AN

INDUSTRIAL TRAINING REPORT

ON

INDIAN FARMERS FERTILIZER CO-OPERATIVE LTD.

GUIDED BY: PREPARED

BY:
JAYMIT PATEL
MAYUR PARMAR
Mr. D.J. VYAS

2013-14

Department of Chemical Engineering

Faculty of Technology

Dharmsinh Desai University, Nadiad-387001

 Dharmsinh Desai University, Nadiad
[Faculty of Technology]

CERTIFICATE

This is to certify that Mr. Patel Jaymit & Parmar Mayur. Roll [Link]-
15&13, Sem- VI of Diploma Chemical Engineering at D. D. University,
Nadiad has satisfactory completed his industrial training at IFFCO - Kalol.
During 05/02/2013 to 04/03/2014 and submitted training report for partial
fulfilment of academic requirement to award Diploma Chemical
Engineering from this university.

Prof. [Link] Mr. [Link]

Head of the Department
D.D.U. Nadiad. D.D.D. Nadiad.
 PREFACE

Technology has been advancing at an incredible pace and so

there has been as enormous demand of skilled professionals but
without practical knowledge an engineer can never be complete.

Industrial training helps to relate theoretical knowledge with practical.

The principal objective of the training is to get the details of the operations
which are carried out in the industries and equipments used in the chemical
process industries.

This report consists of various operations and processes with detailed

diagrams of equipments & flow sheets of ammonia Preparation and that of
urea preparation. It also includes the utility and offsite facilities as well as
the various safety measures taken for the smooth functioning of the industry.
Along with all these information, we also learn how to work in an industry,
how team results in an overall increase in the profits. This training also
taught us how to deal with various people and how to create a disciplined
atmosphere.
 ACKNOWLEDGEMENT

The vocational training at IFFCO Kalol Unit helped us in enhancing

our practical knowledge as well as gave a thorough exposure to industrial
life. This was possible only because of the co-operation and support of all
the members of the IFFCO family. Each and every one in the industry lent
us a helping hand in one way or the other. And for this we are extremely
grateful.

We are thankful to the Chief Manager (training centre), Mr.

[Link], for giving us the permission to undergo training at IFFCO Kalol
Unit. Our gratitude goes to Mr. [Link] for guiding and encouraging us
with his vast knowledge and enthusiastic nature. We are also thankful to Mr.
[Link], Mr. Parmar sir and Mr. [Link] for their constant support in
all us endeavors.

Without the guidance of all the faculties of Diploma Chemical

Engg. Department of Dharmsinh Desai University, who have been
continuous source of inspiration, we would not have been able to complete
training.

We are also obliged to the employees at various sections, who spent

their precious time for showing the plant and explaining to us each and every
aspect in detail.
 INDEX

SR NO. TITLE PAGE NO.

1 Introduction 1
2 About Training Plant 2
3 Process Details 7
4 Major Equipments and 16
Instrumentation
5 Process Utilities 23
6 Health, Hazards, and Safety 30
7 Plant Location and Layout 34
8 Environmental Aspect 35
 Chapter :- 1 Introduction

Introduction to IFFCO :

The farmers fertilizer cooperative limited (IFFCO) was registered as a multi unit
cooperative society on November 3, 1977 and had then an authorized capital of Rs. 200 cores.
This pioneer organization in co-operative sector has been making rapid progress in realms of
fertilizer production, capacity utilization and rendering service to farming community. During
last three decades, it has undergone innovation, ingenuity and implementation. Over the year it
has expanded its activity and acted as a catalyst for strengthening the co-operative movement
including production and distribution of fertilizer within the country. IFFCO has also
visualized a long term comprehensive plant which includes the expansion of existing units,
setting up of fertilizer production facilities inside and outside the country production of
agrochemicals and increasing the average under seed production there by contributing
substantially in the process of nation building and growth IFFCO’s marketing activity is
mainly based on its motto to improve the socio-economic status of rural people.

IFFCO has modern fertilizer plants

1) At Kalol in Gujarat
2) At Kandla In Gujarat
3) At Phulpur in Utter Pradesh
4) At Aonla in Utter Pradesh

They have total annual production capacity of 52.76 lakh tons of fertilizer.

Annual capacity (in lakh tons)

PRODUCT KALOL KANDLA PHULPUR AONLA

Ammonia 3.63 --- 8.315 10.03
Urea 5.445 --- 14.157 17.292

PRODUCTION PERFORMANCE

The production records for all four units are excellent. Since inception, the capacity
utilization achieved is always higher than the national average

IFFCO has won several awards for the Fertilizer Association of India (FAI), National
productivity Council and national and international safety councils for outstanding production
performance and in safety measures.

1
 Chapter-2 About Training Plant

Introduction to IFFCO, kalol unit :

The IFFCO Kalol Unit , spread over on 96 hectors of land is located 26 kms. away
from Ahmedabad on the Ahmedabad Mehsana state highway. The unit started commercial
production in April 1975. The unit consists of plant to produce ammonia, urea, liquid carbon
dioxide and dry ice along with offsite. Originally the 910 tpd ammonia plant was based on
natural gas steam reforming process of M/s. M.W. Kellong, USA and 1200 tpd urea plant was
based on co2 stripping process of M/S Stamicarbon, The Netherlands. Both the plant have
revamped in 1997 to enhance capacity to 1100 tpd ammonia and 1650 tpd urea. RLNG is used
as feed stock for ammonia and associated gas as fuel. Water is supplied from Narmada Canal
from Jaspur. Power is supplied by GEB.

Various Plants:

Ammonia Plant :

The plant is being designated to produce 1100 tonnes of ammonia per day based on M.W.
Kellogg Steam Reforming Process of USA. RLNG is used for ammonia production is supplied
by Reliance Petrochemicals. From total production, about 950 tonnes ammonia per day is used
in the urea plant and remaining is stored in atmospheric storage tank.

Urea plant :

The 1650 tonnes per day plant is based on Stamicarbon CO2 Stripping processs engineered
by Humphreys and Glasgow, U.K. The main raw material ammonia and carbon dioxide are
from ammonia plant.

Utility plant :

(I) Water Treatment Plant

(II) Cooling Towers
(III) Air Compressor and Inert Gas Generation
(IV) Steam Generation

Offsite plant :

(I) Storage Tanks

(II) Narmada Water Treatment Plant
(III) Effluent Treatment Plant

2
Organizational structure :

Head office of IFFCO is located at New Delhi. It houses corporate staff function as:
(I) Engineering Service Division
(II) Management Service Division
(III) Finance and Accounts
(IV) Personnel and Administration
(V) Marketing

Achievements :

Kalol unit is the oldest of the IFFCO family. It has received awards for performance,
productivity, safety and promoting Hindi language from different organizations and
associations. It has been awarded the ISO : 9002 certificate be Verities Quality International.
It’s second Fertilizer Company that has won this award.

List of plant and capacity :

Process Units :

Ammonia : 1160 Tons / Day

Urea : 1650 Tons / Day

Offsite & Utilities :

Water Treatment plant : 2570 Tons / Day

Steam Generation Plant : 1920 Tons / Day
Instrument and Plant Air : 1800 Nm3 / hr
Cooling Tower : 22900 Tons / Day
Raw Water Storage : 2600 m3
Ammonia Storage : 15000 Tons

Ammonia Plant :

Introduction :

The plant was commissioned in November, 1974. It was the first large capacity single stream
plant in India.

