1.

0 INTRODUCTION

1.1 Background study

Ammonia (NH₃) is a colorless, pungent gas composed of nitrogen and hydrogen. It is one of the most
widely produced chemicals in the world, playing a vital role in various industrial, agricultural, and
chemical processes. Understanding ammonia’s properties, production methods, and uses is crucial to
appreciating its importance in modern society.

Chemical Properties

Ammonia is a simple compound consisting of one nitrogen atom bonded to three hydrogen atoms. It
has a molecular weight of 17.03 g/mol and is highly soluble in water. When dissolved, ammonia forms
ammonium hydroxide (NH₄OH), a weak base. This gives ammonia its characteristic alkaline properties.

Ammonia is highly reactive and can form a wide range of compounds, including ammonium salts, with
acids. Its reactivity also makes it an essential building block for the synthesis of other chemicals, such as
fertilizers and explosives.

Production of Ammonia

The most common method of producing ammonia is the Haber-Bosch process, developed in the early
20th century. This method synthesizes ammonia by combining nitrogen (N₂) from the air with hydrogen
(H₂), typically derived from natural gas, under high pressure and temperature in the presence of a
catalyst:

N_2 + 3H_2 = rightarrow 2NH_3 Equation 1.0.

This reaction is exothermic, meaning it releases heat, and it typically occurs at temperatures between
400-500°C and pressures of 150-300 atmospheres. The Haber-Bosch process revolutionized agriculture
by enabling the large-scale production of nitrogen fertilizers, thus boosting food production globally.
Uses of Ammonia

1. Fertilizers: Ammonia is a key ingredient in the production of nitrogen-based fertilizers like ammonium
nitrate, urea, and ammonium sulfate. These fertilizers provide essential nutrients for plant growth,
especially nitrogen, which is a critical component of proteins and chlorophyll.

2. Industrial Applications: Ammonia is used in the production of various chemicals, including nitric acid
(HNO₃), which is used in the manufacture of explosives, plastics, and other chemicals. It is also used in
the production of hydrogen gas through steam methane reforming (SMR), which is crucial for various
chemical processes.

3. Refrigeration: Ammonia is an effective refrigerant due to its thermodynamic properties. It is

4. Water Treatment: Ammonia is used in water treatment processes to help remove impurities and
neutralize acids. It also plays a role in the formation of chloramine compounds, which are used to
disinfect drinking water.

5. Pharmaceuticals: Ammonia is used in the production of various pharmaceuticals, including antibiotics

Environmental Impact

While ammonia has many industrial and agricultural applications, its production and use can have
significant environmental consequences. Excessive use of nitrogen-based fertilizers, for instance, can
lead to water pollution through runoff, contributing to eutrophication in water bodies. This process
depletes oxygen in aquatic environments, harming fish and other marine life.
Additionally, ammonia emissions from industrial activities and agriculture can contribute to air pollution
and pose health risks, particularly to respiratory systems. Ammonia is also a potent greenhouse gas,
contributing to the formation of particulate matter in the atmosphere.

Safety and Handling

Ammonia is toxic and can cause serious health issues if inhaled, ingested, or if it comes into contact with
the skin or eyes. Inhalation of high concentrations can lead to respiratory distress, damage to lung
tissue, and even death in extreme cases. Therefore, it is essential to handle ammonia with care, using
appropriate safety equipment such as protective gloves, goggles, and respiratory protection.

In industrial settings, ammonia is stored and transported in liquid form under high pressure, requiring
strict safety measures to prevent leaks and accidents.(Smil v, 2001).

The production of NPK fertilizers from natural gas involves a complex chemical process that combines
nitrogen, phosphorus, and potassium into a balanced nutrient source for plants. The process include :

a. Nitrogen production: The Haber-Bosch process converts atmospheric nitrogen into ammonia using
hydrogen from natural gas.

b. Phosphorus production: phosphorus is made using using sulfur, coal, and phosphate rock.

c. Potassium production: potassium comes from potassium chloride, a primary component of potash.

d. Mixing and granulation: the raw materials are mixed in the correct ratio and then granulated into
pellets.

e. Drying and cooling: The pellets are dried and cooled.

f. Screening and coating: The pellets are screened and coated with sulfur.

g. Quality control : The quality of the fertilizer is checked.

The production of NPK fertilizers also involves environmental concerns, such as reducing greenhouse gas
emissions and minimizing the impact on waterways. ( Global oriented fertilizers supplier, 2018 ).

Natural gas, colourless highly flammable gaseous hydrocarbon consisting primarily of methane and
ethane. It is a type of petroleum that commonly occurs in association with crude oil. A natural resource
and fossil fuel, natural gas is used for electricity generation, heating, cooking and as a fuel for certain
vehicles. (Atwater and Riva, 2025).
Fertilizer usage in Nigeria lags behind other African nations and the global average. However, recent
years have seen an uptick in consumption. Nigerria's fertilizer usage per hectare was 19.7 kilograms in
2018, lower than Ghana's 29.4 kilograms and the Sub-Saharan Africa average of 33 kilograms. The soil
nutrients deficiency in Nigeria's Northern states, where agriculture thrives, offers opportunities for
fertilizer industry growth (Augustoresearch. com, 2017).

Fertilizer consumption (% of fertilizer production) in Nigeria was reported at 20.38% in 2022 (World
bank collection of development 2022).

The current fertilizer usage in Nigeria should be increased to the optimal recommended of 400kg per
hectare as opposed to the current practice of 7.32kg/ha.

This project aims to design 600,000 tons per annum NPK plant using ammonia to meet the fertilizer
demand in Northwest.

1.2 Problem statement

It is estimated that Nigeria is facing shortage of fertilizer and experiencing deteriorating annual nutrient
depletion, risking its ability to sustain the modest gains achieved from recent agricultural growth despite
its ammonia reserves, especially in Northwest Nigeria leading to food insecurity and lower incomes for
farmers.

1.3 Aims and Objectives

1.3.1 Aim

This project aims to design a 600,000 tons per annum NPK fertilizer plant using ammonia to meet the
fertilizer needs of Northwest Nigeria.

1.3.2 Objectives

Selection of suitable and efficient conversion process and the corresponding process flow diagram.

To carry out detailed equipment design.

ction of suitable equipment.

To determine the controls needed for each equipment.

To ensure compliance with regulatory standards governing NPK production, safety standards and
environmental regulations.

To evaluate the economic viability of the proposed NPK plant project, including capital investment,
operating costs and revenue projection.

To determine the start-up and shutdown procedure for the plant.

The scope of this work is limited to carrying out a process design of 600,000 tons per annum NPK plant
in Northwest Nigeria. Which include literature, process selection, materials selection, materials and
energy balances, equipment sizing, plant layout, process controls, safety, economic analysis, and start-
up and shutdown procedures.

1.5 JUSTIFICATION

As crop yield suffer and limited availability of fertilizer is increasing especially in Northwest Nigeria, it is
paramount to design an NPK plant for Northwest Nigeria and the national economy. this would support
the governments industrialization goals, increasing agriculture growth development and securing
sustainable socioeconomic growth.