Mini-Project Done

On

PRODUCTION OF AMMONIA, UREA AND CFG

MATERIAL BALANCE OF AMMONIA PROCESS (Up to front head)

In NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED KAKINADA

Submitted by:
KONA GANGA RAJU Regd no :L10CH462, B.TECH 3rd year CHEMICAL ENGINEERING BAPATLA ENGINEERING COLLEGE, BAPATLA Under the esteemed guidance of

Shri. P.CHANDRA MOHAN

Deputy General Manager (Technical Services).

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

KAKINADA

ACKNOWLEDGEMENT

I wish to take this opportunity to express myself my deepest sense of gratitude to my project guide Dr N.RAMGOPAL, HOD CHEMICAL ENGG DEPT, for his able guidance and kind co-operation extended to me on successfully bringing this project. I would like to express my sincere gratitude to Shri. P. Chandra Mohan, DGM (Technical services), Mr. M.P. Rama Rao (Training manager), for their valuable guidance timely suggestions and encouragement given to me through out the project work. Last but not the least I thank one and all who have contributed their part in helping me my Endeavour to accomplish the object of completing this project work. K.GANGA RAJU

CONTENTS

Chapter 1 Chapter 2 Chapter3 Chapter 4 Chapter 5 Chapter 6

COMPANY PROFILE AMMONIA PROCESS MATERIAL BALANCE UREA PROCESS CFG PROCESS OFFSITES

Company profile
Nagarjuna fertilizers and chemicals limited is a flagship company of the Nagarjuna group. It is one of the leading manufacturer and supplier of plant nutrients in India. NFCL is engaged in the manufacturing of urea fertilizer in the complex located at Kakinada, A. P. It was founded by Sri KVK Raju, a visionary man with the motto

Serving society through industry

He was a professional technocrat entrepreneur who realized the importance of core section to an economy like ours. Thus was born Nagarjuna Group in 1973 with an investment of Rs. 50 million. The Group has since then come a long way to become a diversified conglomerate with an asset base of Rs. 43 billion. NFCL is the first gas based fertilizer industry in south India. The plant is based on the latest fertilizer technology from SNAMPROGETTI; ITALY for UREA manufacture and HALDOR TOPSOE PROCESS; DENMARK for AMMONIA SYNTHESIS. The name plate capacity of ammonia plant is 990 tpd and that of urea is 1500 tpd. The plants run successfully at high on-stream factor and capacity utilization with low power consumption. The feed stock for both UNIT I and UNIT II is Natural gas. Earlier for UNIT II fuel used to be Naptha, but now due to abundant availability of Natural gas from the Krishna Godavari basin, the unit has been switched over to Natural gas. Also Fuel for entire complex is NATURAL GAS. The current consumption of natural gas is around 1.8 million standard cubic meters per day. This gas is being received

through pipelines from TATIPAKA refinery marketed by GAIL and Gadimagu refinery marketed by Reliance.

The construction of UNIT I started in 1988 and the commercial production commenced from AUGUST 1st 1992. The construction of UNIT II started in 1995 and the commercial production commenced from MARCH 19th 1998. The factory is located in a total area of 1130 acres of which 350 acres is occupied by plant and a green belt of 780 acres. Solutions The potential benefits from improved plant nutrition are virtually limitless. With the right plant nutrition it is not surprising that the grower can produce higher yields, better flavored and greater nutritional content crops of vigor that are less prone to pests and disease attack goals which form the core of our plant nutrition strategy. It is widely recognized by agronomists that plant nutrition is responsible for approximately one-third of the increase in world grain production. The balance is provided by such factors as better irrigation, improved seeds, cultivation practices, pest control and planting density. NFCL supplies a broad portfolio of nutrition products and services that include both macro and micro fertilizers. It employs information technology and soil and tissue analysis for nutrient recommendation and plans include further strengthening of analysis portfolio with advanced tools to measure the actual nutrient requirements and status and deliver customized nutrition solutions to meet the exact needs of the customer. It also provides knowledge-based solutions to the vast farming community through information technology. Micro Irrigation solutions are an effort towards facing perhaps the most serious challenge of mankind in the 21st century - lack of fresh water. Its products and services ensure slow, regular and precise delivery of water and agricultural

inputs to the crop. NFCL offers expertise for taking over total responsibility of operation and

maintenance and other specialist services for the management of chemical process plants. NFCL operations and offerings have been aligned into Farming Solutions and Nagarjuna Management Services. Farming Nagarjuna Fertilizers and Chemicals Limited is involved in the production and marketing of a wide range of fertilizers. Urea, the widely used nitrogenous fertilizer is both manufactured (at Kakinada Plant) and marketed through imports (at Vizag and Kakinada Ports). In the vast Urea market, the brand Nagarjuna is a highly regarded and preferred brand by the farming community. NFCL currently markets about 1.4 million tons of Manufactured Urea and about 0.6 million tons of Imported Urea per annum. With the aim of providing Total Solutions to the farmers, NFCL has commenced marketing of fertilizer mixtures through domestic sourcing and has further plans to enter into Phosphatic and Potassic segments also.

The company also markets a wide range of micronutrients and micronutrient mixes like Zinc Sulphate, Mahazinc, Muriate of potash, Di ammonium phosphate etc. with emphasis on quality. NFCL has associated with Haifa Chemicals Limited of Israel and Yara of Norway to bring world class solutions to customers. It has been importing and marketing water-soluble specialty fertilizers from Haifa Chemicals Limited (HCL), Israel,

since 1997. Haifa Chemicals is a global leader in the development, production and marketing of specialty fertilizers offering a wide range of product lines to match the specific needs of different farming programs.

