1、How Are Urea Fertilizer Granules Manufactured?

Discover how urea fertilizer granules are manufactured, and learn the differences between agricultural, industrial, DEF, and coated urea. Powered by Risso®.

2、Urea Manufacturing Process Explained

This diagram shows the step-by-step process of urea manufacturing, starting from synthesis with ammonia and carbon dioxide to final granulation for fertilizer use.

3、AP42, CH. 8.2 Urea

Granulation is used more frequently than prilling in producing solid urea for fertilizer. Granular urea is generally stronger than prilled urea, both in crushing strength and abrasion resistance. There are 2 granulation methods: drum granulation and pan granulation.

4、Urea Manufacturing Process in Detail and Its Application

The urea manufacturing process involves several steps to produce high-quality urea, including synthesis, purification, and granulation. This process utilises raw materials such as natural gas, phosphate, and ammonia, which are transformed through a series of chemical reactions to produce urea.

Urea Manufacturing Process

The major disadvantage of using urea as a fertilizer is that it may contain a chemical compound named biuret which is formed during manufacturing of urea. If the biuret concentration exceeds 2% then it is harmful to plants especially germinating seeds and also is toxic to animals.

Urea Manufacturing: Processes and Future Trends

Explore the complex urea manufacturing process and its crucial role in agriculture and industry. 🌱 Discover applications, environmental insights, and future trends!

Urea Granulation

The urea melt, concentrated in the evaporation section of the urea synthesis plant, is fortified with a granulation agent and fed to the granulation plant applying the UFT® fluid bed urea granulation process.

Urea Production Process

Urea, NH 2 CONH 2, is largely used as a fertilizer and as a non-protein feed supplement for ruminants. It is also used in the manufacture of urea-formaldehyde resins, plastics, adhesives, coatings, textile agents and ion-exchange resins.

In

Discover the detailed urea production process, including key steps and technologies that ensure product quality and contribute to environmental sustainability. Gain insights for your agricultural needs.

THE UREA MANUFACTURING PROCESS – EBL ENGINEERING LTD

Ammonia and carbon dioxide are the raw materials for the urea manufacturing process; usually, urea is manufactured in an ammonia plant because it yields ammonia as a product and carbon dioxide as a byproduct and this carbon dioxide can be recycled directly into the process.

The filling process in urea production is a critical step to ensure the quality of urea products remains uncompromised during transportation and storage. Below are the detailed procedures and requirements for urea manufacturer filling:

I. Raw Material Preparation

1. Selection of High-Quality Raw Materials: Using raw materials with high purity and minimal impurities is fundamental to ensuring urea product quality. High-quality urea raw materials must exhibit good chemical and thermal stability to withstand various reaction conditions during production.
2. Raw Material Pretreatment: Necessary pretreatment steps, such as crushing and screening, are performed to remove large-particle impurities and improve raw material quality. This process prevents damage to production equipment caused by hard lumps or foreign objects in the raw materials.
3. Measurement and Mixing: Raw materials are accurately weighed and thoroughly mixed according to production plans and formulation requirements to ensure proper component ratios. Uniform mixing is key to guaranteeing urea product quality.
4. Temperature Control: Strict temperature control during raw material mixing is essential to avoid changes in material properties due to excessively high or low temperatures, which could affect urea quality and performance.
5. Storage and Transportation: Prepared raw materials must be stored properly and protected from contamination or damage during transportation. Hygiene and safety measures during storage and transport are critical to maintaining urea product quality.

II. Equipment and Technical Parameters

1. Selection of Filling Machines: Choose filling machines suited to the characteristics and production processes of urea products. Machines should feature high precision, efficiency, and low loss to ensure product quality and performance during filling.
2. Technical Parameter Setting: Key parameters such as filling speed, accuracy, and volume are set based on production needs, balancing efficiency, quality, and cost.
3. Control System Optimization: Optimize the filling machine’s control system to enhance automation and ease of operation. This reduces reliance on manual labor, minimizes human error, and improves efficiency.
4. Inspection and Adjustment: Regularly inspect and adjust the filling machine to ensure optimal performance and compliance with production demands. Check components like moving parts, seals, and measurement accuracy.
5. Maintenance: Implement a maintenance plan for cleaning, lubrication, and repairs to keep equipment in peak condition. Proper maintenance extends equipment lifespan, reduces downtime, and boosts productivity.

III. Process Flow

1. Raw Material Handling: Mix urea raw materials according to specified ratios and preprocess them (e.g., crushing, sieving) to ensure consistency and quality.
2. Measured Filling: Use precise measuring devices for quantitative filling to ensure accurate and consistent fill amounts. This step is crucial for product quality.
3. Sealing and Labeling: Seal filled urea products and apply labels for clear identification. Sealing protects against moisture and deterioration, while labels facilitate traceability and management.
4. Packaging and Stacking: Pack and stack filled products securely to prevent damage during transportation and storage. Proper packaging safeguards products from environmental factors and enables efficient distribution.
5. Quality Inspection: Conduct rigorous inspections of packaged products, including visual and physicochemical tests, to confirm compliance with quality standards. Timely issue resolution maintains product qualification rates and market competitiveness.
6. Defective Product Handling: Isolate, label, and address non-conforming products (e.g., reworking or scrapping) to prevent their entry into the market. This minimizes risks and enhances customer satisfaction.

IV. Environmental and Safety Management

1. Environmental Protection: Adhere to environmental regulations to minimize pollution from wastewater, exhaust gases, and solid waste during urea production.
2. Safe Production: Enforce strict safety protocols and operational standards to ensure workplace safety. Safe practices protect employees and sustain enterprise growth.
3. Emergency Response: Develop emergency plans to anticipate, assess, and address potential accidents effectively.
4. Training and Education: Regularly train employees on safety practices and equipment operation to raise awareness and proficiency.
5. Supervision and Inspection: Establish monitoring mechanisms to conduct regular or spot checks, ensuring compliance with standards and requirements.
6. Continuous Improvement: Analyze production data to identify weaknesses, implement corrective measures, and enhance efficiency and quality. Continuous improvement drives excellence and sustainability.
7. Compliance Operations: Uphold national laws, regulations, and industry standards to ensure legal and ethical business practices, fostering a positive corporate image and reputation.

urea manufacturers must carefully consider raw material preparation, equipment selection, process flow, environmental, and safety management during the filling process. Adherence to these standards ensures high-quality, reliable urea products, strengthens market reputation, and delivers economic benefits.