UREA FERTILIZER PLANT
[CODE NO.3991]
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.
COST ESTIMATION
Plant Capacity 2000 MT/Day
Land & Building (500 Acres) Rs 2321 Cr.
Plant & Machinery Rs 3500 Cr.
Working Capital for 3 Months Rs 96.78 Cr
Total Capital Investment Rs.5952 Cr.
Rate of Return 28%
Break Even Point 49%
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†
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
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
