Project Report On Urea Fertilizer Plant
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EIRI Board of Consultants and PublishersProject Report On Urea Fertilizer Plant
Uploaded by
EIRI Board of Consultants and PublishersUREA FERTILIZER PLANT
[EIRI/EDPR/3991] J.C.: 2120XL
INTRODUCTION
Urea is an important nitrogenous fertilizer. Its utilization is increasing steadily, it
being the preferred nitrogen fertilizer worldwide. It is used in solid fertilizer, liquid
fertilizer, formaldehyde resins and adhesives.
Rouelle first discovered urea in urine in 1773. His discovery was followed by the
synthesis of urea from ammonia and cyanic acid by Woehler in 1828. This is
considered to be the first synthesis of an organic compound from an inorganic
compound. In 1870, Bassarow produced urea by heating ammonium carbamate
in a sealed tube in what was the first synthesis of urea by dehydration. The
chemical formula of, NH2CONH2, indicates that urea can be considered to be the
amide of carbamic acid NH2COOH, or the diamide of carbonic acid CO(OH)2.
Fertilizer is generally defined as “any material, organic or inorganic, natural or
synthetic, which supplies one or more of the chemical elements required for the
plant growth”. The main aim of the fertilizer industry is to provide the primary and
secondary nutrients which are required in macro quantities. Primary nutrients are
normally supplied through chemical fertilizers. They are chemical compounds
containing one or more of the primary nutrients and are generally produced by
chemical reactions. Whatever may be the chemical compounds, its most important
ingredient for plant growth is the nutrient content. The primary nutrients are
Nitrogen, Phosphorus and Potassium. However, their concentration in a chemical
fertilizer is expressed as a percentage of total nitrogen (N), available phosphate
(P2O5) and soluble K2O. The grade of a fertilizer is expressed as a set of three
numbers in the order of percent N, P2O5 and K2O. If a nutrient is missing in a
fertilizer, it is represented by a zero. Thus ammonium sulphate is represented by
20.6-0-0.
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Fertilizers are thus, most important products of the chemical industry. During the
decade 1978-1988 fertilizer production technology continued to advance rapidly.
This is due to the increased population & need for excessive food production to
fulfill their demand.
Nitrogen is the nutrient used in fertilizer in the largest amount. There are various
nitrogenous compounds, which are send as fertilizer, such as, Ammonium Nitrate;
Calcium Ammonium Nitrite; Ammonium Sulfate Nitrate; Urea; Nitrogen Solutions,
Ammonium Sulfate; Calcium Nitrate; Sodium Nitrate; Calcium-Cyanomide;
Ammonium Chloride; etc.
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Among there Nitrogenous fertilizers urea in very important for the following
reasons:
High analysis (46%N), a strong economic factor in its storage handling & shipping
care and safety of applications, especially in comparison to anhydrous Ammonia.
Safety in production and handling (non explosive) care of pollution control in its
manufacture. Its use in compound fertilizers to increase grade.
Efficient production technology:- Its inherent suitability as a Rice-fertilizer (In
contrast to the unsuitability of nitrates)
Urea Contains 46.6% Nitrogen. Of this amount about 41% is in the form of urea,
1.5% in guanyl urea, 1% in ammonium compounds & less than 1% in ammonium
compounds & less than 1% in dicyandiamide.
Commercial urea generally contains a small amount of Bivret. For fertilizer use
other than foliar-application, biuret content of 1% or slightly more, a level easily
achieved in commercial production is satisfactory. For most foliar applications the
level should not exceed 0.1%.
The technology of urea production is highly advance. The raw materials for urea
synthesis are ammonia & the bye-product of ammonia production, Co2 for this
reason urea plants are located at the site of ammonia production.
