UREA FERTILISER (PRODUCTION RATE: 100 TPD)
[EIRI/EDPR/4773] J.C.: 2993XL
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.
Urea is an organic compound with the chemical formula (NH2)2CO. Urea is also known by the International Non-proprietary Name (INN) carbamide, as established by the World Health Organization.
Fertilizers are thus, most important products of the chemical industry. Over a period of time, fertilizer production technology continued to advance rapidly. This is due to the increased population & need for excessive food production to fulfil 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 Sulphate Nitrate; Urea; Nitrogen Solutions, Ammonium Sulphate; Calcium Nitrate; Sodium Nitrate; Ammonium Chloride; etc.
COST ESTIMATION
Plant Capacity 100 MT/Day
Land & Building (10,193 sq.mt.) Rs. 10.11 Cr
Plant & Machinery Rs. 360.84 Cr
Working Capital for 1 Month Rs. 7.78 Cr
Total Capital Investment Rs. 391.66 Cr
Rate of Return 10%
Break Even Point 80%
CONTENTS
INTRODUCTION
USES/APPLICATIONS
AGRICULTURAL USE
ADVANTAGES OF FERTILIZER UREA
SOIL APPLICATION AND PLACEMENT OF UREA
SPREADING OF UREA
INDUSTRIAL USE
FURTHER COMMERCIAL USES
LABORATORY USE
MEDICAL USE
DRUG USE
DIAGNOSTIC USE
TEXTILE USE
1. PHYSICAL CHARACTERISTICS
2. CHEMICAL CHARACTERISTICS
PRODUCT QUALITY (TYPICAL)
MARKET OVERVIEW
TECHNOLOGICAL DEVELOPMENTS IN MANUFACTURING PROCESS TO AID MARKET GROWTH
RISING DEMAND FROM AGRICULTURE AS A FERTILIZER AND ANIMAL FEED TO BOOST MARKET GROWTH
GROWING DEMAND FROM INDUSTRIAL APPLICATIONS TO DRIVE MARKET GROWTH
RISING AWARENESS ABOUT ORGANIC FARMING TO HINDER MARKET
SEGMENTATION ANALYSIS
BY GRADE ANALYSIS
FERTILIZER GRADE TO LEAD MARKET DUE TO EXTENSIVE ADOPTION AS KEY NITROGEN FERTILIZER
BY APPLICATION ANALYSIS
OWING TO HIGHER DEMAND, THE AGRICULTURE SEGMENT ACCOUNTS FOR LARGEST REVENUE SHARE
REGIONAL INSIGHTS
LEADING ENTITIES TO AIM FOR PRODUCTION EXPANSION TO MEET RISING DEMAND
KEY PLAYERS
STORAGE & HANDLING - PRECAUTIONS
STORAGE AND HANDLING - AMMONIA
STORAGE AND HANDLING - UREA
GOOD STORAGE PRACTICE
SAFETY RULES
SAFE HANDLING OF FERTILIZERS
FERTILIZER HAZARDS
GENERAL PRECAUTIONS
EMERGENCY RESPONSE IN CASE OF FIRE
RAW MATERIALS
AMMONIA
CARBON DIOXIDE
CATALYSTS
THE FOLLOWING CATALYSTS WOULD BE REQUIRED FOR THE PROJECT
BASIS - TECHNICAL
INHOUSE PRODUCED RAW MATERIAL
UTILITIES
OFFSITES
PROJECT DESCRIPTION
AMMONIA PLANT
UREA PLANT
ENGINEERING CONSULTANT/PROCESS LICENSOR
AMMONIA PLANT
THE MOST PROMINENT AMMONIA PROCESS TECHNOLOGY SUPPLIERS AT PRESENT ARE AS FOLLOWS:
UREA PLANT
THE CURRENT GLOBAL LEADING LICENSORS OF UREA TECHNOLOGY ARE AS FOLLOWS:
PROCESS SELECTION
CONVENTIONAL PROCESSES
ONCE THROUGH PROCESS
CONVENTIONAL RECYCLE PROCESS
STAMICARBON CO2 – STRIPPING PROCESS
