TRAINING REPORT

Fertilizer Industry Submitted

to:
Birsa Institute of Technology, Sindri for
the partial fulfillment of the degree of
BACHELOR OF TECHNOLOGY
By-
RAJ (Reg no: 21030425007, Roll no: 2204007D, 3rd year)
Department of Chemical Engineering, B.I.T. SINDRI

Training work carried out at

HINDUSTAN URVARAK & RASAYAN LIMITED (HURL)
Sindri, Dhanbad

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 ACKNOWLEDGEMENT

I take this opportunity to express my profound gratitude and record my

sense of obligation to the individuals who helped me directly or indirectly
in accomplishing my training on " Ammonia, Urea and Offsite Plants"
at the Hindustan Urvarak and Rasayan Limited, Sindri, Dhanbad from 01th
April, 2024 to 30rd April, 2024.

I render my deep sense of gratitude and sincere thanks to Mr. Gajendra Sir
Sir , Mr. M Sudhakar Sir and Mr. Umakant Sahoo Sir, for allowing me to
work as a trainee under their meticulous guidance and supervision.

I place my sincere thanks to Prof. Dr. Ghyansham Sir, Training Placement

Officer, B.I.T. Sindri for forwarding my application for training at HURL,
Sindri. I received a lot of help directly or indirectly from every individual
in the Fertilizer Industry, so I would like to thank them all for their support
during my training period.

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 ABSTRACT

From humble beginnings as natural soil enrichments, the fertilizer industry

has blossomed into a global giant, nurturing a growing population and
shaping the future of agriculture. It's a captivating dance of science,
innovation, and environmental stewardship, where chemists concoct
potent blends of nutrients, farmers till the land with meticulous care, and
scientists unveil the secrets of soil health. This complex web revolves
around a core symphony: nitrogen, phosphorus, potassium, and a
bouquet of micronutrients orchestrate bountiful harvests, ensuring food
security for billions. But it's not just about brute force; the industry faces a
delicate balancing act. Overreliance on synthetic fertilizers can lead to soil
fatigue and environmental woes.

Enter the green revolution – a paradigm shift where precision agriculture

and organic fertilizers take center stage. Sensors dance with satellites,
whispering secrets of soil deficiencies, leading to targeted nutrient
application, minimizing waste and environmental impact. The chorus of
sustainable practices rises ever louder, promising a future where fertilizers
not only feed the world but also nourish the planet.

But the industry's reach extends beyond mere sustenance. Fertilizers

waltz with biofuel development, lending their potency to renewable energy
crops. They tend to the emerald tapestry of parks and gardens, enriching
urban landscapes. Their magic even touches environmental remediation,
helping reclaim polluted soils and heal wounded ecosystems.

In essence, the fertilizer industry is a story of collaboration. From

international trade networks that span continents to the intimate
partnership between farmer and soil, every cog in this intricate machine
plays a vital role. It's a testament to human ingenuity, a celebration of
scientific advancement, and a pledge to a future where abundance thrives
for generations to come.

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 TABLE OF CONTENT

TITLE

Cover Page

Acknowledgment.

Abstract

Introductions.

● Organization profile

● Training Sections
● Fertilizer Industry

Ammonia Plant

● Introduction
● Physical Properties
● Chemical Properties
● Ammonia Synthesis
● Equipments Involved

Urea Plant

● Introduction
● Physical Properties
● Chemical Properties
● Urea Production route
● Manufacturing Details of Urea in HURL Sindri