Name of the process : Steam Hydrocarbon Reforming process

Designed by : M.W. Kellogg
Capacity : 1100 tonnes/day
Fuel : Natural Gas

3
Raw materials and products :

Raw materials involved are :

Natural gas
Air
Steam
Power
Electricity

Products obtained after the process are :

Ammonia
Carbon Dioxide

Ammonia :

Physical and Chemical properties:

At Atmospheric temperature & Pressure Ammonia is a sharp colorless gas.

 Formula : NH3
 Specific Gravity : 0.682
 M.W. : 17.03 gm/mole
 Critical temperature : 132.14 °C
 Auto ignition temperature : 651 °C
 Boiling Point : -33.3 °C
 Freezing point : -77.7 °C
 Nature : Alkaline
 Odor : Colorless
 NH3 is very soluble in cold water and NH4OH.
 NH3 is readily released from liquid Ammonia with increase in temperature.

Hazardous Properties :

 When Ammonia stored in closed container NH 3 exert to vapor which increase rapidly with ris-
ing temperature.
 NH3 will explosive mixture with air and Oxygen.
 Moist NH3 will react rapidly with Cu & Zn.
 The use of the Hg in contact with NH3 should be avoided since under certain condition explo-
sive chemical compounds resulting.
 NH3 is an irritating gas & will affect muscles, membrane & eye.

Hazardous identification :

 Color : colorless
 Physical form : gas, liquid
 Odor : pungent odor

4
  Physical hazards : Containers may rupture or explode if exposed to heat

Uses of ammonia :

 Ammonia is used directly as fertilizer.

 Formulating different nitrogenous & phosphoric fertilizer
 For liquid and solid nitrogenous fertilizer like urea, ammonia sulphate, DAP, NaNO 3, NHNO3,
etc.
 For chemical compound like, Caprolactum, nylon-6.
 A refrigerant for large-scale air conditioning & refrigeration.
 Formulating granular mixed fertilizer.
 Ammonia blue print machine.

First aid measures :

 Inhalation :
If adverse effects occur, remove to uncontaminated area. Give artificial respiration if not
breathing. If breathing is difficult, qualified personnel should administer oxygen. Get immediate
medical attention.
 Skin contact :
Wash skin with soap and water for at least 15 minutes while removing contaminates unclothing
and shoes. Get immediate medical attention. Thoroughly clean and dry contaminated clothing and
shoes before reuse. Destroy contaminated shoes.

 Eye contact :
Immediately flush eyes with plenty of water for at least 15 minutes. Then get immediate medical
attention.

 Ingestion :
Do not induce vomiting. Never make an unconscious person vomit or drink fluids.
Give large amounts of water or milk. When vomiting occurs, keep head lower than hips to help
prevent aspiration. If person is unconscious, turn head to side. Get medical attention immediately.

Carbon Dioxide :

Properties :

 At atmospheric temperature and pressure CO2 is colorless gas.

 Formula :CO2
 M.W : 44
 Nature : Acidic in water
 Odor : Odorless
 Color : Colorless

5
 Uses of carbon dioxide :

 Refrigerant in ice-cream industries, dairies, food product industries, bear industries, in cold
industries etc.
 Fire extinguisher
 Mfg of salicylic acid, urea, various carbamates etc.

Urea plant :

Introduction :

The plant was commissioned in January 1975. It was the first large unit manufacturing plant in
India & plant was further upgraded in 1997. Now a day the plant capacity is 1650 tones/day.

Name of the process : Stamicarbon Stripping Process

Designed by : Stamicarbon & Glass Agro U.K.
Capacity : 1650 tones/day
Feed stock : Ammonia & CO2

Raw materials :
(1) Ammonia
(2) Carbon dioxide
(3) Utilities : Steam, water, Air, Electricity

Products :
(1) Urea

Product properties :
 State : Crystalline solid prills
 Chemical formula : NH2-CO-NH2
 Molecular weight : 60
 Melting point : 132.7 C
 Specific gravity : 1.33
 Hydrolyses very slowly in ammonia and carbon dioxide.
 Absorbs moisture from the air.
 Urea undergoes a number of reactions of heating about its boiling point.
 At 160 C, it decomposes to yield ammonium biuret and higher condensation products.
 Longer the urea is held above its melting point, the further reaction proceeds.

Urea specifications:
 Total nitrogen : 46.3% by wt.
 Moisture : 0.3% by wt.
 Biuret : 0.9% by wt.
 Fe – content : up to 1.5 ppm

6
 Chapter:-3 Process Detail

Ammonia Plant :

Various process for ammonia production and selection :

For ammonia production synthesis gas is produced by following process.

Low temperature
Non catalytic partial oxidation
Catalytic partial oxidation
Steam hydro carbon reforming process

And ammonia from synthesis gas is produced by following methods:

The Claude Process

The Forster Wheeler-Casale process
The M.W. Kellogg process
Foster Montecatini process

At IFFCO kalol unit :

“Steam Hydrocarbon Reforming Process” is selected for process synthesis and “The M.W.
Kellogg Process” is selected for ammonia production.

Reasons for selecting this process are as under :

 From the steam reforming process generate more hydrogen than partial oxidation
process.
 Steam reforming process requires less feed than partial oxidation process.
 Production of ammonia from coal plants is more costly than fro, conventional gas
based processes, because of the extensive solids handling and effluent treatment facili-
ties required.
 From steam reforming process generation of pollution is less than other processes.

Advantages of this process are :

 Intensive heat recovery

 Generation of steam which can be imported.
 Less dependency on electricity
 Capital cost is least.

7
Catalysts used In the process :

Equipments Catalysts
1 Desulfurizer : Activated Carbon
2 Primary Reformer : Nickel
3 Secondary Reformer : (i) Chromium (top)
(ii) Nickel (bottom)
4 Shift Converter
H. T. Section : Iron Oxide
L. T. Section : Copper and Zinc Oxide
5 Synthesis Converter : Iron Oxide
6 Methanator : Nickel
7 Pre-reformer : Nickel

Chemical reactions :
Primary reforming ;
CH4 + H2O CO + H2 ;

C2H6 + 3H2O 3CO + 5H2

C3H8 + 3H2O 3CO + 7H2

n-C4H10 + 4H2O 4CO + 9H2

Secondary reforming :

CH4 + 2O2 → CO2 + 2 H2

CH4 + CO2 → 2CO + 2 H2

CH4 + H2O → CO + 3H2O

Shift reaction

CO + H2O → H2 + CO2
Absorption :
CO2 + H2O → H2 CO3
Stripping :
H2CO3 → H2O+ CO2

8
Methanation :
CO + 3H2 → CH4 + H2O
Ammonia synthesis :
N2 + 3H2 2NH3

Process Description :

For the production of ammonia, Hydrogen and Nitrogen are required. Nitrogen is
obtained from air and Hydrogen is obtained from reaction of LNG (Liquified Natural Gas)
with the process steam. LNG is supplied and the steam is produced within the plant.

The manufacturing of ammonia involves the following operations or the processes :

(1) Desulphurization
(2) High pressure catalytic reformation
(3) Water gas shift reaction
(4) Methanation
(5) Ammonia synthesis
(6) Refrigeration

LNG is supplied at the pressure of 40 KSC. It contains sulfur compounds which are
removed by passing the gas through desulphuriser containing activated carbon. Sulphur gas
is pre heated, mixed with steam again and sent to the primary reformer.

