Urea Manufacturing and Process Troubleshooting

Introduction

The course introduces the student technician to the various processes involved in the technology of petrochemical production, the raw materials used, their composition, and processing. The chemical reactions and conversion processes that produce the precursors, and intermediates needed for further processing into petrochemicals are outlined. The production of selected petrochemicals, including a local case study, will be studied with emphasis on unit processes and operations employed. The course is supported by laboratory experiments.

Ammonia synthesis requires large amounts of energy. Nowadays, ninety-eight percent of the ammonia produced in the world is by catalytic steam reforming of natural gas. The gas is converted to hydrogen, purified, and reacted with nitrogen to produce ammonia. The development of ever-larger, gas-based ammonia plants, affording large amounts of by-product carbon dioxide allowed for utilizing this carbon dioxide in the manufacture of urea. Urea is the product of the reaction of ammonia with carbon dioxide. It contains 46% N. Consequently, it offered a further significant advance in plant nutrient concentration, and hence in savings in nutrient transportation and distribution. Today, urea is one of the most common nitrogen fertilizer. Urea manufacture is associated with anhydrous ammonia production in modern plants because carbon dioxide is a by-product of ammonia production and is thus readily available to react with the ammonia. The urea can either be dried and granulated into 46% N urea fertilizer or dissolved in water with ammonium nitrate to make urea ammonium nitrate (UAN) solution.

This workshop is designed to provide engineers in the fertilizer industry with an in-depth view of nitrogen production technologies in general and the production of ammonia and urea using natural gas in particular. The workshop will guide engineers to identify future trends and needs of this fast pace industry. The workshop will examine the status and the most recent Urea production technologies to produce fertilizers and intermediate materials. Looking further ahead, the workshop will review some potentially significant developments and concepts that may impact the manner in which ammonia and urea are produced. Some of these manufacturing routes are being tested or employed at few plants around the world, but have yet to be fully developed into commercial processes.

Objectives

• Provide the students with the knowledge of crude oil and natural gas.
• An ability to describe the production processes of synthesis gas, urea, and ammonia.
•  Discuss the physical and chemical properties of crude petroleum and natural gas.
• Describe the methods used in the preparation of intermediates for petrochemicals processing.
• An ability to sketch and explain process flow diagrams on an industrial scale
• Test and analyze samples of petroleum and petrochemical products.
• Discuss the processes of petrochemicals and related intermediates.
• An ability to understand the physical and chemical properties of oil and natural gas as, specific gravity, flash point, and carbon residue.
• An ability to describe methods used in the preparation of intermediates from methane, ethane, and ethylene.
• Ability to test and analyze specific samples of petroleum and Urea products.
• Sketch and explain process flow diagrams of petrochemical products.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

The workshop is designed for engineers, technicians, and operators working in the Urea industry, particularly those who have recently assumed new responsibilities, to increase their technical knowledge in fertilizer production and for experienced engineers to become better acquainted with new technologies in the industry. The workshop will help to improve the participants’ skills and broaden their vision and understanding of the entire industry, including technology, economics, energy, use, safety, and environmental stewardship.

Course Outline

• Properties of Raw Material for Urea Processing
• Basic Chemistry of Hydrocarbon and Non-Hydrocarbon Intermediates for Petrochemicals Processing
• Basic Knowledge of Various reactors and their Use in Urea Industry
• Synthesis Gas, Ammonia and Urea Manufacturing Processes
• Have an in-depth knowledge on nitrogen fertilizer production such as nitric acid, ammonium nitrate, urea and ammonium sulfate
• Understand and improve ammonia production processes and be able to identify & describe the various processes involved in ammonia production
• Understand and improve urea production processes and be able to identify & describe the various processes involved in urea production
• Identify fertilizer chemical & physical specifications and be able to determine its product quality
• Gain understanding on the methods of packaging, transportation and handling of fertilizer products and recognize its importance in the manufacturing industry
• Review energy, environmental and safety issues of fertilizer manufacturing and suggest ways and means on how to resolve such issues
• Desulphurization
• Steam Reforming
• CO Conversion
• CO2 Removal
• Meth nation
• Ammonia Synthesis
• Case Study Primary Reformer tubes and Box Repair
• Case Study on Methanator Washing
• Case Study on Combustion air flue gas duct failure
• Case Study on CO2 Removal U305
• Cleaner Production
• Energy Conversion
• Package Boiler Presentation
• Case Study on WHB 308E001
• Ammonia Plant Troubles
• Catalysts Performance
• Environment for Nitrogen Compounds