Procedure for the production of high-purity melamine with high yields

1. A process for the production of high-purity melamine comprising the steps of:

(a) pyrolyzing urea in a reactor operating at a temperature comprised between 360 and 420° C. and at a pressure higher than 7 MPa, the reactor producing reaction products that comprise a gaseous phase and a liquid phase;

(b) feeding the liquid phase from the reactor to a downstream post-reactor, the liquid phase from the reactor containing melamine, non-reacted urea, intermediate oxidized products of pyrolysis, dissolved carbon dioxide, and products of de-ammoniating condensation of melamine (“polycondensates”), the post-reactor operating at substantially equal conditions of temperature and pressure as the reactor and producing a liquid product, gaseous superheated anhydrous ammonia being fed under pressure to the post-reactor in order to eliminate the dissolved carbon dioxide and under conditions suitable for completing the pyrolysis reaction of the urea, for transforming the majority of the intermediate oxidized products of pyrolysis into melamine, and for decreasing the polycondensates concentration;

(c) dissolving the liquid product from the post-reactor in an aqueous solution in a quenching column in the presence of ammonia and under conditions of temperature and residence time such to provide a solution substantially free of polycondensates, the solution substantially free of polycondensates being successively subjected to crystallization to provide purified melamine in solid phase and an aqueous mother liquor that contains melamine and reduced quantities of the intermediate oxidized products of pyrolysis, the mother liquor being recycled for the greater part directly to the quenching column without any further treatment; and

(d) subjecting the anhydrous gaseous phase coming from the reactor and post-reactor to washing with molten urea, thereby recovering the melamine contained in the anhydrous gaseous phase as vapor, prior to returning the anhydrous gaseous phase to the urea synthesis plant for the recovery of the ammonia and carbon dioxide contained in it.

2. The process of claim 1 , wherein the mother liquor not directly recycled to the quenching column is subject to treatment in a de-ammoniating column for the recovery of the ammonia and the elimination of the carbon dioxide dissolved in it, and wherein the mother liquor not directly recycled to the quenching column is successively sent to a precipitation and separation section for precipitating and separating the intermediate oxidized products of pyrolysis, the precipitation and separation section having the function of maintaining the concentration of the intermediate oxidized products of pyrolysis in the mother liquor constant at a level below saturation.

3. The process of claim 1 , wherein the gaseous, anhydrous superheated ammonia is blown into the post-reactor in a ratio ranging from 1:10 to 1:1 with respect to the liquid phase from the reactor.

4. The process of claim 1 , wherein the residence time in the post-reactor of the liquid phase from the reactor is comprised between 0 and 2 hours.

5. The process of claim 1 , wherein melamine is recovered at reactor pressure and in anhydrous conditions by washing the gaseous phase containing melamine from the reactor and post-reactor with molten urea.

6. The process of claim 1 , wherein the aqueous solution in the quenching column dissolving the liquid product from the post-reactor is maintained at a temperature of 160–170° C. in the presence of ammonia, the ammonia having a concentration above 10% by weight, the liquid product having a residence time of less than 30 minutes.

7. The process of claim 2 , wherein the aqueous mother liquor subject to treatment in the de-ammoniating column and in the precipitation and separation section is in an amount comprised between 0 and 20% of the aqueous mother liquor recovered after crystallization.