In the primary reformer, the LNG steam mixture is passed through Nickel catalysts,
Packed in the tubes. As the reaction is endothermic, the heat is supplied by firing the gas
and naphtha in the reformer arch burner. From the primary reformer, a mixture of
Hydrogen, Carbon dioxide, Carbon monoxide and methane is obtained.

In the secondary reformer quantity of mixture is burnt with required quantity of air
which is supplied by the air compressor the gas is then passed through the secondary
reformer that contains Chromium and Nickel catalysts, to complete the reforming. The gas
is then exit from secondary reformer passes through Waste Heat Boiler (WHB) to generate
the steam that is then utilized in the plant.

The exit from the WHB is passed through the shift converters where CO is converted
into CO2. Initially the gas passes through high temperature shift converter which contains
Iron catalyst. The exit gas is cooled and passed through a bed of low temperature shift
converter that contains Zn-Cu catalysts. The exit from here contains mainly Hydrogen, CO 2
and Nitrogen with small quantity of CO.

The synthesis of ammonia gas contains only Hydrogen and Nitrogen in a proportion
of 3:1 by volume. The outlet gas from shift converters is sent to CO 2 absorber where the gas
brought in the contact with 30 to 40 % by weight MDEA solution is stripped with steam in
the CO2 strippers at a low pressure where the CO 2 is liberated. Which is cooled and sent to
the urea plant and balanced if any, vented to the atmosphere.

9
 The gas leaving the absorbers contain small amount of CO and CO 2. There Oxides
are converted into methane as they are poisonous to the ammonia synthesis catalyst. This is
achieved in the methanator containing highly active Nickel catalyst. After the methanation
stage the synthesis gas is cooled and sent to synthesis compressor.

In the synthesis compressor, the gas is compressed to high pressure. The recycle gas
from the synthesis loop is mixed with the make up gas in the last of the synthesis gas
compressor and combined gas mixture is then sent to the ammonia synthesis converter after
condensation to form ammonia in the presence of the Iron as a catalyst.

The outlet gas from the converter is cooled and sent to the last sage of the synthesis
compressor thus forming the close loop. Inert gases like argon and methane, which are
present in small quantities in the synthesis gas after methanation, get accumulated in the
synthesis loop. In order to maintain reform them within design limits a small quantity of
synthesis gas out coming from converter is purge. Earlier this gas was used as a fuel in the
primary reformer. In 1980 a purge gas recovery plant was installed to recovered is sent to
suction of synthesis gas compressor. This has increased daily ammonia production by 5 %.

Letting down its pressure in steps purifies the separated ammonia. A refrigerant
compressor is provided to compress the vapor ammonia used in chillers to cool high
pressure synthesis gas process. The product ammonia is sent to plant at 40 C and storage
tank at -33 C.

Urea plant :

Various processes to produce urea :

(1) Once through process
(2) Inventa process
(3) Hot gas recycle process
(4) Pechiney process
(5) Liquid carbamate solution recycle process
(6) Chemico process
(7) Montecetini Process
(8) Toatsu process
(9) CO2 stripping process
(10) Stamicarbon Process

Selection of the stamicarbon process :

In this process, the decomposition of carbamate and stripping is carried out with CO 2 at the
full reactor pressure of about 140 to 150 KC.
The off gases are condensed in the high pressure condenser, also operating at reactor
pressure. As a result no carbamate pump is required to pump carbamate to the reactor directly.
The steam generated in the HP condenser is used for the process purpose.
However, carbamate produced in subsequent stage will have to be pumped to the HP
carbamate condenser and the HP scrubber. The units are so positioned that the flow of

10
carbamate from the scrubber and the condenser to the reactor can be done by the means of
gravity.
As ammonia to CO2 mole ratio is 2.5 to 3.0:1 is used the reduced convection is made good
by the reduced water recycle to the reactor.

The most important advantages of the process are :

(1) Reduced power consumption.
(2) Reduced cooling water consumption.
(3) Reduced steam consumption.
(4) Simplified procedures for plant start up and shut downs.
(5) Better process controls.

Reactions :

1) Formation of ammonia carbamate :

2NH3 + CO2  NH4COONH2
2) Formation of Urea :
NH4COONH2  NH2CONH2 + H2O
3) Overall reaction at 25 0C:-
2NH3 + CO2 NH2CONH2 + H2O

11
Process Description :

Urea plant at IFFCO, kalol unit is based on STAMICARBON CO 2 STRIPPING PROCESS.

The plant was designed for 1200 tpd urea production capacity and was commissioned in the
year 1974. The revamped plant capacity is 1650 tpd.
Main features of the process are recovery of most unconverted ammonium carbamate at
synthesis pressure itself with the help of CO2 stripping in the HP heat exchanger an low
pressure steam generation by exothermic heat of carbamate formation the HP condenser.
Urea is produced by reacting liquid NH 3 gaseous CO2 at about 180 to 185 C and 145 to 155
KSC according to the following reactions :

2NH3 + CO2  NH4COONH2

NH4COONH2  NH2CONH2 + H2O
In the first reaction, CO2 and NH3 are converted into ammonium carbamate. This reaction
is fast and exothermic. In high temperature second reaction, ammonium carbamate
dehydrated to produced urea and water. The overall conversion efficiency of CO 2 in the
synthesis section is typically 80 to 81%.

The urea production process consists of the following steps :

(1) CO2 supply and compression
(2) NH3msupply and pumping
(3) Reaction synthesis
(4) LP recovery & recirculation system
(5) Urea hydrolyser and desorber
(6) Steam and condensate

(1) CO2 supply and compression :

The CO2 gas is available from ammonia plant at normal pressure of 0.14 to 0.22 kg/cn2 g
and at a temperature of 50 to 60 C. This gas is cooled and saturated in CO 2 spray water. CO2
and water flows counter currently through packed bed of polypropylene pall rings for cooling.
A demister pad above the distribution tray is provided the carryover along with exit CO 2 from
spray cooler.

Water from the bottom of the spray cooler is sent to the cooling tower by CO 2 spray cooler
sump pump. The exit saturated CO2 with water vapor enters CO2 knock out drum where the
moisture is knocked out and drained.

Anticorrosion air is injected to maintain the oxygen level of 0.60% in the CO 2 stream for
HP equipments activation to prevent corrosion. The CO 2 leaving knock out drum is
compressed in Hitachi make CO2 centrifugal compressor.

Hitachi CO2 compressor consists of two casings LP and HP casings each having two stages
of compression. LP case is directly coupled with turbine running at 7160 rpm and HP casing
runs at 14153 rpm through a step up gearbox. The CO2 is compressed from 0.16kg/cm2g to
157 Kg/cm2g.

12
 Drive turbine extraction cum admission condensing type is installed to run compressor
with minimum governor speed of 6375 rpm and maximum speed of 7875 driven by 60 ata
steam and 4 ata steam as induction steam.60 ata steam is supplied by generation plant at about
61.5 ata and 410*C.

