UNIVERSITI TEKNIKAL MALAYSIA MELAKA
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process) (Hons.)
by
MUHAMMAD YAZUAN BIN YAAKUP
B050810104
89080105069
FACULTY OF MANUFACTURING ENGINEERING 2012
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Physical Characterization of Urea Binder Extrude at Various Weight
Concentrations
SESI PENGAJIAN: 2011/12 Semester 2
Saya MUHAMMAD YAZUAN BIN YAAKUP
mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Laporan PSM adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
3. Perpust akaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
Alamat Tet ap:
** Jika Laporan PSM ini SULIT at au TERHAD, sil a l ampirkan surat daripada pihak berkuasa/ organisasi
DECLARATION
I hereby, declared this report entitled “Physical Characterization of Urea Binder Extrude at Various Weight Concentration” is the results of my own research except as
cited in references.
Signature : ……….
Author’s Name : Muhammad Yazuan Bin Yaakup
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process) (Hons.). The member of the supervisory committee is as follow:
ABSTRAK
Tujuan kajian ini adalah untuk menentukan peranan sifat-sifat fizikal Urea pengikat
meleler pada pelbagai nisbah kepekatan. Analisis akan dilakukan dengan menggunakan
mesin Pemampatan, Penganalisis Saiz Butir dan Densimeter Elektronik di pelbagai
nisbah kepekatan. Hasil dari ujian pemampatan, analisis saiz butir dan ujian ketumpatan
akan memberitahu kita sifat-sifat fizikal Urea Pengikat. Parameter yang digunakan
dalam kajian ini adalah kepelbagaian nisbah kepekatan Urea Pengikat. Ujian
Pemampatan ini digunakan untuk melihat kekuatan menghancur butir Urea Pengikat.
Analisis saiz butir Urea Pengikat digunakan untuk mencari sama ada terdapat sebarang
butir bahan-bahan mentah yang hilang atau tidak hilang selepas proses penyemperitan.
Daripada analisis saiz butir, ia juga boleh menunjukkan sama ada bahan mentah telah
digabungkan dengan baik atau tidak baik. Keputusan bagi ujian ketumpatan Urea Binder
adalah untuk mencari sama ada terdapat mana-mana yang ketumpatan berbeza yang
terhasil akibat pelbagai nisbah kepekatan Urea Pengikat. Akhirnya data yang diperolehi
akan memberitahu kita hubungkait antara kekuatan menghancur butir Urea Pengikat,
saiz butir Urea Pengikat dan ketumpatan Urea Pengikat untuk memahami lebih lanjut
ABSTRACT
The aim of this study is to determine the role on the physical properties of Urea Binder
extrude at various weight concentrations. The analysis will be done using the Compress
machine, Particle Size Analyzer and Electronic Densimeter at various weight
concentrations. The result from compress test, particle size analysis and density test will
tell us the physical properties of Urea binder.The parameters that are used in this study
are concentration of Urea binder. The compress test is used to look the granule crushing
strength of Urea binder. The analysis of particle size is to find whether there is any
particle of raw materials lost or not after extrusion process. From particle size analysis it
also can show either the raw materials had combined and granule well or not. The results
for density test is to find whether there is any different of density occur because of the
various weight concentration of Urea binder. Finally the data obtained will tell us the
correlation between granule crushing strength, particle size and density in order to
DEDICATION
I especially dedicate this report to my father and my mother.
Without their patience, understanding, support, and most of all love, the completion of
this study would not have been possible.
I also dedicate this report to my friends no matter where they are now.
We have built this tight relationship and being together for many years.
Without all of you, surely I could not all the challenges.
ACKNOWLEDGEMENT
Firstly I would like to take this chance to thank all lecturer and friend for giving an
advice and support since the beginning of Final Year Project1 until today Final Year
Project 2. A very thankful for my Supervisor, Mr. Mohd Fairuz Bin Dimin @ Mohd.
Amin for giving me much support and guidance in order to complete this project and
report within the given period. He gave me so many ideas and suggestions in order to
perform well along this period.
