Ammonia and Urea Process Technology

Overview

Ammonia and urea plants are among the largest consumers of natural gas in the Middle East and worldwide, and they supply the nitrogen fertilisers that support global food production. These complexes combine steam reforming, gas purification, high-pressure synthesis loops and urea reactors, strippers and granulation units, all operating with toxic, flammable and corrosive materials at high temperatures and pressures. Catalyst problems, corrosion, leaks and equipment failures can quickly reduce production, damage expensive equipment and create serious safety and environmental risks for operators and the surrounding communities.

This course provides a practical understanding of the processes, equipment and operation of ammonia and urea plants. Participants learn the steps of ammonia production, including feed desulphurisation, primary and secondary reforming, shift conversion, carbon dioxide removal, methanation, synthesis gas compression and the ammonia synthesis loop. The course then covers urea chemistry, high-pressure synthesis and stripping processes, recirculation, evaporation, prilling and granulation. It also explains catalyst management, energy efficiency, corrosion and materials in carbamate service, ammonia hazards and emergency response, environmental emissions, and the troubleshooting and reliability improvement of key equipment in fertiliser complexes.

Objectives

• Explain each step of ammonia production from natural gas feed to synthesis
• Operate reforming, shift, CO2 removal and methanation sections effectively
• Understand the ammonia synthesis loop, its catalyst and its control
• Describe urea chemistry, synthesis, stripping and finishing processes
• Manage catalysts, energy efficiency and corrosion in fertiliser plants
• Recognise ammonia hazards and apply safe handling and emergency response
• Troubleshoot common operating problems and improve equipment reliability

Who should attend

Training methodology

The course combines explanation of process chemistry and equipment with real flow diagrams, operating data and incident reports from fertiliser complexes. Participants calculate steam to carbon ratios, conversion and energy consumption, analyse reformer and synthesis loop performance, and interpret urea reactor and stripper data. Catalyst performance trends and corrosion inspection findings are reviewed to identify problems early. Case studies of ammonia releases, reformer tube failures and urea equipment corrosion are analysed in groups. Each day ends with a short quiz and an open discussion of operating issues at participants' plants.

Programme outline

Dates and fees

Certificate

Frequently asked questions