IN-PLANT TRAINING REPORT

Shahjalal Fertilizer Company Limited (SFCL)

Submitted By
Master of Science (M.Sc) Students
Sadia Mehjabin Jim
Nishat Tamanna Adiba
Adiba Zaman
Saptarshi Paul
Lamisa Rahman

Department of Applied Chemistry

and Chemical Engineering,
University of Dhaka.
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 Index

Index ....................................................................................................................................................... 3
Acknowledgement .................................................................................................................................. 6
1. INTRODUCTION................................................................................................................................. 7
1.1 SHAHJALAL FERTILIZER COMPANY LTD (SFCL) ............................................................. 8
1.2 SFCL at a glance ....................................................................................................................... 8
1.3 Units of SFCL ............................................................................................................................... 9
1.4 Raw materials.............................................................................................................................. 10
1.4.1 Natural Gas .......................................................................................................................... 10
1.4.2 Water .................................................................................................................................... 10
1.4.3 Air ........................................................................................................................................ 11
2.1 Introduction ................................................................................................................................. 11
2.2 Key Information about Ammonia Plant ...................................................................................... 12
2.2.1 Catalyst & Chemicals........................................................................................................... 12
2.2.2 List of Equipment................................................................................................................. 12
2.3 Process Description ..................................................................................................................... 14
2.4 Exclusive Features ...................................................................................................................... 19
3. Urea production ................................................................................................................................ 26
3.1 Introduction ................................................................................................................................. 26
3.2 Key Information about Urea Plant .............................................................................................. 26
3.3 List of Equipment ....................................................................................................................... 27
3.4 Process Description ..................................................................................................................... 28
3.4.1 Liquid Urea Processing Plant ............................................................................................... 29
Step-1: Synthesis Section .............................................................................................................. 30
Step-2: Low Pressure Recirculation Section ................................................................................. 31
Step-3: Evaporation and Condensation Section ............................................................................ 32
Step-4: Process Condensate Treatment Section ............................................................................ 32
3.5 Granulation (Fluid Bed) .............................................................................................................. 38
4.Bagging and Packing Section ............................................................................................................ 43
5.Utility Section .................................................................................................................................... 45
5.1 Water Intake Pretreatment Station .............................................................................................. 45
5.1.1 River Water .......................................................................................................................... 45
5.4 Demi Water Plant ........................................................................................................................ 47
5.4.1 Cation Exchanger and Degasifier ........................................................................................ 47
5.4.2 Anion Exchanger.................................................................................................................. 47

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 5.4.3 Regeneration ........................................................................................................................ 47
5.4.4 Mixed Bed Polisher.............................................................................................................. 48
5.4.5 Vacuum Deaerator ............................................................................................................... 48
5.5 Nitrogen and Instrumentation Air Plant ...................................................................................... 48
5.5.1 Plant Air ............................................................................................................................... 48
5.6 Waste Water Management .......................................................................................................... 51
5.6.1 General Review .................................................................................................................... 51
5.6.2Processes Used ...................................................................................................................... 51
5.6.2.1 Phase Separation ............................................................................................................... 51
5.6.2.2 Sedimentation ................................................................................................................... 51
5.6.2.3 Filtration ............................................................................................................................ 52
5.6.2.4 Oxidation........................................................................................................................... 52
5.6.2.4 .1 Biochemical Oxidation ................................................................................................. 52
5.6.2.4 .2 Chemical Oxidation ...................................................................................................... 52
5.6.2.5 Polishing ........................................................................................................................... 53
6. Laboratory Facilities ......................................................................................................................... 55
6.1 Purpose of Lab in Industry .......................................................................................................... 55
6.3 Laboratory Equipment List ......................................................................................................... 57
7. MTS (Maintenance and Technical Services) .................................................................................... 58
7.1 Introduction ................................................................................................................................. 58
7.2 Objective of Maintenance ........................................................................................................... 58
7.3 Sectors under MTS Department .................................................................................................. 58
7.4 Mechanical Workshop Equipment .............................................................................................. 58
7.5 MTS (Mechanical) ...................................................................................................................... 60
7.5.1 MM- Machinery Maintenance ............................................................................................. 60
7.5.2 PM- Plant Maintenance ........................................................................................................ 61
7.5.3 CMW- Central Maintenance Workshop .............................................................................. 61
7.5.4 SHSM- Solid Handing System Maintenance ....................................................................... 61
7.6 MTS (EIP) Section ...................................................................................................................... 62
7.6.1 EM- Electrical Maintenance ................................................................................................ 62
7.6.2 IM- Instrumental Maintenance............................................................................................. 63
7.6.3 PP- Power Plant ................................................................................................................... 63
Key Process Features .................................................................................................................... 63
Main Process Flow ........................................................................................................................ 64
8. Fire & Safety ..................................................................................................................................... 65
8.1 Industrial Safety .......................................................................................................................... 65

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 8.2 Industrial Hazards ....................................................................................................................... 65
8.3 Fire .............................................................................................................................................. 65
8.3.1 Fire triangle .......................................................................................................................... 65
8.4 Safety Equipment ........................................................................................................................ 66
1. Water and Foam .................................................................................................................... 67
2. Carbon Dioxide ..................................................................................................................... 67
3. Dry Chemical ........................................................................................................................ 67
8.5 Industrial Safety Rules to be Followed ....................................................................................... 67
8.6 Safety Signs ................................................................................................................................ 68

Mohammad Nour Alam (Deputy Chief Engineer (Chemical), HEST Department, SFCL), Professor Dr.
Md. Mustafizur Rahman & Professor Dr. Md. Kamruzzaman (department of Applied Chemistry and
Chemical Engineering, University of Dhaka, Mr. Shambhu Lal Das (Additional Chief Engineer
(Chemical) and Department Head, HSET, SFCL) with Trainees from department of Applied Chemistry
and Chemical Engineering, University of Dhaka.

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 ACKNOWLEDGEMENT

We would like to express our gratitude to the Almighty for bestowing upon us the opportunity, strength,
and capability to present this in-plant training report, symbolizing the fulfillment of the master's degree
requirements.

We would like to express our deepest gratitude to Mr. Shambhu Lal Das, Additional Chief Engineer
(Chemical) and Department Head, HSET, and Mohammad Nour Alam, Deputy Chief Engineer
(Chemical), HEST Department, SFCL (Shahjalal Fertilizer Company Ltd), for granting us the
opportunity to undertake this academic journey. Their unwavering support, guidance, and
encouragement at every stage of our training were invaluable. Without their continuous support,
insightful guidance, inspiration, and invaluable feedback, the successful completion of this work would
not have been possible. It was truly an honor to collaborate with such an intelligent and diverse team.

We extend our heartfelt thanks to Professor Dr. Sayed Md Shamsuddin, the respected course
coordinator for the M.Sc. program, for providing us with the opportunity to engage in this in-plant
training. We also extend our gratitude to Professor Dr. Md. Nurnabi, the respected chairman, for his
cooperation and expert guidance, not only in the context of this training but also in all academic
activities throughout the entire year.

We would like to convey our appreciation to all the officers, employees, and staff for their significant
support and assistance during this training period.

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 1. INTRODUCTION

In Bangladesh, a nation where agricultural pursuits play a central role in the socio-economic landscape,
nearly half of the population is predominantly engaged in this sector, which claims over 70 percent of
the country's land for crop cultivation. Yet despite agriculture contributing to such a large percentage
of Bangladesh's overall economy, it has mainly remained subsistence based, with uncertain crop yields
and inefficient infrastructure limiting the ability of farmers to fully commercialize their production.
Fertilizers play a pivotal role in bolstering crop yields, particularly in Bangladesh's predominantly crop-
centric agricultural landscape, where urea reigns supreme in fertilizer consumption.

Bangladesh has partially fulfilled its fertilizer demand through local production, holding the sixth
position in Asia and ranking 28th globally in this sector. However, despite its importance within
Bangladesh's manufacturing framework, recent years have seen a shortfall in meeting the total demand,
prompting the operation of multiple fertilizer plants to bridge the gap. Karnaphuli Fertilizer Company
Limited (KAFCO), in collaboration with foreign entities, contributes significantly to urea and ammonia
production, catering to both local usage and export.

Over the past few decades, Bangladesh has experienced a decline in fertilizer production due to various
issues like poor maintenance, talent drain, inadequate planning, and outdated technology. This decline
has led to challenges such as storage limitations, with approximately 0.25 million tons of urea being
stored in the open air annually, causing substantial losses due to quality deterioration and wastage. To
combat this issue, the government has laid plans to establish 13 buffer warehouses across the country.

Shahjalal Fertilizer Company Limited (SFCL), under the administrative control of the Bangladesh
Chemical Industries Corporation (BCIC), was established as a government-owned facility for
nitrogenous fertilizer (urea) production. BCIC itself came into being in 1976 through the merger of
several corporations. SFCL represents modern technology-based, energy-efficient, and environmentally
friendly granular urea fertilizer production. This facility, boasting an annual capacity of 580,800 Metric
Tons, was successfully installed at the adjacent site of the recently decommissioned Natural Gas
Fertilizer Factory Limited (NGFFL) in Fenchuganj, 30 kilometers south of Sylhet, to address the
increasing demand for urea fertilizer in the country.

Currently, BCIC oversees twelve enterprises, five of which are urea fertilizer facilities including
Shahjalal Fertilizer Company Limited, Chittagong Urea Fertilizer Factory Limited, Jamuna Fertilizer
Company Limited, Ashuganj Fertilizer and Chemical Company Limited, and Ghorashal Polash
Fertilizer Public Limited Company (under construction). However, the combined installed capacity of
the operational urea fertilizer facilities is at 2.30 million metric tons per year, slightly below the
country's annual urea fertilizer demand of 3 million metric tons. Aging and continuous operation have
led to a reduction in the production capacities of these factories, necessitating the establishment of more
modern and efficient facilities like SFCL to meet the growing demand.

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 1.1 Shahjalal Fertilizer Company Ltd. (SFCL)

1.2 SFCL at a glance

Table-01: Overview of the plant

Name of the Plant Shahjalal Fertilizer Company Limited (SFCL)

Owner Bangladesh Chemical Industries Corporation (BCIC)
General Contractor of the China National Complete Plant Import & Export Corporation Ltd.
Project (COMPLANT)
Design-Engineering Company China Chengda Engineering Company Ltd.
of the Project
Main Objective of the Project To set up a new Urea Fertilizer Factory having production capacity
1760 MTPD
Location of the project Located at 6 km of Fenchuganj upazila head quarter and 4 km
south of Maijgaon Railway Station, Sylhet, Bangladesh
Area of land o Factory: 66.73 acres
o Housing & Others: 351.03 acres
Name of Product and Liquid Ammonia: 1000 MTPD
Production Capacity o Granular Urea: 1760 MTPD
Storage Capacity o Bulk Urea: 70,400 MT
o Bagged Urea: 15,000 MT
o Liquid Ammonia: 10,000 M.T
Bagging Capacity 240 MT/hour
Power generation Capacity o STG: 12x2 = 24 MW
o DEG: 1.6 x2 = 3.2 MW
o EDEG: 1.09x1 = 1.09 MW
o PBS: 33/6.3 KV =10 MVA (Standby)
Quality of Urea o Nitrogen (min) - 46.1% by wt
o Moisture (max) - 030% by wt
o Biuret (max) - 0.90% by wt
o Formaldehyde (max) - 035% by wt
Granular size 2-4mm
Project cost (crore BDT)
a) Estimated cost 5409.00
b) Ammended cost 4984.97
Mode of financing
a) Government of China a) 1.60 billion RMB Yuan from Chinese Govt’s Concessional
b) Government of Bangladesh Loan (about US$ 235 million) and US$ 325 million preferential
Buyer's Credit from
Exim Bank of China. Total US$ 560 million.
b) Tk. 998.89 Crore
(a) Rates of interest on Loan a) 4.5% per annum
(b) Repayment Schedule b) 20 years (including 5 years grace period in 30 equal
installments)
Project Implementation Period January 2012-June 2016.
Process Licensors a) Ammonia: Kellogg, Brown & Root (KBR), USA.
b) Urea: Stamicarbon b.v., The Netherlands.
c) Urea Granulation: Stamicarbon b.v., The Netherlands
(a) Main Raw Material (a) Natural Gas, water, air
(b) Usage Ratio (b) 22 mmcf/MT of Urea.
Departments o Administration
o Accounts & Finance

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 o Commercial
o Technical
o Operation
o MTS (mechanical)
o MTS (EIP)
o Health Safety, Environment & Training (HSET)

1.3 Units of SFCL

Inside The Plant Area

✓ Administration Building ✓ Ammonia Storage Vessel

✓ Technical Building ✓ Ammonia Unit
✓ Complex Pumping Station ✓ Urea Unit
✓ Ployethene Bag Plant ✓ Nitrogen Supply Unit
✓ Urea Bagged Storage Unit ✓ Demi Water Unit
✓ Urea Bulk Storage Unit ✓ Cooling Water Unit
✓ Steam and Power Generation ✓ Ammonia Storage Tank (1, 2)
Unit ✓ Chemical Storage
✓ Main Sub-Station ✓ General Storage
✓ Ammonia Sub-Station ✓ Waste Water Unit
✓ Laboratory Building ✓ Guards House
✓ Central Control Building ✓ Railway Station
✓ Maintenance Workshop ✓ Watch Towers
✓ Ammonia Bottling Station ✓ Parking Lot
Outside The Plant Area

✓ Water Intake and Pretreatment Station

✓ Officer’s Quarter and Staff’s Quarter
✓ Central Mosque
✓ Guest House
✓ Canteen
Organogram of Shahjalal Fertilizer Company Ltd.

