GMR Institute of Technology - Rajam

An Autonomous Institute Affiliated to JNTUK, Kakinada

Department of Chemical Engineering
1st Sessional Examination
Academic Year: 2014-15
Program: B.Tech.
Semester: VI
Course: Fertilizer TechnologyCode: CHEM 3423
Date: 08/01/2015
Time: From 9.00AM to 10.30AM
Max. Marks: 40
NOTE: Answer any FOUR of the following FIVE questions. Each question carries 10 Marks.
Students should write the answers in serial number i.e. 1a, b, 2a, b, 3a, b, etc. and in one space
in the answer book.
Q1. a) Differentiate between Primary and Secondary Nutrients.
b) What is Grade of Fertilizers? Give Examples.
Q2. a) Explain the sources of Nitrogen and Hydrogen.
b) Explain the H2 production from Steam reforming of hydrocarbons.

[5M
[5M
[5M
[5M

Q3. Distinguish between the high temperature and low temperature shift conversion.

[10M

Q4. a) Explain the Partial oxidation of fuel oils?

b) How to remove CO from the stack gases?
Q5. Explain the manufacturing process of ammonia with a neat sketch.

[5M
[5M
[10M

GMR Institute of Technology - Rajam

An Autonomous Institute Affiliated to JNTUK, Kakinada
Department of Chemical Engineering
1st Sessional Examination
Academic Year: 2014-15
Program: B.Tech.
Semester: VI
Course: Fertilizer Technology Code: CHEM 3423
Date: 08/01/2015
Time: From 9.00AM to 10.30AM
Max. Marks: 40
NOTE: Answer any FOUR of the following FIVE questions. Each question carries 10 Marks.
Students should write the answers in serial number i.e. 1a, b, 2a, b, 3a, b, etc. and in one space
in the answer book.
Q1. a) Differentiate between Primary and Secondary Nutrients.
b) What is Grade of Fertilizers? Give Examples.
Q2. a) Explain the sources of Nitrogen and Hydrogen.
b) Explain the H2 production from Steam reforming of hydrocarbons.
Q3. Distinguish between the high temperature and low temperature shift conversion.

[5M
[5M
[5M
[5M
[10M

Q4. a) Explain the Partial oxidation of fuel oils?

[5M

b) How to remove CO from the stack gases?

[5M

Q5. Explain the manufacturing process of ammonia with a neat sketch.

[10M

GMR Institute of Technology - Rajam

An Autonomous Institute Affiliated to JNTUK, Kakinada
Department of Chemical Engineering
1st Sessional Examination

SOLUTION KEY
Q1. a) Differentiate between Primary and Secondary Nutrients.

[5M

Ans: The primary nutrients are nitrogen (N), phosphorus (P), andpotassium (K). These major
nutrients usually are lacking from the soil first because plants use large amounts for their growth
and survival.
The secondary nutrients are calcium (Ca), magnesium (Mg), and sulfur (S). There are usually
enough of these nutrients in the soil so fertilization is not always needed. Also, large amounts of
Calcium and Magnesium are added when lime is applied to acidic soils. Sulfur is usually
found in sufficient amounts from the slow decomposition of soil organic matter, an important
reason for not throwing out grass clippings and leaves.

b) What is Grade of Fertilizers? Give Examples.

[5M

Ans:

Q2. a) Explain the sources of Nitrogen and Hydrogen.

[5M

Sources of Nitrogen and Hydrogen:

Nitrogen and hydrogen are the two basic raw materials used in the manufacturing of ammonia
(NH3) which is the intermediate feed stock for the production of nitrogen fertilizers.
The abundance source of nitrogen is atmospheric air.
The major sources of hydrogen are: Natural gas, Naphtha, Fuel oils, Coal, Coke oven Gas,
Wood (but not used due to economic reason), Electrolytic hydrogen, Refinery gas etc.
The natural gas occurs either in associated with crude petroleum or as non-associated gas.
When it occurs as non-associated gas, it is called free gas.
When it occurs as in association with crude petroleum, it is called gas.

b) Explain the H2 production from Steam reforming of hydrocarbons.

[5M

Ans: Steam Reformation of Hydrocarbon:

Steam reforming of hydrocarbons (ranging from natural gas to light petroleum distillates) has
been preferred route for the manufacturing of hydrogen and chemical synthesis gases.
In India steam reforming process has been extensively used in the fertilizer industry for which
most commonly used feed stock is naphtha, natural gas and refinery gas.
In this process, the desulphurized naphtha or natural gas is subjected to thermal cracking over
nickel catalyst at about 28 30 atmosphere and temperature around 800 0C in the presence of
steam.
This is followed by an auto-thermal secondary reformer where air is added to give the desired
3:1 hydrogen to nitrogen ratio in the synthesis gas.
During the steam reforming the following reaction takes place:
CH4 + H2 O --CO + 3H2
Steam reforming of Naphtha process is being adopted in; CFL-Vizag, FACT-Alwaye phase-IV,
FACT- Cochin, FCI-Barauni, FCI-Durgapur, FCI-Gorakhpur, GSFC-Baroda, IEL- Kanpur,
MCFL-Mangalore, SCI-Kota, SPIC- Tuticorin, ZACL-Goa etc.
Q3. Distinguish between the high temperature and low temperature shift conversion.
Ans: High Temperature Shift Conversion:

[10M

Q4. a) Explain the Partial oxidation of fuel oils?

[5M

b) How to remove CO from the stack gases?

[5M

Ans:
GAS PURIFICATION
As the synthesis gas contains CO, H2, CO2, CH4, H2S and N etc. it is necessary to purify the gas
as the requirement of only H2.
There is different processes use for the purification of the synthesis gas as:
1. Liquid Nitrogen wash process (scrubbing with liquid Nitrogen)
2. High temperature shift conversion.
3. Low Temperature shift conversion.
4. Carbon dioxide absorption
5. Scrubbing with cuprous ammonium acetate and cuprous ammonium formate or combination
of two.
6. Catalytic Methanation
Q5. Explain the manufacturing process of ammonia with a neat sketch.

[10M

Ans: Manufacture of Ammonia (NH3)

Introduction:
Ammonia is an intermediate product in the manufacturing of Nitrogenous fertilizers.
It also used in direct application to the soil and in aqua conditions with solution of other
nitrogenous fertilizers like ammonium nitrate and / or urea.
Ammonia finds application in the production of nitric acid, soda ash, cleaning agents, leather
tanning, petroleum refining, pulp and paper industry, textiles, refrigeration, rubber and synthetic
resin industries, explosive, food and beverage industries.
Production Capacity:
Ammonia is produced as an intermediate for the production of nitrogenous fertilizers in 22
plants in India.
In addition to this capacity ammonia is recovered as ammonium sulphate from coke oven liquor
in 6 plants.
Raw materials / Sources:
Ammonia is a compound of N2 and Hydrogen.
Process for manufacturing of ammonia comprises three steps:

Raw gas preparation

Its purification
Ammonia synthesis

Synthesis gas provides hydrogen and to this added nitrogen in the form of air or purified
nitrogen depending on the feed stock and the method of hydrogen preparation.
Ammonia Synthesis:
It is carried out at elevated temperature of 500 0 C and pressure of 270 350 atm, passing N 2 and
H2 over an activated iron oxide catalyst, which activates the reaction and improves the
equilibrium.
The reaction takes place is N2 + 3H2 ----2NH3