Synthetic fertilizers are produced via a multi-step process. Ammonia is first produced from natural gas and air, then combined with carbon dioxide to form urea in a high-pressure tower. The urea solution is concentrated, sprayed into a prilling tower to form granules, then bagged. Nitric acid is made by reacting ammonia and air over a catalyst. It is mixed with ammonia to create ammonium nitrate, an important nitrogen fertilizer component. The document outlines the key industrial processes used to synthesize common nitrogen-based fertilizers from basic feedstocks.

1. SYNTHETIC
FERTILIZERS
MEHRAN UNIVERSITY OF ENGINEERING AND TECHNOLOGY
JAMSHORO
Rahat Inayat Ali
14 CH 23

2. FLOW CHART DIAGRAM OF UREA
1
3
2
4
5
6
7

3. INTRODUCTION
It is a substance added to soil to improve plants'
growth and yield.
Synthetic fertilizers are composed mainly of
nitrogen, phosphorous, and potassium compounds
with secondary nutrients added.
 Quality of food in enhanced by adding fertilizers.
 Some environmental drawbacks are recorded.
 Growth of plant and reproduction is possible
It is a substance added to soil to improve plants'
growth and yield.
Synthetic fertilizers are composed mainly of
nitrogen, phosphorous, and potassium compounds
with secondary nutrients added.
 Quality of food in enhanced by adding fertilizers.
 Some environmental drawbacks are recorded.
 Growth of plant and reproduction is possible

4. PROCESSPROCESS
1. Ammonia pumping :
Liquid ammonia is pumped from the multistage pump which
maintains the reaction pressure in the vertical stainless steel
vessel.
2. Carbon dioxide compression:
Ammonia plant directly boost the carbon dioxide from the
compression section as it readily form at the CO2 section of
ammonia production plant.
3. Urea synthesis tower:
• It is lined with film of oxides to protect from corrosion.
• Catalyst bed is placed in the inner side of the autoclave
structure and 180- 200 atm pressure at temperature about 180-
200 o
C is maintained.
Plug flow operation take places and molten urea is removed
from the top of the tower.
1. Ammonia pumping :
Liquid ammonia is pumped from the multistage pump which
maintains the reaction pressure in the vertical stainless steel
vessel.
2. Carbon dioxide compression:
Ammonia plant directly boost the carbon dioxide from the
compression section as it readily form at the CO2 section of
ammonia production plant.
3. Urea synthesis tower:
• It is lined with film of oxides to protect from corrosion.
• Catalyst bed is placed in the inner side of the autoclave
structure and 180- 200 atm pressure at temperature about 180-
200 o
C is maintained.
Plug flow operation take places and molten urea is removed
from the top of the tower.

5. PROCESS
Cont…..
PROCESS
Cont…..
4. Distillation tower and Flash drum:
• This high pressure slurry is flashed to 1 atm pressure and distilled to
remove excess ammonia.
• Decomposed ammonia carbamated salts are removed and recycled.
5. Vacuum Evaporator:
•The solution is fed to vacuum evaporator for concentrating the slurry.
6. Prilling Tower:
• It is dryer where the molten slurry is passed from top of the
tower into a bucket which rotates and sprinkles the slurry and air is
passed from the bottom.
• All the moisture is removed as the urea form into granules during it
journey to the bottom of the tower. This granules are sent by
conveyor to the bagging section.
4. Distillation tower and Flash drum:
• This high pressure slurry is flashed to 1 atm pressure and distilled to
remove excess ammonia.
• Decomposed ammonia carbamated salts are removed and recycled.
5. Vacuum Evaporator:
•The solution is fed to vacuum evaporator for concentrating the slurry.
6. Prilling Tower:
• It is dryer where the molten slurry is passed from top of the
tower into a bucket which rotates and sprinkles the slurry and air is
passed from the bottom.
• All the moisture is removed as the urea form into granules during it
journey to the bottom of the tower. This granules are sent by
conveyor to the bagging section.

6. 1. System is developed to produce ammonia
from air.
1. System is developed to produce ammonia
from air.
PROCESS
Cont…..
PROCESS
Cont…..

7. Production of Ammonia
1. Natural gas and steam are pumped into a large vessel.
2. Air is pumped into the system, and oxygen is removed by the
burning of natural gas and steam.
3. This leaves primarily nitrogen, hydrogen, and carbon dioxide.
4. The carbon dioxide is removed and ammonia is produced by
introducing an electric current into the system.
5. Catalysts such as magnetite (Fe3O4) is used to improve the speed
and efficiency of ammonia synthesis.
6. Any impurities are removed from the ammonia, and it is stored in
tanks until it is further processed.
Production of Ammonia
1. Natural gas and steam are pumped into a large vessel.
2. Air is pumped into the system, and oxygen is removed by the
burning of natural gas and steam.
3. This leaves primarily nitrogen, hydrogen, and carbon dioxide.
4. The carbon dioxide is removed and ammonia is produced by
introducing an electric current into the system.
5. Catalysts such as magnetite (Fe3O4) is used to improve the speed
and efficiency of ammonia synthesis.
6. Any impurities are removed from the ammonia, and it is stored in
tanks until it is further processed.
PROCESS
Cont…..
PROCESS
Cont…..

8. NITRIC ACID
1. Nitric acid is produced by mixing ammonia
and air in a tank.
2. In the presence of a catalyst, a reaction
occurs which converts the ammonia to nitric
oxide.
3. The nitric oxide is further reacted in the
presence of water to produce nitric acid.
NITRIC ACID
1. Nitric acid is produced by mixing ammonia
and air in a tank.
2. In the presence of a catalyst, a reaction
occurs which converts the ammonia to nitric
oxide.
3. The nitric oxide is further reacted in the
presence of water to produce nitric acid.
PROCESS
Cont…..
PROCESS
Cont…..

9. 1. Nitric acid and ammonia are used to make
ammonium nitrate.
2. This material is a good fertilizer component
because it has a high concentration of nitrogen.
3. Nitric acid and ammonia are mixed together in a
tank.
4. Then it is stored until it is ready to be granulated
and blended with the other fertilizer components.
1. Nitric acid and ammonia are used to make
ammonium nitrate.
2. This material is a good fertilizer component
because it has a high concentration of nitrogen.
3. Nitric acid and ammonia are mixed together in a
tank.
4. Then it is stored until it is ready to be granulated
and blended with the other fertilizer components.
PROCESS
Cont…..
PROCESS
Cont…..
Granules

10. The End