Figure 1: Organogram of Shahjalal Fertilizer Company Ltd.

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1.4 Raw materials
Major raw materials for Ammonia and Urea production: Natural gas

✓ Natural gas: 22 MCF/MT of Granular Urea Water

✓ Water: 713 MT/Hour
✓ Air Air
1.4.1 Natural Gas
Natural Gas from national grid by pipelines is brought to the factory for process feed & fuel from
Haripur & Kailshtilla Gas Fields in the district of Sylhet, transmitted by Jalalabad Gas Transmission &
Distribution Systems Ltd. (JGT&DS).

Table-02: Specification of Natural Gas

% Mol % Weight
Nitrogen 0.302 0.502
Carbon dioxide 0.056 0.145
Methane 95.987 91.387
Ethane 2.643 4.717
Propane 0.537 1.405
i-Butane 0.238 0.822
n-Butane 0.076 0.262
i-Pentane 0.052 0.223
n-Pentane 0.026 0.112
Total 100 100
Total Sulfur 15 ppm max
Higher Heating Value 1046 BTU/SCF
Lower Heating Value 943 BTU/SCF
Pressure 150 psig
Temperature 5ºC - 15ºC

1.4.2 Water
Kushiara river nearby the plant supply the raw water; 1000 m3/hour at water intake & 742 m3/hour at
complex pumping station from water intake; for industrial purpose, demi plant, cooling tower & potable
water for domestic use.

Table-03: Quality of Raw Water from Kushiara river

Parameter Measured Amount

Turbidity (NTU) 300 – 1000
Ca-Hardness (mg/L) 35 – 50
Total Alkalinity (mg/L) ˂ 200
Total Fe (mg/L) 0.2 - 0.5
Cl- (mg/L) 50

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1.4.3 Air
Air is sucked from the atmosphere and supplied to several units such as,

➢ primary & secondary reformer via gas turbine

➢ power plant via blower for combustion chamber of boiler
➢ cooling tower to reduce the temperature of process hot water
➢ granulation unit for transformation of urea solution into granules
➢ instrument air & nitrogen generation plant

2. Ammonia Production in SFCL

2.1 Introduction
Ammonia is indispensable for urea plants as it serves as the essential precursor for the synthesis of urea
fertilizer, a crucial agricultural input for global food production. The primary objective of an ammonia
plant revolves around the production of liquid ammonia and carbon dioxide gas, the essential
components for manufacturing urea. This process involves utilizing natural gas, steam, and air as the
core ingredients to generate ammonia and carbon dioxide. The industrial production of ammonia
encompasses several methodologies, such as the MW Kellogg process, the Haldor Topsoe process, and
the KBR process. SFCL employs the KBR production method, known for its exceptional technologies
and energy-efficient, versatile solutions tailored for ammonia plants, covering all stages of the project
lifecycle.

The layout of the ammonia plant is designed based on a standard output of 1,000 Metric Tons Per Day
of warm ammonia. This setup ensures efficiency and streamlines the production process for consistent
and optimal ammonia creation, which is essential for subsequent urea production.

KBR PURIFIER PROCESS

Ammonia is produced in a process known as the KBR Purifier Process, in which nitrogen and
hydrogen react in the presence of an iron catalyst to form ammonia. The hydrogen is formed by reacting
natural gas (95% CH4) and steam at high temperatures and the nitrogen is supplied from the air. Other
gases (such as water and carbon dioxide) are removed from the gas stream and the nitrogen and
hydrogen are passed over an iron catalyst at high temperature and pressure.

KBR's Purifier™ removes all methane and most of the argon from the syngas, by liquid nitrogen wash.
The Purifier™ works by auto-refrigeration assisted by a small expander. The Purifier™ Ammonia
Process offers lower capital costs, more competitive energy consumption, increased reliability, & lower
maintenance costs.

Advantages of the KBR ammonia process:

✓ High efficiency: The KBR ammonia process has a relatively high efficiency.
✓ Low capital costs: The KBR ammonia process is a relatively mature technology, and the capital
costs for new plants are relatively low.

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✓ Reliability: The KBR ammonia process is a reliable technology with a long history of commercial
operation.

2.2 Key Information about Ammonia Plant

a) Process Licensor: Kellogg, Brown & Root (KBR), USA

b) Raw Materials for Ammonia Plant:

▪ Natural gas (CH4) for fuel and as a process gas

▪ Water (as steam)

▪ Air (for nitrogen)

c) Produced Ammonia Phase: Liquid

d) Produced Ammonia amount: 1000 MTPD

2.2.1 Catalyst & Chemicals

Table-04: Catalyst & Chemicals used in Ammonia Plant

Components Units
Nickel Primary and Secondary Reformer
Iron/Chrome (Copper promoted) High Temperature Shift
Copper-Zinc (on Alumina) Low Temperature Shift
Promoted Iron Ammonia Synthesis Converter
Nickel Oxide Methanator
Cobalt-Molybdenum Hydrotreator
Zinc Oxide Desulfurizer
Type A Zeolite Molecular Sieve Dryer
Amdea CO2 Removal Unit
Anti-Foaming Agent CO2 Removal Unit
Hydrazine Water Treatment Unit
Phosphate Water Treatment Unit
Caustic Soda Water Treatment Unit

2.2.2 List of Equipment

Table-05: Equipment used in Ammonia Plant

ITEM NO. DESCRIPTION

Class B: Furnaces/Fire Heaters
101-B Primary Reformer
101-BJ Induced Draft Fan
101-BJT Turbine
2202-BL Flame Front Generator etc.
Class C: Heat Exchanger

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101-C Secondary Reformer Waste Heat Boiler
105-C CO2 Stripper Reboiler
116-C Syn Gas Compressor Interstage Cooler
120-CF1, 120-CF2 Refrigerant Flash Drum
183-C Mol Sieve Regeneration Heater
327-C Ammonia Heater etc.
Class D: Dryer & Reactor
103-D Secondary Reformer
104-D1, 104-D2 High & Low Temperature Shift Converter
105-D Ammonia Synthesis Converter
106-D Methanator
107-D Primary Reformer Effluent Transfer Line
108DA Hydrotreater
108DB/DC Desulfurizer
Molecular Sieve Dryer
109-DA/DB

Class D: Towers
121-D CO2 Absorber
124-D HP Ammonia Scrubber
125-D Ammonia Distillation Column
137-D Purifier Rectifier
163-D HP Flash Column etc.

Class D: Drums & Accumulator

141-D Steam Drum
142-D2 CO2 Absorber Overhead Knockout Drum
147-D Ammonia Letdown Drum
174-D Feed Gas Knockout Drum
186-D HP Steam Blowdown Drum
196-D, 197-D, 198-D 3 Stage Air Compressor Knockout Drum etc.

Class F: Tanks
114-F OASE Solution Storage Tank
115-F OASE Slution Sump
2201-F Ammonia Storage Tank

Class J: Pumps & Compressors

101-J Process Air Compressor
101-JGT Gas Turbine for 101-J
102-J Feed Gas Compressor
102-JT Steam Turbine for 102-J
103-J Synthesis Gas Compressor
103-JT Steam Turbine for 103-J
104-J/JA HP BFW Pump
104-JT Steam Turbine for 104-J etc.

Class L : Special Equipments

101-L Air Filter integral with Process Air Compressor
102-L Air Filter integral with Gas Turbine

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 104-L OASE Solution Filter
106-L Oxygen Scavenger Injection System
107-L Ammonia Injection System
108-L Phosphate Injection System
109-L OASE Antifoam Injection System
110-L OASE Solution Mixer
115-L OASE Sump Filter
117-L Purge Gas Ejector
137-L Purifier Cold Box Package
144-L Purifier Waste Gas Filter
2201-L Ammonia Refrigeration Package

Class U : Utilities Equipments

101-U Deaerator

2.3 Process Description

All process equipment is single train. All compressors are centrifugal compressors. The process air
compressor is driven by a gas turbine. The feed gas compressor is steam turbine driven. The syngas
compressor & refrigeration compressor are driven by steam turbine. The boiler feed water pump also
has a steam turbine drive, with a motor drive spare for reliability of operation.

The ammonia plant uses KBR Purifier Process which is shown on process flow diagram. The process
can be briefly described in the following steps:

✓ Feed gas compression and desulfurization

✓ Primary reforming
✓ Process air compression
✓ Secondary reforming
✓ Carbon monoxide shift conversion
✓ Carbon dioxide removal
✓ Methanation
✓ Drying
✓ Cryogenic purification
✓ Compression
✓ Ammonia synthesis
✓ Ammonia refrigeration
✓ Ammonia storage
✓ Steam system
✓ Flare systems for ammonia plant

Step 1: Feed Gas Compression & Desulfurization

Natural gas for feed and fuel is provided at ambient temperature and 0.95 MPa. Part of natural gas is
sent to the primary reformer furnace as fuel gas. The feed gas and the fuel gas to gas turbine are
compressed in a 2-stage feed gas compressor. The fuel gas is withdrawn from the discharge of the first
stage of the compressor and the remaining reformer feed gas is then compressed in the second stage of
the feed gas compressor to 5150 kPa pressure before desulfurization.

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Hydrogen is produced by the reaction of methane with water. However, before this can be carried out,
all sulfurous compounds must be removed from the natural gas to prevent catalyst poisoning. Natural
gas (P= 5100kPa, T= 371oC) is compressed and mixed with H2. Then it is heated to 400oC and reacted
with zinc oxide (ZnO).

Step 2: Primary Reforming

This step can be divided into two further steps- primary reforming and secondary reforming. In primary
reforming superheated steam (P= 4701kPa, T= 394oC) is fed to the reformed with methane coming out
of the desulfurization unit. The temperature and pressure is maintained at 717 oC and 37583 kPa
respectively. High temperature and low pressure favor the formation of the products (Le Chatelier's
Principle). In practice, the reactants are passed over a catalyst of nickel, finely divided on the surface
of a calcium oxide/aluminum oxide support contained in vertical nickel alloy tubes.

The Process Air Compressor provides process air for the secondary reformer, instrument and plant air
for both the ammonia and urea units and passivation air for the urea plant.

Step 3: Secondary Reforming

In secondary reforming, steam reacts with oxygen from the air (which is compressed at P= 4382kPa,
T= 172oC) with some of the hydrogen present and the resulting mixture is passed over a nickel
catalyst. The steam and heat produced from the combustion reforms most of the residual methane. The
reaction takes place at T= 901.7oC, and P= 3946kPa. Among the key reactions are:

In a conventional secondary reformer, the quantity of air is limited to the amount that is required to
produce a 3:1 ratio of hydrogen to nitrogen in the synthesis gas. Whereas, with the Purifier Process used
in SFCL, the hydrogen to nitrogen ratio is controlled at the Purifier so that extra air can be used in the
secondary reformer. The extra air provides additional reaction heat. Nearly 100 percent of the heat
released in this vessel is recovered, compared to 40 to 50% percent in the radiant zone of the primary
reformer. In addition, the allowable methane leakage is much higher than conventional plants, which
further relaxes the reforming load by lowering the secondary reformer outlet temperature.

