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

• Understand the overall process flow and interconnection of major fertilizer plant units.

• Operate and monitor Methanation Systems for feed gas purification.

• Explain the operation and importance of Carbon Monoxide and Shift Conversion

Systems.

• Describe the functions and control parameters of Desorption and Hydrolyzation

Systems.

• Operate and troubleshoot Desulphurization Systems effectively.

• Apply operational best practices to enhance process safety, reliability, and efficiency.

• Control Room Operators
• Field Operators
• Process Supervisors
• Production and Process Engineers involved in fertilizer operations

• Lectures
• Workshop & Work Presentation
• Case Studies and Practical Exercise
• Videos and General Discussions

Day 1 – Introduction to Fertilizer Plant Operations

• Overview of fertilizer production processes and technologies

• Major process stages: feed purification, synthesis, and finishing

• Process flow diagram (PFD) review of a typical fertilizer plant

• Plant utilities and supporting systems (steam, air, water, etc.)

• Role of operators in maintaining safe and stable plant performance

• Overview of key operational parameters and performance indicators

Day 2 – Methanation System Operation

• Purpose of methanation in feed gas preparation

• Process chemistry and reactions involved

• System configuration and key components

• Operating conditions and control parameters

• Catalyst function and protection

• Common operational issues (e.g., high CO slip, temperature control) and

troubleshooting methods

• Case study: optimizing methanation efficiency

Day 3 – Carbon Monoxide and Shift Conversion System Operation

• Overview of CO and shift conversion in fertilizer production

• Reaction principles: CO + H₂O → CO₂ + H₂

• Types of shift converters (high-temperature and low-temperature)

• Process control and heat management

• Catalyst activity monitoring and replacement considerations

• Troubleshooting: carbon deposition, temperature spikes, and CO breakthrough

• Best practices for maintaining conversion efficiency

Day 4 – Desorption and Hydrolyzation System Operation

• Purpose of desorption and hydrolyzation in gas treatment systems

• Process flow and major equipment overview

• Hydrolysis reaction mechanisms and design considerations

• Operating parameters and system control

• Common performance issues and corrective actions

• Integration with CO₂ removal and purification systems

• Practical examples from operating fertilizer plants

Day 5 – Desulphurization System Operation and Course Review

• Importance of sulfur removal in feed preparation

• Types of desulphurization systems (chemical and physical absorption)

• Reaction mechanisms and catalyst types

• Monitoring system performance and managing breakthrough

• Troubleshooting: sulfur slip, pressure drop, and regeneration problems

• Overall plant integration and performance optimization

• Comprehensive course review and Q&A discussion

BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration

Request Info

Salutation MR Miss ENG DR

Full Name*

Designation

Company*

Country * Egypt Saudi Arabia Ireland UAE France Turkey Bahrain South Africa Nigeria Oman Nethersland United Kingdom Malaysia Kuwait Online Indonesia Qatar Morocco Jordan Switzerland Singapore Spain Italy Uganda

City * Cairo Mansoura Ireland Abu Dhabi Riyadh Dubai Istanbul Manama Abuja Paris Kuala-Lumpur Amsterdam Muscat Salalah Jeddah Dammam Cape Town London Kuwait Online Indonesia Doha Casablanca Marrakesh Singapore Geneva Zürich Amman Barcelona Rome Marbella Milan Uganda Scotland Madrid Jakarta Manchester

Email*

Enquiry*

Captcha*

Enter Captcha*

Submit