ENVIRONMENTAL PROFILE

The company employees state of the art technology and designed to meet high standards of energy conservation and pollutant discharge, lands.

a) Description of green belt: In consonance with NFCL founder Mr. K. V. K. Rajus philosophy, a vast Green Belt has been developed over an area of 780 acres consist of 4,00,000 plants with 170 species transforming the once highly saline marshy area devoid of any vegetation into a lush green arboreal park. Green belt on the west of the factory is formed by planting selected species of vegetarian of different heights, foliage and other morphological features so as to constitute a thick green leaf wall between factory site and township. Similarly the available land on the southern side and various free spaces in the factory area is fully planted with vegetation of various types of an environment congenial in all respects. The ecological system created in and around the plant site provides water bodies. Suitably located so that the total atmosphere is made conductive to animals, birds, fish etc. Liquid effluent from the plant treated to

adequate levels of purity is utilized both for sustaining the vegetation and for formation of the water bodies suitable for aqua culture. A Deer park been developed in green belt which consists of rabbits, peacocks, ducks and turtles etc. NFCL green belt has been accorded the status of mini zoo by central zoo authorities. The evaluation of this ecological system in the out come of efforts combined wisdom and extensive experience of eminent experts in diverse disciplines such as forestry, horticulture, soil, chemistry, ornithology land scarping animal and aquatic sciences. The NFCLs green belt development stands out as model for future industrial ventures in maintenance of environment and development of ecology. The company is also maintaining a lawn under the name of KVK Sunderavanam.

Significant environmental benefits of green belt

The Green Belt constitutes a thick green leaf wall full of life with flora and fauna between factory site and Kakinada town. This acts as a safety measure, arresting particulate matter physically and releasing O2. Green belt development stands out as model for future industrial ventures in maintenance of environment and development of ecology. Carbon-di-oxide absorption Oxygen release Prevention of ground water evaporation Sub soil erosion Dust curtain Barrier between factory and Kakinada town

Increasing soil fertility Reduce the temperature through moisture Ecological balance

Safety Services Ammonia, Urea and Steam & Power plant operations are hugely hazardous by nature. Safety professionals are key resources for working in close coordination with plant personnel to ensure total safety of the plant and machinery and human resources. This group also ensures meeting all statutory requirements. Safety guidelines are prepared, standards are framed and compliance is monitored. Site and Offsite emergency plans are prepared and issued. Emergency mock drills are conducted for all-time preparedness. Fire fighting system is kept in full readiness to fight any major or minor fire. The group imparts training and retraining to all plant professionals, factory workers, office workers and contract workmen. The group is credited with helping the NFCL plants achieve the 5-star rating from British Safety Council. Safety standards followed by the company are: ISO 9001 Quality Management System (QMS) ISO 14001 Environmental Management System (EMS) ISO 18001OHSAS Occupational Health Safety And Associated Systems PSMSProcess Safety Management System EPPEmergency preparedness Plan

AMMONIA PROCESS
Natural gas supply Desulphurisation section Reforming section CO conversion section CO2 removal section Methanation Process condensate stripping section Ammonia synthesis section Refrigeration section Ammonia absorption section Purge gas recovery unit

The raw materials of this plant are AIR and NATURAL GAS. Natural gas contains 0.2 ppm of sulfur. So, when Natural gas is used as feedstock its sulfur contents must be reduced first. For this a unit called as pre-desulphurization unit is used, where S is removed.

PRE-DESULPHURIZATION:
Natural gas contains sulfur compounds of types R-SH, R1-S-R, R-S-S-R1 etc and many more. These compounds are removed by hydrogenation process where H2 is added. The reactions that take place inside the hydrogenator are:

 R-SH + H2 R-S-R1 + 2H2 R-S-S-R1 + 4H2

R-H + H2S R-H + R1-H + H2S R-H + R1-H + 2H2S

CATALYST: NIMOX (NICKEL-MOLYBDENUM) OPERATING CONDITIONS: 380OC, 24 KSC. So, S is removed to a large extent as H2S and then sent to the final desulphurization unit. FINAL DESULPHURIZATION: In this section the same process of HYDROGENATION is done. So the H2S formed now is sent into the reactors where ZNO beds are present. The sulfur removal inside the beds takes as follows: ZNO + H2S ZNS + H2O

The process gas thus obtained is sent to the Reforming section. REFORMING SECTION: Reforming means conversion of hydrocarbons to CO2 with the help of steam. This takes place at high temperatures since it is an endothermic reaction. The reactions that take place are called as shift reactions.
CH4 + H2O CH4 + 2H20

CO + 3H2 CO2 + 4H2

CATALYST Ni based catalyst. TEMPERATURE - The temperature required is nearly 950oC.

Reaching this temperature at once is very difficult and thus it is done in 2 stages: 1. Primary Reforming 2. Secondary Reforming PRIMARY REFORMER: This reformer contains 190 tubes in 2 parallel sections and each section into 56 rows. The furnace operates with side firing of fuel gas on both sides of each row of tubes. There are 360 side fired wall burners arranged in 6 rows and each row having 15 burners. These tubes are filled with Ni catalyst. Super heated steam along with natural gas is sent into small tubes. Nearly 86% conversion takes place. Thus the product stream contains C0+C02+CH4+H20. This is sent to secondary reformer.

SECONDARY REFORMER:
Product stream along with air is sent inside the reformer where it is heated to 945oC for the rest 14% conversion of CH4. The product stream now contains only CO, CO2, H2 and AIR. In order to convert CO to CO2 it is sent into the CONVERTER via WASTE HEAT BOILER. This waste heat boiler recovers the heat from the product stream and is used for rising temperature. This section should be maintained at low pressures. Because high temperatures and high pressures favors for unit operation called CRACKING which results in the formation of CARBON. This carbon formation reduces the Ni catalyst activity and so it is to be avoided.