Step 4: The Shift Reactions

This process converts carbon monoxide to carbon dioxide, while generating more hydrogen. It takes
place in two stages:

HTS: In the first, the High Temperature Shift Converter (HTS), the bulk of the shift conversion
takes place in a relatively low cost and durable copper-promoted iron oxide catalyst bed. With about
70% conversion of carbon monoxide, the shift effluent contains about 3.1 mole% CO (Dry base). The
copper-promoter suppresses unwanted side reactions that could occur on the shift catalyst due to the
low steam-to-gas ratio used for this plant. The gas is mixed with steam and passed over an

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iron/chromium (III) oxide catalyst at T= 310oC and P= 3758kPa in a fixed bed reactor. The
concentration of CO is decreased from 11.26% to 0.29%.

LTS: In the second stage, the Low Temperature Shift Converter (LTS), the mixture of gases is
passed over a copper-zinc catalyst at 200oC.The carbon monoxide concentration is further reduced to
0.2%. The reaction is done in two stages for several reasons. The reaction is exothermic. However, at
high temperature, the exit concentration of carbon monoxide is still quite high, due to equilibrium
control. The copper catalyst used in the low temperature stage is very sensitive to high temperatures,
and could not operate effectively in the high temperature stage. Thus, the bulk of the reaction is carried
out at high temperature to recover most of the heat. The gas is then removed at low temperature, where
the equilibrium is much more favorable, on the very active but unstable copper catalyst.

Step 5: Removal of Carbon Dioxide

The CO2 removal system uses the energy efficient two-stage OASE process licensed by BASF. After
the shift reactions, the gas mixture contains about 18% carbon dioxide which is removed by this method.
First, the mixture goes through the absorption stage where it gets adsorbed by the adsorbent bed and
then gets stripped out going through a stripper, releasing the CO2through the proper channels to
transport it in the urea production section. The bed used in both the absorber and the stripper is
constructed with activated MDEA, commercially known as the OASE solution. In the bottom section
of the absorber, the process gas is washed with the semi-lean OASE solution. The gas then passes into
the top packed section, where it is washed with the lean OASE solution.

CO2 Absorption: H3C-N-(CH2CH2OH)2 + CO2 + H2O → H3C-NH+-(CH2CH2OH)2 + HCO3¯

CO2 Desorption: HCO3¯ → OH¯ + CO2

In the CO2 Stripper, the semi-lean solution is converted into lean solution as it flows down the packed
bed and gets in contact with stripping steam produced by the heat input through the stripper reboiler.
The stripped carbon dioxide flows up the stripper and passes through the LP flash column to be collected
as product. The whole absorption process is carried out into the flash column. And the gas mixture
from the flash column is then taken to the Overhead Knockout Drum.

Step 6: Methanation
Some trace of CO and CO2 remaining in the gas (From Step 5) which act as catalyst poison in the
ammonia synthesis process have to be converted into methane to neutralize the system. The gas from
the CO2 Absorber Overhead Knockout Drum is preheated from 50°C to 316°C in the methanator
feed/Effluent exchanger. The remaining CO2 (as well as any CO that was not converted to CO2 in Step
3) is converted to methane (methanation) using a Ni/Al2O3 catalyst at 325oC. The gas that is obtained
has a typical composition: N2: 32%, H2: 64%, CH4: 2%, Ar: 0.4%

For the methanation step, heat addition by the start-up steam heater is essential when the shift catalyst
is new and the amount of CO leakage from the shift converters is low, which means the methanator

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effluent temperature would also be low. During that period, the methanator startup heater supplements
the heat input to the methanator feed to keep the methanator inlet temperature above 290°C, which is
ample to ensure the initiation of the methanation reaction.

Step 7: Cooling, Drying and Regeneration

In preparation for drying, the methanator effluent is cooled by heat exchange with the methanator feed,
and then with cooling water, and finally with ammonia refrigerant (in Coldbox), to about 4°C.
Condensate is separated in the knockout drum and pumped back to the raw syngas knockout drum. The
chilled gas is then dried in the molecular sieve driers. Each drier is sized to remove ammonia, residual
carbon dioxide and water in a 24-hour drying cycle. The regeneration facilities are designed for a 12-
hour cycle to provide a comfortable safety margin. The normal regeneration and cooling media for the
driers is the dry waste gas from Purifier. The regeneration gas is heated with medium pressure steam in
the regeneration gas heater and regeneration is carried out at 245ºC. Two filters, are provided
downstream of the driers to capture any dust molecular sieve escape from the driers. For the same
purpose, a filter is provided in the waste gas line to fuel.

Step 8: Cryogenic Purification

The cryogenic purification system includes the plate & fin type Purifier Feed/Effluent Exchanger,
Purifier Expander, Purifier Rectifier and Purifier Rectifier Condenser. The dried feed gas to the Purifier
is first cooled to about -129°C in the upper part of the exchanger, by heat exchange with the purified
syngas and purifier waste gas. The feed gas then flows through the turbo expander, where energy is
removed to develop the net refrigeration required for the cryogenic purification system. The expander
effluent is further cooled and partially condensed in the lower part of the exchanger and then fed to the
bottom of the purifier rectifier column.

Excess nitrogen, most of the methane, and about 60% of the argon contained in the purifier feed are
removed from the bottom of purifier rectifier column. The liquid stream from purifier rectifier column
is let-down in pressure and sent to the shell side of the rectifier overhead condenser to provide
refrigeration for cooling the purifier rectifier column’s overhead and generating reflux for the column.
After partially vaporized in the head exchanger’s shell side, the rectifier bottom is reheated and
vaporized in Feed/Effluent Exchanger, by heat exchange with the purifier feed, and then leaves the
cryogenic system as waste gas. The overhead which has a nearly 3:1 hydrogen to nitrogen ratio, is also
reheated to about 1.9°C and then sent to the syngas compressor as makeup syngas. The operation of the
purifier is controlled to maintain the exact ratio of 3:1 hydrogen to nitrogen at the converter inlet.

Step 9: Syngas Compression

The makeup syngas from the Purifier system is compressed in the first two stages of theSynthesis Gas
Compressor to 14,800kPa. Recycle gas from the synthesis loop is added to the makeup syngas before
the last wheel of the second stage, and the combined flow is compressed in the final stage to 15,512kPa
for end of run operation. This combined gas is preheated and then fed directly to the synthesis converter.
The synthesis gas compressor is driven by a steam turbine. The compressor is controlled to maintain
the suction pressure. During turndown operation, cold recycle gas can be spilled back to the suction of
the first stage to prevent the compressor from going into surge.

Step 10: Synthesis of Ammonia

The gas mixture in cooled, compressed and pumped into the ammonia synthesis loop in the ammonia
converter. A mixture of ammonia and unreacted gases which have already been around the loop are

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mixed with the incoming gas stream and cooled to 5oC. The ammonia present is removed and the
unreacted gases heated to 440oC at a pressure of 15200kPa and passed over an iron catalyst. Under these
conditions 26% of the hydrogen and nitrogen are converted to ammonia. The outlet gas from the
ammonia converter is cooled from 220oC to 30oC. This cooling process condenses more the half the
ammonia, which is then separated out. The remaining gas is mixed with more cooled, compressed
incoming gas. The reaction occurring in the ammonia converter is:

The ammonia is rapidly decompressed to 2400kPa. At this pressure, impurities such as methane and
hydrogen become gases. The gas mixture above the liquid ammonia (which also contains significant
levels of ammonia) is removed and sent to the ammonia recovery unit. This is an absorber-stripper
system using water as solvent. The remaining gas (purge gas) is used as fuel for the heating of the
primary reformer. The pure ammonia remaining is mixed with the pure ammonia from the initial
condensation above and is ready for use in urea production, for storage or for direct sale.

Step 11: Ammonia Purge Gas Recovery

The high pressure purge gas is used as the driving stream for the purge gas ejector, which pulls up the
lower pressure flash vapor and the refrigeration system purge gas. The combined purge gas is
discharged from the ejector and fed to Ammonia Scrubber, for recovery of ammonia. Ammonia content
in the scrubber overhead vapor is less than 120 ppm. Part of the overhead vapor from scrubber is
recycled to the feed gas compressor as hydrogen source for the hydrotreater. The rest is sent to the
primary reformer as fuel. As the front end of the plant has slightly higher capacity for syngas production
than what is required for the ammonia capacity, this vapor is not routed back to the Purifier system to
recover the syngas. Ammonia is recovered from the scrubber bottom as an aqueous ammonia solution.
This aqua-solution is fed to the ammonia distillation column, where ammonia and water are separated.
Ammonia vapor from distillation column overhead is routed to the discharge of the refrigerant
compressor to be condensed in the refrigerant condenser. Water from the bottom of the distillation
column, containing less than 0.15 mol% ammonia, is cooled and returned to the ammonia scrubber.

Step-12: Ammonia Refrigeration

Ammonia is condensed from the converter effluent stream by chilling with ammonia refrigerant at two
levels in chiller. The ammonia vapors are routed to Ammonia Refrigeration Compressor 105-J. The
refrigeration compressor ultimately compressed ammonia vapor to about 1600 kPa. The compressed
ammonia is condensed in a water-cooled Ammonia Condenser 127-C, and goes to the warm section of
ammonia accumulator.

The refrigeration system is designed to be capable of producing cold ammonia product at -33°C. This
is accomplished by flashing ammonia product to atmospheric pressure in atmospheric ammonia flash
drum, 152-D. The flashed vapors are then compressed by ammonia storage booster compressor, 105-
J1. The compressed ammonia vapors are sent back to the suction of 105-J.

Step-13: Ammonia Product and Storage

The ammonia product is drawn from the warm section of the ammonia accumulator and is sent to the
urea unit via the ammonia product pump 113-J/JA. The ammonia storage is provided by 10,000 MT
tank at atmospheric pressure and -33°C. The tank includes a package refrigeration unit to maintain
storage temperature and a flare system.

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A set of liquid ammonia bottling systems is provided, which contains two parts.

1. The ammonia pressure storage units including an ammonia storage vessel and an ammonia
reclaimed vessel.

2. The ammonia loading station including ammonia loading bottle pumps, ammonia reclaimed
compressor, ammonia loading facility, 200 ammonia bottles with 50 kg capacity for each, truck
loading and associated facility.

Step-14: Vent and Flare Systems

The flare system designed to incinerate and vent gas streams containing ammonia and combustible
hydrocarbon components from the plant. The natural gas can be vented to the air with the enough height
for safe operation.

Three different flare systems are provided to serve the plant.

a) Front end vent flare system with stack height about 70m from the ground level of the plant
b) Ammonia vent flare system with stack height about 70m from the ground level of the plant
c) Ammonia tank farm flare system with stack height about 30m to 50m from the ground level of the
plant

2.4 Exclusive Features

a) As absorbent in the CO2 removal section, Activated Methyl Di-Ethanol Amine (MDEA) is used
instead of Benfield Solution due to its higher absorption capacity and easier handling.
b) Before synthesis of the ammonia in ammonia converter, the methanator effluent goes through the
Coldbox where it is cooled by refrigerant ammonia which is previously produced, reducing cost of
cooling.
c) Compared to other methods, Coldbox offers easier installation, support and connection to customer
piping, as well as improved insulation and protection against external atmospheres.
d) The process is fully automated and only few operators are needed on a daily basis for operation.
e) The plant is fully equipped with Distributed Control System (DCS) monitored by Engineers and
Technicians.

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Figure 2: Block Diagram of Ammonia Production

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Figure 3: Process Flow Diagram of Desulfurization, Reforming and Shift

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Figure 4: Process Flow Diagram of CO2 Removal (Two Stages)

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Figure 5: Process Flow Diagram of Methanation and Purification & Miscellaneous Units

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Figure 6: Process Flow Diagram of Ammonia Synthesis, Refrigeration and Recovery

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 UREA PLANT

Figure 7: Urea 2000PLUSTM POOL Reactor

Urea Bagging &

Granulation
production Packing

25 | P a g e
 3. Urea production

3.1 Introduction
Urea, a vital component in modern agriculture, plays a crucial role in providing essential nitrogen to
crops, thereby promoting robust plant growth and maximizing yields. As the world's population
continues to burgeon, the demand for food production escalates, necessitating efficient and sustainable
methods of agricultural fertilization. Urea, a white crystalline compound with the chemical formula
CO(NH2)2, stands out as a cornerstone in the realm of nitrogenous fertilizers. Urea has a nitrogen content
of 46%, a higher concentration than this is available in other solid sources of nitrogen. Unlike phosphate
and potassium fertilizers, which normally require a single application, urea needs to be applied several
times during the growing season. Urea is an ideal source of nitrogen for all kinds of crops (wheat,
barley, rice, maize etc

In addition, urea is a major raw material for melamine, and an important raw material for the
manufacture of other industrial products. The chemical formula of Urea is (NH2)2CO. The molecule has
two -NH2 groups joined by a carbonyl (C=O) functional group. Urea serves an important role in the
metabolism of nitrogen-containing compounds by animals, and is the main nitrogen-containing
substance in the urine of mammals. It is colorless, odorless solid, highly soluble in water, and practically
non-toxic. Dissolved in water, it is neither acidic nor alkaline. The body uses it in many processes, most
notably nitrogen excretion.