The steam after passing through exhaust end section of the turbine is condensed at a
pressure of 0.94 Kg/cm2g at turbine outlet in the surface condenser. Non-condensable from
the condenser are removed by steam ejector system operating by 4 ata steam .The steam exit
of the ejectors is condensed in the heat exchangers with cooling water flowing in the tubes and
is pumped to the dearator of the steam generation plant by the surface condensate pumps, The
vacuum in the surface condensers is maintained by a set of two ejectors in two stages.

(2) NH3 supply and pumping :

Liquid ammonia directly from ammonia plant enters the urea plant battery limit at 20 KSC
and 40 C. The alternate source from ammonia supply is from atmospheric ammonia storage
tank. The cold liquid ammonia is preheated at 40*C in the ammonia preheater.

Liquid ammonia from filter outlet enters the ammonia suction vessel which serves the
purposes of providing a suction volume for HP ammonia pumps and acting as a pulsation
dampener. The liquid ammonia from the ammonia suction vessel is pumped at reaction
pressure of 153 Kg/cm2.

Out of total ammonia discharged by pumps, 90-95% ammonia goes to HP carbamate

condenser and 5-10% goes to autoclave.

(3) Reaction / high pressure systems :

Liquid ammonia supplied at 20 ksc and 40 C from the ammonia plant is pumped by HP
ammonia pump to HP condenser and autoclave. Two HP ammonia pumps remain in line in
which one rums and one remains in standby. There is also a provision to draw cold ammonia
by the ammonia loading pump to the HP system. The CO 2 from the compressor section enters
HP strippers where it counter currently contacts the liquid effluent from the autoclave. The
liquid from the base of the HP stripper consisting mainly of 55 % urea goes to the LP recovery
section. The gases enter the top of the HP condenser, where they are condensed along with
NH3 and carbamate solution along with uncondensed NH 3, CO2 and water vapor in
equilibrium enters the bottom of the autoclave. In the autoclave, conversion of carbamate to
urea is achieved during the residence time of 1 hour approximately. The conversion takes
place at 180 C temperature and 150 ksc pressure. The urea solution along with unconverted
carbamate is withdrawn overflow line and fed to the top of the HP stripper by gravity. The
inert gases present in the CO2 feed stock, some CO2 and NH3 pass into the HP scrubber, where
it is condensed along with carbamate solution. Inert gases from the HP scrubber are vented to
the atmosphere.

The complete HP system consisting of autoclave, HP condenser, HP stripper and HP

scrubber operated at the same pressure of 150 ksc which facilities the gravity flow.

13
(4) LP recovery & Recirculation system :

 LP recovery and recirculation system :

Urea solution from the HP stripper is let down to about 3.3 ksc and fed to the
rectifying column, where the temperature of the solution drops to 120 C. Urea solution
from the bottom of the rectifying column is heated in the recirculation heater, where the
dissociation of carbamate is completed. The product urea solution of about 70 %
concentration at about 135 C passes from the bottom of the rectifying column through a
control valve where the pressure is let down to about 1 ksc and then passed into the flash
tank separator. Her part of the water in solution is flashed off and the temperature drops to
104 C. The remaining urea solution flows under pressure difference to the pre evaporator.
A second flashing of the urea solution takes place at vacuum of about 466 mmHg in
the pre evaporator. This pre evaporator consists of two shell and tube heat exchangers in
series. In the first heat exchanger, circulating water from the HP scrubber is supplied.
The second heat exchanger is operated with low pressure steam. The urea solution, at a
concentration of about 83 % by wt. is collected in the urea solution tank vapor leaving the
separator is condensed in a pre evaporator condenser. The vapor from the pre evaporator
condenser is condensed in the first evaporator condenser.
The gases leaving from the top of the rectifying column are introduced in falling film
LP carbamate condenser, where partial condensation of the gas takes place. The flow
leaving from the falling film condenser is introduced into the bottom part of the
submerged low pressure carbamate condenser, where the vapors are condensed almost
completely.
The pressure of the low pressure carbamate condenser is controlled at about 3.3 ksc,
the carbamate solution flows to the HP carbamate pump where its pressure is raised to 153
ksc and from where the carbamate solution is carried to the HP scrubber.

 Evaporation and prilling :

80 % Urea solution from the pre evaporator is collected in the urea solution tank, and
pumped to the evaporation section by the urea solution pump, where it is concentrated in
two stages.
In the first stage, urea solution passes through the first stage evaporator which is
maintained at about 532 mmHg vacuum by the ejector. Flash vapors from the solution is
scrubbed in the first evaporator scrubber by the NH 3 water and condensed in the first
evaporator condenser. Then it is passed to the second stage evaporator which is maintained
at 737 mmHg vacuum by the ejector set in the series.
The 95 % concentrated urea solution after the first stage evaporation is heated in the
second stage evaporation to produce the molten urea containing approximately 0.3 %
moisture. The flash gases from the second stage evaporator is condensed in the two
condensers.
NH3 water with high content of the highly concentrated urea solution from the first
stage evaporator scrubber and the first stage evaporator condenser are collected in the urea
recovery pump, from where it is sent to the reflux condenser.
NH3 water from the second evaporator condenser and the first evaporator condenser is
collected in the NH3 water tank. Molten urea from the second evaporator is pumped to the
top of the priling tower, where it is sprayed in the tower by the rotating prill bucket. Prills
formed in the tower are cooled by counter current air flow and collected at the base of the
tower from where prills are transferred to the bagging plant conveyor through prill cooling
system by conveyors.

14
  Prill cooling system :
The hot urea prills from the prilling tower base flows on perforated plate in cooler
through belt conveyor. Atmospheric air is injected at the bottom of perforated plate by
inlet air fan. Due to fluidization between the urea prills and the air on the top of perforated
plate, heat of urea prills is transferred to air and cooled urea prills product is discharged on
belt conveyor, from where it is transferred to the bagging plant through the conveyor.

(5) Urea hydrolyser and Desorber :

The strong NH3 water is having 6.5 % NH 3, 4.3 % CO2 and around 1.3 % of urea in the
normal operating condition.

NH3 and urea of this stream are recovered in hydrolyser section, and NH 3 free water is sent
to the cooling tower. The recovered NH 3 is sent to reflux condenser in the liquid form. In this
section there are two desorbers and one hydrolyser in between.

The NH3 water goes to the first desorber, where NH3 is stripped off with the help of steam.
The bottom solution goes to the hydrolyser, where the urea is decomposed to NH 3 and CO2.
The urea free liquid goes to the second desorber, where any residual NH 3 is stripped off with
the help of steam. The final effluent having around 5 ppm of the urea is sent to the cooling
towers.

(6) Steam and condensate :

In the urea plant, steam is supplied from the BHEL (Bharat heavy electrical limited) boiler
which is then utilized in the turbine to run the Hitachi CO 2 centrifugal compressor. Partial
requirement of the steam is met by extracting steam from the Hitachi compressor when the
stand by compressor stands in line. Similarly steam is generated from the condensate and it is
also utilized to drive the Hitachi compressor turbine, the desorber, and all the steam ejectors.

