COURSE OVERVIEW

This course provides participants with a solid understanding of fertilizer plant operations, focusing on feed preparation, process systems, and product handling. It is designed for control room and field operators who are directly involved in the day-to-day operation of fertilizer production plants, including ammonia and urea-based facilities.

The course introduces the key process units and their operational principles, including evaporation, granulation, carbon dioxide removal, recirculation, and synthesis systems. Participants will gain insights into the feedstock requirements, chemical processes, and product preparation stages, with emphasis on troubleshooting, process optimization, and safety in plant operations.

Through practical examples, real plant scenarios, and troubleshooting case studies, the course will equip operators with the knowledge and confidence to maintain stable operations, respond effectively to process deviations, and optimize system performance.

COURSE OBJECTIVES

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

1. Understand the overall process flow of a fertilizer production plant and its key feed and product systems.
2. Describe the feedstock requirements and their preparation processes before entering the main production stages.
3. Explain the function and operation of the evaporation system and its role in feed concentration.
4. Understand the granulation process and how it influences final product quality.
5. Operate and monitor the carbon dioxide removal system for process gas purification.
6. Explain the recirculation system operation and its impact on process efficiency and yield.
7. Understand the synthesis system operation and chemical reactions involved in fertilizer production.
8. Recognize common operational issues and troubleshooting techniques across various systems.
9. Apply safe operating practices and process monitoring skills in both control room and field operations.
10. Learn from real-life examples and case studies from similar fertilizer production facilities.

TARGET AUDIENCE

-Control Room Operators

-Field Operators

-Operation Supervisors

-Process Technicians

-Shift Engineers

-Junior Process and Chemical Engineers

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 will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

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 completing a minimum of 80% of the total attendance time requirement.