HT CO CONVERTER:
From waste heat boiler the process gas enters High Temperature CO converter. This is maintained at 380oC. Although CO conversion to CO2 takes place at low temperatures this converter is used in order to increase the speed of reaction. CATALYST: Cu promoted IRON OXIDE is used. CO+H2O CO2+H2

LT CO CONVERTER:
The stream from HT CONVERTER enters the LT CONVERTER and the CO formed in the process is converted to CO2. This is maintained at 140 oC. The product stream contains CO2, N2, H2, Ar and traces of CO. CO+H2O CO2+H2

CO2 REMOVAL SECTION:

CO2 that is present is to be separated and thus it is sent into a tower where it is made to mix with a solution called GV SOLUTION (GIMMARCO VETRACOKE SOLUTION) whose constituents are K2CO3, V2O5, DEA and GLYCINE. V2O5 acts as the catalyst and DEA, GLYCINE are the initiators of the reaction. The operating conditions are 2.5 KSC, 250oC. The reaction that takes place is:
K2CO3 + H20 + CO2

2KHCO3

CO2 REGENERATOR:
This KHCO3 is to be stripped for removing the CO2 from the GV SOLUTION. This stripping is done both at high pressures and low pressures. High pressure regeneration at 1 KSC is done where steam is made to flow counter-currently to KHCO3 solution. This helps in CO2 stripping off. Traces of CO2 that are present are also to be stripped and thus they are sent into the low pressure regenerator. This regenerator is made to work at 0.1 KSC. This process gas is now made to pass through the METHANATOR so that traces of CO2 left out is converted into CH4 once again and this is called as reverse shift reaction.
CO2 + 4H2

CH4 + 2H20

NH3 SYNTHESIS SECTION:

N2 + 3H2

2NH3 heat

1. 2.
3.

The forward reaction can be favored by high temperatures and low pressures. The catalyst used is Fe based. High Ar and CH4 concentrations reduce the partial pressure of N2 and H2. Hence the inert gas percentage must be not more than 8%. H2/N2 ratio is maintained at 2.78:1. The ammonia synthesis reactor consists of series of catalyst beds. The synthesis gas enters the first bed at 252oC and when it comes out the temperature increases to 530oC and as it goes to the second bed the temperature is again brought back to 252oC with the help of exchangers. The pressure maintained is 145 KSC. Only 17% of NH3 is formed and the rest is recycled back.

4.

PROCESS CONDITIONS: Ammonia Synthesis reaction is affected by the following parameters: Ammonia content in the feed gas Inert gas content in the feed gas

H2 to N2 ratio in the feed gas

Reaction temperature Circulation Rate Operating pressure Catalyst activity

REFRIGERATION SYSTEM:
NH3 formed is sent into series of chillers where the same compound acts as the refrigerant. Thus liquid ammonia formed is separated out and the purge gas that is sent is sent for recovery process where we can recover 90% of hydrogen.

PURGE GAS RECOVERY:

The purge gas contains traces of ammonia, hydrogen, CH4, Ar and this gas is reduced to very low temperatures where ammonia separates out and still its temperature is made to come down so that Ar and methane are also separated and only H2 gas is left and it is recycled back to ammonia reactor.

MATERIAL BALANCE OF AMMONIA PROCESS

(upto front head)
Steam to carbon ratio entering the primary reformer
Composition of Natural Gas feed (dry basis)
Component Mole% 0.13 1.24 0.11 96.98 1.54

O2 N2 CO2 CH4 C2+

Composition of Recycle Gas(dry basis)

Component Mole% 72.59 26.08 0.31 1.02

H2 N2 AR CH4

PROCESS STEAM NATURAL GAS FEED PRE-HEATER & DESULPHURIZATION UNIT

PRIMARY REFORMER

RECYCLE GAS STREAM Considering Natural gas stream Flow of NG(dry basis) =26139/22.414= 1166.1908 kmoles/hr. Carbon no in NG stream =(0.11+96.98+2*1.54)/100=1.0017. Amount of carbon in Natural gas =1.0017*1166.1908 =1168.1733 kmoles Considering Recycle gas stream Flow rate of gas stream =1306/22.414=58.2672 kmoles. Carbon no in Recycle gas stream =(1.02)/100=0.0102. Amount of carbon in Recycle gas =0.0102*58.2672=0.5943 kmoles Total amount of carbon entering =1168.1733+0.5943=1168.7676 kmoles Flow rate of Steam =70327 kg/hr Flow rate of condensate =136 kg/hr Amount of steam entering F-201(reformer) =(70327+136)/18 kmoles/hr =3914.6121 kmoles. Ratio of steam to carbon entering F201=3914.6121/1168.7676 =3.349

Material balance over primary reformer

Component H2 N2 CO CO2 CH4 C2+
CARBON BALANCE Carbon no in inlet stream

Mole % in inlet stream 3.21 2.43 ----0.11 92.77 1.47

Mole % in outlet stream 66.58 0.82 7.74 10.83 14.03 -----

=(0.11+92.77+2*1.47)/100 =0.9582

Carbon no in oulet stream

=(7.74+10.83+14.03)/100 =0.326

Amount of carbon entering F-201 =1168.7676 k moles Amount of dry gas entering F201=1168.7676/0.9582=1219.7533 kmoles Applying carbon balance Inlet carbon content = outlet carbon content 1168.7676 leaving)*0.326 amount of dry gas leaving =3585.1767 kmoles =80358.15 NM3/hr = (amt of dry gas

HYDROGEN BALANCE Hydrogen no in inlet stream Hydrogen no in outlet stream =3.8632 =1.8928

Amount of hydrogen entering F-201=1219.7533*3.8632 =4710.6872 kmoles. Amount of steam entering F-201 =3914.5177 kmoles. Amount of hydrogen in steam =3914.5177*2 =7829.0354 kmoles. Total amount of hydrogen entering F-201 =7829.0354+4710.6872 =12539.7226 kmoles. Amount of hydrigen reacted =1.8928*3585.7676 =6787.1409 kmoles Amount of unreacted hydrogen =12539.7226-6787.1409 =5752.5817 k moles Amount of unreacted steam =2876.2908 kmoles.