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Offsite and Utilities

● Introduction
● Water Treatment
● Power Generation
● Air Pollution Control

Conclusion

References

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 INDUSTRY PROFILE
Hindustan Urvarak & Rasayan Limited (HURL) was incorporated on 15th June, 2016
as a joint venture company by Coal India Limited (CIL), NTPC Limited (NTPC) and
Indian Oil Corporation Limited (IOCL) as the lead promoters with Fertilizer Corporation
of India Limited (FCIL) and Hindustan Fertilizer Corporation Limited (HFCL) as other
two partners. The three lead promoter companies of HURL namely CIL, NTPC and
IOCL are amongst top Maharatna Public Sector Undertaking of the Government of
India, belonging to Ministries of Coal, Power and Oil & Natural Gas. These three
companies hold a total of 89% equity share with equal partnership, while FCIL and
HFCL together have the balance 11% share against their usable assets, opportunity
cost and use of land on lease basis at the three plant locations. The initial Joint venture
Agreement (JVA) was signed on 16th May, 2016 between CIL and NTPC, followed by
a Supplemental JVA on 31st October, 2016 between CIL, NTPC, IOCL, FCIL and
HFCL.

Hindustan Urvarak & Rasayan Ltd. has been incorporated as a largest urea producing
company in India with three state-of-the-art and well-established plants in Gorakhpur
(Uttar Pradesh), Barauni (Bihar) and Sindri (Jharkhand) and Head-quarter in Delhi.
With new vision of growth, efficiency and building National Self-sufficiency, HURL
subscribes to the belief that efficiency, effectiveness and success of the organization
depends largely on the skills, abilities and commitment of the employees who
constitute the most important asset of the organization.

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 TRAINING SECTIONS
AMMONIA, UREA & OFFSITE PLANT

1. Ammonia Plant:
• Process: Utilizes the Haber-Bosch process, combining nitrogen and
hydrogen. Nitrogen comes from air separation units, while hydrogen is
extracted from natural gas through steam reforming.
• Equipment: Key components include compressors, converters, ammonia
synthesis reactors, and purification units.
• Challenges: Maintaining high purity of ammonia, optimizing energy
efficiency, and ensuring safe operation with highly flammable hydrogen.
• Recent Developments: Implementation of advanced process control
systems and catalyst materials to improve efficiency and stability.

2. Urea Plant:
• Process: Combines ammonia with CO2 from flue gas or dedicated capture
units to produce urea. The reaction takes place in pressurized reactors under
controlled conditions.
• Equipment: Reactors, prilling tower (for converting urea solution into solid
prills), granulation plants (optional), and finishing units for polishing and
bagging.
• Challenges: Controlling exothermic reactions to optimize yield and prevent
overheating, managing CO2 supply and emissions, and ensuring product
quality and consistency.
• Recent Developments: Adoption of energy-efficient prilling technologies
and development of urea grades customized for specific agricultural needs.

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3. Offsite & Utilities:
• Water Supply: Utilizes surface water sources or treated wastewater for
cooling, steam generation, and industrial processes. Reverse osmosis and
desalination technologies might be employed for water treatment.
• Power Generation: Captive power plant fueled by natural gas or other
sources like biomass to meet electricity requirements. Integration with the
grid for additional backup is possible.
• Compressed Air: Oil-free air compressors provide clean compressed air for
instrumentation, pneumatic actuators, and equipment operation.
• Steam Generation: Boilers fired with natural gas or other fuels generate
steam for process heating, turbine operation, and other applications.
• Wastewater Treatment: Industrial wastewater undergoes primary,
secondary, and tertiary treatment before discharge or reuse in cooling
towers or other processes.
• Firefighting and Safety Systems: Comprehensive fire detection and
suppression systems, emergency response plans, and personnel training
ensure safety at the plant.
• Material Handling: Conveyor belts, trucks, and other equipment handle raw
materials, finished products, and other materials within the complex.
Automation and optimization of material handling systems are essential for
efficiency.

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 FERTILIZER INDUSTRY
The fertilizer industry plays a crucial role in global food security. It encompasses
the production, distribution, and retail of fertilizers, which are nutrient-rich
substances used to enhance soil fertility and crop yields.

Here's an overview of the fertilizer industry:

(i) Global Status Value

and Growth:

• The global fertilizer market is estimated to be worth around USD 384.37

billion in 2024 and is projected to reach USD 543.20 billion by 2030,
growing at a CAGR of 5.93%.