Commercial production of Urea now involves the reaction of ammonia and carbon di-oxide under high
pressure (approximately 150 atm) and at high temperature (approximately 180 °C). The product
ammonium carbamate is then dehydrated to produce urea. A summery reaction is shown below:

2NH3 + CO2 H2N-COO-NH4+

(Ammonium carbamate)

The first reaction is exothermic. Whereas the second reaction is endothermic. Both reactions combined
are exothermic. The second reaction is-

H2N-COO-NH4+ H2N-CO-NH2+H2O
(Urea)

The commercial production of Urea in Bangladesh was started in 1961 for its necessity in agriculture.
Bangladesh being predominantly an agricultural country possesses several fertilizer companies to meet
up demand of the local areas so that the projected target of production can be achieved. In present there
are many fertilizer factories. But the demand of fertilizer is increasing day by day. For that, a modern
technological factory is needed to appeasement the demand of fertilizer.

3.2 Key Information about Urea Plant

a) Raw Materials : Ammonia (NH3), Carbon dioxide (CO2) both from ammonia plant

b) Basic Product : Granular Urea (2-4 mm in size)

c) Process Licensor : Stamicarbon B.V the Netherland

d) Production rate : 1760 MT/ day

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 e) Production Efficiency : 67%

f) Reactor Type : Urea 2000PLUSTM POOL Reactor concept

3.3 List of Equipment

Table-06: Equipment list for urea plant

Item no. Description

Class C: Columns
C201 4 bar Absorber
C203 HP Scrubber
C303 Rectifying Column with Separator
C305 Atmospheric Absorber
C803 Hydrolyzer etc.
Class E: Heat Exchangers
E201 HP Stripper
E206 4 bar Absorber Feed Cooler
E302 Rectifying Heater
E303 LP Carbamate Condenser
E401, E402 2 Stage Evaporator
E702, E703 2 Stage Evaporation Condenser
E901 Steam Condenser
Class J: Ejectors
J702, J704 Ejectors at 2 Stage Evaporation Condenser
Class K: Compressors
K102 CO2 Compressor
KT102 Turbine for K102
Class P: Pumps
P102A/B HP Ammonia Pump
P301A/B HP Carbamate Pump
P303A/B Urea Solution Pump
P401A/B Urea Melt Pump
P703A/B Desorber Feed Pump
P705A/B 4 bar Absorber Feed Pump etc.

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 Class R: Reactors
R101 H2 Converter
R202 Pool Reactor
Class S: Separators
S101 Knock Out Drum
S106A/B Liquid Ammonia Filter
S304 Flash Separator
S401, S402 Separators At 2 Stage Evaporation
Class V: Vessels
V301 Level Tank for LP Carbamate Condenser
V302 Urea Solution Tank
V305 Head Tank
V703 Ammonia Water Tank
V901 Steam Condensate Tank
V904 LP Steam Drum
V905 HP Steam Saturation
V909 MP Steam Saturation etc.
Class X: Stack
X801 Stack

3.4 Process Description

In modern fertilizer industry Urea can be synthesized by many processes. Here in Shahjalal Fertilizer
company the general contractor COMPLANT and CHENGDA signed a contract with Stamicarbon for
the design of the urea synthesis and urea granulation plant. According to the Stamicarbon process the
key features of the plant is divided into two main parts. They are

1. Liquid Urea processing plant

 CO2 compressor stripper
 Scrubber
 Urea pool reactor
 Rectifying column
 LP carbamate condenser
 Level tank
 HP carbamate pump
 Flash tank
 Condenser and ejection system
 Atmospheric absorber
 Ammonia water tank

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  Desorber
 Hydrolyzer
 Reflux condenser and r.c level tank
 Urea solution tank
 1st evaporator
 2nd evaporator

2. Granulation unit

Urea 2000plustm Pool Reactor Concept

The Pool Reactor concept combines the condenser and reactor within a single pool reactor. This is
achieved by enlarging the horizontal condenser so as to incorporate additional reactor volume. As a
result, it becomes possible to achieve sufficiently high residence times, eliminating the need for a
separate vertical reactor, while creating the conditions that will allow the reaction to reach its optimum
condition. The high-pressure scrubbing operation can also be simplified in the Pool Reactor concept by
placing the scrubber sphere above the pool reactor and adding the ammonia to the synthesis via this
scrubber. This ensures that no separate heat exchanging section in this scrubbing operation is required.
In the Pool Reactor concept, carbamate from the low-pressure recirculation section flows together with
the absorbed gases and the ammonia via a sparger into the pool reactor. As the static liquid height
ensures gravity flow, no high-pressure ejector is needed. Exothermic and Endothermic reaction occur
in pool reactor.

2NH3 + CO2 ⸻⸻→ H2N-COO-NH4+ ; (Exothermic), 57% conversion

H2N-COO-NH4+ → NH2-CO-NH2 + H2O; (Endothermic), 33% conversion

3.4.1 Liquid Urea Processing Plant

The main responsibility of liquid urea processing plant is to collect the ammonia and carbon dioxide
from the ammonia plant in their input condition. Prepare them for the reaction and in the perfect reacting
condition making the reaction happen between ammonia and carbon dioxide to produce liquid urea in
the presence of catalyst to produce liquid urea. Another work that is done through this process is to Use
the waste heat to produce steam to lower the energy consumption and make the process more efficient.
Additionally in this unit, all the process condensate is treated and reduces the waste of resources. On
the basis of the work the whole liquid urea processing plant is divided into five individual sections.
Details of all the five sections are discussed bellow

Ammonia and Carbon dioxide Compression

Ammonia and carbon dioxide are supplied from the ammonia plant. The input characteristics of
ammonia that we take from the ammonia plant are given in the following table

For Ammonia Amount For Carbon dioxide Amount

Ammonia 98.8 wt% Carbon dioxide 94 vol%
Water .2 wt% Water 5 vol %
Temperature 400C Temperature 40oC

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 Pressure 25 kg/cm2 Pressure 1.5 kg/cm2
Ammonia is supplied from two giant storage tank or directly from the ammonia plant. The ammonia is
sent to the high pressure ammonia pump where the pressure is increased. The pump we used here are
centrifugal pumps. There are normally tow pumps are available one is operational and another remains
in standby in case of an emergency. We increase the pressure 25 kg/cm2 to 146 kg/cm2

On the other hand Carbon dioxide from battery limits is supplied, together with a small amount of air,
to the carbon dioxide compressor before it is compressed to about 147 kg/cm 2. The carbon dioxide is
compressed by a single compressor which has two sides a) Low pressure side b) High pressure side. In
each side there are two stages in the low pressure side the pressure is increased from 1.5 kg to 27 kg
and in the high pressure side the pressure side the pressure is increased to 146 kg which is the design
pressure from 27 kg pressure. The compressor is from the company named HETACH. The power input
for the compressor is 7.4 MW which utilizes steam turbine to do the compression. In the hydrogen
converter, the hydrogen present in the carbon dioxide feed is removed by catalytic combustion to values
less than 10 ppm. It is dehydrogenated in order for it to remain outside the combustible range of
hydrogen‐air mixtures in the vent gas of the high‐pressure scrubber in the synthesis section. Part of the
air is used for catalytic combustion and the remaining part is used to passivate the equipment in the
synthesis section to prevent active corrosion.

The carbon dioxide is introduced into the bottom of the high‐pressure stripper in the synthesis section.
The two feedstock, ammonia and carbon dioxide, are fed to the synthesis section.

Step-1: Synthesis Section

The production of ammonium carbamate and dehydration of ammonium carbamate into urea and water
takes place in the pool reactor. The reactor effluent is distributed over the tubes of the high pressure
stripper. Here, the reactor effluent is contacted counter currently with carbon dioxide, causing the partial
ammonia pressure to decrease and the carbamate to decompose. The heat, required for this purpose, is
supplied by passing saturated high pressure steam around the tubes of the high pressure stripper.

The urea solution from the high pressure stripper flows to the low pressure recirculation section whilst
the high pressure strippers off gases are sent to the pool reactor via a gas spurger over the full length of
the reactor.

The pool reactor consists of a cooled and an adiabatic part. The cooled part is a special design U‐ tube
type heat exchanger. The main part of the strip gasses is introduced in the cooled part, where
condensation takes place through the principle of pool condensation. The heat of condensation is used
to generate low pressure steam of 4.5 kg/cm2. This steam is used for heating and desorption as well as
for the vacuum ejectors. The pool of liquid in the cooled part allows for a considerable amount of urea
formation to take place. The formed urea, non-converted carbamate and excess ammonia subsequently
flow to the adiabatic part of the reactor where further conversion of carbamate into urea takes place.
The reactor volume allows sufficient residence time for the reaction to approach equilibrium. To reach
the required approach to equilibrium the smaller part of the strip gasses is introduced in the adiabatic
part.

Part of the ammonia and carbon dioxide from this gas portion will condense in the adiabatic part,
providing the required heat for the conversion and for heating the solution. The reactor effluent flows
via an overflow compartment to the high pressure stripper. The overhead vapors of the reactor

30 | P a g e
compartments are collected in the top of the reactor and from there on are introduced to the high pressure
scrubber.

In the high pressure scrubber the reactor off gas is first brought in contact with the liquid ammonia from
the HP ammonia pump in the lower part of the scrubber. After that the remainder of the reactor off gas
is washed in a packed bed in the upper part. In the lower part of the high pressure scrubber the bulk of
the ammonia and carbon dioxide is condensed, the heat of condensation being taken up by the cold
ammonia. In the upper part the gasses leaving the bottom section are contacted counter currently with
the carbamate solution which is formed in the low pressure recirculation section. The gas from the
packed bed, substantially consisting of nitrogen and oxygen and containing only small amounts of
ammonia and carbon dioxide, is vented to the atmosphere via an LP absorber operating at 4 kg/cm2.
The ammonia/carbamate solution from the high pressure scrubber flows into the cooled compartments
of the pool reactor.

Step-2: Low Pressure Recirculation Section

This stage recovers the ammonia and carbon dioxide still present in the urea solution coming from the
high-pressure stripper. Because of low ammonia and carbon dioxide concentrations in the stripped urea
solutions, the Stamicarbon CO2stripping process is the only process that requires just one single low-
pressure recirculation stage.

Coming out of the stripper, the urea solution is fed into the dissociation heater, where most of the
ammonia and carbon dioxide are removed. The ammonia and carbon dioxide are then fed into the low-
pressure carbamate condenser, where they are condensed. Because the ratio between ammonia and
carbon dioxide in the recovered gases is optimal, the quantity of water needed to dilute the resultant
ammonium carbamate solution can be kept to a minimum, maximizing conversion figures for the urea
plant. The resultant carbamate solution is fed, via a high-pressure carbamate pump, back to the synthesis
as a scrubbing agent in the high-pressure scrubber.

Before entering the urea solution tank, part of the water present in the urea solution is evaporated by
further pre-flashing. The vent gas from the recirculation stage is practically free from ammonia because
it is scrubbed in an atmospheric absorber. The heat required for this section is derived from the
condensation of the low-pressure steam produced in the urea synthesis.

In this section essentially all of the small amounts of non‐converted ammonia and carbon dioxide are
recovered from the effluent leaving the high‐pressure stripper. This effluent is expanded to about 4.2
kgf/cm2. As a result, a proportion of the carbamate in this effluent solution decomposes and evaporates.
The urea solution is distributed onto a bed of Pall rings in the rectifying part of the rectifying column.
The urea solution containing carbamate is sent from the bottom of this rectifying part to a heater where
the temperature is raised to 135℃ in order to decompose the left carbamate.

The heat required is supplied by low‐pressure steam generated in the high‐pressure pool reactor. The
formed vapor is separated from the urea solution in a separator below the rectifying part of the rectifying
column. Via this separator the gas is sent to the rectifying part where they are cooled by the colder urea
solution from the top part. This causes a part of the water vapor contained in the gas to condense.

