Abstract: A process for producing formaldehyde-stabilised urea is described comprising generating a synthesis gas, subjecting the synthesis gas to water-gas shift to form a shifted gas; recovering carbon dioxide from the shifted gas; synthesising methanol from the carbon dioxide-depleted synthesis gas; subjecting recovered methanol to oxidation; subjecting the methanol synthesis off-gas to methanation; synthesising ammonia from the ammonia synthesis gas and recovering the ammonia; reacting ammonia and recovered carbon dioxide stream to form a urea stream; and stabilising the urea by mixing the urea stream and a stabiliser prepared using the recovered formaldehyde, wherein a portion of the synthesis gas by-passes either the one or more of the water-gas shift reactors, carbon dioxide removal unit, or water-gas shift reactors and the carbon dioxide removal unit used in the process.

Abstract: A process for the production of formaldehyde-stabilised urea is described comprising the steps of: (a) generating a synthesis gas comprising hydrogen, nitrogen, carbon monoxide, carbon dioxide and steam in a synthesis gas generation unit, (b) subjecting the synthesis gas to one or more stages of water-gas shift in one or more water-gas shift reactors to form a shifted gas; (c) recovering carbon dioxide from the shifted gas in a carbon dioxide removal unit to form a carbon dioxide-depleted synthesis gas; (d) synthesising methanol from the carbon dioxide-depleted synthesis gas in a methanol synthesis unit and recovering the methanol and a methanol synthesis off-gas comprising nitrogen, hydrogen and residual carbon monoxide; (e) subjecting at least a portion of the recovered methanol to oxidation with air in a formaldehyde production unit; (f) subjecting the methanol synthesis off-gas to methanation in a methanation reactor containing a methanation catalyst to form an ammonia synthesis gas; (g) synthesising ammo