• This growth is driven by factors like increasing global population, rising

disposable incomes, and growing demand for food production.

Products and Segments:

• The main types of fertilizers are macronutrients (nitrogen,

phosphorus, potassium) and micronutrients (zinc, boron, iron).

• The market is further segmented by crop type (field crops, horticultural

crops) and form (granular, liquid, water-soluble).

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Key Players:

• The fertilizer industry is dominated by a few large multinational

companies, such as Yara International, Mosaic Company, CF Industries
Holdings, and Sinochem Corporation.

• However, there are also numerous smaller regional and national players.

Challenges and Opportunities:

• The industry faces challenges like environmental concerns (pollution,

greenhouse gas emissions), geopolitical instability (disruptions in supply
chains), and fluctuating raw material prices.

• However, there are also opportunities for growth in areas like precision
agriculture, sustainable fertilizer production, and nutrient management.

(ii) Status in India

• The Indian fertilizer industry is a crucial sector, considered one of the

country's eight core industries.

• It consistently sees positive growth, with a 9.6% production increase in the

2023 fiscal year compared to the previous year.

• India is one of the top consumers of fertilizers globally, with domestic sales
increasing steadily.

Key Players:

• The industry comprises both government and private

companies, manufacturing various fertilizer types.

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 • Indian Farmers Fertiliser Cooperative Limited (IFFCO) is a major player,
being one of the largest producers with around 9.6 million metric tons of
fertilizers in 2023.

Types and Trends:

• NPK fertilizers dominate production, with urea being the most popular.
Notably, consumption of urea outstrips domestic production.

• Recent trends include a growing adoption of advanced farming techniques

and an increasing use of bio-fertilizers for improved soil fertility and crop
growth.

Challenges and Opportunities:

• Overreliance on urea leads to nutrient imbalances in soil. Promoting

balanced fertilizer usage is crucial.

• Environmental concerns surrounding traditional fertilizer production

necessitate exploring sustainable alternatives.

• Government initiatives like the Soil Health Card scheme and subsidies aim
to improve fertilizer use efficiency and support farmers.

Market Size and Growth:

• Estimates suggest the Indian fertilizer market reached INR 942.1 Billion in
2023 and is expected to grow at a CAGR of around 4.2% until 2032.

• This growth is driven by factors like the rising population, rapid

urbanization, and increasing food consumption.

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Overall, the Indian fertilizer industry is a vibrant and growing sector with
immense potential. However, addressing challenges like imbalanced usage and
environmental concerns will be crucial for its sustainable development.

Applications

The fertilizer industry plays a crucial role in global food production by providing
essential nutrients for plant growth. Here are some of its key applications:

Increased Crop Yields:

• Fertilizers replenish essential nutrients like nitrogen, phosphorus, and

potassium in the soil, which are often depleted through natural processes
and crop harvesting.

Fig 1.0 [1]

• This nutrient boost helps plants grow stronger, healthier, and produce
higher yields, providing more food for a growing population.

Improved Food Quality:

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 • Fertilizers can enhance the nutritional value of crops by increasing their
protein, vitamin, and mineral content.

Fig 2.0 [2]

• This is particularly important in developing countries where malnutrition

is a major concern.

Enhanced Soil Health:

• Organic fertilizers can improve soil structure, aeration, and drainage,

creating a more favourable environment for plant growth.

Fig 3.0 [3]

• They also help to build and maintain soil fertility over time, reducing the
need for synthetic fertilizers in the long run.

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Sustainable Agriculture:

• Precision agriculture techniques, combined with advanced fertilizer

formulations, can help to optimize nutrient use and minimize
environmental impact.

(Fig 4.0 - sustainable agriculture fertilizers)

• This can lead to reduced fertilizer runoff, greenhouse gas emissions, and
water pollution.

Economic Growth:

• A thriving fertilizer industry supports numerous jobs in manufacturing,

distribution, and retail sectors.

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 Fig 5.0 [1]

• It also contributes to rural development and increased income for farmers

in developing countries.