15
 Chapter-4 Major Equipments & Instrumentation

Major Equipments used in the Ammonia Plant :

The major equipments used in the ammonia plant are as under :

(1) Desulfurizer
(2) Primary reformer
(3) Secondary reformer
(4) Primary waste heat boiler
(5) Secondary waste heat boiler
(6) Shift converter
(7) CO2 Absorber
(8) CO2 Stripper
(9) Methanator
(10) Ammonia separator
(11) Synthesis converter

(1) Desulfurizer :

Purpose: To remove sulfur compounds, which are poisonous for the catalysts,
from LNG with activated carbon by absorption.
Operating conditions: LNG contains about 0.5 to 3 ppm sulfur. Sulfur is absorbed by
activated carbon. The Outlet gas should contain 0.2 ppm sulfur.
Operating: 39.8 ksc and 38 C
Regeneration: 3.2 ksc and 205 C
Catalyst details : Activated carbon (28 m3)
Description:
The feed gas contains about 0.5 to 3ppm sulfur compounds in the form of
sulphides, disulphides, thiophenes etc, and these should be removed as they are poisonous for
the process to follow. There are two desulpharisers out of which one is online while the other
is a stand by which is used when the first one is regenerations. The process employed here is
adsorption. For desulphurization activated carbon catalyst is used. There are two beds of
catalyst at the top and bottom. It adsorbs the sulphur compound. LNG enters the desulfurizers
at the top and is removed from the bottom with a sulphar impurity of about 0.2 ppm.

16
(2) Primary reformer :

Purpose: To react liquefied natural gas with steam in presence of nickel catalyst
to get H2 for synthesis of NH3.
Operating conditions: 35.9 ksc and 523 C
Catalyst details : Ni – based (6.8 m3)
Description:
Reforming is an initial process of forming Hydrogen and Nitrogen in ammonia plant
after the process of desulphurization. The primary reforming is carried out in the primary
reforming. The gas from the desulphuriser is first preheated in the feed preheated in the
convection section. The inlet and outlet temperatures are 93°C and 232°C respectively.
The above natural gas is mixed with super heated steam. The mixer at 295°C is then
passed through the second feed pre heater coil in the convection section to achieve a
temperature up to 525°C. The final mixer goes to the primary reformer.
The primary reformer is rectangular in shape. Outside is consisting of S.S body and
there are insulator bricks inside. It consists of tubes packed with nickel which is used as
catalyst. Between the vertical rows of these tubes the burners are installed which use natural
gas and associated gas as a fuel for heating the tubes. There are in total 336 tubes and 126
burners.
Inside primary reformer endothermic reaction takes place at about 818°C. The product
each raw of tubes is connected at the bottom. The product from each of 42 tubes meets at the
centre and forms the single line called ‘Transfer line’ which rises upward. The temperature of
the gases inside the tube is 852°C. The ‘Transfer Line’ directs the flow to the secondary re -
former.

(3) Secondary reformer :

Purpose: To complete the reforming of methane which comes out from primary reformer.
Operating conditions :
Pressure: 31 ksc
Temperature: (Combustion zone) 1237 C
(Gas outlet) 996 C
Catalyst details: (At top portion) 19 mm sphere, 6.62 m3 and 581 mm height
(At bottom portion) 19 mm rings, 26.76 m3 and 2347 mm height
Description:
The partially reformed gas from primary reformer enters the secondary reformer at a
temperature of 820°C. The flow is downward a centrally located air inlet pipe, air supplied by
process. Air compressor is preheated with steam. A small quantity of steam is mixed at air
inlet to the air pre heater coil to ensure continuous flow into the secondary reformer.
The process is namely exothermic and the temperature in the combustion zone is about
995°C. In the secondary reformer the working pressure is about 31 ksc. The purpose of the
secondary reformer is to complete the reforming of methane which comes out from the
primary reformer.
The hot gases pass through the bed of nickel catalyst and their temperature is around
992°C. The heat is recovered from the reformed gas by use of waste heat boiler and the steam
produced is again used in the other operations.

17
(4) Primary waste heat boiler :

Purpose: Steam generation from secondary reformer effluent gases.

Operating conditions : Shell side Tube side
Temperature: 996 C (inlet) 313 C (inlet)
482 C (Outlet) 313 C (Outlet)
Pressure: 30 ksc 105 ksc
Other details :
No. of pass : One
No. of tubes : 206
Tube material : Mo
Shell diameter : 1295 mm
Shell material : Steel

(5) Secondary waste heat boiler :

Operating conditions : Shell side Tube side

Fluid circulated : Water Effluent gases
Inlet temperature : 313 C -
Outlet temperature : 313 C 482 C
Pressure : 105 ksc 30 ksc
Other details :
No of tubes : 750
Description ;
The reformed gas from primary reformer enters the top of the secondary reformer,
which is mixed with air by the air mixer. Nitrogen is introduced into the process by burning of
air in the HT top section. The heat of combustion is made available for the endothermic
reaction of the methane reforming at elevated temperature at the bottom section.

(6) Shift converter :

Purpose: To convert CO of the reformer gas to gain one mole of H 2 per mole of CO for the
ammonia synthesis.
Operating conditions:
HT Section:
Working pressure: 29 ksc
Inlet temperature: 360 to 370 C
Outlet temperature: 420 to 430C
ID: 3886 mm
Height: 48006 mm
Material: Steel
LT section:
Working pressure: 28 ksc
Inlet temperature: 220 C
Outlet temperature: 233 C
ID: 3886 mm
Height: 5101 mm
Material: Steel
Catalyst details: Cu & FeO in the HT section and Cu & ZnO in the LT section.

18
(7) CO2 Absorber:

Purpose: To remove the CO2 contained in the raw synthesis gas by scrubbing it with 30% to
40% MDEA (Methyl Diethyl amine) solution.
Operating conditions:
Pressure: 27.4 ksc
Temperature: 64 C
Dimensions:
Height: 2537 mm
ID: 3352 mm
No. of trays: 20 sieve trays

(8) CO2 stripper:

Purpose: To regenerate rich MDEA solution by steam stripper with the help of reboiler and
there by realizing CO2.
Operating conditions:
Temperature: 118 C
Pressure: 0.7 ksc
Dimensions:
Height: 17678 mm
ID: 3352 mm
No. of trays: 17 sieve trays

(9) Methanator:

Purpose: To convert small quantity of CO and CO2 to methane by reacting with Hydrogen.
Operating conditions:
Temperature: 375 C (Top) and 360 C (Bottom)
Pressure: 26.7 ksc
Dimensions:
Height: 2875 mm
ID: 2895 mm

(10) Ammonia separator:

Purpose: To separate and remove maximum amount from recycle gas and slight traces of
water, CO, CO2 contained in the make up gas which are chilled to 28 C.
Operating conditions:
Temperature: -28.9 C
Pressure: 147 ksc
Dimensions:
Length: 4876 mm
ID: 1981 mm
Material: Carbon Steel

(11) Synthesis converter:

19
Purpose: To convert N2 and H2 contained synthesis gas to Ammonia.
Operating conditions:
Temperature: 283 C at top
537 C at the outlet

Pressure: 146 ksc

Major equipments used in the Urea plant:

The major equipments used in the Urea plant are as under:

(1) Autoclave
(2) CO2 Stripper
(3) HP scrubber
(4) Rectifier
(5) LP Carbamate condenser
(6) First stage evaporator separator

(1) Autoclave:

Supplier: Foster wheeler, U.K.