Amount of process gas leaving F-201(including steam)=2876.2908+3585.7676 =6462.0584 kmoles flow rate of outlet stream of F-201 =144840.6 NM3/hr

Material balance over secondary reformer(R-203)

Compositions of streams

Component

H2 N2 CO CO2 CH4

Mole % in inlet stream (from primary reformer) 66.58 0.82 7.74 10.83 14.03

Mole % in outlet stream

55.36 23.76 12.09 7.91 0.6

CARBON BALANCE Mole % of carbon entering through process air Amount of carbon entering (process air) =(38665/22.414)*0.03/100 =0.5175 kmoles. carbon no in inlet stream Amount of carbon entering R-203(from F-201) =0.326*3585.1767 =1168.7676 kmoles Total amount of carbon entering R-203 =1168.7676+0.5175 =1169.2851 kmoles carbon no in outlet stream=0.206 By applying carbon balance 1169.2851=(outlet dry gas)*0.206 Amount of process gas leaving R-203=1169.2851/0.206 =5676.1413 kmoles =0.326 =0.03

Flow rate of outlet stream =127225.03NM3/hr.

HYDROGEN BALANCE Hydrogen no in inlet stream =1.8928

Amount of hydrogen enteringR-203(dry gas)=1.8928*3585.1767 =6786.0225 kmoles Amount of steam entering =2870.144 kmoles

Amount of hydrogen entering (steam) =5740.288 kmoles. Total amount of hydrogen entering R-203 kmoles Amount of hydrogen reacted =12526.3105

=1.1312*5676.1413 =6420.851 kmoles

Amount of unreacted hydrogen

=12526.3105-6420.851 =6105.4595 kmoles

Amount of unreacted steam kmoles Total amount of outlet stream Flow rate of outletstream

=3052.7298 =8728.871 kmoles =195648.9157NM3/hr

Material balance over high tempeature shift converter

Composition of streams across R-204

Component H2 N2 CO CO2 CH4

Mole % in inlet stream 55.36 23.76 12.09 7.91 0.60

Mole % inoutlet stream 59.11 21.76 2.68 15.64

0.55

CARBON BALANCE

Carbon no in inlet stream

=0.206

Carbon no in outlet stream =0.1887 Amount of carbon entering R204=0.206*5676.1413=1169.2851 kmoles Applying carbon balance 1169.2851=(outlet dry gas)*0.1887 Amount of dry gas in outlet stream=6196.5294 kmoles Flow rate of dry gas stream =138889.01NM3/hr. HYDROGEN BALANCE Hydrogen no in inlet stream =1.1312 Hydrogen no in outlet stream =1.2042 Amount of hydrogen entering R-204(dry basis)=1.1312*5676.1413=6420.851 kmoles Amount of steam entering =3052.7298 kmoles Amount of hydrogen entering (steam) =6105.4596 kmoles Total amount of hydrogen entering R-204=12526.3106 kmoles Amount of hydrogen reacted =1.2042*6196.5294 =7461.8607 kmoles Amount of unreacted hydrogen =5064.4499 kmoles Amount of unreacted steam =2532.225 kmoles Total amount of outlet stream =2532.225+6196.5294 =8728.7544 kmoles

Material balance over low temperature shift converter

Composition of streams

Component H2 N2 CO CO2 CH4

CARBON BALANCE

Mole % in inlet stream 59.11 21.76 2.68 15.64 0.55

Mole % in outlet stream 60.09 21.24 0.22 17.66 0.54

Carbon no in inlet stream =0.1887 Carbon no in outlet stream =0.1842 Amount of carbon entering R-205 =0.1887*6196.5294 =1169.2851 kmoles Applying carbon balance 1169.2851=(outlet dry gas)*0.1842 Amount of dry gas flowing out of the converter=6347.9104 kmoles Flow rate of dry gas in outlet stream =142282.0637 NM3/hr HYDROGEN BALANCE Hydrogen no in inlet stream =1.2042

Hydrogen no in outlet stream =1.2234 Amount of hydrogen entering R-205 (dry gas basis)=1.2042*6196.5294 =7461.8607 kmoles Amount of steam entering the reactor=2532.225 kmoles Amount of hydrogen in steam =5064.4499 kmoles Total amount of hydrogen entering R-205=12523.3106 kmoles Amount of hydrogen reacted =1.2234*6347.9014 =7766.0226 kmoles Amount of unreacted hydrogen =4760.288 kmoles Amount of steam unreacted =2380.144 kmoles Total amount of outlet stream =2380.144+6347.9014 =8728.0454 kmoles Flow rate of outlet stream =195630.4096NM3/hr. GIAMMARCO VETROCOKE SECTION

LOW TEMP SHIFT CONVERT

GIAMMARCO VETROCOKE CO2 REMOVAL

CO2 TO UREA PLANT METHANAT OR

Considering CO2 balance CO2 entering GV section= Co2 to urea plant+ CO2 to methanator 0.1766*6347.9014=0.9850(dry gas flow to urea plant) +0.001(CO2 entering methanator)----(1) Considering H2 balance H2 entering GV section=H2 entering urea plant+H2 entering Methanator 0.6009*6347.9014=0.01*(dry gas flow to urea plant) +0.7292(H2 entering methantor)----(2) Solving (1)&(2) equations We get Amount of dry gas entering Urea plant=1132.8162 kmoles Amount of dry gas entering methantor=5215.4769 kmoles Consider CO2 to urea stream Conditions of steam are0.6kg/cm2.g and 40C Vapour pressure of water at temperature T is given by ln P=A+B/T+ClnT+DT2------(2) Where pressure(p) is in Pascal and temperature(T) is in kelvin and A=73.649 B=-7258.2 C=-7.3037 D=0.00000417

vapour pressure of the water at above conditions=3094.0287 Pa =0.0315kgf/cm2 mole fraction of water=0.0315/0.6=0.052 wet flow rate of CO2 to urea stream=dryflow/(1-m.f) =1132.8162/(1-0.052) =1194.9538 kmoles=26783.69NM3/hr similarly considering inlet flow to methanator conditions pressure =25.9kgf/cm2. temp=65C=338K by above equation (2) vapour pressure of water at above conditions=24875.8486 Pa=0.2537kgf/cm2. Mole fraction of water =0.2537/25.9=9.795*10-3 Wet flow of stream entering methanator=5215.8162/(19.795*10-3) =5267.4124 kmoles=118063.7815 NM3/hr.