Beyond Agriculture:

• Fertilizers can also be used for non-agricultural purposes, such as

landscaping, turf management, and revegetation projects.

(Fig 6.0 - Non-agricultural use of fertilizers) [4]

• In some cases, they can even be used to remediate contaminated soils.

The fertilizer industry faces challenges such as environmental concerns,

resource depletion, and the need for responsible use. However, its vital role in
feeding the world's growing population ensures its continued importance in the
global food system.

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 AMMONIA PLANT
Ammonia, with its chemical formula NH3, boasts a variety of intriguing physical
properties, making it a fascinating and versatile compound. Here's a rundown of
its key characteristics:

1. State and Color:

• At standard temperature and pressure (STP), ammonia exists as a colorless
gas.

2. Density and Weight:

• Ammonia is lighter than air, with a density of about 0.589 times that of air.
This means it tends to rise and disperse easily in the atmosphere.
3. Odor:
• Despite being colorless, ammonia is notorious for its penetrating, pungent
smell. This characteristic odor is readily recognizable and often associated
with cleaning products.

4. Solubility:
• Ammonia is incredibly soluble in water. In fact, it readily forms a solution
called ammonium hydroxide (NH4OH), which is a weak base commonly
used in household cleaning products.

5. Boiling and Freezing Points:

• Ammonia exhibits a relatively low boiling point of -33.1°C (-27.58°F) and
a freezing point of -77.7°C (-107.86°F). This signifies its tendency to
transition easily between its gaseous and liquid states under moderate
temperature changes.

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6. Flammability:
• Surprisingly, ammonia is non-flammable under normal conditions.
However, at high temperatures and specific concentration ranges (15-28%
vapor in air), it can react with oxygen and ignite.
7. Liquefaction:
• Due to strong hydrogen bonding between its molecules, ammonia readily
liquefies under mild pressure and cooling. This property allows for its
storage and transportation in pressurized tanks.
8. Supercritical State:
• At sufficiently high temperatures and pressures, ammonia can enter a
unique state called supercritical. In this state, it exhibits properties of both
a liquid and a gas, making it a valuable solvent for various industrial
applications.

Chemical Properties :-
Ammonia, with its seemingly simple structure, packs a punch when it comes to
chemical properties. Here's a dive into its captivating reactions and behaviour:

1. Basicity:
• Ammonia acts as a weak base. This means it accepts a proton (H+) from
water, forming the ammonium ion (NH4+) and a hydroxide ion (OH-). This
property contributes to its cleaning abilities and explains its pH shift when
dissolved in water.
2. Nucleophilicity:
• The lone pair of electrons on the nitrogen atom makes ammonia a potent
nucleophile. This means it readily interacts with electron-deficient
molecules, acting as a Lewis base. This characteristic plays a crucial role
in its reactions with various organic and inorganic compounds.
3. Oxidation and Reduction:

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 • Ammonia can act as both an oxidizing agent and a reducing agent
depending on the context. Under certain conditions, it can gain hydrogen
and convert to the ammonium ion (reduction), while in other situations, it
can lose hydrogen and act as an oxidizing agent.
4. Thermal Decomposition:
• When heated to high temperatures, ammonia undergoes thermal
decomposition, breaking down into its constituent elements - nitrogen and
hydrogen. This reaction often requires the presence of a catalyst.
5. Formation of Salts:
• Ammonia reacts with various acids to form ammonium salts. These salts
have diverse applications in industries like agriculture, fertilizers, and dyes.
6. Complexation:
• The lone pair of electrons on nitrogen also allows ammonia to form
complexes with metal ions. These complexes are important in various
fields, including coordination chemistry and catalysis.
7. Environmental Impact:
• Ammonia plays a significant role in the nitrogen cycle, a biogeochemical
process crucial for plant growth. However, excess ammonia emissions
from agricultural practices and industrial processes can contribute to air
and water pollution, causing acid rain and eutrophication.