I also would like to thank all my friends for giving an opinion and helping me in
searching for information and guidelines for my study. I believed that all the knowledge
I got here might be useful later in my career. I would like to convey my appreciation to
all Manufacturing Engineering Faculty Lecturers and staff for being so kind and helpful
along this period of studies. Without all of them, I am nothing and my four years studies
TABLE OF CONTENT
List of Abbreviations, Symbols and Nomenclature x
2.4.1.1 Effects on Agronomic Response 10
2.4.1.2 Effects on Granulation and Process Performance 11
2.4.1.3 Effects on Storage, Handling, and Application Properties 11
2.4.1.4 Effects on Blending Properties 12
2.4.1.5 Particle Size Analysis 14
2.4.2 Density 14
2.4.3.2 Abrasion Resistance 17
2.4.3.3 Impact Resistance 18
3.3 Machines and Equipment 22
3.3.1 Extruder machine 22
3.3.2 Particle Size Analyzer 24
3.3.3 Electronic Densimeter MD-300S 26
4.1.1 Compression Test 35
4.1.2 Density Test 37
4.1.3 Particle Size Analysis 38
4.2 Discussion 41
5.0 CONCLUSIONS AND RECOMMENDATIONS
5.1 Conclusions 44
5.2 Recommendations 45
REFERENCES 46
APPENDICES
A Gantt chart for PSM 1
B Gantt chart for PSM 2
C Parts of Extruder machine
D Parts of Extruder machine
E Parts of Extruder machine
LIST OF TABLES
3.1 Sample Ratio by Gram 23
3.2 Sample Ratio by Percentage 23
4.1 Result of Compression test 35
4.2 Result of Density test 36
4.3 The Range size of Soy Bagasse for Particle Size analysis 38
4.4 The Range size of Wheat Flour for Particle Size analysis 39
4.5 The Range size of Urea for Particle Size analysis 40
LIST OF FIGURES
2.1 Schematic representation of Urea synthesis 5
3.1 Flow Chart for Methodology 21
3.2 Extruder machine 22
3.3 Particle Size Analyzer 24
3.4 Flow Chart for Particle Size Analyzer 25
3.5 Electronic Densimeter 26
3.6 Flow Chart for Electronic Densimeter 28
3.7 Compression Tester 28
4.4 Sample D (Soy Bagasse 33.34%: Wheat Flour 33.34%: Urea 33.34%) 35
4.5 Graph of Compression test 36
4.6 Graph of Density test 37
4.7 Graph of Soy Bagasse for Particle Size analysis 38
4.8 Graph of Wheat Flour for Particle Size analysis 39
4.9 Graph of Urea for Particle Size analysis 40
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
C - Carbon
H - Hydrogen
He - Helium
ISO - International Organization for Standardization
K Potassium
MTPD - Mertic Tonne per Day
N - Nitrogen
Ne - Neon
No.exp - Number of experiment
O - Oxygen
P - Phosphorus
QC - Quality control
R - Correlation coefficient
R2 - The value of coefficient of determination
UPM - Universiti Putra Malaysia
USM - Universiti Sains Malaysia
UTeM - Universiti Teknikal Malaysia Melaka
CHAPTER 1
INTRODUCTION
Fertilizer is known as a catalyst or supply the plant nutrient essential to growth the plant. Typically the term of fertilizer is used to refer to the industry of agriculture that researches, designs, manufactures, operates, and maintains the growth of the plant on the earth. Fertilizer is very important in agriculture industry because it also contribute in the economy of country. These specifications narrowed the manufacturing processes of fertilizer of Urea.
1.0 Background
comparable quality and cost against the current available technology. A compound fertilizer is a complex homogenous product containing two or more of nutrients that has undergone chemical interaction during the manufacturing process. The chemical compounding is followed by the process of granulation with the addition of anti caking agents to form free-flowing compound granules. One of the processes in fertilizer manufacturing is blending process. In this process, Urea will be blended in various weight concentrations. The types of the processing parameters are various weight concentrations. This process is done to combine Urea and binder to produce fertilizer. From this process, there are some physical properties that being used which are hardness, particle size and density. This three characteristic are used to see whether there is changes when Urea binder is blend in various weight concentrations. Besides, the compress test, particle size analysis and densitometer are the tools that being used to test the hardness, particle size and density of Urea binder.
1.2 Problem statement
(a) The physical properties of Urea binder extrude at various weight concentrations. (b) Hence this study, will determine whether there is any changes when the granule
crushing strength, particle size and density against various weight concentrations.
1.3 Objectives
The objectives of this study are:
(a) To determine the physical characterization of Urea binder extrudes at various weight concentrations.
(c) To analyze the correlation between the granule crushing strength, particle size and density against various weight concentrations whether, if there is any changes in the physical properties of Urea binder.
1.4 Scope
CHAPTER 2
LITERATURE REVIEW
2.1 Fertilizer
2.2 Urea Fertilizer
Urea (NH2CONH2) is very importance to the agriculture industry as a nitrogen-rich fertilizer. Ammonia and carbon dioxide are the two elements that are produced Urea in two equilibrium reactions. The ammonia and carbon dioxide are fed into the reactor at high pressure and temperature, and the urea is formed in two steps reaction:
2NH3 + CO2 NH2COONH4 (ammonium carbamate)
NH2COONH4 H2O + NH2CONH2 (urea)
Unreacted NH3 and CO2 and ammonium carbamate are the several elements that is contains in urea. The ammonia and carbon dioxide are recycled as the pressure is reduced and heat applied the NH2COONH4 decomposes to NH3 and CO2. The urea solution is then concentrated to give 99.6% w/w molten urea, and granulated for use as fertiliser and chemical feedstock (Copplestone and Kirk, 1991).
