DESIGN OF UREA GRANULATION PROCESS WITH EMPHASIS ON ITS DYNAMIC STUDIES.

Abstract

The principal activity of the Company is manufacturing and marketing of fertilizer. Fertilizers provide essential elements for nourishment, development, and growth of plants as well as grain or fruit. Urea is produced using the Haber Borsh process. Granulation technology is applied to the urea melt solution. FFBL is the only company in Pakistan that employs granulation process for urea production. The total capacity of the company is 1670 MTPD of urea granule. FFBL produces and markets the • SONA DAP • SONA Urea (Granular) Granulation is one of the fundamental operations in particulate processing; however, there is still needed to provide insight into the complex dynamic state behavior of these units. The aim is to develop a granulation system that enhances the efficiency and quality of urea production, addressing key challenges such as particle size uniformity, process scalability, and energy consumption. The process will be designed accordingly followed by a feasible economic analysis. The unsteady state of an industrial granulator for urea production is studied under different imposed step changes in key operating variables. In fact, variables like bed height, pressure drop, solid mass flow, etc. require time to achieve the steady state. This non-steady behavior signifies the need for efficient control to return the system rapidly to the desired operational point. The discharge area, fluidization air flow rate, and temperature will be determined to be the more appropriate manipulative variables, for granulator stability control purposes. Thus, we have covered the major areas of design and simulation for urea granulation production capacity of 1670 MTPD.