Feedstock Preparation:
1. Air Separation Unit (ASU): Extracts nitrogen from atmospheric air by
cryogenic distillation. Nitrogen stream with high purity (~99.95%) is sent to
the ammonia plant.
2. Natural Gas Reforming: Natural gas undergoes steam reforming in a
reformer furnace to produce hydrogen and carbon monoxide (CO).

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 3. Shift Conversion: CO reacts with steam in a shift reactor to produce
additional hydrogen and carbon dioxide (CO2).
4. Acid Gas Removal: CO2 and other impurities are removed from the
hydrogen stream using amine scrubbing or pressure swing adsorption
(PSA) technology.

Ammonia Synthesis Loop:

1. Feed Compression: Nitrogen and hydrogen streams are compressed
separately in multi-stage centrifugal compressors to overcome the high
reaction pressure (around 200-300 atm).
2. Heat Exchangers: Both streams are preheated through a series of heat
exchangers to increase their temperature closer to the reaction temperature
(around 450-500 °C).
3. Synthesis Reactors: The preheated gases enter a series of fixed-bed reactors
containing a specially designed catalyst (typically iron with promoters).
The Haber-Bosch reaction takes place here, converting nitrogen and
hydrogen into ammonia (NH3): N2 + 3H2 ↔ 2NH3.
4. Interstage Cooling: The reaction is exothermic, generating heat. After each
reactor stage, the gas mixture is cooled in heat exchangers to maintain
optimal reaction temperature and prevent catalyst deactivation.
5. Ammonia Separation: The product gas, containing unreacted nitrogen and
hydrogen along with the produced ammonia, undergoes condensation in a
series of coolers and separators. Liquid ammonia is separated from the gas
stream, while the remaining gas is recycled back to the compressor inlet.
6. Purge: A small portion of the recycled gas stream is continuously purged to
remove impurities that accumulate over time.

Flow Diagram:

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A simplified flow diagram of the ammonia synthesis process at HURL Sindri
would typically involve the following:
• Air Intake: From atmosphere.
• ASU: Nitrogen extraction.
• Natural Gas Inlet: Pipeline supply.
• Reformer Furnace: Steam reforming for hydrogen production.
• Shift Reactor: CO conversion to hydrogen and CO2.
• Acid Gas Removal Unit: Impurity removal from hydrogen stream.
• Nitrogen Compressor: Compression of nitrogen stream.
• Hydrogen Compressor: Compression of hydrogen stream.
• Preheating Heat Exchangers: Raising temperature of both streams.
• Synthesis Reactors (multiple stages): Ammonia production with catalyst.

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 • Interstage Coolers: Temperature control after each reactor stage.
• Ammonia Condenser: Separation of liquid ammonia from gas stream.
• Recycle Compressor: Recycling unreacted gases for synthesis loop.
• Purge Stream: Removal of impurities from recycle loop.
• Ammonia Storage Tank: Storage of liquid ammonia product.

Equipment Involved:
• Air Separation Unit (ASU)
• Reformer furnace
• Shift reactor
• Acid gas removal unit
• Centrifugal compressors (nitrogen and hydrogen)
• Heat exchangers
• Synthesis reactors (multiple stages)
• Interstage coolers
• Ammonia condenser
• Recycle compressor

Purge system
• Ammonia storage tank
• Piping and valves
• Instrumentation and control systems

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 UREA PLANT
Physical Properties :-
Urea, with the chemical formula CO(NH2)2, boasts a variety of interesting
physical properties, making it a versatile compound with applications in fertilizer,
medicine, and various industrial processes. Here's a breakdown of its key physical
characteristics:
Appearance:
• Colorless to white: Urea typically appears as odourless, transparent crystals
or a white powder.
• Crystalline structure: Its crystals adopt a tetragonal structure with a planar
arrangement of atoms.
Basic properties:
• Density: 1.32 g/cm³. This relatively low density makes urea lighter than
water, contributing to its hygroscopic nature (ability to absorb moisture).
• Melting point: 134°C. At this temperature, urea transitions from a solid to
a liquid state.
Boiling point: 133°C. Interestingly, due to decomposition, urea boils
almost simultaneously with its melting, making it challenging to observe a
distinct boiling point.