Material balance over methanator

Composition of stream entering methanator Component Mole% H2 72.92 N2 25.76 CO 0.27 CO2 0.10 CH4 0.64

CARBON BALANCE Carbon no inlet stream =0.0101 Carbon no in oulet stream =0.0102 Amount of carbon entering R-301=0.0101*5215.8162 =52.66797 kmoles Applying carbon balance 52.6797=(dry gas out flow )*0.0102 Amount of carbon leaving R-301=5164.6807 kmoles. HYDROGEN BALANCE Low pressure steam entering GV solutions =2750 kg/hr=152.77 kg moles Amount of hydrogen in steam =305.55 kmoles Amount of unreacted steam entering R-301 =2380.144 kmoles Amount of hydrogen in unreacted steam =4760.288 kmoles Total amount of hydrogen entering =12806.1092 kmoles Amount of hydrogen reacted =1.4926*5164.6807 =7708.802 kmoles Amount of unreacted hydrogen =12704.8152-7708.802 =5097.3072 kmoles Amount of unreacted steam =2548.65336 kmoles Wet out flow rate of dry gas stream =5164.6807 kmoles =115761.135 NM3/hr

AMMONIA REACTOR
Tie component is Argon Amount of argon entering R-501=(2.14/100)*5164.6807=110.5242 kmoles Exit argon mole %=2.41% 110.5242=(2.41/100)*(out flow gas) Exit dry gas out flow=4586.065 kmoles=102792.061 NM3/hr. Hydrogen(H2) conversion % Hydrogen entering reactor=65.92*5164.6807/100=3404.5575 kmoles. Amount of hydrogen leaving R-501=55.43*4586.065/100=2542.056 kmoles % of conversion=(inlet-outlet)/inlet=(3404.55752542.056)/3404.5575=25.33% Nitrogen(N2) conversion % Amount of nitrogen entering R-501=0.2198*5164.6807=1135.197 kmoles Amount of nitrogen leaving R-501=0.1847*4586.065=847.0462 kmoles % of conversion=(inlet-outlet)/inlet=(1135.197-847.0462)/1135.197=25.38%

The Urea production takes place through the following main operations:

Urea Synthesis and High Pressure Recovery Urea purification in the medium, low and pre-vacuum pressure recoveries. Urea concentration Urea Prilling Process Condensate Treatment

CO2 and NH3 obtained in ammonia plant are sent into UREA PLANT. Since the reaction requires high pressures both the reactants are compressed. 1. NH3 being a liquid is compressed with the help of AMMONIA BOOSTER PUMPS and the feed is pumped into the reactor with the help of RECIPROCATING PUMPS. The reactant is compressed till it reaches 240 KSC. 2. CO2 is compressed with the help of compressors from 0.6 KSC to 159 KSC. This is done with the help of a steam turbine driven 4-stage CENTRIFUGAL COMPRESSOR SYSTEM. 3. CO2 is compressed to 6.5 KSC during the first stage and then to 21 KSC after the second stage and to 91 KSC after the third stage and finally to 159 KSC. The condensates are removed after each and every stage and this compressed CO2 is directly sent into the UREA REACTOR.

SYNTHESIS AND H. P. SECTION:

NH3 [240 KSC, 135oC] and CO2 [159 KSC, 105Oc] are sent inside the reactor. The residence time is 22 minutes. The reacting conditions are 189oC and 157 KSC. The reactions taking place are: 2NH3 + CO 2
NH2COONH4

NH2COONH4 NH2CONH2 + H2O

The outlet contains 33% urea. This product is sent into the stripper where NH3 acts as the self-stripping reagent. Thus, NH3, CO2 and H2O are separated to some extent. 43% concentration of urea is obtained. CARBAMATE DECOMPOSITION TAKES PLACE AT LOW PRESSURES AND OPTIMUM TEMPERATURES.

M.P.DECOMPOSITION & RECOVERY SECTION:

1. Urea [17 KSC, 155oC] is sent into the decomposer where the concentration

rises to 62% and the off gases (NH3, Carbamate) are sent into the condenser where ammonia is separated and sent into ammonia storage tank. Carbamate that is present is sent into the Carbamate solution tank for storage and further usage. 2. This whole loop is maintained at 17 KSC and thus is called as medium pressure loop and now it is sent into low pressure decomposer.

L. P. DECOMPOSITION:
1. Urea [4 KSC, 145oC] is sent into low pressure decomposer where 72% urea

is obtained. The gases that are formed are condensed and condensates are removed and the remaining solution is sent to the Carbamate tank.

2. The urea is sent into PRE-VACUUM CONCENTRATE where the urea concentration rises to 87%. 3. In this whole process water formed has to be removed and so it is sent into vacuum section

VACUUM CONCENTRATION:
1. Two vacuum separators are present in which urea is pumped into the first maintained at 0.35 KSC and 130oC. 2. This separator outlet is the input of the second one maintained at 0.035 KSC. This fine pressure is obtained with the help of EJECTORS. 3. These 2 separators separate out water with urea and 99% concentration is achieved.
4. This highly concentrated is maintained at 136oC because at high

temperatures BIURET FORMATION takes place. 5. Water obtained is condensed and then sent into waste water tank. It contains 5% Ammonia and 1% Urea. Molten urea is sent to the

PRILLING SECTION:
1. The height of the urea prilling tower is 100 meters and 22 meters in diameter. 2. We have a bucket at the top of the tower rotating at speed of 250 RPM which has holes in it. This molten urea is pumped to make it fall through the bucket and air is supplied from the bottom of the tower. So the liquid falling from the bucket gets cooled and thus small prills are formed. These are collected on a rotary scrapper which is connected to a belt that is directed to the BAGGING PLANT for bagging purpose.

