Detailed Project Report on urea fertilizer plant (Prilled, Granular, Neem Coated) and Ammonia

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Description
How to Start Business

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

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