Purpose: Used to convert Ammonium Carbamate to Urea
Operating conditions:
Temperature: 183 C at Top and 172 C at Bottom
Pressure: 140 atm
Dimensions:
Height: 30 m
No. of trays: 11 sieve trays
Material: Carbon Steel
Description:
This equipment is having 11 sieve trays. The liquid carbamate and the uncondensed
NH3 and CO2 are introduced at the bottom of the autoclave with liquid NH 3 as per the
requirement. The carbamate solution from HP scrubber is also introduced. Endothermic
reaction takes place at a temperature of 180 C and the pressure of 140 atm. Conversion of
around 33% is obtained here.

(2) CO2 Stripper:

Purpose: To strip out the unconverted carbamate from the autoclave effluents.
Operating conditions:
Fluid: Steam on shell side and Urea carbamate solution on tube side
Temperature: Shell side Tube side
In 210 C 183 C
Out 210 C 160 C
Pressure: 32 ksc 140 ksc

20
(3) HP scrubber:

Purpose: To scrub out unconverted NH3 and CO2.

Operating conditions: Shell side Tube side
Temperature
In 183 C 120 C
Out 145 C 130 C
Pressure: 145 ksc 9 ksc
Description:
The HP scrubber consists of a heat exchanger section and a top scrubbing section NH 3
and CO2 in the gases from the autoclave are condensed to form carbamate at a temperature of
about 160 C in the presence of recycled carbamate from LP carbamate condenser. The
circulating condensate temperature must be maintained to avoid crystallization.

(4) Rectifier:

Purpose: To concentrate urea solution by rectification of urea carbamate solution.

Operating conditions:
Pressure: 3 ksc
Temperature: Top Bottom Feed
108 C 135 C 103 C
Description:
The rectifier consists of a bed of rasching ring at top and separator at the bottom. The
urea carbamate solution having the HP exchanger is let down from 145 ksc to 3 ksc. As a
result of this let down part of carbamate decomposes to NH 3 and CO2. The solution from
packing bed is heated in circulation heater and the vapor, separated from the liquid in
separator section, rises up the tower packing counter currently to the colder urea solution. The
concentrated urea solution containing some NH3 and CO2 goes to the flash tank.

(5) Low pressure carbamate condenser:

Purpose: To condense overhead vapors from the rectifying column and from the desorber.
Operating conditions:
Fluid: Shell side Tube side
NH3, CO2, H2O Circulating condensate
Temperature:
In 110 C 45 C
Out 74 C 55 C
Pressure: 2.5 – 6 ksc 3.5 ksc
Description:
He over head vapors from the rectifier and the desorber are introduced at the bottom of
Low pressure carbamate condenser. Ammonia water is also added to maintain water level of
33 % od the carbamate solution to prevent the crystallization. The temperature is maintained
between 70 to 75 C.

(6) First stage Evaporator separator:

Purpose: To concentrate the urea solution from 75% to 95%.

Operating conditions:
Fluid: Shell side Tube side

21
 Steam Urea solution
Temperature:
In 143 C 90 C
Out 143 C 135 C
Pressure: 4.3 ksc 0.34 ksc
No. of passes: One One
Description:
It is climbing film single pass evaporator with the separator mounted in the evaporator.
The urea solution is heated in tube side with 5 atm pressure steam shell side from 90-100 to
125-135 C. Heated solution flashed in the separator. Water vapor and ammonia are separated
and removed by the ejector.

22
 Chapter-5 Process Utilities

In the utility plant, the units are as under:

(1) Water treatment plant
(2) Cooling towers
(3) Steam generation plant (Boiler)
(4) Ammonia storage and handling

(1) Water treatment plant:

Narmada water is supplied by Sardar Sarovar Narmada Nigam Limited from Jaspur village to
pre-treatment plant and then to water treatment plant. The water treatment plant consists of
cation, anion, storage base anion (SBA) and secondary mixed bed (SMB) units. The advantage
of property of resin material to exchange in ion in its structure, for an ion in solution is utilized
in the process of water treatment plant

Demineralization

Demineralization is the process of removing the mineral salts from water by ion exchange.
Only those substances which ionize in water can be removed by this process.
Demineralization use exchange of ion as a method of purification. Ion exchange is actually a
chemical reaction in which ions are exchanged for ions like charge in solution.
Demineralization process involves two ion exchange reactions.

o The cations (positive-ions) such as calcium, magnesium, and sodium are removed in
cation exchanger
o Anions (negative-ions) such as chlorides, sulphates, nitrates etc. are removed in anion ex-
changer.

Cation exchange reactions:

Raw water is passed through a bed of cation exchange resin which retains cationic part
of the impurities. Reaction in cation exchanger can be represented by the following equations.

ReH + NaCI  ReNa + HCL

2ReH + CaSO4  Re2Ca + H2SO4
2ReH + CaCO3  Re2Ca + H2CO3
In these equations, symbol Re is used to represent the portion of the exchanger material which
does not go into solution.

Anion exchange reactions:

Water from outlet of cation exchange unit is passed through a bed of weak base anion
exchange resin, which retains anion part of the impurities. The anion exchange resins are
organic resins containing active amine or quaternary amine groups. The following equation
can be used to illustrate the manner in which anion exchange resins operate.

23
 ReOH + HCI  ReCl + H2O
2ReOH + H2SO4  Re2SO4 + 2H2O

The anion exchange resins are available in two types known as weakly basic and
strongly basic anion resins. The weakly basic type will remove sulphate, chloride and nitrate
but can not remove silica or carbonates.

Degassing:

For removing the carbonic acid formed by the removal of cations of carbonates a degasser is
provided which will remove H2CO3 by the process of stripping with air.

The reaction is as follows. No additional chemical is used in this process.

H2CO3  H2O + CO2

Strong base anion exchange:

Degassed water passes through a bed of strong base anion exchange resin. Strong basic anion
exchangers will remove silica, sulphides and carbonates as well as the other common anions.
For this reasons, direct silica removal is possible. The removal of silica by strong basic anion
exchanger resin can be represented as follows.

ReOH + H2SiO3  ReHSiO3 + H2O

Mixed bed exchange unit:

In MB exchange unit water is passed through a bed of mixed resin i.e. cation resin and
strong base anion resin. Here any residual cation and anion of the salts in water are removed.
Chemical reaction for service and regeneration are sane as in case of cation and strong base
anion (SBA) exchangers.

24
(2) Cooling towers:

Most industrial processes need cooling medium for efficient and proper operation.
Water is the most effective cooling medium used today because,

It is normally plentiful
It is easy to handle and can carry large amount of heat per unit volume
It does not decompose
It is normally readily available and is in-expensive

The system using water as coolant is called as cooling water systems. During process,
the cooling water gets heated up and must be either cooled before it can be used again or
replaced with fresh water.

The tendency of water tables for the bore wells is forcing the industries to conserve the
water wherever possible and reusing the water to a maximum extent. For reusing the cooling
after, it must be cooled back to nearly ambient direct contact cooling tower where it is cooled
with air.

There are three basic cooling water systems.

(1) Closed recirculating system:

This system uses the same cooling water repeatedly in continuous cycle. First the
water absorbs heat from process fluid, and then releases it in another heat exchanger. In this
system, an evaporative cooling tower is not included.

(2) Once through systems:

In these systems, the cooling water passes through heat exchanger equipment only
once. The mineral content of the cooling water remains practically unchanged, as it passes
through the systems.