The gas leaving the rectifying column is introduced into the bottom of the low‐pressure carbamate
condenser where it is condensed almost completely. The heat of condensation is dissipated into a

31 | P a g e
tempered cooling water system. Process condensate is also supplied to the low‐pressure carbamate
condenser together with the carbamate from the reflux condenser in the process condensate treatment
system in order to control the water concentration in this carbamate solution. The optimum ammonia to
carbon dioxide molar ratio allows the water concentration to be as low as about 31% by weight. The
pressure in the low‐pressure carbamate condenser is controlled at about 3.3 kgf/cm2.

From the level tank of this low‐pressure carbamate condenser, the carbamate solution flows to the high‐
pressure carbamate pump where its pressure is raised to about 146 kgf/cm2 and from where the
carbamate solution is carried to the high‐pressure scrubber. The urea solution leaving the bottom of the
rectifying column flows to the sub‐atmospheric flash separator, which is operated at a pressure of about
0.45 kgf/cm2. The overhead gas of this flash separator together with the overhead vapor of the first
stage evaporator is condensed in an evaporator condenser.

Step-3: Evaporation and Condensation Section

Before the entire urea production process is complete, the urea solution present in the urea solution tank
must be concentrated. The urea solution is therefore sent to an evaporation section. The topology of this
evaporation section depends on the applied finishing section (granulation). Depending on the
requirements of the finishing section, the evaporation section may, for example, consist of two
consecutive evaporators, where the water in the urea solution is evaporated under vacuum conditions.
The remaining urea melt has a urea concentration varying from 96 to 99.7wt%, depending on the
requirements of the downstream finishing section.

The urea solution from the sub‐atmospheric flash separator, containing about 72 % by weight of urea,
is sent to the urea storage vessel. The urea solution is pumped from this storage vessel to the first stage
evaporator where the urea solution is concentrated to about 95% by weight. The sub‐atmospheric
pressure in this evaporator is about 0.341 kgf/cm2 and the temperature of the solution leaving this
evaporator is about 130℃.

This urea solution is sent to a second stage evaporator in which the solution is concentrated to a melt.
The urea concentration in this melt is 98.5 % by weight. The sub‐atmospheric pressure in the second
stage evaporator is 0.139 kgf/cm2 and the temperature of the melt leaving this evaporator is 140℃. The
urea melt is then sent via a urea melt pump to the granulation section.

The overhead vapors of both evaporators are condensed in condensers and the process condensates
leaving the condensers are collected in the ammonia/water tank. Non‐condensed vapors leaving the
condensation section are sent to an absorber, operating at atmospheric pressure, in which the ammonia
in these vapors is absorbed almost completely.

Step-4: Process Condensate Treatment Section

Process condensate from the condensation section, containing ammonia, carbon dioxide and entrained
urea, is collected in the ammonia/water tank and used as absorbent in the absorbers. Next, the process
condensate is pumped from this ammonia/water tank to the desorber via a desorber heat exchanger.

In the top part of the desorber the bulk of the ammonia and carbon dioxide is stripped off by means of
the overhead vapors from the bottom part of the desorber and hydrolyser. The effluent of the top part

32 | P a g e
of the desorber containing about 0.8% by weight urea is pumped via a hydrolyser heat exchanger, where
this condensate is heated to approximately 190℃, to the top of the hydrolyser column.

In the hydrolyser, the urea is decomposed into ammonia and carbon dioxide while being heated by
means of live high‐pressure steam to about 200℃. To obtain urea concentrations as low as about 1
ppm, the process condensate is counter currently contacted with this live steam. Leaving the hydrolyser,
the process condensate, containing just traces of urea, goes via the hydrolyser heat exchanger to the
bottom part of the desorber. The overhead vapor is sent to the top part of the desorber.

In the bottom part of the desorber, the remaining ammonia and carbon dioxide in the feed process
condensate from the hydrolyser is stripped off by means of live low‐pressure steam generated in the
pool reactor of the synthesis section. The process condensate leaving the desorber is cooled down in the
desorber heat exchanger followed by a process condensate cooler where after it is sent to battery limits.
This purified process condensate contains only traces of ammonia and urea and can be used for several
purposes. The overhead gases from the desorber are condensed in a reflux condenser and are transferred
as a carbamate solution to the low‐pressure carbamate condenser. The non‐condensed vapor in this
reflux condenser is sent to the absorber operated at atmospheric pressure.

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Figure 8: Block Diagram for Urea Production

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Figure 9: Process Flow Diagram of Compression, Synthesis and Recirculation

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Figure 10: Process Flow Diagram for Recirculation and Evaporation
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Figure 11: Process Flow Diagram for Desorption and Hydrolysis

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3.5 Granulation (Fluid Bed)
Today, the most commonly used finishing technology is fluid-bed granulation, which was
commercialized by Stamicarbon in response to changing market needs. Their patented fluid bed Urea
technology is in use in several urea plants. Stamicarbon’s fluid-bed granulation technology offers:

→ Large reductions in formaldehyde content compared to other fluid-bed granulation technologies

→ Unprecedented uninterrupted run times, which can exceed 100 days before washing is required
→ Excellent product quality (round and uniform with a smooth surface)
→ More stable operation conditions
→ Low urea dust formation, resulting in a lower recycle of urea solution to the urea synthesis plant
→ Low opacity at outlet granulation vent stack
→ Substantial savings on operational costs when compared to other fluid-bed granulation technologies
→ Excellent properties for downstream coating (for specialty fertilizers)
Stamicarbon’s fluid-bed granulation process works as follows: A urea melt stream with a urea
concentration of 98.5wt% is introduced into the fluid-bed Granulator through the injection headers,
which are connected to the urea melt line and the secondary air system. Each injection header comprises
vertically placed risers fitted with spray nozzles that spray the urea melt onto the seed particles.

Urea Melt Feed

→ temperature at melt headers 132 ‐ 140 [°C]

→ pressure at melt headers 3.6 ‐ 4.5 [kgf/cm2(a)]
→ moisture at melt headers < 1.7 [wt.%]
→ formaldehyde at melt headers > 0.27 [wt. %]
The secondary air, required to transport the granules through the urea melt fi lm, is provided by a
secondary air blower. Urea formaldehyde is added to the urea melt as a granulation additive and anti-
caking agent. This also improves the granule crushing strength.

Secondary Air

→ flow rate 40000‐‐44000[Nm3/hr]

→ temperature 138 ‐ 142 [°C]
→ pressure 1.45 ‐ 1.50 [kgf/cm2(a)]
The granulator is divided into a granulation section and a cooling/conditioning section. In both sections,
fluidization air is evenly distributed to fluidize and cool the granules. Seed (recycled) material is
introduced into the first chamber of the granulation section. The urea melt is then sprayed onto this seed
material. As the granules move through the granulation section, their size is steadily increased by
layering until they reach the required granule diameter.

At this point, the product finally flows out of the granulator. The granules flow from the granulation
section to the cooling section (without spray nozzles), where they cool down and harden. Fluidization
air and secondary air are exhausted from the top of the granulator by means of an off-gas fan in the off-
gas line of the granulator scrubbers. In the scrubbers, the air is cleaned using a scrubbing solution, and
the cleaned air is exhausted into the atmosphere. The scrubbing solution (a dilute urea solution) is partly
recycled to the scrubber as a scrubbing solution. A purge stream is also pumped to the urea-dissolving
vessel and recycled to the urea melt plant.

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 The product from the granulator flows through a screen to prevent any lumps from reaching the
granulate cooler. The fluidization/cooling air, which contains some dust, is exhausted from the top of
the granulate cooler and is combined with the air from the product cooler and the de-dusting air. This
combined stream is cleaned in the cooler scrubber system.

A bucket elevator lifts the cooled urea granules onto screens, where they are sorted according to size.
Fine product is recycled to the granulator. Coarse product is crushed to a smaller size and then recycled
to the granulator. On-size product is transported to the product cooler, where it is air-cooled in a
fluidized bed cooler or a bulk-flow heat exchanger.

Granule quality:

→ Total nitrogen 46.3 wt‐%

→ Biuret 0.85 wt‐%
→ Water 0.2 wt‐%
→ Formaldehyde 0.3 wt‐%
→ Free ammonia 50 wt‐ppm
→ Temperature ≤50℃
Particle size distribution:

→ 2 ‐ 4 mm 95 wt‐%
→ 1 – 2 mm 4 wt‐%
→ <1mm 1 wt‐%
→ Average Granule size 3.0 mm

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Figure 12: Block Diagram for Granulation Section

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Figure 13: Process Flow Diagram for Granulation Section

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 Bagging and Packing

Bagged Polyethene
Bulk urea Bagging Truck Railway
urea bag
storage building loading loading
storage loading

42 | P a g e
 4.Bagging and Packing Section

4.1 Bulk Urea Storage Unit

Granulator discharge belt conveyer and Trestle belt conveyer brings granular urea via electric three-
way valve. Capacity of bulk urea storage unit is 70000Ton. Electric tripper car is used to ensure that
bulk urea is being stored in right position. Scrape reclaimer is used to send ureato bagging building.

4.2 Bagging Building

It’s a four stored building where main bagging action initiated. Both bulk storage and granulator
supplies urea to it. Main features of bagging building are:

➢ Bagging and packing control room: from where most of the part can be handle automatically
➢ Empty bags storage: where empty bags are kept
➢ Bagging machine there’re six bagging machine where empty bag is being packed. Each bag consists
of 50kg granular urea each machine can bag 600+ bag per hour.
➢ Sewing machine: There’re six sewing machines as well. Function of it is to sew those packed bags.
➢ Delumper
Other features:

➢ Bin de-dust machine

➢ Bag de-dust system
➢ weight sensor
➢ weight checker
➢ batch number printer etc.

4.3 Bagged Urea Storage Unit

This unit is adjacent to bagging building. Conveyor brings bagged urea to this unit.

Capacity: 15000 bag (50 kg each bag)

4.4 Polythene Bag Plant Unit

Polythene bag that is needed for bagging in bagging building is supplied by polythene bag plant unit.

4.5 Truck Loading Yard

This part is situated very next to bagged urea storage. Bagged urea can be loaded in truck both from
direct conveyor that comes from bagging building and from storage.

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4.6 Railway Loading Yard
Railway is much cost consuming transport system. SFCL has already made a substation for loading
their goods. But still it’s not functional because of railway line. NGFF had used a railway line before.
SFCL also have a plan to use same route, their railway loading yard suggests that.

Figure 14: Process Flow Diagram of Urea Handling and Bagging System

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 5.Utility Section

water intake
station and
Pretreatment
section

Waste water Complex

treatment pumping
sttaion

Utility
Nitrogen and
Cooling water
instrument
plant
air plant

Demi water
plant

Utility section of Shahjalal Fertilizer Project consists of following units:

1. Water intake station and pretreatment section 4. Demi water plant

2. Complex pumping station 5. Nitrogen and instrument air plant
3. Cooling water plant 6. Wastewater treatment

5.1 Water Intake Pretreatment Station

The Shahjalal Fertilizer Project (SFP) necessitates a substantial volume of water for its daily
production operations. To meet this requirement, the Kushiara River serves as the primary
source of raw water for the SFP. The raw water is extracted from the river and subsequently
undergoes a process of clarification and filtration at the pre-treatment plant. The treated water
is then conveyed to the main plant via a pipeline.

5.1.1 River Water

Rivers serve as essential water resources for humanity. Historical patterns reveal a strong
correlation between social, economic, and industrial development and the accessibility of fresh
water in river systems. Evaluating the surface water available for regional, national, or
transboundary use can be accomplished by assessing the total discharge of river water.

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Analysis:
➢ PH: 8.02 ➢ Conductance:340 micro-sec/cm) ➢ Turbidity: 3.69 ppm
➢ SiO2: 9.45 ➢ Ammonium: 0.40 ppm ➢ Ca-hard: 99.08 ppm
➢ Alkalinity: 190.95 ppm ➢ Total Hardness: 147.12 ppm ➢ Chloride: 6.02 ppm
➢ Free Chlorine, Phosphate, Nitrite, Nitrate, Iron

5.1.2 Water Pre-Treatment

▪ Chlorination: Chlorine is used to kill microorganisms.
▪ Poly Aluminum Chloride (PAC): It represents a novel class of high-performance inorganic
macromolecular flocculating agents. With significant absorptive capabilities, it facilitates crucial
physical and chemical processes like sedimentation, adsorption, and angulation. Moreover, its
application requires minimal quantities, prevents sludge formation, and poses minimal health
risks. This agent is commonly utilized for coagulation purposes. The chemical formula of PAC is:
[Al2 (OH) nCl6-n. xH2O] m, Here 1≤n≤5, m≤10.
▪ Turbidity, SS Test: Turbidity SS refers to the turbidity and total suspended solids in surface
water, indicating a reduction in water clarity caused by the presence of suspended or colloidal
particles. Measurement involves assessing the light reflected by these particles, quantified in
Nephelometric Turbidity Units (NTUs).

