Urea synthesis with improved heat recovery and conversion

Claim 1

In a substantially exothermic urea synthesis system wherein fluid NH 3 and fluid CO 2 are contacted at elevated pressure and temperature to form a total urea synthesis mixture in a vertical cylindrical urea synthesis reactor to form urea, and heat is removed from said system, the improvement which comprises contacting from about 5 to less than about 100 mol percent of a fluid NH 3 reactor feed stream and a fluid CO 2 reactor feed stream at substantially reactor pressure in a heat exchanger external to the urea synthesis reactor to form ammoinum carbamate in said heat exchanger and simultaneously removing from said external heat exchanger heat of reaction evolved from reaction of NH 3 and CO 2 to form said ammonium carbamate, and charging the resulting reaction mixture to a conduit positioned in said urea synthesis reactor in a counter current indirect heat exchange relation to a total urea synthesis mixture, defined below, contained in said reactor, wherein the NH 3 to CO 2 molar ratio inside said conduit is maintained at from about 2.2 to about 3.5 to 1, the inlet of said conduit being located at the upper section of said reactor and the outlet of said conduit being located in a bottom section of said reactor, charging the remaining NH 3 reactor feed stream to the bottom section of the reactor proximate said outlet of said conduit, and mixing said remaining NH 3 reactor feed stream charged to the bottom section of the reactor with a stream of said resulting mixture discharged from said outlet of said conduit to form a total urea synthesis mixture having a NH 3 to CO 2 molar ratio of from about 2.8 to about 7 to 1 and to maintain a substantially isothermal balance in said reactor.