Industry Overview
Urea is an important nitrogenous fertilizer whose utilization has increased steadily, making it the preferred nitrogen fertilizer worldwide. It is used in solid and liquid fertilizers as well as in the manufacture of formaldehyde resins and adhesives. Urea was first discovered in urine by Rouelle in 1773, followed by Woehler's synthesis of urea from ammonia and cyanic acid in 1828, an important milestone in the synthesis of an organic compound from an inorganic compound. In 1870, Bassarow produced urea by heating ammonium carbamate in a sealed tube, representing the first synthesis of urea through dehydration.
The chemical formula of urea, NH2CONH2, indicates that it can be considered the amide of carbamic acid or the diamide of carbonic acid. Fertilizers are materials, either organic or inorganic and natural or synthetic, that supply chemical elements required for plant growth. Chemical fertilizers primarily provide the macronutrients nitrogen, phosphorus and potassium. Fertilizer grades are expressed as percentages of nitrogen (N), available phosphate (P2O5) and soluble potassium oxide (K2O), in that order. Urea manufacturing involves ammonia and carbon dioxide as key feedstocks and incorporates synthesis, purification, concentration and granulation stages.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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
Frequently Asked Questions
Urea is a high-nitrogen fertilizer widely used to supply nitrogen required for plant growth. Its popularity is associated with its high nitrogen content, relatively convenient handling, and broad agricultural applicability. Urea can be applied in solid form and is also used as a feedstock for certain fertilizer and chemical applications. The report describes urea as the preferred nitrogen fertilizer worldwide and also covers its use in formaldehyde resins and adhesives.
Urea is manufactured by reacting ammonia with carbon dioxide to form ammonium carbamate, followed by dehydration to produce urea. Industrial production generally includes synthesis, purification, concentration and granulation stages. The manufacturing process also incorporates recovery and recycling systems to improve material utilization. The report discusses urea synthesis technologies, including ammonia stripping and carbon dioxide stripping processes, together with the engineering considerations associated with high-temperature and high-pressure operation.
The main stages include urea synthesis, purification, concentration and granulation. During synthesis, ammonia and carbon dioxide react to form urea through intermediate ammonium carbamate. Purification separates and recovers unconverted materials, while concentration increases the urea content of the process stream. Granulation converts concentrated urea into a manageable solid product. A complete plant may also incorporate utilities, material handling, environmental control systems, storage and other supporting facilities.
Temperature, pressure, concentration and residence time are important factors affecting urea synthesis reactions. These variables influence reaction conversion, process equilibrium and the efficiency of material recovery. The formation of biuret is another important consideration because excessive formation can affect product quality. Industrial process design therefore requires careful control of operating conditions, equipment configuration and recycle streams to maintain stable operation and achieve the required product specifications.
Major engineering challenges include carbamate decomposition and recycle, granular urea production, heat dissipation in the autoclave and corrosion. Urea plants operate under demanding temperature and pressure conditions, requiring suitable equipment design and process control. Corrosion resistance is particularly important because process streams can be chemically aggressive. Efficient recovery and recycling of ammonia and carbon dioxide are also essential for improving process efficiency and maintaining reliable plant operation.
Ammonia is commonly produced by preparing a synthesis gas containing hydrogen and nitrogen, followed by purification and ammonia synthesis. The report describes process stages including hydrogen production, nitrogen addition, removal of carbon monoxide, water removal, removal of carbon oxides and ammonia synthesis. It also discusses conventional steam reforming and related process steps such as feedstock desulphurization, primary and secondary reforming, shift conversion, carbon dioxide removal and methanation.
A urea manufacturing plant requires process equipment together with utilities and supporting infrastructure. Depending on plant configuration, major systems can include ammonia and carbon dioxide handling facilities, synthesis and purification equipment, concentration and granulation systems, material handling equipment, cooling towers, boilers and effluent treatment facilities. The report also identifies suppliers for equipment such as agitators, conveyors, fire-fighting systems, air pollution control equipment and bag stitching machines, reflecting the range of systems required for an integrated industrial facility.
Why Choose Us
- More than 45 years of experience
- Managed by expert industrial consultants
- ISO 9001-2015 Certified
- Registered under MSME, UAM No: DL01E0012000
How We Work
- 24/5 Research Support Get your queries resolved from an industry expert. Ask before you purchase.
- Custom Research Service Speak to our consultants to design an exclusive study for your needs.
- Quality Assurance All reports are prepared by qualified consultants & verified by experts.
- Information Security Your personal & confidential information is always safe and secure.
Detailed Project Report (DPR) includes Present Market Position and Expected Future Demand, Technology, Manufacturing Process, Investment Opportunity, Plant Economics and Project Financials. comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.
Each report include Plant Capacity, requirement of Land & Building, Plant & Machinery, Flow Sheet Diagram, Raw Materials detail with suppliers list, Total Capital Investment along with detailed calculation on Rate of Return, Break-Even Analysis and Profitability Analysis. The report also provides a birds eye view of the global industry with details on projected market size and then progresses to evaluate the industry in detail.
We can prepare detailed project report on any industry as per your requirement.
We can also modify the project capacity and project cost as per your requirement. If you are planning to start a business, contact us today.
- Market growth drivers
- Factors limiting market growth
- Current market trends
- Market structure
- Key highlights
- Up-to-date analyses of market trends and technological improvements
- Pin-point analyses of market competition dynamics to offer you a competitive edge over major competitors
- An array of graphics, BEP analysis of major industry segments
- Detailed analyses of industry trends
- A well-defined technological growth with an impact-analysis
- A clear understanding of the competitive landscape and key product segments
- Ask for FREE project related details with our consultant/industry expert.
- Share your specific research requirements for customized project report.
- Request for due diligence and consumer centric studies.
- Still haven't found what you're looking for? Speak to our Custom Research Team.
EIRI Board is a single destination for all the industry, company and country reports. We feature a large repository of latest industry reports, leading and niche company profiles, and market statistics prepared by highly qualified consultants and verified by a panel of experts.
Note: We can also prepare project report on any subject based on your requirement and country. If you need, we can modify the project capacity and project cost based on your requirement.
Our reports provide an expansive market analysis of the sector by covering areas like growth drivers, trends prevailing in the industry as well as comprehensive SWOT analysis of the sector.
Our Clients
- Our research reports comprehensively cover Indian markets (can be modified as per your country), present investigation, standpoint and gauge for a time of five years*.
- The market conjectures are produced on the premise of optional research and are cross-accepted through associations with the business players.
- We use dependable wellsprings of data and databases, and data from such sources is handled by us and incorporated into the report.
- Our project reports include detailed analysis that helps get the industry's Present Market Position and Expected Future Demand.
- Offer real analysis driving variables for the business and the most recent business sector patterns in the industry.
- This report comprehends the present status of the business by clarifying a complete SWOT examination and investigation of the interest-supply circumstance.
- Report gives analysis and in-depth financial comparison of real players/competitors.
- The report gives estimates of key parameters which forecast business execution.