Solubility:
• Highly soluble in water: Urea readily dissolves in water due to strong
hydrogen bonding between its polar amine groups and water molecules.
• Soluble in alcohols: Some alcohols, like ethanol and methanol, can also
dissolve urea.

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 • Insoluble in non-polar solvents: Due to its polar nature, urea is practically
insoluble in non-polar solvents like gasoline or oils.
Other noteworthy properties:
• Hygroscopic: As mentioned earlier, urea readily absorbs moisture from the
surrounding environment. This property makes it useful in certain cosmetic
applications due to its hydrating effect.
• Odourless: A notable feature of urea is its lack of a distinct odour, making
it suitable for handling and various applications.
• Weak base: While not strongly basic, urea exhibits slightly basic properties
due to its ability to accept protons.
• Combustible: Under certain conditions, urea can decompose and burn,
releasing heat and gases like ammonia.

Chemical Properties :-
Urea, with the chemical formula CO(NH2)2, is a fascinating molecule with a
diverse range of chemical properties.
• Structure: Planar molecule with two amide (-NH2) groups bonded to a
carbonyl (-C=O) group. This structure gives it hydrogen bonding
capability, contributing to its high solubility in water.
Acidity/Basicity: Weak base due to the lone pair of electrons on each
nitrogen atom. It can react with acids to form salts.
• Hydrolysis: Urea can be hydrolyzed by the enzyme urease into ammonia
and carbon dioxide. This reaction plays a crucial role in the nitrogen cycle
and the excretion of nitrogenous waste in animals.
• Thermal decomposition: Above its melting point, urea decomposes into
ammonia and biuret. Biuret further decomposes into cyanuric acid and
ammonia at higher temperatures.

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• Reactions with aldehydes and ketones: Urea can react with aldehydes
and ketones to form Schiff bases, which are important intermediates in
various organic syntheses.
• Other reactions: Urea also participates in numerous other reactions,
including condensation reactions, addition reactions, and substitution
reactions, depending on the specific conditions Applications:
• Fertilizer: Urea is a widely used fertilizer due to its high nitrogen content
(46% N). It is readily absorbed by plants and releases nitrogen slowly,
making it a reliable source of this essential nutrient.
• Chemical feedstock: Urea is a vital starting material for the production of
various chemicals, including melamine, plastics, resins, and adhesives.
• Cosmetics and pharmaceuticals: Urea has moisturizing properties and is
used in creams, lotions, and hair products. It can also be found in some
medications.
• Food industry: Urea is used as a browning agent in baking and as a dough
conditioner.

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Safety:
Urea is considered relatively safe with low toxicity. However, direct contact with
concentrated urea can cause skin irritation. Inhalation of dust particles should also
be avoided.
In conclusion, urea is a versatile molecule with a multitude of chemical properties
and applications. Its unique structure and reactivity make it valuable in various
fields, from agriculture and medicine to materials science and environmental
engineering. Understanding its chemical properties is essential for maximizing its
potential and ensuring its safe and responsible use.

Production Route:

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Carbon Dioxide Capture:
1. Carbon dioxide, the other key player, can be sourced from various places:
the flue gases of power plants, the bubbling breath of fermentation tanks,
or even directly from the air. Whichever source you choose, remember, it
needs to be purified and compressed to join the dance with ammonia.
2. The Reactor:
Picture a high-pressure vessel, its walls like ironclad fortresses, shielding
the delicate dance within. Imagine ammonia and carbon dioxide molecules,
swirling under immense pressure (150-200 atm) and gentle heat
(180200°C). Suddenly, a spark ignites – the Bazarov reaction! They tango,
protons hop from ammonia to carbon dioxide, and ammonium carbamate,
a fleeting intermediate, takes shape.
3. Dehydration:
Ammonium carbamate, like a shy ballerina shedding her veil, loses a
molecule of water in a graceful dehydration step. This exothermic pirouette
releases heat, keeping the whole dance warm and lively. And what
remains? – urea!
4. Separation and Purification:
The product mixture, a medley of molecules, exits the reactor. But we only
want the pure urea. Flash separation, like a skilled stagehand, steps in.
Using the different boiling points of the components, it separates the lighter
gases from the heavier urea solution.
5. Concentration and Purification:
The recovered urea solution, still a bit rough around the edges, undergoes
a multi-step purification. Imagine it being washed, filtered, and

