COURSE OVERVIEW

This course provides participants with a comprehensive introduction to fertilizer plant operations, focusing on the core process systems that support the production of synthetic fertilizers such as ammonia and urea. It covers essential operational knowledge and process understanding related to methanation, carbon monoxide and shift conversion, desorption and hydrolysis, and desulphurization systems — all critical for maintaining the efficiency and safety of fertilizer plants.

Through practical instruction, participants will learn how to operate, monitor, and troubleshoot these systems, ensuring process stability, environmental compliance, and equipment reliability. The course also emphasizes the integration of various subsystems and their role in achieving high quality product and plant performance.

Real-world case studies and troubleshooting exercises from operating fertilizer plants will help participants link theory with practice, developing the technical awareness needed for control room and field operation roles.

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 main operational units.
2. Explain the function and operation of the methanation system, including catalysts and reaction control.
3. Describe the carbon monoxide and shift conversion systems, including process chemistry and efficiency optimization.
4. Understand the purpose and operation of desorption and hydrolysis systems for gas treatment and purification.
5. Gain insight into the desulphurization process and its importance in feed gas cleaning.
6. Identify key process parameters, instrumentation, and control strategies used in each system.
7. Apply troubleshooting techniques to solve common operational challenges.
8. Interpret process data and performance indicators to optimize plant efficiency.
9. Enhance coordination between field and control room personnel to ensure smooth and safe operation.
10. Implement best practices for safety, environmental protection, and equipment maintenance in fertilizer plants.

TARGET AUDIENCE

-Control Room Operators

-Field Operators

-Shift Supervisors

-Process Technicians

-Junior Chemical and Process Engineers

-Operations and Maintenance Personnel

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.