PROCESS CONDENSATE TREATMENT:

Waste water from the tank is sent to the DISTILLATION COLUMN. STEAM is provided from the bottom. Pure water obtained at the bottom end is sent to the DM plant for further processing. Ammonia that is present escapes from the top of the tower and it is cooled in a condenser and is then directed to the AMMONIA STORAGE TANK. UREA is collected at the plate that is present at the middle of the distillation column. This is sent into HYDROLYZER where HIGH PRESSURE STEAM [37 KSC, 370Oc] is pumped in. Because of high pressures Urea decomposes into NH3 and CO2. CO2 escapes out into atmosphere and NH3 is again condensed and sent back into storage tank.

UREA PRILLS SPECIFICATION: COMPONENT Nitrogen Biuret Moisture Content Sizing CONCENTRATION 46% minimum by weight 1% maximum by weight 0-3% maximum by weight 90% [2 4 mm size]

CFG PROCESS
DESCRIPTION OF PROCESS PLANT
BRIEF DESCRIPTION OF THE PROCESS:

The solid raw materials like DAP. MOP, Urea, Filler compounds like Dolomite , clay etc and Micronutrients like Boron, Sulphur etc are proportioned (weighed) and premixed in a paddle mixer and fed to granulation drum (a rotary drum unit )where agglomeration is initiated. In the granulator steam and/or water is added to provide sufficient liquid phase and plasticity to cause the dry raw materials to agglomerate further into product-size granules. The moist and plastic granules are dried, in a rotary drum-type, Natural gas -fired dryer and screened to remove the product-size fraction. Cooling is performed in a rotary drum-type unit that is very similar to the rotary dryer. The oversize material is crushed and recycled to the granulator along with the undersize fraction. The product size fraction is passed through a coating drum where it is coated with anti caking agent and micronutrients like Zinc is added to the fertilizer and then is sent for bagging. The process flow diagram is shown in Annexure III. The process air from various equipment of the plant is taken to de-dusting and water scrubbing system and after thorough cleaning it is vented to atmosphere through stack. The scrubbed liquor is recycled to the granulator. DETAILED DESCRIPTION OF THE PROCESS: The plant can be divided into the following sections a. b. c. d. e. Raw material receiving section Raw material feed section Granulation and the main process section Finished product Coating and bagging section Pollution control section.

UREA, DAP, MOP,

1.08 MT/ hr 13.91 MT/ hr 2.67 MT/ hr

DOLOMITE, 2.36 MT/ hr +CONDITIONER + Micro nutrients(Sulphur,Boron etc.)

RAW MATERIAL HOPPERS WEIGH FEEDERS

RECYCLE

STEAM (satd) @ 3.5 bar NG @ 6-45 bar

1.20 MT/ hr AIR HOT AIR GEN

GRANULATOR DRYER

280 Sm3/ hr

DEDUSTING AND SCRUBBING SECTION (WITH CYCLONES, SCRUBBERS, CIRCULATION, PUMPS & STACK)

WATER @ 4 Bar

1.5 MT/ hr COOLER

SCRUBBER LIQUOR 5 m3 / week Recycle to Granulator/PURGE (TO GREEN BELT after treatment)
OVERSIZE CRUSHER

SCREEN

Micronutrients (Zinc)

COATING DRUM PRODUCT BAGGING

BAGGED CF PRODUCT

20 MT/ hr

CUSTOMISED FERTILIZER PROCESS FLOW (TYPICAL)

PROCESS DESCRIPTION Raw material section: The different raw materials, namely, Urea, DAP, MOP, Filler etc received in bulk or in bagged form, are stored Raw Material Storage area accessible for front pay loader loading or manual feeding. Micro-nutrients, coating agent, required would be handled and stored separately in the Raw Material Storage area. Raw material feed section: The different raw materials are fed into respective feed hoppers(3 Nos. each 5MT Capacity) using front pay loader or by manual feeding. The materials are

then transferred to the Raw material feed elevators (3 nos.) through Raw Material feed conveyors (3 Nos). The material from the elevators top is fed into different hoppers (6Nos. of capacity 30MT each). Depending on the product blend, these hoppers are loaded for several hours of operation requirement. From the hoppers the material is fed at the specified rate through Weigh feeders (6Nos) to the crushers (2Nos.) through Mixed Raw Material Conveyor. Crushers out let material is fed to the paddle mixer. The Paddle Mixer outlet material is fed to Granulator feed elevator through Mixer Discharge belt conveyor. The granulator feed elevator lifts this entire material to the Granulator floor for further processing. A stacker is provided to lift Micronutrient bags to the Micronutrient hopper floor to feed the hoppers(4 Nos. 1MT capacity each) manually. Depending on the product blend, these hoppers are loaded for several hours of operation requirement. From the hoppers the material is fed at the specified rate through Weigh feeders (4Nos) to the Paddle mixer elevator through Mixer Discharge through Mixed Raw beltconveyor. Material Conveyor. The Paddle Mixer outlet material is fed to Granulator feed

Granulation and main process section: The material at the out let of Mixer Discharge belt conveyor is fed to the granulator through a Bucket elevator named Granulator feed elevator. The granulator is a rotating drum( 2.2meter Dia,7.5 Meter long) designed to increase the size of the incoming seed by adding layers during the rolling motion. In this process densification and roundness of the granule are achieved. Sparger pipes are located in the granulator for spraying Water/Steam and Scrubber liquid (From the Scrubber liquor sump) onto the bed of material. From the granulator the material having approximately 10% Moisture is dropped to the rotary dryer. The dryer is a rotating drum( 2.2meter Dia,16 Meter long), where the moisture is evaporated from the material through heat transfer with co-current hot air flow. A natural gas fired furnace is used for generating hot air of 10,000 M3/Hr. of air upto 250 Deg C . Flights are used in the dryer for lifting the material, for achieving better heat transfer. The product moisture content is usually reduced to a target of 1% exit dryer.