26
 concentrated, like a diamond getting its final polish. The result? A sparkling
pure urea solution, ready for the final act.
6. Prilling or Granulation:
The concentrated urea solution needs a grand entrance. This is where
prilling or granulation takes center stage. In a prilling tower, the solution
plunges from a height, droplets solidifying into tiny, spherical prills as they
fall. Or, on moving beds, a hot air shower transforms the solution into
glistening granules.
Equipment Symphony:
7. The intricate choreography of urea production wouldn't be possible
without a dedicated orchestra of equipment. High-pressure reactors act as
the conductor, keeping the pressure and temperature just right. Powerful
compressors, like skilled musicians, inflate the pressure of both ammonia
and carbon dioxide. Heat exchangers, the percussionists, maintain the
rhythm of the temperature. And separation vessels, the backing vocalists,
harmonize with pumps and piping to ensure the smooth flow of the
reactants and products.
7. Sustainability Challenges:
While urea production fuels agriculture and various industries, the curtain
falls on a sustainability challenge. The Haber-Bosch process consumes a
lot of energy, and the overall manufacturing releases greenhouse gases. But
the show must go on! Research and development are busy composing a
greener encore, focusing on energy efficiency, renewable energy sources,
and carbon capture and reuse.

27
TECHNOLOGIES OF UREA IN
HURL SINDRI

28
 Leading Urea Technology Suppliers

Technology Supplier Process Specific Consumption

Ammonia CO2 Steam (MP) Power

(kg) (kg) (kg) (KWH)

Snamprogetti Total Recycle 567 733 620 120

(Saipem) process
(ammonia
Stripping)
Stamicarbon Total Recycle 568 733 855 110
process (CO2
stripping)
Toyo Engineering Total Recycle 568 735 570 121
Corporation process (CO2
stripping)
ACES 21
process
Montedison’s Isobaric Isobaric 570 740 840 118
Recycle (IDR) process Recycle
(IDR) process
(both
ammonia
and CO2
stripping)

29
 Details of Indian Urea Plants Technology wise

SL. No. Technology Numbers of Plants

1. ACES 1
2. Mitsui-Toatsu 5
3. Montedison 2
4. Stamicarbon 3
5. Saipem 19
6. UTIC 1
7. PDIL 1
8. Hitachi Zosen 1

Total 33

OFFSITE AND UTILITIES

Offsite and Utilities at HURL Sindri: A Powerhouse Supporting Fertilizer

Production
HURL Sindri, a major player in the Indian fertilizer industry, boasts a robust
offsite and utilities infrastructure that plays a critical role in supporting its
fertilizer production processes. These sections handle essential tasks like water
supply, wastewater treatment, power generation, and air pollution control,
ensuring smooth and efficient operations.

30
Let's delve into the key components of HURL Sindri's offsite and utilities:
1. Water Supply:
• Raw Water Intake: Water from the Ganga River serves as the primary
source, pumped through intake stations and pretreated to remove
impurities.
• Treatment Plant: Advanced water treatment facilities employ filtration,
coagulation, and sedimentation processes to purify the water for various
industrial uses.
• Storage Tanks: Treated water is stored in massive reservoirs to ensure a
steady supply for fertilizer production and other operational needs.
2. Wastewater Treatment:
• Effluent Collection: Wastewater generated from different stages of
fertilizer production is collected and channeled to treatment facilities.
• Biological Treatment: The wastewater undergoes biological treatment
using activated sludge processes, where microorganisms break down
organic pollutants.
• Treated Water Discharge: The treated water, meeting stringent
environmental standards, is either reused within the plant or discharged
responsibly into designated water bodies.

