Detailed Project Report on UREA FERTILISER (PRODUCTION RATE: 100 TPD)

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org





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.

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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

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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

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CARBON DIOXIDE

CATALYSTS

THE FOLLOWING CAT ALYSTS 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

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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

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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:

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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 POLLU TION

ENGINEERING DESIGN CONSIDERATIONS

PLANT & MACHINERY (BROADLY)

COMPLETE PLANT AND TECHNOLOGY SUPPLIERS

POTENTIAL EQUIPMENT SUPPLIERS

CONDENSER/HEAT EXCHANGER

WASTE WATER TREATMENT PLANT

REACTORS/VESSEL/TANKS

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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

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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:

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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

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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 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%