COURSE OVERVIEW:

The course will cover advanced fertilizers plant operations with a focus on the integrated ammonia and urea production chain and associated utility systems. Participants will gain an in depth understanding of carbon monoxide and shift conversion, desorption and hydrolyzation systems, desulphurization, evaporation and concentration, methanation, recirculation and synthesis circuits, reformer byproducts (steam and air), reformer catalyst behavior, and overall urea synthesis and granulation. Emphasis will be placed on practical operational aspects, optimization, troubleshooting, and safe, reliable operation of modern fertilizer plants.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

-Explain the overall process flow of a typical fertilizers complex, from feed gas preparation to urea granulation.

-Describe the principles and operating parameters of carbon monoxide and low-temperature CO shift conversion.

-Understand the purpose and operation of desorption and hydrolyzation systems in fertilizers plants.

-Explain desulphurization processes and their importance in protecting downstream catalysts.

-Describe the design and operation of evaporation systems and their role in urea concentration and product quality.

-Explain the methanation process and its role in gas purification before synthesis.

-Describe the operating principles of primary and secondary reformers, including reformer byproducts (steam and air) and reformer catalyst behavior.

-Explain the concepts of recirculation in urea plants, including urea recirculation systems and associated process constraints.

-Describe the urea synthesis process and its relationship to upstream ammonia production.

-Understand the role and operation of steam and condensate systems, boiler feed water and steam systems, and waste heat recovery in fertilizers plants.

-Explain the key steps in granulation systems and how operating parameters affect product quality and environmental performance.

-Apply practical troubleshooting approaches to common operational issues across desorption, hydrolysis, desulphurization, evaporation, methanation, reforming, synthesis, recirculation, and utility systems.

TARGET AUDIENCE:

-Operations engineers working in fertilizers production plants

-Panel and field operators involved in ammonia, urea, and utilities units

-Process and production engineers supporting fertilizers plant operations and optimization

-Shift supervisors and operations team leaders in fertilizer complexes

-Maintenance and reliability engineers who require a deeper understanding of plant process behavior

-Technical support staff and junior engineers assigned to fertilizers plant operations

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures and discussion sessions, as well as case studies, will be managed to maximize the amount and quality of information, knowledge, and experience transfer. The course will be intensive but practical and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance learning. Course material through PowerPoint equipped with necessary animation, learning videos, and general discussions will be provided.

The course participants shall be evaluated before, during, and after the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants who complete at least 80% of the total attendance time requirement.