(3) Open recirculating systems:

It consists of cooling tower, pumps and heat exchangers. The pumps keep the water
circulating through heat exchangers where it picks up heat in the cooling tower heat is released
from the water through evaporation.
This system permits great economy in make up water requirement and average
operating temperature range is 5 C to 17 C.

Common problems associated with this system are:

 Corrosion
 Fouling
 Scaling
 Wood decay
 Microbiological contamination

25
Principle of cooling tower:

The cooling tower is one type of heat exchanger which cools hot water with air. It is
basically a tower containing treated wood as feeling material. Water falls on the filling and
breaks into fine droplets. The function of the filling materials is to increase the contact surface
between the water and air. The filling at IFFCO-Kalol is replaced arranged in such a way that
the water entering the distribution trays near the top of the tower. Fan mounted on top of the
tower induces air into the tower through air inlet, placed on either side of the tower. Across
this air flow, water drops fall through fillings.

In case that the temperature of hot water is higher than that of surrounding air, the heat
removed from water and transferred to air is the sum of the sensible heat and latent heat of
evaporation. The sensible heat is less as compared to latent heat.

Types of cooling towers:

Cooling towers are classified according to the means by which air is supplied to the
tower and the method of contact between water and air. There are two types of cooling towers.

1) Atmospheric and natural draft cooling tower

2) Mechanical draft tower

Atmospheric cooling tower:

The atmospheric tower works on the atmospheric wind current. The air blows through
the lower sides in one direction at a time, which shifts as per the season of the year and other
atmospheric conditions. Since the atmospheric currents must penetrate the entire width of
tower, the towers are made very narrow in comparison with other type and must be very long
to afford equal capacity. Towers of this type are over 2000 ft long.

Natural draft cooling towers:

These types of cooling towers operate in same way as a furnace chimney. Air is heated
in the tower by hot water, so that its density is lower. The difference between the density of
the air in the tower and outside the tower causes a natural flow of cold air into the tower must
be tall for sufficient buoyancy and must have large section because of low rate at which the air
circulates. Natural draft towers consume more pumping power. However it eliminates fan
power and may be more reliable than atmospheric tower. Natural draft tower will also operate
during hot portion of the day because the primary consideration is the temperature of air.

The mechanical draft towers is subdivided into two types

(1) Forced draft towers

(2) Included draft towers

26
Forced draft towers:

Forced draft cooling towers are the oldest types of mechanical draft towers. The fan
being-located at the base of the tower so that they force the air into the sides of the tower and
flows upwards through the falling water and out at the top of the tower.

The air Distribution is poor since the air must make a 90 deg turn while at high velocity. In
forced draft tower the air is discharged at low velocity from a large opening at the top of the
tower. Under this condition the air posses a small velocity head and tends to settle into the
path of fan intake.

(2) Induced draft cooling towers:

This tower efficiently and thoroughly eliminates the difficulties experienced from the
forced draft type. The fan being located at the top of the tower, flows upwards through the
falling water and discharges to atmosphere. In induced draft tower, air is discharged through
the fan at a high velocity and thus prevents air from settling of the induced draft tower causes
entrainment loss of water.

In these induced draft towers, air flow may be either cross flow counter current. At
IFFCO-Kalol unit cooling towers are induced draft, cross flow type.

Details of the cooling towers at IFFCO, Kalol unit:

 Induced draft type

 Pumps : Centrifugal, both – turbine as well as motor driven
 Total no. of towers: Urea plant – 3
Ammonia plant – 8
Combined – 3
 3
Capacity: 18000 m per hour
 Cooling range: 10 C
 Air sucked at 45 C
 pH maintained at around: 6 – 7.4
 pH maintained by NaOH and H2SO4
 Inhibitors are added in order to prevent the microbiological growth.

27
(3) Steam generation plant:

The modem steam generator is an integrated assembly of several essential components

its function is to convert water into steam at a predetermined pressure and temperature. It is a
physical change of state, accomplished by transferring heat produced by combustion: of a fuel,
to water. Commonly it is a constant pressure process. The steam generator is pressure vessel
into which liquid water is pumped at the operating pressure. After heat has vaporized the
liquid, the resulting steam is then ready either for delivery to the use or for heating in a super
heater.

At IFFCO-Kalol plant, a BHEL make boiler of 80 tonn per hour capacity was
commissioned on 5th October 1982 and is in operation since then. The BHEL boiler is water
tube, bid rum, forced draft furnace. It is oil and gas fired boiler at 61.5 ksc gas pressure and
410 C temperature.

Steam:

Steam is vaporized form of water. The vapor is commonly visible as cloud escaping
from the spout of tea kettle in which water in the tea kettle produces 1600 times more volume
in steam from.

We generate steam at high pressure to operate steam turbines, drive generator,

compressor and pumps. The low pressure exhaust steam from the turbines is then used for
process requirements. Steam itself will not bum nor will it support combustion and this
property of steam is utilized to purge or remove oil or gas extinguish a small fire.

Principles of steam generation and circulation:

Within the steam generation, the steam formation of steam is hinged upon a successful
transfer of heat. Once this transfer is made, steam formation will start. Steam formation can
describe by use of a simple drum heated. Steam forms in bubbles to the surface where .the
steam is released into the space above. Here in simplest form, three part cycles is common to
every steam generator.

(1) Flow water to the heated areas

(2) Flow of steam and heated water to upper areas
(3) Release of steam

There is a drum which has connected to it a loop of tubing, one of which is heated and
the other unheated. Steam bubbles from in the heated leg, generally called a riser. The
resulting steam water mixture is displaced by the relatively heavy water in the unheated leg or
down comer and circulation flow of water is established. Under operating conditions, there is
a continuous flow of water from the drum where steam releases. The factors influencing
circulation are that the column of water in the down comer leg weight more than equal column
of steam water mixture in the down comer leg. This difference represents the force available
to overcome friction and maintain circulation.

As actual steam generator consist of many tubular circuits, with a drum or drums acting as a

28
distributing and collecting device and releasing point for steam. However, actual steam,
generators are not built up by merely multiplying the number of simple individual loops, the
circuits are more complex and the number of individual paths for steam water flow varies
from point to point. The three system of circulation adopted in boiler are

a) Natural circulation system

b) Controlled circulation system
c) Combined circulation system

(4) Ammonia storage and handling:

10,000 tone ammonia storage tank:

10,000 tone liquid NH3 storage tank was built by M/s Vijay tanks & vessels Pvt. Ltd. It
is a single wall cylindrical vessel with a fixed self supporting cone roof & insulated with
polyurethane foam. Its diameter is 30m & height is 21.5m. The tank is provided with
refrigeration system & sufficient safety gadgets.

5000 tone ammonia storage tank:

5000 tone liquid NH3 storage tank constructed by India tube mills Ltd. & it was installed in
year 1992. It is in cup double wall type, cylindrical vessel with suspended deck on inner wall
& fixed self supporting cone roof on outer wall. The outer wall is insulated with polyurethane
foam. The space between two walls remains filled with NH 3 vapour which works as an
insulator. The outer shell diameter is 23.29m & height is 21.74m while inner diameter is
21.79m & height is 20.25m.

Rail tanker loading:

The surplus liquid NH3 from tanks is dispatched to IFFCO (Kandla Unit) through rail tankers.
For loading into rail tankers, five loading points are provided. At a time batch of five tankers
wagons, each having capacity of 32 tone can be loaded to NH 3 loading pumps each having
discharge capacity of 105 tone/hr at a pressure of 19.58 kg/cm2 are installed.
These pumps are also utilized for supplying liquid NH3 to urea plant as & when required.