5.2 Complex Pumping Station

The water, having undergone initial treatment at the water intake station, is then transported to a
sophisticated pumping station. In this facility, there are two tanks, each with a capacity of 7000m3.
Four major lines are distributed from complex pumping stations they are:
1. Industrial water line 3. Makeup water line
2. Fire and safety water line. pressure 6-8 kg 4. Portable water

5.3 Cooling Water Plant

As per the owner's demand, the recirculation cooling water system has been segregated into two
autonomous systems. One of these systems is responsible for supplying cooling water and reducing the
temperature of hot return water for the Ammonia Unit and Power Plant. The second system serves the
Urea Unit and Nitrogen Supply Unit, providing cooling water and cooling down the hot return water.
The ammonia and urea plants inherently require distinct heat pressure, volume, mass flow, and
concentration at various stages of their reactions or processes. Diverse types of heat exchangers are
employed, capable of exchanging heat through gas or water. The water utilized in this process is drawn
from the cooling water plant, which, in turn, is sourced from the complex pumping station.
Subsequently, this water undergoes further processing to meet specific usage requirements.

The factor that is checked in cooling water is-

➢ Scale inhibitor ➢ NaOH

➢ Corrosion Inhibitor ➢ Factors: pH , Ca2+ , COD, Fe, K+ ,NO2- , NO3-
➢ H2SO4 , Turbidity
Make-up water is provided from a complex pumping station. Hot water process water comes back from
the power plant, ammonia plant, and urea plant. There are eight giant fans to cool hot water. Water is
supplied there in such a mechanism that it slides over a surface. The fan was above the water in such a
way that it evaporated some water from the surface.

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For ammonia
CW Supply: temperature: 33°C; pressure: 450kPa
CW Return: temperature: 42.5°C; pressure: 250kPa

For Urea
CW Supply: temperature: 33°C; pressure: 33MPa
CW Return: temperature: 43°C; pressure: 0.3MPa
For Granulator
CW Supply: temperature: 33°C; pressure: 33MPa
CW Return: temperature: 43°C; pressure: 0.3MPa

5.4 Demi Water Plant

This plant consists of Cation Exchanger, Degasifier, Anion Exchanger, One mixed bed polisher
exchanger, Carbon filter, and Acid / Caustic regeneration package unit.

5.4.1 Cation Exchanger and Degasifier

Essentially clarified and filtered water is fed into cation exchanger where the majority of metal ions are
replaced by hydrogen ion of the strong cross-linked cation exchanger resin. CO2 is removed in
degasifier by contacting the water with the air provided by degasifier blower. The reaction of cation
exchanger and degasifier is given below-

R-SO3H + M+ = R-SO3M + H+ (Cation exchanger)

5.4.2 Anion Exchanger

Water is pumped to Anion Exchanger where the majority of salts are replaced by hydroxides ions of
resins, leaving water with a pH of approximate with a small residual level of dissolved metal salts.
These are removed in the mixed bed exchanger. The mixed bed contains both Cation and Anion resins.

2R-OH + SO42- = R2SO4 + 2OH- (Anion exchanger)

5.4.3 Regeneration
When the ion units have removed a set quantity of ions from the water, they need regeneration. The
cation units are regenerated by dosing Sulfuric Acid, the Hydrogen ions displacing the metal ions in the
resin.

R-SO3M + H2SO4 = R-SO3H + M2SO4 (Cation exchanger regenaration)

The Anion units are regenerated by dilute Sodium Hydroxide, the Hydroxide ions replacing the salts in
the resin. The hydroxide is stored at 30% concentration in Caustic Storage Tank. Caustic dilution heater
ensures the complete removal of Silica. Mixed bed units are blown after regeneration to ensure that the
Anion and Cation resins are completed mixed.

R2SO4 + 2NaOH = R-OH + Na2SO4 (Anion exchanger regenaration)

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The effluent from a number of regenerations is thoroughly mixed. The Acid effluents neutralize the
caustic or acid to bring the effluent into the pH 6-8 range. Then it is pumped to the effluent treatment
plant.

5.4.4 Mixed Bed Polisher

Finally water is passed through the mixed bad polisher containing Cation Exchanger Resin and anion
exchanger resin to remove the trace ions remain in water. Then the water is stored in polished water
storage tank from which it is supplied to the boilers after being passing through a vacuum deaerator.

5.4.5 Vacuum Deaerator

In this, there is a large hollow vessel and at the top of the vessel there is suction unit causing vacuum.
Dissolved O2 in water goes to the suction line and water gets free from oxygen, air and any gaseous
contamination

Complex 4 steps
Raw water 2 Carbon
pumping Active Degasification
tank Bed
station carbon filter

Anion Resin Middle Mixed bed

Demi Water User
exchanger water polisher

5.5 Nitrogen and Instrumentation Air Plant

The compressed air system is consist essentially of two compressors with a power source, control
system, intake air filter, after cooler and separator, air receiver, air dryer, and inter connecting
piping, plus a distribution system to carry the air to points of application.

Atmospheric air is sucked by air Compressor which basically contains water vapor & dust.

The object of installing a compressed air system is to provide air to the various points of
application in sufficient quantity and quality and with adequate pressure for efficient operation
of air tools or other pneumatic devices.

The total air requirement is the sum of the plant air and instrument air inclusive of
contingency for each category.

5.5.1 Plant Air

The plant air requirements are not be designed for coincident operation. Optimum schedule for
overhaul, regeneration, decoking, etc. shall be considered when arriving at the total capacity of the
complex.

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Plant air consumption is intermittent and difficult to estimate at early project stages. For initial estimate
add 130-170 dm3/h to compressor capacity.

5.5.2 Instrument Air Quality and Quantity

The instrument air shall be dust-free, oil-free and dry. To prevent condensation in the supply piping or
in the instruments, the dew point of the air at operating pressure after drier shall always be at least
10°C lower than the lowest ambient temperature ever recorded in the area.

Under normal operation the instrument air shall have a pressure of at least 8 bar in the buffer vessel,
and a pressure of 7 bar in the supply piping.

The required quantity of instrument air shall be estimated as accurately as possible, taking into
account the requirements for,

➢ Pneumatically operated instrumentation, based on the data stated by the manufacturer or

suppliers of such equipment.
➢ Pressurizing the enclosures of electrical instruments located in hazardous areas.
➢ Continuous dilution for enclosures of process stream analyzers, etc.
➢ Regeneration of air drier, especially for heatless type as the required quantity is about 15-20% of
drier outlet.

5.5.3 Air Supply Plant

An instrument air supply plant shall be provided, comprising

o Air Compressors
o Buffer Vessel
o Air driver

5.5.3.1 Air Compressor

To ensure maximum reliability of the instrument air supply, there are two compressors is installed.
Each compressor is arranged for normal operation and for stand-by, and those are capable of
supplying the designed quantity of instrument air, plus the required quantity of plant air, and, if
applicable, the required quantity of regeneration air.

Where it is essential to have stand-by also if one of the two compressor operational, e.g. because of
repairs or maintenance, the installation of a third compressor shall be considered. The installation of
more than two compressors may also be considered for other reasons, e.g. where the fluctuations in air
consumption are greater than the range ability of one compressor, or where purchasing and maintaining
a number of compressors each with relatively low capacity is more attractive than a (small) number of
compressors each with relatively large capacity. In any case, the total capacity of the compressors driven
by the most reliable utility shall be sufficient to supply the design quantity of instrument air.

5.5.3.2 Buffer Vessel

The sizing of the buffer vessel based on the design quantity of instrument air, plus the plant air
consumption until the safeguarding device closes.

The buffer vessel has automatic draining facilities. The wall thickness has a 3 mm corrosion
allowance, and the lower part of the vessel is provided internally with a protective coating.

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The vessel is installed between the compressors and the drier. Where limited space makes it impossible
to install the buffer vessel in this place, part of the required buffer volume located downstream of the
drier, provided the buffer vessel between compressor and drier remains of sufficient size for condensate
separation.

5.5.3.3 Air Receiver

The receiver serves several important functions. It damps pulsations from the discharge line, resulting
in essentially steady pressure in the system. It serves as a reservoir to take care of sudden or unusually
heavy demands in excess of compressor capacity. It prevents too frequent loading and unloading of the
compressor. In addition, it serves to precipitate some of the moisture that may be present in the air, as
it comes from the compressor or that may be carried over from the after cooler. The horizontal receiver
should be so sloped that the collected water in the receiver moves toward the pot under the receiver for
better drainage.

It also assumes that no air is supplied to the receiver during the time interval.

The buffer vessel shall be sized to maintain the air supply between the moments of compressor
failure caused by mechanical failure of one compressor or failure of one utility supply for the
compressor(s) normally in operation, and the moment that the stand-by compressor is or are
operating.

The period between these moments shall be taken as the time required for starting the stand-by
compressor(s) manually if automatic starting is unsuccessful, and shall be determined by plant
operations in connection with mechanical engineering and utility engineering, but shall be at least 15
minutes.

During this period, the instrument air pressure shall not drop below the minimum value required for
proper operation of the instruments (especially control valves) and other services depending on
instrument air.

5.5.4 Air Drier

This equipment will dry compressed air having 100% relative humidity to the stipulated dew point, and
durable for continuous operation under the specified pressure, humidity and flow rate. The design dew
point for instrument air is more than 10°C below the lowest recorded outside temperature under the line
pressure. The design dew point for plant air is lowest ambient recorded outside temperature under the
line pressure

Compressed air may be dried by:

➢ Absorption
➢ Adsorption
➢ Compression
➢ Cooling
➢ Combination

5.5.5 Oxygen Adsorbed

Oxygen adsorbent vessel works with the PSA process, which means Pressure Swing Process. In this
process the instrumental air comes from drier to an adsorbent vessel which absorbs O2 from instrument
air and makes it oxygen free air. After this process the instrument air contain 99.9% nitrogen on it.

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5.5.6 Filters
An air prefilled with a drain trap shall be installed at the entrance of the desiccant drum. An air after-
filter with a drain valve shall be installed at the exit of the dryer system. For the desiccant type dryer,
the filter mesh shall be less than 3 micrometers (microns). Measures shall be provided so that the flow
of air will not stop even in the case of replacement or cleaning of the filter elements.

5.5.7 Instrumentation
Operation control of the dryer shall be fully automatic control. Switching valves should not block the
air flow in their failure unless an automatic back-up bypass valve across the dryer is installed.

Control panels shall be provided as follows:

o A local control panel for the air dryer shall be employed

o The control panel shall be equipped with necessary instrument for monitoring operation of the
dryer

5.6 Waste Water Management

5.6.1 General Review
Wastewater treatment is a process to convert wastewater - which is water no longer needed or suitable
for its most recent use - into an effluent that can be either returned to the watercycle with minimal
environmental issues or reused. The latter is called water reclamation and implies avoidance of disposal
by use of treated wastewater effluent for various purposes. Treatment means removing impurities from
water being treated; and some methods of treatment are applicable to both water and wastewater. The
physical infrastructure used for wastewater treatment is called a "wastewater treatment plant".

The treatment of wastewater belongs to the overarching field of Public Works - Environmental, with
the management of human waste, solid waste, sewage treatment, stormwater (drainage) management,
and water treatment.

5.6.2Processes Used
5.6.2.1 Phase Separation
Phase separation transfers impurities into a non-aqueous phase. Phase separation may occur at
intermediate points in a treatment sequence to remove solids generated during oxidation or polishing.
Grease and oil may be recovered for fuel or saponification. Solids often require dewatering of sludge
in a wastewater treatment plant. Disposal options for dried solids vary with the type and concentration
of impurities removed from water.

Production of waste brine, however, may discourage wastewater treatment removing dissolved
inorganic solids from water by methods like ion exchange, reverse osmosis, and distillation.

5.6.2.2 Sedimentation
Solids and nonpolar liquids may be removed from wastewater by gravity when density differences are
sufficient to overcome dispersion by turbulence. Gravity separation of solids is the primary treatment
of sewage, where the unit process is called "primary settling tanks" or "primary sedimentation tanks".
It is also widely used for the treatment of other wastewaters. Solids that are heavier than water will

51 | P a g e
accumulate at the bottom of quiescent settling basins. More complex clarifiers also have skimmers to
simultaneously remove floating grease like soap scum and solids like feathers or wood chips.
Containers like the APIoil-water separator are specifically designed to separate non-polar liquids.

