| 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.
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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