Urea synthesis

Costacurta specialises in the mechanical engineering and manufacture of down flow reactor internals used in the chemical sector for urea synthesis.

Urea production is based on the reaction of ammonia with carbon dioxide, typically in a down flow reactor.

The most common use of urea is for fertilisers, which accounts for approximately 80% of the amount produced. Approximately 10% is used for the production of adhesives and plastics (urea formaldehyde and melamine formaldehyde resins).

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Urea synthesis reactor internals

Urea production generally involves two stages in what is called a ‘synthesis loop’: ammonium carbamate is formed first and then decomposes into urea and water.

The urea solution obtained from the decomposition of carbamate is expanded and heated at low pressure and the ammonia is recycled. The resulting solution is further concentrated and crystallised in a prilling tower where it is sprayed from above and passed through a countercurrent air stream.

The reaction generating the production of urea and carbamate takes place inside a down flow synthesis reactor, where the mixing of the reagents is improved by the internal elements, special trays, which optimise the conversion rate.

Distinctive characteristics of the Costacurta down flow reactor internals for the production of urea (urea synthesis reactors) are:

  • Internal control of all the production phases for making the internals
  • Over 60 years of experience in mechanical design and production of internals
  • Dedicated teams with long-standing experience in project management

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