Reduced environmental impact

 Enhanced energy efficiency

 Improved productivity

 Increased flexibility

While the Stamicarbon process shows great potential, its widespread adoption will depend on factors such
as economic viability, technological maturity, and market demand. As efforts to reduce greenhouse gas
emissions and improve sustainability continue, the Stamicarbon process is well-positioned to play a
significant role in the future of urea production.
 Reference
https://www.stamicarbon.com/
Austin G. T, Shreve’s Chemical Process Industries, 5th edition, Mc. Graw Hill
Publications

http://ethesis.nitrkl.ac.in/4237/1/Manufacture_of_Urea.pdf
Thank you