Advanced Ammonia and Urea Production Technologies

Course Overview

This course provides in-depth technical knowledge of advanced ammonia and urea production technologies. It is designed for engineers and professionals working in fertilizer plants or petrochemical industries. Participants will gain a comprehensive understanding of the latest advancements in process optimization, energy efficiency, emission reduction, and plant safety in ammonia and urea production units.

Course Objectives

By the end of the course, participants will be able to:

• Understand the chemistry and thermodynamics of ammonia and urea production.

• Analyze the design and operation of key equipment such as reformers, converters, and strippers.

• Apply best practices for process control and optimization.

• Evaluate energy integration strategies and emission reduction techniques.

• Identify common troubleshooting scenarios and operational risks.

• Learn about new trends and technologies in low-carbon ammonia and green urea production.

Target Audience

• Process Engineers

• Chemical Engineers

• Plant Supervisors & Operators

• Technical and Maintenance Staff

• Safety and Environmental Engineers

• Project Managers in Fertilizer or Petrochemical Plants

Course Outline

Day 1: Fundamentals of Ammonia Production

• Overview of ammonia market and applications

• Steam reforming and synthesis loop basics

• Process flow diagram (PFD) and mass/energy balances

• Equipment overview: primary/secondary reformers, shift reactors

Day 2: Urea Production Principles

• Ammonia to urea process chemistry

• Urea synthesis loop and recirculation

• Reactor, stripper, condenser – design and operation

• Prilling, granulation, and finishing systems

Day 3: Process Optimization Techniques

• Energy saving and integration techniques

• Use of simulation tools for plant optimization

• Monitoring key performance indicators (KPIs)

• Catalysts management and lifespan optimization

Day 4: Safety, Reliability, and Troubleshooting

• Safety considerations in ammonia and urea plants

• Pressure relief systems and safety interlocks

• Common operating problems and troubleshooting

• Case studies of incidents and best practices

Day 5: Emerging Technologies & Green Trends

• Low-carbon and green ammonia production

• CO₂ capture and utilization in urea synthesis

• Innovations in plant automation and digitalization

• Future outlook: blue ammonia, hydrogen economy

Course Features

• Interactive technical sessions led by industry experts

• Real-world case studies from leading plants

• Hands-on problem-solving workshops

• Course material and certificate of completion

• Optional field visit to ammonia/urea facility (for onsite courses)