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CONTENTS
INTRODUCTION
PROPERTIES OF UREA
PHYSICAL PROPERTIES OF UREA
CHEMICAL PROPERTIES OF UREA
SPECIFIC HEAT OF UREA
USES AND APPLICATIONS
B.I.S. SPECIFICATION
MARKET OVERVIEW OF FERTILIZER
PRESENT MANUFACTURERS/EXPORTERS OF UREA FERTILIZERS
PROCESS DESCRIPTION OF UREA
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF UREA FROM
AMMONIA AND CARBON DIOXIDE
TECHNOLOGY OF UREA PRODUCTION
PROCESS IN GENERAL
THE VARIABLES THAT AFFECT THE AUTOCLAVE REACTIONS ARE:
1) TEMPERATURE:
2) PRESSURE:
3) CONCENTRATION:
4) RESIDENCE TIME:
5) BIURET FORMATION:
MAJOR ENGINEERING PROBLEMS
1) CARBAMATE DECOMPOSITION AND RECYCLE:
2) PRODUCTION OF GRANULAR UREA:
3) HEAT DISSIPATION IN THE AUTOCLAVE:
4) CORROSION:
SNAMPROGETTI AMMONIA STRIPPING PROCESS
MANUFACTURING PROCESS
UREA SYNTHESIS
AMMONIA AND UREA PRODUCTION
AMMONIA SYNTHESIS
UREA SYNTHESIS
THE AMMONIA MANUFACTURING PROCESS
STEP 1 - HYDROGEN PRODUCTION
THIS GASEOUS MIXTURE IS KNOWN AS SYNTHESIS GAS.
STEP 2 - NITROGEN ADDITION
STEP 3 - REMOVAL OF CARBON MONOXIDE
STEP 4 - WATER REMOVAL
STEP 5 - REMOVAL OF CARBON OXIDES
STEP 6 - SYNTHESIS OF AMMONIA
COMPOSITION OF THE GAS STREAM AFTER EACH PROCESS STEP†
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AMMONIA SPECIFICATIONS
THE UREA MANUFACTURING PROCESS
STEP 1 - SYNTHESIS
SCHEMATIC REPRESENTATION OF UREA SYNTHESIS
STEP 2 - PURIFICATION
STEP 3 - CONCENTRATION
STEP 4 - GRANULATION
DETAILS OF UREA PRODUCTION
DIOXIDE CARBAMATE
FIGURE - BLOCK DIAGRAM OF A TOTAL RECYCLE CO2 STRIPPING
UREA PROCESS
FIGURE- BLOCK DIAGRAM OF A TOTAL RECYCLE NH3 STRIPPING PROCESS
PRODUCTION PROCESS OF AMMONIA
AMMONIA PRODUCTION PROCESS
CONVENTIONAL STEAM REFORMING:
OVERALL CONVERSION
FIGURE: BLOCK DIAGRAM OF STEAM/AIR REFORMING PROCESS.
FEEDSTOCK DESULPHURIZATION
PRIMARY REFORMING
SECONDARY REFORMING:
SHIFT CONVERSION:
CO2 REMOVAL
METHANATION
HEAT EXCHANGE AUTO THERMAL REFORMING:
PARTIAL OXIDATION OF HEAVY OILS
THE PROCESS BLOCK DIAGRAM IS AS UNDER.
FIGURE BLOCK DIAGRAM OF THE PARTIAL OXIDATION PROCESS
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF AMMONIA GAS
SUPPLIERS OF CARBONDIOXIDE
SUPPLIERS OF LABORATORY CHEMICALS
COMPLETE PLANT AND TECHNOLOGY SUPPLIERS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF EFFLUENT TREATMENT PLANT
SUPPLIERS OF AIR POLUTION CONTROL EQUIPMENTS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF BOILER
SUPPLIERS OF GRANULATION PLANTS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENT
SUPPLIERS OF FIRE FIGHTING SYSTEMS
SUPPLIERS OF AGITATORS
SUPPLIERS OF CONVEYORS
SUPPLIERS OF BAG STITCHING MACHINE
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APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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COST ESTIMATION
Plant Capacity 2000 MT/Day
Land & Building (20,00,000 sq.mt.) Rs. 2321.34 Cr
Plant & Machinery Rs. 3500.00 Cr
Working Capital for 3 Months Rs. 96.78 Cr
Total Capital Investment Rs. 5952.00 Cr
Rate of Return 29%
Break Even Point 50%
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