Fertilizers & Urea Automation Solutions
Fertilizer and Urea plants (Urea, NPK, DAP) are massive chemical complexes requiring strict control of synthesis reactions at extreme temperatures and pressures. We provide comprehensive automation solutions spanning from Ammonia (NH3) and Urea synthesis units to granulation and packaging facilities. Our integrated DCS/SIS and field instruments optimize conversion rates, save energy, and ensure absolute safety for critical centrifugal compressors.
1. Synthesis Process Automation
Ammonia (NH3) Synthesis
Integrating DCS for precise control of steam reforming, H2/N2 ratios, and synthesis converter temperatures, optimizing catalyst performance.
Urea Synthesis
Automating the High-Pressure Loop and stripping processes, ensuring maximum CO2 to Urea conversion rates.
2. Compressor Control & Actuation
Anti-Surge Control (ASC)
Providing dedicated Anti-Surge Control algorithms to protect critical Syngas and CO2 centrifugal compressors from mechanical destruction.
High-Pressure Letdown Valves
Supplying specialized anti-cavitation control valves for severe pressure letdown loops in the Urea plant.
3. Granulation & Packaging Automation
Granulation Plant
Synchronized VFD control for granulators, dryers, coolers, and conveyors, ensuring uniform granule size and crushing strength.
Automated Packaging Lines
Integrating PLCs, robotic palletizers, and high-speed electronic weighers, with direct data integration to the plant's ERP system.
4. Safety & Analytical Systems
Emergency Shutdown (ESD)
SIL 3-rated SIS for instantaneous interlocking and isolation of combustible gas flows (Natural Gas, Syngas) during anomalies.
Online Analyzers
Integrating online gas analyzer shelters to continuously measure H2, CO, CO2, and CH4, providing live feed-forward data to the DCS.
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