5.6.2.3 Filtration
Colloidal suspensions of fine solids may be removed by filtration through fine physical barriers
distinguished from coarser screens or sieves by the ability to remove particles smaller than the openings
through which the water passes. Other types of water filters remove impurities by chemical or biological
processes described below.

5.6.2.4 Oxidation
Oxidation reduces the biochemical oxygen demand of wastewater, and may reduce the toxicity of some
impurities. Secondary treatment converts some impurities to carbon dioxide, water, and bio solids.
Chemical oxidation is widely used for disinfection.

5.6.2.4 .1 Biochemical Oxidation

Secondary treatment by biochemical oxidation of dissolved and colloidal organic compounds is widely
used in sewage treatment and is applicable to some agricultural and industrial wastewaters. Biological
oxidation will preferentially remove organic compounds useful as a food supply for the treatment
ecosystem. Concentration of some less digest able compounds may be reduced by co metabolism.
Removal efficiency is limited by the minimum food concentration required to sustain the treatment
ecosystem.

5.6.2.4 .2 Chemical Oxidation

Chemical oxidation may remove some persistent organic pollutants and concentrations remaining after
biochemical oxidation. Disinfection by chemical oxidation kills bacteria and microbial pathogens by
adding ozone, chlorine or hypochlorite to wastewater.

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5.6.2.5 Polishing
Polishing refers to treatments made following the above methods. These treatments may also be used
independently for some industrial wastewater. Chemical reduction or pH adjustment minimizes
chemical reactivity of wastewater following chemical oxidation. Carbon filtering removes remaining
contaminants and impurities by chemical absorption onto activated carbon. Filtration through sand
(calcium carbonate) or fabric filters is the most common method used in municipal wastewater
treatment

Figure 15: Block Diagram of Waste Water Treatment

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Figure 16: Process Flow Diagram of I.A, P.A, and Nitrogen System

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 6. Laboratory Facilities

6.1 Purpose of Lab in Industry

A laboratory is a facility that provides controlled conditions. Engineers use laboratories as well to
design, build, and test technological devices. Scientific laboratories can be found as research and
learning spaces in schools and universities, industry.

Solid, liquid and gaseous contents from different unit (methanator, converter, primary reformer) of
Ammonia, urea or utility plant are needs to be testified for specification or determination. Finding the
correct composition or deviation from the designed value are identified or specified by lab experts.

➢ To find out the basic shortfalls as designed of the factory

➢ Shortfalls of Raw materials used as design
➢ Shortfalls of operational setup as design
➢ Commercial Shortfalls as design
➢ We do analysis usually to find out the Technical shortfalls of the factory
➢ Quality and quantity are not optimum
➢ Operating parameter are not satisfied as smooth, safely and profitable run
➢ Manpower are not satisfied skills, quality and quantity as required
➢ To determination of characterization, structure, composition and Foreign particles of the
chemicals and substance
➢ To determination of elements or the foreign substance if any may contain in process product
➢ To find out correct amount of the components
➢ To satisfied the customer and save the environment
Objectives of good analysis
➢ To confirm and increase satisfaction
➢ To reduce cycle time
➢ To control dosing delivery for save environment
➢ To help for good production
➢ To confirm optimum dosing
➢ To help for commercial more benefit
How we do assurance analysis
➢ To find out correct components present in a chemical sample
➢ To find out analytical problem of the method
➢ To find out limit of analytical concentration
➢ To find out analytical reagent
➢ To find out measuring tools
Collecting the sample
➢ Appropriate method of sampling
➢ Appropriate amount, size/ volume
➢ Appropriate containers should be taken
➢ Appropriate No. of collection
➢ Appropriate sample preparation
➢ Appropriate & safely carrying would be need for good sample
➢ Immediately analysis is better after sample collect
➢ Select correct preservation system for a particular chemical sample
➢ Select correct preservation temperature

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 ➢ Select correct storage place & correct environment

6.2 Some Purification and Isolation Methods

→ Solid Substance
➢ Desiccation or drying
➢ Crystallization
➢ Sublimation
➢ Dissolved & extraction i.e., Solution & Chemical analysis
➢ Solution & Electro-chemical
➢ Screening & magnetic separation
➢ Polymerization
➢ Dyzation & Distillation

→ Liquids Substance
➢ Distillation & Fractional distillation
➢ Decantation
➢ Sediment
➢ Filtration
➢ Precipitation & Aspirations
➢ Chemical analysis method

→ Gaseous Substance
➢ Absorption & separation
➢ Liquefaction &Analysis
➢ Evaporation & Separation

Common Techniques of Inorganic Analysis

1. Qualitative test

 Physical test.
 Chemical test
 Instrumental analysis
2. Quantitative Analysis

 Gravimetric Analysis
 Chemical reaction analysis
 Isotopic Analysis
 Micro Analysis
3. Volumetric or Titrimetric Analysis

 Neutralization or Acid –Base Titration

 Precipitation or Residue analysis
4. Instrumental analysis

 Instrumental titration
 Spectrophotometric analysis
 Chromatographic analysis

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  Emission Spectrograph
 Flame test, Spectrometry method
 Atomic Energy analysis

6.3 Laboratory Equipment List

 Natural Gas Analyzer  Analytical Balance
 Gas Chromatograph  Analytical Balance
 Gas Chromatograph  Dew Point meter
 Total Sulphur Analyzer  Karl Fisher meter（volumetry)
 Automatic titrator  Karl Fisher meter (coulometry)
 UV/VIS Spectrophotometer  Electric Thermosatic Oven
 Spectrophotometer  Muffle Furnace
 PH meter  Dissolved Oxygen analyzer
 Conductivity meter  Silicate analyzer
 BOD5 Apparatus  Flame Photometer
 Constant temperature water bath  Turbidimeter
 Vacuum pump  Orsat apparatus
 Pure water device  Portable Oxygen meter
 Colorimeter meter  Gas flow meter
 Hot plate  Explosive meter
 Biological Microscope  Optical Pyrometer
 Biochemical incubator  Atomic Absorption
 Sieve shaker  Spectroscopy
 Magnetic Stirrer  Granule intensity meter
 NOx meter  Glass apparatus dryer
 Laboratory centrifuge  Ultrasonic Bath

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 7. MTS (Maintenance and Technical Services)

7.1 Introduction
The importance of an effective maintenance program cannot be overlooked because it plays such an
important role in the effectiveness of Lean manufacturing. As in personal health care insurance,
maintenance may be considered the heath care of our manufacturing machines and equipment. It is
required to effectively reduce waste and run an efficient, continuous manufacturing operation, business,
or service operation. The cost of regular maintenance is very small when it is compared to the cost of a
major breakdown at which time there is no production.

7.2 Objective of Maintenance

The main purpose of regular maintenance is to ensure that all equipment required for production is
operating at 100% efficiency at all times. Through short daily inspections, cleaning, lubricating, and
making minor adjustments, minor problems can be detected and corrected before they become a major
problem that can shut down a production line. A good maintenance program requires company-wide
participation and support by everyone ranging from the top executive to the shop floor personnel.

7.3 Sectors under MTS Department

Shahjalal Fertilizer Project has well equipped maintenance system and skilled personnel as well like
modern complex fertilizer industry. The main sectors of MTS department in SFP are as follows:

1. MTS (Mechanical) Section

2. MTS (EIP) Section

1. MTS (Mechanical): It deals with its purposes in four different branches which are-
a. MM- Machinery Maintenance
b. PM- Plant Maintenance
c. CMW- Central Maintenance Workshop.
d. SHSM- Solid Handing System Maintenance.
2. MTS (EIP) Section-It deals with its purposes in three different branches which are-
a. IM- Instrumental Maintenance
b. PP- Power Plant
c. EM- Electrical Maintenance

7.4 Mechanical Workshop Equipment

Table-07: List of Equipment in Mechanical Workshop

No. Item No. Service Specifications

01 20L0001 Lathe machine dia：max￠850,
swing dia-850 mm, P：~11 kw
02 20L0002 Lathe machine dia：max￠500, Lathe dia 21" mm, P：
~7.5 kw

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03 20L0003 Lathe machine dia：max￠320, P：~5kw,
13"Hollow spindle
04 20L0004 Lathe machine dia：max￠320, Swing Dia-13", p：~5 kw
05 20L0005 Vertical Boring & Turning range:2m, M/c-72", N= ~15 kw

06 20L0006 Radial Drill & Tapping dia：φ80, M/c-3",p：~7.5kw

07 20L0007 Pedestal Drill dia：max￠50, M/C V-2" p：~5.5 kw
08 20L0008 Drill press dia：max￠20, M/C V-7/8", p：~3 kw
09 20L0009 Universal Milling table：1250X320, rpm：2840r/min, p：
11kw
10 20L0010 Shaper Range:0~φ400, M/C 24", N=~3kw
11 20L0011 Precision Cylindrical Grinding Range：φ200X500, consume：~14kw

12 20L0012 Surface grinding Range：300X1000X400mm, p ：~11kw

13 20L0013 Power Hack saw range：16", N=3.22kw, 0~250mm
(square),0~φ250 mm (circinal)
14 20L0014 Surface plate 1500X1000X220, Cast Iron, Thk. 28mm
15 20L0015 Planner Range: L500x500mm, N=3kw
16 20L0016 Pedestal Grinding Range：0~Φ350, N=3 KW
17 20L0017 Hydraulic Press Q=100t,N= ~ 7.5kw
18 20L0018 Valve Test Bench Range: DN 300-600,N= ~ 5.5 kw press：
1-16 bar
19 20L0019 Insitue Valve grinding & acentric & horizontal, N= ~1.5 kw
Lapping
20 20L0020 Balancing quoit & horizontal, N=~11 kw Dia-
1.5M,Length3M,Weight-3Ton
21 20L0021 Hydraulic Torque Wrenches Range：M22-48

22 20L0022 Bolt Tensional Device Range：M24-36, max press 150MPa

23 20L0023 Mini steam jet Cleaner Press：4 Bar, p：~ 2.2Kw, Steam
temp145°C
24 20L0024 Overhead Crane Q=16 /3.2 t,Span13.5m H9m N= ~30 kw
25 20L0025 Hydraulic Share crocodile edge, N= ~7.5 kw, Range：
30×30,φ35
26 20L0026 Hydraulic Bending Depth ：200mm, Table：2000mm Press：
40t, N= ~5.5 kw
27 20L0027 Hydraulic Rolling Thickness：20mm, N= ~15 kw Size：
5600*1600*1900
28 20L0028 Manual Tungsten Argon Arc capacity: 315 A, leisure voltage:78V
Welder (DC and AC)

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 29 20L0029 Air Plasma Cutting Machine Max. Cutting, Thk: 20~50mm Press： 0.3-
0.6
MPa Current： 70A
Size： 1150*640*770 N= ~15 kw
30 20L0030 AC Arc Welder capacity:40/22~400/36A
31 20L0031 DC Arc Welder capacity: 40~400A
32 20L0032 Bow Sawer range：0~250mm (square), 0~φ250 mm
(criminal), N=3.22kw
33 20L0033 Electric threading machine Range 1/2" ~ 4", N= ~1 kw

34 20L0034 ab Circumrotate Duty Machinist's Range ：120 mm

Vices
35 20L0035 ab Portable Electric Drill range0~φ13, N=0.27kw,1Ph 220v 50HZ

36 20L0036 ab Portable Grinders Wheel diaφ150mm, N=0.27kw,1Ph 220v 50HZ

37 20L0037 Welding Rod Oven N=3.6kw,1Ph 220v

38 20L0038 Manual Hoist Q=2Ton, H=6m
39 20L0039 Manual Hoist Q=1Ton, H=3m
40 20L0040 ab Lifting Jack Q=10Ton, H=150mm
41 20L0041 Gas Welding
Equipment for Acetylene

42 20L0042 Gas cutting

Equipment for
Acetylene
43 20L0043 Crane 150 ton
44 20L0044 Crane 80 ton
45 20L0045 Crane 40 ton
46 20L0046 Fork lift 2t= Nos. 5t= nos.
a~c
47 20L0047 shovel loader Q=5t
a~c
48 20L0048 Crane Q= 5 t

7.5 MTS (Mechanical)

7.5.1 MM- Machinery Maintenance
Machinery Maintenance branch or more specifically rotatory and moveable equipments maintenance
branch basically works upon reading calibrating, adjusting, disassembling, repairing and replacing, all
kinds of rotating machines such as –

