Urea Fertiliser (Production Rate: 100 TPD)

UREA FERTILISER (PRODUCTION RATE: 100 TPD)

[EIRI/EDPR/4773] J.C.: 2993XL

INTRODUCTION

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. 

Urea white crystalline solid containing 46% nitrogen is widely used in the agriculture industry as an animal feed additive and fertilizer. Agriculture forms the major sector in the national economy of the majority of the countries in the Southeast Asian region. As these countries try to expand the sector, through diversification of agriculture and extensive multiple cropping programs, the demand for agriculture chemicals growing day by day.

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.

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.

Urea is produced on a scale of some 100,000,000 tons per year worldwide. For use in industry, urea is produced from synthetic ammonia and carbon dioxide. Urea can be produced as prills, granules, flakes, pellets, crystals, and solutions. More than 90% of world production is destined for use as a fertilizer. Urea has the highest nitrogen content of all solid nitrogenous fertilizers in common use (46.7%). Therefore, it has the lowest transportation costs per unit of nitrogen nutrient. Urea is highly soluble in water and is, therefore, also very suitable for use in fertilizer solutions (in combination with ammonium nitrate).

Urea is commercially produced from two raw materials, ammonia, and carbon dioxide. Large quantities of carbon dioxide are produced during the manufacture of ammonia from coal or from hydrocarbons such as natural gas and petroleum-derived raw materials. This allows direct synthesis of urea from these raw materials. The production of urea from ammonia and carbon dioxide takes place in an equilibrium reaction, with incomplete conversion of the reactants. The various urea processes are characterized by the conditions under which urea formation takes place and the way in which unconverted reactants are further processed. Unconverted reactants can be used for the manufacture of other products, for example ammonium nitrate or sulphate, or they can be recycled for complete conversion to urea in a total- recycle process.

Large population countries like China, India, Pakistan, and Bangladesh are largely manufacturing the Urea for Domestic consumption. Due to high cost of the production facility. Government incentives are common in 3rd world countries. In Middle East Saudi Arabia developed the large production facility of Urea production as an allied industry of the petroleum product. 

Urea Market size was valued at USD 131.54 billion in 2021 and is poised to grow from USD 137.85 billion in 2022 to USD 200.59 billion by 2030, growing at a CAGR of 4.8%.

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)