2.3 Urea manufacturing process
2.3.1 Synthesis
Ammonium carbamate is form from the reaction of a mixture of compressed CO2 and ammonia at 240 barg. This is an exothermic reaction, and heat is recovered by a boiler which produces steam. The first reactor achieves 78% conversion of the carbon dioxide to urea and the liquid is then purified. The solution from the decomposition and concentration sections are recycle after second reactor receives gas from the first reactor. Conversion of carbon dioxide to urea is approximately 60% at a pressure of 50 barg. The solution is then purified in the same process as was used for the liquid from the first reactor (Copplestone and Kirk, 1991).
2.3.2 Purification
Water from the urea production reaction and unconsumed reactants (ammonia, carbon dioxide and ammonium carbamate) are the major impurities in the mixture at this stage. The unconsumed reactants are removed in three stages. Firstly, the solution is heated after the pressure is reduced from 240 to 17 barg, which causes the ammonium carbamate to decompose to ammonia and carbon dioxide:
NH2COONH4 2NH3 + CO2
2.3.3 Concentration
75% of the urea solution is heated under vacuum, which fade off some of the water and increase the urea concentration from 68% w/w to 80% w/w. At this stage some urea crystals also form. The solution is then heated from 80 to 110°C to redissolve these crystals prior to evaporation. In the evaporation stage molten urea (99% w/w) is produced at 140°C. The remaining 25% of the 68% w/w urea solution is processed under vacuum at 135°C in a two series evaporator-separator arrangement (Copplestone and Kirk, 1991).
2.3.4 Granulation process
used to prepare powders for compression into a table that is wet granulation and dry granulation (Tousey, 2002).
2.3.4.1Wet Granulation
Wet granulation, the process of adding a liquid solution to powders, is one of the most common ways to granulate. The process can be very simple or very complex depending on the characteristics of the powders, the final objective of tablet making and the equipment that is available. Some powders require the addition of only small amounts of a liquid solution to form granules. The liquid solution can be either aqueous based or solvent based. Aqueous solutions have the advantage of being safer to deal with than solvents. Although some granulation processes require only water, many actives are not compatible with water. Water mixed into the powders can form bonds between powder particles that are strong enough to lock them together. However, once the water dries, the powders may fall apart. Therefore, water may not be strong enough to create and hold a bond. In such instances, a liquid solution that includes a binder (pharmaceutical glue) is required. The existing binder that had been use in Urea NPK is Formaldehyde (Tousey, 2002).
2.3.4.2Dry Granulation
excessive fines. Again, successful compaction depends on the compatibility of the products being compressed. If fines are not removed or reprocessed, then the batch may contain too many of them, a situation that can contribute to capping, laminating, weight, and hardness problems on the tablet press. The need for screening large amounts of fines is common to roller compaction, and the degree to which it can be managed depends on the nature of the ingredients. Any product that is removed from the rest of the batch because of particle size must be analyzed to determine what is being removed (Tousey, 2002).
2.4 The Physical Characteristic Of Urea
Sastry and Fuerstenau (1973)detailed the mechanisms for granule growth (granulation) which included: nucleation; growth; random coalescence; pseudo-layering, and crushing and layering. Litster and Liu (1989) in their studies on the granulation of fertilizer have found that coalescence is the most probable mechanism for low-temperature fertilizer granulation using a feed with a broad particle size distribution. To establish an understanding of the fundamental mechanisms of granule formation, the forces involved in the collision of two spherical particles were investigated by a number of researchers. The capillary and viscous contributions were both found to significantly affect the bonding mechanism of colliding particles and were correlated using the viscous number. The regime map theory of Iveson and Litster (1998)postulates that the type of granule growth behavior is a function of the amount of granule deformation during collision and the maximum pore saturation. The amount of granule deformation has been characterized by Tardos et al. (1998) as a Stokes deformation number. The maximum
pore saturation and the Stokes deformation number characterize the growth regime in which granulation takes place. The exact boundary between the regimes depends on the type of granulation equipment and properties of the binder such as viscosity. Miyazaki et al. (1998) had stated that in order to obtain solid granules, it is important to pay
2.4.1 Particle Size
Particle size distribution of Urea fertilizer products or Urea raw materials is defined as the particle diameter range of the material. Particle size analysis is typically measured by sieving, a process of separating a mixture of particles according to their size fraction. Particle size affects agronomic response, granulation and process performance, and blending, storage, handling, and application properties. Some of the reasons for size control follow (Hoffmeister, 1979).
2.4.1.1 Effects on Agronomic Response
Hoffmeister (1979) had stated that fertilizer of very low water solubility generally must
