An Interactive 5-Day Training Course

Urea Production Technology & Plant Operations

Synthesis, Recovery, Granulation & Plant Troubleshooting

Urea Production Technology & Plant Operations

Scheduled Dates

05 - 09 Jul 2027
London - UK
$5,950
06 - 10 Dec 2027
London - UK
$5,950

Why Choose this Training Course?

This Urea Production Technology & Plant Operations training course explains how ammonia and carbon dioxide are converted into finished urea fertiliser and how operating conditions affect production, equipment integrity and product quality. It follows the process from high-pressure synthesis through carbamate recovery, concentration and finishing. Participants learn to interpret key operating variables, recognise developing problems and support stable plant performance.

A disturbance in one section of a urea plant can affect the entire production route. Changes in feed ratio or water balance, for example, can increase recycle demand, while concentration and finishing conditions influence the quality of the final product. This training course connects the chemistry with the operating decisions made by plant teams. It also addresses high-pressure equipment, corrosion risks, emissions and structured troubleshooting. 

This training course will feature:

  • The production route from ammonia and carbon dioxide to finished urea 
  • Carbamate formation, urea synthesis and high-pressure operation 
  • Recovery, recycle, concentration and evaporation 
  • Prilling, granulation and the factors affecting product quality 
  • Corrosion awareness, troubleshooting and plant performance 

What are the Goals?

By the end of this training course, participants will be able to:

  • Explain the purpose of each major section of a urea plant. 
  • Describe carbamate formation and urea synthesis. 
  • Assess how feed ratio, pressure, temperature and water content affect conversion and recycle. 
  • Evaluate the operating performance of recovery, recycle and concentration systems. 
  • Recognise conditions associated with corrosion and high-pressure equipment degradation. 
  • Explain how evaporation, prilling and granulation systems operate. 
  • Relate finishing conditions to particle size, moisture, strength, dust and caking. 
  • Diagnose common plant disturbances using a structured approach. 
  • Support safer, more stable urea plant operation. 
  • Identify opportunities to improve production efficiency and product quality. 

Who is this Training Course for?

This training course is intended for professionals directly involved in urea production or the technical support of urea plants:

  • Urea Plant and Fertiliser Plant Engineers 
  • Process, Chemical and Production Engineers 
  • Operations Engineers, Shift Engineers and Shift Supervisors 
  • Senior Process Operators 
  • Process Control and Technical Services Engineers 
  • Reliability, Inspection and Maintenance Engineers supporting urea units 
  • Process Safety Engineers supporting urea operations 
  • Urea Plant and Operations Team Leaders 

It is also relevant to technical personnel moving into urea production who need a clear understanding of the complete plant process.

How will this Training Course be Presented?

Technical explanations are connected to process flows, operating data and realistic plant problems. Participants examine how conditions in synthesis, recovery, concentration and finishing affect production rate, plant stability and product quality. Guided troubleshooting exercises focus on interpreting symptoms, considering likely causes and identifying appropriate areas for investigation.

Organisational Impact

  • Stronger understanding of urea plant operating conditions 
  • More consistent investigation of production problems 
  • Greater awareness of high-pressure and corrosion risks 
  • Better coordination between operations, engineering and maintenance 
  • Clearer identification of finishing and product-quality issues 
  • Improved focus on stable, efficient fertiliser production 

Personal Impact

  • Understand how each process section contributes to urea production. 
  • Interpret operating variables and their effects across the plant. 
  • Recognise signs of abnormal operation earlier. 
  • Contribute more effectively to troubleshooting discussions. 
  • Explain the causes of common finishing and product-quality problems. 
  • Communicate technical issues more clearly across plant teams. 

Daily Agenda

Day 1: Urea Production Fundamentals & Process Configuration
  • Urea applications and the nitrogen fertiliser production chain 
  • Ammonia and carbon dioxide feedstocks and quality requirements 
  • Carbamate formation and urea synthesis chemistry 
  • Major plant sections and overall material flow 
  • Variables affecting conversion, recycle and production rate 
Day 2: High-Pressure Urea Synthesis

  • Reactor principles and synthesis operating conditions 
  • Ammonia-to-carbon-dioxide ratio and process-water effects 
  • High-pressure stripping and carbamate decomposition 
  • High-pressure condensation and recycle integration 
  • Operating considerations for high-pressure equipment 
Day 3: Recovery, Recycle & Urea Concentration

  • Medium- and low-pressure carbamate recovery 
  • Ammonia and carbon dioxide recycle management 
  • Urea solution purification and concentration 
  • Vacuum evaporation and water removal 
  • Links between recovery, concentration and finishing 
Day 4: Prilling, Granulation & Product Quality

  • Prilling and granulation as urea finishing routes 
  • Prilling tower operating principles 
  • Granulation, recycle and particle growth 
  • Cooling, screening, coating and product handling 
  • Control of particle size, moisture, strength, dust and caking 
Day 5: Corrosion, Troubleshooting & Plant Performance

  • Urea process corrosion and vulnerable plant locations 
  • Common disturbances in synthesis, recovery and finishing 
  • A structured approach to urea plant troubleshooting 
  • Ammonia losses, emissions and operating efficiency 
  • Plant performance indicators and improvement cases 

Certificate

  • Upon successful completion of this training course, delegates will be awarded an official PetroKnowledge Certificate of Completion, signed by the course facilitator. The certificate confirms successful participation and records the total learning hours completed.
  • Continuing Professional Education credits (CPE): In accordance with the standards of the National Registry of CPE Sponsors, one CPE credit is granted per 50 minutes of attendance.

Accreditation

NASBA Approved Training Courses

Would an alternative date be more suitable?

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