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Operator training simulator to train operators at Gemlik urea melt and granulation plant

Published by
World Fertilizer,


Stamicarbon has said that an operator training simulator (OTS) that will be used to train operators of Gemlik Gübre’s urea melt and granulation plant in Gemlik, Turkey, is planned to be in operation in 2023.

Operator training simulator to train operators at Gemlik urea melt and granulation plant

With a capacity of 1640 tpd urea and 500 tpd UAN, the plant will be based on Stamicarbon’s LAUNCH MELT™ Ultra-Low Energy (ULE) urea process design. This is Stamicarbon’s fourth grassroots urea plant based on the ULE design, with three previously licensed plants located in China.

Stamicarbon’s OTS allows for training of plant operators on start-up and shutdown procedures, day-to-day plant operations and various scenarios in the plant. In addition, it helps understand the dynamic behaviour of the urea melt and granulation plant and simulates upset conditions in a digital environment to safely and effectively prepare operators for emergencies. Stamicarbon’s standard OTS for the ULE process was already used to train operators of the first ULE urea plant in China to achieve a smooth and successful startup in February 2021.

The Gemlik Gübre’s OTS is tailor-made, with a high-fidelity real-time dynamic plant model accurately (accuracy > 98%) simulating the dynamic behaviour of the plant.

“Chances of incidents occurring in the plant are low, but the potential consequences of even one failure should not be ignored – from safety, environmental, and financial perspectives. By having an OTS, plant operators receive better training and gain more knowledge about plant behavior, contributing to faster startup, faster recovery from plant upsets, higher on-stream time, increased plant safety, and environmental benefits (lower emissions), resulting in significant cost-savings while operating the urea plant,” said Emiel Mehlkop, Licensing Manager at Stamicarbon.

Read the article online at: https://www.worldfertilizer.com/project-news/13012022/operator-training-simulator-to-train-operators-at-gemlik-urea-melt-and-granulation-plant/

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Fertilizer project news Urea news