Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Fertilizer Production Processes

• Understand fertilizer classifications and their agricultural applications.
• Learn about primary fertilizers:
• Nitrogen-based fertilizers (ammonia, urea, ammonium nitrate).
• Phosphate fertilizers (DAP, MAP, TSP, SSP).
• Potassium fertilizers (potassium chloride, potassium sulfate).
• Explore blended fertilizers (NPK, micronutrient-enriched fertilizers).

2. Ammonia and Urea Production Processes

• Study Haber-Bosch ammonia synthesis and its operational parameters.
• Understand urea manufacturing via the Bosch-Meiser process.
• Optimize reactor conditions, pressure, and catalyst efficiency.
• Identify common operational challenges and efficiency improvements.

3. Phosphoric Acid and Phosphate Fertilizer Production

• Understand wet-process phosphoric acid (WPA) and thermal phosphoric acid production.
• Analyze phosphate rock beneficiation and acidulation reactions.
• Study the production of Di-Ammonium Phosphate (DAP) and Mono-Ammonium Phosphate (MAP).

4. Granulation, Prilling, and Blending Techniques

• Explore fertilizer granulation technologies (fluidized bed, drum granulation, and compaction).
• Learn prilling tower operations for urea production.
• Optimize blending processes for NPK fertilizers and micronutrient coatings.

5. Equipment and Process Optimization

• Understand key plant equipment:
• Reactors, high-pressure compressors, heat exchangers.
• Absorbers, evaporators, centrifuges, and prilling towers.
• Apply condition-based monitoring and predictive maintenance techniques.
• Reduce energy consumption and optimize heat recovery systems.

6. Process Safety and Hazard Management in Fertilizer Plants

• Implement HAZOP (Hazard and Operability) studies for fertilizer production units.
• Address corrosion control and high-pressure system risks.
• Ensure safe handling of hazardous materials (anhydrous ammonia, nitric acid, phosphoric acid, and sulfuric acid).
• Develop emergency response procedures for toxic gas leaks and chemical spills.

7. Environmental Compliance and Waste Management

• Minimize greenhouse gas emissions (CO₂, NOx) in fertilizer production.
• Manage waste by-products such as phosphogypsum and spent catalysts.
• Ensure compliance with environmental regulations (EPA, EU REACH, OSHA, IFC Guidelines).

8. Advanced Process Control and Digitalization

• Implement DCS (Distributed Control System) and SCADA for real-time monitoring.
• Utilize AI-driven analytics for predictive maintenance and process optimization.
• Integrate IoT-enabled sensors for energy and emission monitoring.

9. Case Studies and Practical Applications

• Analyze real-world fertilizer plant failures and optimization strategies.
• Participate in hands-on process simulation exercises using Aspen HYSYS or equivalent software.
• Develop a customized plant efficiency improvement plan.

Target Audience

• Fertilizer plant operators and chemical process engineers
• Maintenance and reliability engineers
• Plant managers and production supervisors
• Safety and environmental compliance officers
• Research and development professionals in the fertilizer industry