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  Conventional Recycle process

In the first generation of total-recycle processes, the recycle of nonconverted NH3 and CO2 was performed in two stages. The first recirculation stage was operated at medium pressure (18-25 bar), the second, at low pressure (2-5 bar). All nonconverted CO2 was recycled as an aqueous solution and a large portion of NH3 was recycled as pure NH3. The detrimental effect of water on the reaction conversion in the urea synthesis, achieving a minimum CO2 recycle was considered more important than achieving a low NH3 recycle. All conventional processes typically operate at high NH3: CO2 ratios (4-5 mol/mol) to maximize CO2 conversion per pass.
The main disadvantages of the conventional process are the relatively high synthesis pressure of approx. 200 bar and the NH3 recycle.

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All urea plants with a recycle process are a combination of the following process sections:

  • Compression of CO2 and NH3
  • Synthesis
  • One or more recycle stages
  • Evaporation and waste water treatment (or crystallizaton section with waste water treatment)
  • Finishing section (prills or granules)
 
   

 

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