SNAMPROGETTI AMMONIA AND SELF-STRIPPING PROCESSES
ISOBARIC DOUBLE RECYCLE PROCESS
ACES PROCESS
PROCESS COMPARISONS
SAIPEM/SNAMPROGETTI PROCESS IS PROPOSED FOR UREA PLANT FOR THIS FEASIBILITY REPORT
STOICHIOMETRIC BALANCE
FORMULATIONS
WATER BALANCE
SPECIFICATION
RAW MATERIAL SUPPLIERS
AMMONIA & UREA PRODUCTION
AMMONIA SYNTHESIS
UREA SYNTHESIS
MANUFACTURING PROCESS STEPS
THE PROCESS IS SHOWN SCHEMATICALLY IN FIGURE
STEP 1 - HYDROGEN PRODUCTION
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
OVERALL CONVERSION
AMMONIA SPECIFICATIONS
FEEDSTOCK DESULPHURIZATION
PRIMARY REFORMING
SECONDARY REFORMING
SHIFT CONVERSION:
CO2 REMOVAL
METHANATION
PROCESS FLOW
UREA MANUFACTURING PROCESS
STEP 1 - SYNTHESIS
SCHEMATIC REPRESENTATION OF UREA SYNTHESIS
STEP 2 - PURIFICATION
STEP 3 - CONCENTRATION
STEP 4 - GRANULATION
OPERATING VARIABLES FOR REACTOR OPERATION
TEMPERATURE:
PRESSURE:
CONCENTRATION:
RESIDENCE TIME:
BIURET FORMATION:
ENGINEERING CONSTRAINTS
CARBAMATE DECOMPOSITION AND RECYCLE:
PRODUCTION OF GRANULAR UREA:
HEAT DISSIPATION IN THE AUTOCLAVE:
CORROSION:
PROCESS FLOW
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
WATER (ESTIMATED)
FLUE GAS (ESTIMATED)
UTILITIES
UTILITIES REQUIREMENT PER MONTH (ESTIMATED)
ENVIRONMENTAL ISSUES
AIR POLLUTION
THERMAL POLLUTION
ENGINEERING DESIGN CONSIDERATIONS
PLANT & MACHINERY (BROADLY)
COMPLETE PLANT AND TECHNOLOGY SUPPLIERS
POTENTIAL EQUIPMENT SUPPLIERS
CONDENSER/HEAT EXCHANGER
WASTE WATER TREATMENT PLANT
REACTORS/VESSEL/TANKS
DISTILLATION COLUMN/SCRUBBER/EXCHANGER/TANKS
HEATER
D.G. SETS
POWER TRANSFORMERS
COOLING TOWER
ETP PLANTS
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSOR
PLATEFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
SUBMERSIBLE WATER PUMP
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
DCS SYSTEM
POTENTIAL RISKS
ENVIRONMENTAL STANDARDS AND COMPLIANCE - WASTE WATER (IF DISCHARGE TO SEA)
HARMFUL TO MARINE LIFE
DEPLETION OF OXYGEN IN SEAWATER
A THREAT TO HUMAN HEALTH
GENERAL REQUIREMENTS
TECHNICAL REQUIREMENTS
QUALITY CONTROL
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)
SAFETY DATA SHEETS
ENVIRONMENTAL/SAFETY LIABILITY AND ENVIRONMENT CLEARANCE PROCESS - HAZARD
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
PRELIMINARY PLANT LAYOUT
PROPOSED IMPLEMENTATION SCHEDULE
ENGINEERING PACKAGE/DOCUMENTS
BASIS – PROJECT ECONOMICS
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
THE UREA PRODUCTION WILL BE 36000 TPA
CONCLUSIONS
LICENCES NEEDED BY THE UREA FERTILIZER MANUFACTURING UNIT
CERTIFICATE OF MANUFACTURE OF FERTILISER
POLLUTION NOC/CONSENT CERTIFICATE
FACTORY LICENCE
ADDITIONAL LICENCES AND PERMISSIONS TO SET UP A FERTILIZER INDUSTRY
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)