❖ Pumps (deals with non-compressive fluid)

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 ❖ Turbines, (steam turbine /gas turbine)
❖ Compressors (deals with compressive fluid)
❖ Gear box
❖ Fans/ Blowers (Induced draft/ forced draft)

7.5.2 PM- Plant Maintenance

This section mainly maintains all kinds of static sites or machineries spread across the whole factory,
especially in the plant areas. Inspecting the static plant machineries and taking proper actions regarding
the problematic issues is the principal job of this section of MTS. It runs through all sorts of plant sites
such also Reactor Vessels

▪ Boiler Heat Exchanger

▪ Non – destructive Tests
▪ Metal Inspection
▪ Dealing with corrosion threat

7.5.3 CMW- Central Maintenance Workshop

CMW is a very important and vital part of MTS department. Basically, instruments that are needed to
be repaired or replaced can be made here with the help of a skilled group of technicians and operators
who are appointed to this very purpose according to their precise skills and eligibility only. It has
numerous equipment which are needed for the industry to carry on with its desired pace by elbowing
out any machinery turbulence or problems. Among the modern equipment that are being used in the
CMW section of SFCL, a few names are as follows Lathe machine:

➢ Shaper machine
➢ Radial drill machine
➢ Roller machine
➢ Shear machine
➢ Bending machine
➢ Welding machine
➢ Cutting machine
➢ Crane
➢ Fork lift

7.5.4 SHSM- Solid Handing System Maintenance

➢ Urea granulation plant
➢ Urea handing and bagging system
➢ Urea gallery transport station
➢ Railway loading
➢ Bagged building

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 ➢ Bulk urea storage
➢ Bagged urea storage
➢ polyethylene bag plant
➢ Maintenance workshop
➢ General storage
➢ Chemical storage

7.6 MTS (EIP) Section

7.6.1 EM- Electrical Maintenance

Electrical Maintenance is the sub-section of the maintenance and Technical Service (MTS). Under this
sub-section following things are being monitored:

➢ Receiving power and distribution among

➢ Various plants according to their demand through various substation.
➢ Main substations are:
a) Circulating water (CW)
b) Urea plant.
c) Ammonia plant
d) water intake substation
e) Bagging and loading.
f) Admin and waste water treatment
g) Housing
➢ Types of power they are using:
a) Captive power
b) PBS
➢ Main equipments they are handing:

 Transformer
 Circuit breaker
 wire
 Earthing box
 UPS and IPS
 Stabilizer

Receiving voltage from the generator connected with boiler= 6.3 KV

Output voltage from transformer = 380 V

Receiving voltage from PBS = 33KV

In case of emergency = 30 min back up comes from UPS

In case of blank start 2 generators driven by DG provides 1.6 MW each.

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7.6.2 IM- Instrumental Maintenance

Instrument & Control Maintenance is concerned with the regulating and maintaining of measurement
systems for gas flow, level, pressure and temperature

7.6.3 PP- Power Plant

Steam power plants consist of one or a group of steam boilers and one or more steam power
sources (steam engines or steam turbines) with auxiliary mechanisms, apparatus, and instruments.
The simplest steam power plant is the steam power unit, which is composed of a fire-tube boiler
on which a piston steam engine is mounted. High-power steam power plants consist of steam
boilers and steam turbines with condensing equipment

Key Process Features

Power plant of SFCL can produces 24MW electricity. Demi water comes from demi water
plant that is needed as Boiler feed water. It has two boilers that can produce 75MT/h steam
each. Total 150MT steam supplies it to two turbines each is connected to a generator that can
produce 12MW electricity each. In the process needs to control the pH level there small
amount of NH3 is dosed. There’s also a chemical dosing system facility. Small amount of PO4
is used to remove impurities.

There are two steam levels in the power plant:

MP Steam: 5.0 MPa, 400°C

LP Steam: 0.3 MPa, 161°C (Max 198°C)

During normal operation, 87.2 t/h MP steam produced by power station boilers are introduced
into MP steam network, among which 61 t/h steams is converted into electric power by the
two 12 MW condensing type steam turbo-generator, and 26.2 t/h steam is used by ammonia
plant. The 14.1 t/h LP steam from ammonia plant and 18.7 t/h LP steam from urea plant is
sent to LP network, in which 24.9 t/h is used as injection steam of the 12 MW condensing
type steam turbo-generator unit and 7.9 t/h is supplied to power station used as deaerator and
feed water preheat.

During commissioning of the plants, the power plant will provide steam and electric power
for the whole plant. The turbine condensate water will all be recovered and sent to power
station deaerator when the quality criterion of condensate water is normal range. If the
condensate water is unqualified it be sent to the demi-water unit.

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 Main Process Flow
Combustion System
The combustion system consists of combustion system and air/flue gas system.

Natural gas is introduced into the firebox through natural gas pipe and air is blown by air
blower also into the firebox for combustion. Flue gas is sent to the stack via. A flue duct to
the stack for emission. Sketch of the combustion system is as follows:

Pressure
Natural gas and Flow Burner Furnace Air
Control

Stack Economizer Superheater Boiler

Steam-Water System
The demi water from the demi water unit is sent as make-up water to the deaerator for oxygen
scavenging. Boosted by the water feed pump, deaerated water is sent to the MP boiler. Produced MP
steam is introduced into the MP steam header of the complex and distributed to the process units and
steam turbo-generator unit. Sketch of the steam-water system is as follows:

Demi Water Deaerator BFW Pump Boiler

Process Units &

Steam MP Steam
Turbine Steam
Condansate Heater
Generator Unit

Deaeraror
Condensate
(Unqualified to
Pump
demi water unit)

Electricity produced the power plant is distributed via main sub-station through ammonia substation
and urea sub-station in different plant that and process.

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 8. Fire & Safety

HSET Department of SFCL

8.1 Industrial Safety

HSET dept. of SFCL
Industrial safety involves techniques implemented to reduce the risk of injury, loss and danger to
persons, property, process, products and environments. In industry safety can be categorized in two
ways:

1. Safety of the Company 2. Safety of the employee

→ Proper Instruction → Use of the safety facilities
→ Necessary Supervision → Follow safety rules
→ Safety means(PPE)
→ Immediate Actions

8.2 Industrial Hazards

Industrial hazard may be defined as any condition produced by industries that may cause injury or death
to personnel or loss of product or property. It refers to any accident that may create any potential
situations for accidents.

Types of hazards

 Mechanical Hazards
 Electrical Hazards
 Chemical Hazards
 Health Hazards: Toxic, Biological, Chemicals, Radiation, Sound, Heat, Light etc.

8.3 Fire
Fire is a combustion or burning, in which substances combine chemically with oxygen from the air
and typically give out bright light, heat, and smoke.

8.3.1 Fire triangle

The fire triangles or combustion triangles are simple models for understanding the necessary
ingredients for most fires. The triangle illustrates the three elements a fire needs to ignite: heat, fuel,
and an oxidizing agent (usually oxygen).

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Table- : Classifications of fire

Class A Wood, paper, cloth, trash, plastics,

Solid combustible materials that are not metals.
Class B Flammable liquids: gasoline, oil, grease, acetone ,
Any non-metal in a liquid state, on fire.
Class C Flammable gaseous eg. ammonia
Class D Metals: potassium, sodium, aluminum, magnesium

Class E Electrical, energized electrical equipment, As long as it's "plugged in," it

would be considered a class C fire.
Class F Cooking Oils

8.4 Safety Equipment

→ Personal protective Equipment (PPE)
PPE is equipment that will protect the user against health or safety risks at work. It can include items
such as safety helmets, gloves, eye protection, high-visibility clothing, safety footwear and safety
harnesses. It also includes respiratory protective equipment (RPE)

→ Fire proximity suit

It is a suit designed to protect a firefighter from high temperatures, especially near fires of extreme
temperature such as aircraft fires.

→ Fire Alarm System

A fire alarm system has a number of devices working together to detect and warn people through visual
and audio appliances when smoke, fire, carbon monoxide or other emergencies are present. Alarms can
be either motorized bells or wall mountable sounders or horns.

→ Fire hydrant
A fire hydrant, also called fireplug, is a connection point by which firefighters can tap into a water
supply. It is a component of active fire protection.

→ Fire truck
A fire engine or fire truck is a vehicle that is used for firefighting operations in local sites .it also
equipped with tools needed by firefighters

→ Fire sprinkler system

A fire sprinkler system is an active fire protection method, consisting of a water supply system.

→ Fire Extinguisher
Fire Extinguisher are installed inside hose. These are designed for extinguishing incipient fires.

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Types of fire extinguishers are given below:

1. Water and Foam

Water and Foam fire extinguishers extinguish the fire by taking away the heat element of the fire
triangle. Foam agents also separate the oxygen element from the other elements.
Water extinguishers are for Class A fires only - they should not be used on Class B or C fires. The
discharge stream could spread the flammable liquid in a Class B fire or could create a shock hazard on
a Class C fire.

2. Carbon Dioxide
Carbon Dioxide fire extinguishers extinguish fire by taking away the oxygen element of the fire triangle
and also be removing the heat with a very cold discharge.

Carbon dioxide can be used on Class B & C fires. They are usually ineffective on Class A fires.

3. Dry Chemical
Dry Chemical fire extinguishers extinguish the fire primarily by interrupting the chemical reaction of
the fire triangle.
Today's most widely used type of fire extinguisher is the multipurpose dry chemical that is effective on
Class A, B, and C fires. This agent also works by creating a barrier between the oxygen element and
the fuel element on Class A fires.

Using method of Fire Extinguisher:

Squeeze the Sweep from

Pull the pin Aim at target
lever side to side

→ Pull the pin.

→ Aim the nozzle or hose at the base of the fire from the recommended safe distance.
→ Squeeze the operating lever to discharge the fire extinguishing agent.
→ Starting at the recommended distance, Sweep the nozzle or hose from side to side until the fire
is out. Move forward or around the fire area as the fire diminishes. Watch the area in case of
re-ignition.

8.5 Industrial Safety Rules to be Followed

1. Avoid smoking in the plant area
2. Effective Housekeeping work area and machines.
3. Emergency telephone number to be called in the event of an accident.
4. Know and follow the safety rules and procedure that apply to the operation.
5. Use the proper type of personal protection equipment
6. Working duration not more than 8 hrs./day and 48 hrs./week.
7. Over age and under age human resource will not allowed.
8. Company must have occupational Safety & Health Management.
9. Be alert to unsafe conditions & hazards.

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10. Uncorked sewer drains promptly corked as they cause flooding and fire hazards.
11. Watch for and report all leaks promptly so that repairs can be made to prevent excessive
damage.
12. Check rigorously and frequently safe showers, eye wash fountains.
13. Records MSDS and other Data.

8.6 Safety Signs

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 CONCLUSION

In conclusion, the Urea Fertilizer Plant represents a significant milestone in the realm of agricultural
productivity and sustainability. Throughout this report, we have delved into the various aspects of the
plant, from its design and construction to its operational processes and environmental impact. The
production of urea, a vital nitrogenous fertilizer, plays a pivotal role in enhancing crop yields and
ensuring food security for a growing global population. The careful consideration of environmental
factors, such as emissions control and resource optimization, underscores the commitment to
sustainable practices within the fertilizer manufacturing industry. The implementation of advanced
technologies and adherence to stringent safety standards further contribute to the overall efficiency and
reliability of the plant. Shahjalal Fertilizer Company stands as a technologically advanced large-scale
factory. Our in-plant training of only 28 days was not enough for a comprehensive understanding of the
factory's intricacies. However, the support of the officers and employees helped us a lot to learn about
processes, maintenance, operations, involvement of economics, management, administration and many
other aspects of the factory. Undoubtedly, the guidance of skilled and experienced personnel not only
facilitated learning but also significantly contributed to our knowledge acquisition. Observing many
different plants of the factory, we realized that Shahjalal Fertilizer Company has a relatively low
negative impact on the environment despite being a large-scale chemical industry. The effluent water
treatment process of the factory is contemporary, addressing environmental concerns adequately.
However, the equipments of the factory generate a considerable noise, leading to sound pollution for
both employees and residents. There is a pressing need for a good technological implementation to
minimize this sound pollution. Nevertheless, Shahjalal Fertilizer Company Ltd. (SFCL) is one of the
leading fertilizer industries in our country which is consistently supporting our agricultural sector
through Urea production. Our direct experience provided valuable insights into the chemical processes,
and we anticipate that this knowledge will greatly benefit our professional lives.

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