The material from the dryer falls on the transfer belt conveyor to which feeds the material onto a rotary cooler. The cooler is also a rotating drum similar to dryer ( 2.2meter Dia,12 Meter long). The flights allow for proficient cooling of the product with the ambient air. The outlet product temperature depends on the conditions of the air used for cooling. The cooler outlet material is fed to the screen feed elevator which feeds material to the Rotary screen ( 1.0 meter Dia,4.0 Meter long). Here the fines and over size are separated .The fines are fed to the paddle mixer through recycle conveyor. The over size material is crushed in crusher and is put to recycle conveyor. Finished product coating and bagging section: The on size product from the rotary screen is fed into a coating drum, where the finished product is coated with anticaking agent for avoiding cake formation through spray system. Anti caking agent is stored in a tank under constant electric heating and is pumped to the spray nozzle fitted in side the coating drum. The product after getting coated with anti caking agent is sprayed with micronutrient like Zinc sulphate powder through weigh feeder located below Micronutrient storage bin of 1.0 MT capacity. The product then, through a product conveyor is fed to bucket elevator which in tern feeds product bins (2Nos.30MT each) directly. The product is bagged in 50Kg bags by automatic Weighing and bagging machines (2Nos. 500 Bags/Hr each) and stitching machines (2Nos) is then dispatched either through rail or road. Pollution control section: The plant contains stack and pollution control equipments for guarding the environment and to avoid material loss. The dryer air(25,000M3/Hr) and the cooler air (25,000M3/Hr) are taken to dedicated dust scrubbers(316 SS) through dedicated cyclones for removal of dust and after scrubbing it with circulating water in scrubber, the dust free air is sent to stack (30 Meter Hight). All the collected dusts are recycled back in the process. The Scrubber liquor is fed to granulator . Instrumentation and control:

A CCS (Centralized Control System) takes care of the overall control of the plant and the product mix. In specific, Weigh feeders will ensure precise measurement and supply of raw materials /Micronutrients from the hoppers to the paddle mixer , which is considered critical for the quality of the finished product. Temperature indicator for furnace air and Natural gas burner control systems are provided for process control.

RAW MATERIALS AND UTILITIES

Raw Materials & their availability: The Customized Fertilizers plant is being located at Kakinada, in Andhra Pradesh. Depending upon the formulation and the process needs specific raw materials are required.

It is envisaged that currently only subsidized raw materials like Urea, DAP and MOP along with filler materials and micronutrient would be used. requirement of Urea shall be met from in-house production The of Nagarjuna

Fertilizers and Chemicals Ltd. For DAP, it can be sourced from Indian manufacturers like Paradeep Phosphates Ltd, Iffco etc, or can be imported or Godavari Fertilizers Ltd which is next door can be one of the options. MOP will be sourced from IPL or can be imported. To have a cost effective and reliable source of raw materials, it is proposed to have Long term purchase agreement with companies in India and abroad. Raw Materials - Quantities: The quantities of various raw materials required in the production of 1.30 lakhs MTPY of Customized Fertilizers are variable depending on the grades we produce . Raw Material Consumption Typical quantities of raw materials comprising of Urea, DAP ,MOP and with or without micronutrients* to manufacture Customized Fertilizer

Input Hourly rate Output Hourly rate 1. Urea 1.08 MT 2. DAP 13.91 MT 3. MOP (KCl) 2.66 MT 4. Dolomite 2.36 MT 5. Product CF 20.0 MT _________________________________________________________ Total 20.0MT 20.0 MT * Zinc,Boron,Magnesium,Iron,Copper etc. Utilities &Packing materials Consumption Raw Water Low Pressure Steam Power Natural Gas Packing material : 35 M3/Day : 30MT/Day : 25KWH/MT : 7400SM3/Day :8000 Nos.of 50 Kg Empty HDPE Bags

BAGGING PLANT

Bagging means pre-weighing UREA in a machine, dumping the preweighed urea material into a bag and stitching the bag.

NFCL has 8 bagging streams. Each stream having a

Bunker Electronic bagging machine Wooden slat conveyor Stitching machine

Urea coming from the urea plant via conveyor belt is dumped into bunkers. From this urea is weighed 50 Kgs by a weighing machine and with the help of electronic bagging machine this is dumped into bags and the stitching is done. These packed beds via conveyor belts are sent for lorry and wagon loading .

UREA GRANULE SPECIFICATION:

COMPONENT Nitrogen Biuret Moisture Content Sizing

CONCENTRATION 46% minimum by weight 1% maximum by weight 0-3% maximum by weight 90% [2 4 mm size]

POWER PLANT

The total power requirement to the plant is 32-33 MW.25MW power is obtained from the gas turbines. The rest is obtained from the power Grid. The instrument air is sent into the air compressor where it is compressed to a certain pressure and is made to flow into the combustion chamber. Here it is mixed with fuel (Natural Gas) which is injected by fuel nozzles. The burning fuel will raise the temperature without changing in pressure. The hot gases expand in the turbine through which the rotation of turbines is made.

