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16 - CHM - Chemical and Process Engineering

CHM 140A - Urea Know How Workshop for Engineers

Code Start Date Duration Venue
CHM 140A 30 October 2023 5 Days Istanbul Registration Form Link
CHM 140A 25 December 2023 5 Days Istanbul Registration Form Link
Please contact us for fees


Course Description

The commercial synthesis of urea is achieved by the reaction of ammonia and carbon dioxide at high pressure forming ammonium carbamate, which is then dehydrated by applying heat, forming urea and water.

It is profitably and cost effectively important that your team understand the fundamentals of Urea process plant operation and maintenance concepts and best implementation of Key Operational Excellence required to improve their production, maximise profitability, and maintain safe, reliable, and environmentally responsible operations in the Urea Plant.

This 5 day workshop covers all topics Urea Engineers need to know and designed for Process, Operational, Mechanical, Maintenance, Instrumentation, Process Control and Inspection Engineers, Leaders and Supervisors working in any kind of Urea Plant. 

Course Objectives

  • Guiding participates to develop key concepts and techniques for optimizing urea plant unit operations. 
  • Utilizing the key concepts to make operating decisions that can improve your unit’s performance.
  • Improving operational excellence, product recoveries, purities and energy utilization, safety & reliability. 
  • Realizing the basic fundamental principles of design and operation. 
  • Carrying out effective trouble shooting.
  • Recognizing the core building blocks of the urea plant in fertilizer complex. 
  • Identifying the core building blocks of the process systems, equipment and economics. 
  • Realizing the process unit operation fundamentals.
  • Utilizing of the process unit operation fundamentals safely.
  • Optimizing the operational Excellence aspects:  Safety, Reliability, Continuity of Operations, Quality, Cost, and People Development 

Who Should Attend?

  • Process and Operational Engineers 
  • Mechanical and Maintenance Engineers 
  • Reliability Engineers 
  • Inspection Engineers 
  • Instrumentation and Process Control Engineers 
  • Safety Engineers 
  • Projects & Technical services Engineers
  • Others involved in the design, operation,  modification or maintenance of Ammonia and Urea process plants

Course Details/Schedule

Day 1

  • Overview:  fertilizer and urea 
  • Urea process technologies
  • Corrosion in carbamate solutions
  • How to detect active corrosion? 
  • Urea plants materials of construction 
  • Corrosion inspection in urea plants
  • Thermodynamics and phase diagrams
  • Quality aspects of urea prill 

Day 2

  • Urea plants operational aspects 
  • Control philosophy of various sections
  • Key performance indicators
  • Key analysis for process control and corrosion control
  • Explosion diagrams
  • Urea plants troubleshooting 
  • Safety, health & environmental aspects
  • Revamp technologies

Day 3

  • High-pressure synthesis equipment
  • Corrosion cases caused by failing leak detection systems
  • Failure modes high-pressure equipment
  • Co2 compressors operating problems and troubleshooting
  • HP reciprocating pumps, materials of construction, vibration issues
  • HP piping & valves
  • Typical corrosion failure modes HP piping
  • Safety valves in urea plants

Day 4

  • Atmospheric Corrosion (CUI)
  • Forms of atmospheric corrosion and preventive measures
  • Corrosion/fouling aspects utilities
  • Corrosion control in boiler feed water and steam systems
  • Root cause of typical failure modes and preventive measures
  • Corrosion and fouling control in cooling water systems
  • Overview of inhibitor systems
  • Cases of typical failure modes and preventive measures

Day 5

  • Carrying out repairs
  • Best Repair is No Repair … and when to do Repair?
  • Repair procedures of various materials of construction
  • Design aspects HP reactors and HP heat exchangers
  • Codes and standards
  • Quality assurance HP equipment & HP piping components
  • Atmospheric and Utility Corrosion cases