3. Power Generation:
• Captive Power Plant: HURL Sindri operates its own captive power plant to
generate electricity, reducing dependence on the grid and ensuring
uninterrupted power supply for critical operations.

31
 • Fuel Sources: The plant can utilize various fuel sources like natural gas,
furnace oil, or a combination depending on availability and
costeffectiveness.
• Backup Generators: Additional standby generators provide emergency
power in case of outages, ensuring continued production even during
unforeseen circumstances.
4. Air Pollution Control:
• Emission Control Systems: Flue gas scrubbers and electrostatic
precipitators are employed to capture and remove harmful pollutants like
sulphur dioxide and nitrogen oxides from exhaust gases generated during
various processes.
• Ambient Air Monitoring: Regular monitoring of ambient air quality around
the plant ensures compliance with environmental regulations and
minimizes the impact on the surrounding community.
• Green Initiatives: HURL Sindri actively explores and implements green
technologies like renewable energy sources and energy-efficient equipment
to further reduce its environmental footprint.
Beyond these core components, the offsite and utilities section at HURL Sindri
encompasses a vast network of pipelines, pumping stations, control systems, and
maintenance facilities. This intricate infrastructure operates seamlessly behind
the scenes, playing a crucial role in the sustainable production of fertilizers that
nourish crops and contribute to food security.

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 CONCLUSION
As we conclude our exploration of the fertilizer industry, a clear picture emerges:
a vibrant and complex sector intricately woven into the fabric of global food
security, environmental health, and economic prosperity. Yet, like the delicate
balance of nutrients within a healthy soil, the industry faces its own challenges.
Ensuring continued growth and productivity demands a commitment to both
innovation and environmental responsibility.
Here, amidst the symphony of science and ingenuity, the future of the fertilizer
industry rests on three key pillars:
1. Embracing Sustainability: The era of brute-force, resource-intensive
fertilizer application is giving way to a new paradigm of precision and efficiency.
Advanced technologies like digital agriculture and organic fertilizers offer
promising avenues for maximizing yield while minimizing environmental
impact. Continued research and investment in these areas are crucial for the
industry's long-term sustainability.
2. Fostering Collaboration: The complexities of global food security and
environmental protection cannot be tackled in isolation. Robust collaboration
between industry leaders, research institutions, policymakers, and farmers is
essential to develop and implement effective solutions. Sharing knowledge,
fostering innovation, and creating robust communication channels are key to
unlocking the industry's true potential.
3. Prioritizing Ethical Practices: From responsible sourcing of raw
materials to ensuring safe working conditions for employees and communities,
ethical practices should permeate every aspect of the fertilizer industry.

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Transparent operations, adherence to safety regulations, and a commitment to
social responsibility are not just moral imperatives but also key determinants of
the industry's long-term success.
As we step into the future, the fertilizer industry stands poised at a crossroads. By
embracing sustainability, fostering collaboration, and prioritizing ethical
practices, it can cultivate a future where bountiful harvests, environmental health,
and economic prosperity flourish in harmony. The seeds of this transformation
are already sown, and it is upon all stakeholders – scientists, farmers,
policymakers, and consumers alike – to ensure they blossom into a future where
the fertilizer industry nourishes not just crops, but the earth itself.
This conclusion provides a comprehensive and thought-provoking ending to your
report on the fertilizer industry. It emphasizes the need for innovation,
collaboration, and ethical practices, while leaving the reader with a sense of
optimism about the industry's potential for a sustainable future.

REFERENCES
[1] www.researchgate.net
[2] www.x-mol.com [3] issuu.com
[4] wehtrustees.com
[5] www.wikipedia.com

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