This mechanical energy is converted to electrical energy with the help of generator and this electricity produced is used for running the plant. The flue gases are left into air with the help of stacks. The recovered heat is used for further heating of natural gas that is supplied to the combustion chamber. There are three gas turbines which satisfy most of power requirements of the plant. The three gas turbines are:

Turbine

Power Generated

I. II. III.

GT-A GT-B GT-C

7.5 MW 7.5 MW 17.5 MW

PRE-TREATMENT PLANT

Raw water from samalkot reservoir is stored in raw water storage tank. This water which consists of mud and micro-organisms are to be removed. For this process the raw water is sent to the STILLING CHAMBER where CHLORINE is added. This chemical is helpful for killing bacteria and the mud that is present is settled in the stilling chamber. Then raw water free of micro-organisms now contains suspended particles and colloidal particles. This is now treated with coagulation agent ALUM (chemical formula Al2(SO4)3.18H20). What alums do is that they collect all the suspended particles as a particular mass and then they help in separating them out. This helps in separation of finely suspended matter. This water is now sent into CLARIFLOCCULATOR, which is a circular tank with flocculation zone in the centre and outer being the clarifying zone for sedimentation. Raw water entering the clariflocculator discharges at the top of the flocculation zone through central opening provided in the central shaft. Water entering the flocculation zone is subjected to slow agitation by paddles that are provided. Thus, pure water obtained is now passed through the filter beds to remove the residual suspended impurities from clarified water. The media contains sand and gravel of desired quality. The water still containing residual suspended matter passes down the filter during which solids are retained on the filter media. This water is now sent to the DM plant for further purification.

DM PLANT

Water from PRE-TREATMENT PLANT is firstly sent into the FILTER ACTIVATED CARBONS which helps in removal of TURBIDITY, CHLORINE etc. This is now sent into a STRONG CATION EXCHANGER which is 4 in number. In this exchanger ions of sodium, magnesium, aluminum etc are removed as mineral acids. Then it is sent to DEGASSING TOWER. In this tower the water is made to fall in the tower from the top and then air is sent from the bottom. This helps in removal of carbon-di-oxide and hydrogen and other dissolved gases inside the water. Then it is stored in the tower. Then it is now sent to the WEAK ANION EXCHANGER where weak anions are removed and then directed into the STRONG ANION EXCHANGER where the rest strong anions are removed. This water which might have traces of minerals (like Si) is separated when it is passes through MIXED BED DE-MINERALIZER. Thus, pure water obtained is free of minerals is sent into process plants and boilers for usage.

PROCESS CONDENSTE TREATMENT:

The water from the process condensate comes to the DM plant for further processing. It is first sent into the FILETR ACTIVATED CARBONS and then through MBDM (MIXED BED DE-MINERALIZER). This water is also sent to storage tank and for further processing.

TURBINE CONDENSATES:

The water that is obtained as the turbine condensates are also processed here. That is first sent into FILTER ACTIVATED CARBON and then to MBDM (MIXED BED DE-MINERALIZER) and then to MBGT (MIXED BED GUARD TOWER). This guard tower is used for removal of traces of minerals that are present inside the water. This water is also sent for usage to boiler section or process plants.

EFFLUENT TREATMENT PLANT

This involves the removal of oil, sludge and Ph correction. First of all oil bearing effluent from the process plant is collected in the oil separation pit which has a disc oil separator supported by 3 floats which are firmly secured to the two siding grids provided in the pit. The principle is based on the adhesion of oil to the lateral surface of metallic discs arranged perpendicular and partially submerged and rotating with respect to horizontal axis. For this ammonia and urea bearing effluents, HCl is added to bring down the Ph range from 7 to 8. When Ph of the mixed effluent is stabilized, it is pumped to equalization pond by effluent recirculation transfer pump.

INERT GAS PLANT

This plant is designed to produce gaseous and liquid nitrogen with a high level of purity. Process involves separation of air into nitrogen and waste gas rich in oxygen. The air first is sent into the main air compressor where it is compressed to high pressures and then sent into chillers where the temperature is decreased from 49oC to 12oC there by removing the bulk of moisture content. It is then sent into molecular sieve bed which absorbs contaminants like CO2, hydrocarbons etc. Then the pure N2 is then fed into the cold box where it is sent into expander and then the liquid nitrogen is stored in storage tanks. This nitrogen is used for purging inside the pipelines.

AUXILIARY BOILERS
Water from DM plant enters the de-aerator (mechanical and chemical), where CO2, O2 etc are separated out. Then this is sent into the economizer where it is pre-heated to certain extent. This preheated water is then sent into water drum which is present at the bottom of the furnace. Now air here is forced by a fan into the gas air heater where it is heated to very high temperatures and then it is sent into the furnace. We have a steam drum present at the top of the furnace. Now as the preheated air is supplied to the furnace the water gets heated up and becomes steam and as the density decreases the water rises from the bottom to the top i.e. from water drum to the steam drum. This air after it heats the water now is sent outside as the flue gas but as its temperature is as high as 500oC it is made to pass through gas air heater where the heat is recovered. After the heat being regained at the gas air heater it is sent outside via stack which works on the principle of natural draught. The steam formed in the steam drum is sent into the primary super heater and then to attemptator and then it is

sent into secondary super heater. Attemptator is used for maintaining constant temperature. The super heated steam is sent for various purposes inside the plant.

COOLING TOWERS
Cooling towers are the towers which work on the principle of the OPEN RE-CIRCULATING SYSTEM. Hot water from the pumps is re-circulated via heat exchangers where it picks up the heat on the cooling towers and it is made to fall from the top of the cooling towers where the water is cooled by evaporation. Thus the heated water gets cooled in cooling towers with the mechanical draft (exhaust fan) provided at the top of the tower.

CONCLUSION

I got acquainted with how Ammonia and Urea are prepared and various operations carried out for their preparation at NFCL Also learnt the functioning of different types of equipments both minor and major and the way they are integrated into Ammonia and Urea plants. I also had a chance for the practical application of my knowledge regarding the subjects. . At last staying with the well experienced company officials has been a rewarding and motivation for me to design my career.