Ghadir Petrochemical Complex - Urea & Ammonia Unit 1 Profile
Located in Asaluyeh, Iran, Ghadir Petrochemical’s first urea/ammonia unit is a cornerstone of Iran’s fertilizer production with:
- Ammonia capacity: 1,155,000 t/year
- Urea capacity: 1,980,000 t/year
- Technology providers: Ammonia (Haldor Topsoe), Urea (Stamicarbon CO₂ stripping)
Key Specifications
Process Technology:
▸ Ammonia Unit:
- Natural gas-fed primary + secondary reforming
- KAAPplus technology (Kellogg Advanced Ammonia Process)
- Energy consumption: 6.7 Gcal/t ammonia (Topsoe benchmarks)
▸ Urea Unit:
- Stamicarbon’s CO₂ stripping process
- MPR reactor technology for corrosion control
- Granulation vs. prilling capabilities
Technical Specifications:
✔ Pressure Levels:
- Synthesis gas compression: 150 bar
- Urea synthesis: 145 bar, 185°C
Project Details
Corrosion management in urea synthesis loop (Titanium/Zirconium lined equipment)
Catalyst life optimization (Ru-based ammonia catalyst)
NOx emissions control from reformers
Prill tower dust suppression
Sustainability Features:
☆ Wastewater reduction: 0.2 m³/ton urea (vs. industry 0.5 m³)
☆ Carbon footprint: 0.85 tCO₂/ton urea product
☆ Waste heat recovery: 25 MW thermal energy
Market Position:
- Supplies 20% of Iran’s urea exports
- Key export markets: India, Brazil, Africa
- Feedstock advantage: South Pars gas at $0.15/m³
✔ Key Equipment:
- 3-stage centrifugal compressors (MW-class drivers)
- Pool condenser design for urea
- Dual-pressure waste heat boiler
Energy & Utilities:
- Steam consumption: 1.35 ton/ton urea
- Cooling water: 120 m³/ton urea
- Power demand: 45 MW (self-generated + grid)
Expansion Projects:
• Debottlenecking to 2.2 million t/year urea
• Urea-formaldehyde value-added product line
• Green ammonia pilot plant (5,000 t/year)
Data Sources:
- Stamicarbon process manuals
- Topsoe ammonia technology reports
- NPC Iran annual performance data
SEC Scope:
- Design + Procurement + Fabrication Drawing Preparation for 34 Units of Pressure Vessel 180 Tons
- Design + Procurement + Fabrication Drawing Preparation for 29 Units of Heat Exchanger 120 Tons
- Design + Procurement + Fabrication Drawing Preparation for 34 Units of Tower 980 Tons
- Design + Procurement + Fabrication Drawing Preparation for 4 Units of Reactor 520 Tons
- Design + Procurement + Fabrication Drawing Preparation for 2 Units of Stack 110 Tons
- Material take-off + Procurement + Fabrication Drawing Preparation for 1 Unit Reformer 1,040 Tons (Steel Structure)
- Design + Procurement + Fabrication for Ducts & Miscellaneous 300 Tons
Fabrication Drawing Preparation for Steel Structure 2,350 Tons