Urea production begins with the synthesis of ammonia (NH₃), typically via the Haber-Bosch process. This involves reacting nitrogen (N₂) from the air with hydrogen (H₂) derived from natural gas or other hydrocarbon sources under high pressure (150-300 bar) and temperature (400-500°C) with an iron catalyst.

Reaction: N₂ + 3H₂ → 2NH₃

Carbon dioxide (CO₂) is obtained as a byproduct from the steam reforming process during hydrogen production. Alternatively, it can be sourced from other industrial processes.

Ammonia and carbon dioxide are reacted under high pressure (120-250 bar) and temperature (160-200°C) to form ammonium carbamate, an intermediate product. This is followed by the decomposition of ammonium carbamate into urea and water.

Reactions:

2NH₃ + CO₂ → NH₂COONH₄ (Ammonium Carbamate)

NH₂COONH₄ → (NH₂)₂CO + H₂O (Urea and Water)

The resulting urea solution contains unreacted ammonia and carbon dioxide. These are typically stripped from the solution and recycled back into the process to improve efficiency.

The urea solution is concentrated by evaporation to achieve a high urea content.

The concentrated urea melt is then formed into solid granules or prills. Prilling involves spraying the melt from the top of a tower, where it cools and solidifies as it falls through an upward stream of air. Granulation involves layering urea onto seed particles in a rotating drum or fluid bed.

The prills or granules are cooled and may be coated with an anti-caking agent to prevent clumping during storage and handling.

Similar to urea production, the process often starts with the production of ammonia (NH₃) using the Haber-Bosch process.

Phosphoric acid (H₃PO₄) is produced by reacting phosphate rock with sulfuric acid (wet process) or hydrochloric acid. The wet process is more common.

Reaction (simplified): Ca₃(PO₄)₂ + 3H₂SO₄ + 6H₂O → 3CaSO₄·2H₂O + 2H₃PO₄

Ammonia gas is reacted with phosphoric acid in a reactor. The reaction is carefully controlled to achieve the desired ratio of ammonium to phosphate, resulting in diammonium phosphate.

Reaction: 2NH₃ + H₃PO₄ → (NH₄)₂HPO₄

The resulting DAP slurry is then granulated in a rotating drum or fluid bed granulator. This involves spraying the slurry onto recycled DAP particles or seed granules.

The granules are dried to remove excess moisture and then cooled to improve handling and storage characteristics.

The product is screened to ensure uniform particle size, with oversized and undersized particles being recycled back into the process.

The final product may be coated with an anti-caking agent to improve storage and handling properties.