This document provides an overview of the Production Department at a leading Urea manufacturer in Pakistan. The Production Department is responsible for the safe, smooth, and efficient operation of three ammonia-urea plants with a total annual production capacity of over 2 million tons. The department ensures sustained plant operation, compliance with standards, continual improvement efforts, and handling of emergencies. It oversees plants located at two complexes, Goth Machhi and Mirpur Mathelo, which produce urea through various ammonia-urea production processes and utilize utilities like gas turbines and steam boilers.

1. Introduction
Production Department
PRODUCTION
Sr. Executive Technical Services
Muhammad Yousaf

2. Leading Urea Manufacturer
•Operating 03 Ammonia-Urea Plants
•Aggregate Design Capacity is greater
> 02 million tons per annum
•45 % market share in Pakistan
Introduction
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3. Production Department Responsibility
Safe Smooth Efficient
Production Dispatch
P L A N T O P E R A T I O N
Best Quality Sona Urea
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4. Production Department Organization
Senior Manager
Production
Manager Production (P-II)
Bagging
Urea-II
Ammonia-II
Coordination Engineers
Manager Production (P-I)
Urea-I
Ammonia-I
Utilities
Coordination Engineers
Overall Strength
Management: 67
Staff: 235
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5. Goth Machhi Complex Overview
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6. FFC – Goth Machhi Complex
PLANT- I
PLANT- II
UTILITIES PRODUCT
HANDLING &
SHIPMENT
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7. NG Gas Compressors at Deh Shahbaz Pur
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8. Ammonia Urea Complex – FFC-GM
Ammonia 1000 MT/D
Commissioned - 1982
Urea 1725 MT/D
PLANT-I
Ammonia 1220 MT/D
Revamped - 1992
Urea 2105 MT/D
Cost USD 310 M
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9. Ammonia Urea Complex – FFC-GM
Ammonia 1100 MT/D
Commissioned - 1993
Urea 1925 MT/D
PLANT – II
Cost USD 324 M
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10. Ammonia Urea Complex – FFC-MM
Ammonia 1000 MT/D
Acquired - 2002
Urea 1740 MT/D
PLANT – III
Ammonia 1250 MT/D
Revamped - 2008
Urea 2175 MT/D
Cost USD 136 M
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11. Ammonia Urea Complex – FFC
02 Gas Turbines: 18 MW each
POWER
UTILITIES
02 Emergency Diesel Generators
02 Waste Heat Boilers
STEAM
02 Auxiliary Fired Boilers
Water Treatment
MISCELLANEOUS
Well Water Area & NG Lines
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12. Ammonia Urea Complex – FFC
 Plant-I: 10 Lines
Road & Rail
LOADING POINT
BAGGING & SHIPPING
 Plant-II: 05 Lines
Road Only
 50,000 MeT
BULK STORAGE CAPACITY
 Urea Dissolving & Recycling
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13. Production Department Functions
Annual Production Planning
Sustained Plant Operation
Continual Improvement
Amm-I
B&S
Uty
Amm-II
Urea-I
Urea-II
Production
Compliance of Standards
Emergency & Disaster Handling
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14. Annual Production Planning
 Gas Availability
 Plant Performance
 Plant Limitations
 Turnaround Cycles
 Unplanned Shutdowns
Basis
Production Department Functions
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15. Production Department Functions
 24 / 7 Plant Monitoring
 Routine Audits & Remedial Measures
 Process Parameters Optimization
 Problem Diagnostic &Trouble shooting
 On the Job Training & Evaluation
 Safe & Smooth Startup / Shutdowns &
Equipment Handover
Sustained Plant Operation
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16. Emergency & Disaster Handling
 Plant Operational Emergencies
 Ammonia Disaster
 Fire at Plant
 Leakages at Plant & NG Line
 Chemical and Oil Spillage Containment
Production Department Functions
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17. Production Department Functions
 SOP’s development & Implementation
 Work Permit Procedure
 Product Quality Control
 Integrated Management System (IMS)
Compliance of Standards
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18. Production Department Functions
 Plant Performance & Safety Reviews
 Plant Reliability Improvement
 Plant Modifications
 Energy Conservation
Continual Improvement
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Growth Profile

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