(159b) Modeling and Simulation of Blue Ammonia: Challenges and Best Practices for Ammonia – Urea Processes

Modeling and Simulation of Blue Ammonia: Challenges and Best Practices for Ammonia – Urea Processes

Amzan Alsabri^a, Ahmed AlNouss^b, Fadwa Eljack^a

^a Department of Chemical Engineering, College of Engineering, Qatar University, P.O. Box-2713, Qatar

^b Division of Sustainable Development, College of Science and Engineering, Hamad Bin Khalifa University, Qatar Foundation, Doha, Qatar

^*Corresponding Author’s E-mail: Fadwa.Eljack@qu.edu.qa

Keywords: Ammonia, Urea, Simulation, Challenges, Best practices

Topic: Computing and Systems Technology Division

Session: 63 Process Modeling and Simulation

Abstract

The ammonia and urea synthesis reactors are the most important units in urea production. Rigorous simulation of the urea reactor is necessary and significant. The modeling and simulation of this system is challenging due to the complex thermodynamic system and chemical reactions.

The market size of nitrogen-based fertilizers has expanded significantly due to the high global demand. At a compound annual growth rate (CAGR) of 5.1%, the market size increased from $87.48 billion in 2022 to $91.97 billion in 2023, and it is expected to reach $111.84 billion in 2027[1]. Urea is the most manufactured type of nitrogen-based fertilizers, where the global capacity is expected to increase by a net of 17 metric tons annually. In 2021, the total production capacity of urea has been estimated at 226 metric tons [2].

Due to the significance of urea production, as well as the availability of modern flow sheeting tools, this study employs basic thermodynamic principles and software engineering to create a tool that can be utilized for modelling key aspects of the urea production processes that are commercially available. While there are several urea production technologies available [3, 4, 5, 6,7], our modelling efforts were focused on the Stamicarbon and Snamprogetti processes because they account for roughly 76% of the global market [8]. In this paper we present a mechanism model using rigorous thermodynamic model, reaction kinetics and fluid dynamics. The urea reactor model is formulated as a set of non-linear equations; it is solved using a stage-by-stage method. The numerical solution of the equations is performed using a conventional iterative method, while the algorithm is simple and robust. Moreover, a literature review was conducted to address the most recent findings in this research scope and compare it with the challenges raised in this study.

References

[1] Nitrogen Fertilizer Market Demand, Growth Analysis, Outlook 2032. (n.d.). https://www.thebusinessresearchcompany.com/report/nitrogen-fertilizer-global-market-report

[2] International Fertilizer Industry Association, http://www.fertilizer.org/index.htm

[3] L. W. Codd, "Chemical Technology: An Encyclopaedic Treatment: The Economic Application of Modern Technological Developments ", Barnes and Noble, 1975

[4] J.A. Kent, "Riegel's Handbook of Industrial Chemistry", Van Nostrand Reinhold Company Inc, 1983

[5] I. Froment, F. Gilbert, "4th International Symposium on Large Chemical Plants", Antwerp, 1979, Elsevier; Scientific Publishing Company, 1979

[6] R.A. Meyers, "Handbook of Chemical Production Processes", McGraw-Hill, 1986

[7] "Production of Urea and Urea Ammonium Nitrate", European Fertilizer Manufacturers' Association, 1995.

[8] Dente, M.; Pierucci, S.; Sogaro, A.; Carloni, G. and Rigolli, E.; "Simulation Program for Urea Plants", Comput. Chem. Engng., Vol. 21., No. 5, 389-400, 1988