29
 Chapter-6 Health, Hazards and Safety

Introduction to industrial safety:

Safety is becoming very important with every management as it has come to play a
very vital role in the modern development. Before many years, accidents were considered as
acts of God and nature.
Scientific minded people have analyzed accidents and developed a separate engineering
branch of accident prevention. This analysis was required due to

1. Rising trend of accidents

2. Increased use of machinery
3. Increased material handling
4. Lack of safety standard
5. Lack of training
6. Better reporting of accidents

Safety:
Safe use of man, material and machine by safe system method of work is to achieve
zero accidents which results in higher productivity.

Accident:
An accident is unplanned and unexpected events which interfere or interrupts the
planned process of work and results in personal injury.
Accident factors:
1. A personal accident injury occurs as a result of an accident
2. An accident due to unsafe act and/or unsafe condition
3. Unsafe act/unsafe condition exists due to fault of persons
4. Fault of persons are due to negligence.

List of safety equipments:

Respiratory personal protective equipments:

1. Self contained breathing apparatus sets of 30 minutes and 10 minutes
2. Continuous air line masks.
3. Trolley mounted self contained breathing apparatus set 2.5 hours
4. Canister gas mask.
5. Dust mask/cloth mask.

30
Non respiratory personal protective equipments:
1. Helmet
2. Ear muff and ear plugs
3. Goggles
4. Face shield
5. Hand gloves
6. Aprons
7. Safety Shoes
8. Suits
9. Safety harness

Warning instruments:
1. Oxygen, carbon dioxide, chlorine, ammonia indicator with replaceable sensors. Explosive
meters for measuring explosive range.
2. Fire fly instrument for confined space entry.

Gas leakage protection installation:

1. Safety Showers
2. Manual water sprinklers
3. Communication systems

Safety precautions:
 When taking samples of anhydrous ammonia and when operating or working on ammonia
valves, equipment containing ammonia such as ammonia feed pumps, operators, labora-
tory and maintenance personnel must wear overalls, safety goggles and rubber gloves. If
any part of the skin has been exposed to ammonia, wash immediately and thoroughly with
water.
 Work on the ammonia equipment should be done from the upwind side of the equipment
to avoid or minimize contact with escaping ammonia.
 The location of fire hydrants, safety showers, eyewash fountains ammonia canisters gas
mask, emergency air breathing apparatus should be well known to all person.
 Instruments containing mercury must not be used if ammonia is likely to come in contact
with the mercury.
 Heavy leakage of ammonia can be dealt by spraying large quantity of water with spray
nozzles.

31
Fire hazards:
The general types of fire are encountered in the process plants. One involves common
combustible material such as wood, rags, paper, etc. (Class ‘A’ fires), the next flammable
liquids and gases such as lubrication oils and solvents, ammonia vapors etc. (Class ‘B’ fires)
and the third involve electrical equipment (Class ‘C’ fires).

In general three things are required to make a fire

 Something which will burn, a combustible material
 Oxygen-air
 A source of ignition
Principles of fire extinguishing:
 Fire may be extinguished by withdrawing of flammable contents, interrupting flammable
flow, isolating fuel from air, heat removal to below reaction temperature or by dispersal.
 In the event of fire on electrical mains or apparatus, the affected part shall be immediately
isolated from its source of supply of electrical energy.
 Carbon tetrachloride extinguishers and Carbon dioxide extinguishers are intended mostly
for use on electrical fires and may be used on energized electrical equipment without dan-
ger to operator provides. They are properly maintaining no moisture.
 It is dangerous to throw a stream of water, a wet blanket or a stream from an ordinary soda
acid or foam type fire extinguishers on line main apparatus. When found necessary to use
them, have all neighboring mains or apparatus made dead.
 In case of fire, it is the duty of the operating personnel to protect life and property and to
extinguish the fire as quickly as possible.
 The greatest cause of fire is welding which may be required during plant operation. It
should be a stringent rule of the plant that no welding without permission of the supervi-
sor.
 Fire and safety equipment, under conditions of extreme exertion provide protection only
for a few minutes. Equipment must be cleaned, replenished and inspected for damage be-
fore being returned to service. Equipment should be maintained in excellent condition and
inspected frequently so that they are available in case of emergency.

Principle of protection and prevention:

Industrial accidents are caused by negligence of employer, the worker or the both. Employers’
efforts to reduce the accidents are generally motivated by four considerations.
a) To lessen human suffering
b) To prevent damage to plant and machinery
c) To reduce the amount of time lost as a result
d) To hold the expenses of workman’s compensation to a minimum.

 The basic reasons for preventing industrial accidents are human and economic. The most
important of these should be to avoid human suffering. Pain, suffering and wrecked lives
are not to be the byproducts of any industry.

32
Fire fighting appliances:

Type of Class A Class B Class C

extinguisher
Carbon dioxide Suitable for surface Suitable. Does not Suitable. Non-
fires only leave residue or conductor and
affect equipment or does not damage
food stuff. equipment.
Dry chemical Suitable for small Suitable. Chemical Suitable.
fire releases smothering Chemical is non-
gas and shields conductor or dry
operator from heat. chemical shields
operator from
heat.
Foam Suitable. Has both Suitable. Unsuitable. Foam
smothering effect Smothering blanket being a conductor
and wetting action. does not dissipate, should not be
floats on top of used on live
spilled liquid. equipment.
Water Suitable. Water Unsuitable. Water Unsuitable. Water
saturates material a will spread and not being conductor

Fire protection:
 Segregation buildings, fire resistant walls, flame arrestor, automatic fire extinguishers.
 Portable extinguishers, hydrants, sprinklers, fire water and trailer pump, fire fighting team
and drills.
 Safe access for fire fighting, protection against lightening and ignition and detailed provi-
sions of fire exists.
 Safety from gas cylinders and flammable liquids, dust gas, vapor and waste.

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 Chapter-7 Plant Location and Layout

The economic construction and operation of a process unit will depend on how well the plant
equipment specified on the process flow sheet and laid out.

The principal factors to be considered are:

1. Economic consideration: construction and operation cost.
2. The process requirement
3. Convenience of operation
4. Convenience of maintenance
5. Safety
6. Plant location

The plant is located 26 kms far away from the ahmedabad city on the ahmedabad-mehsana
high way.
This location is selected due to the following reasons:
(1) Costs: The costs of the land was very reasonable for the plant.
(2) Operation: The climate conditions are very favorable to the processes to be carried out.
(3) Power and fuel supply is available from the UGVCL.
(4) Transportation is very easier via road ways as well as via rail ways.
(5) Labor supply can be done from the nearest village.

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 Chapter-8 Environmental Aspect

Effluent treatment and disposal:

Approximately 18000m3/day of raw water is utilized at IFFCO kalol mainly for

process water & boiler feed water generation. Effluent treatment facilities have been installed
to handle the 3500-4000m3/day bulk & 50-600m3/day strong effluent coming out of various
out of various plants every day.

Equipment specification:-
 Strong effluent tanks
 Bulk effluent tanks
 Balancing ponds
 Effluent pit
 H2SO4 storage tanks

Effluent treatment system is installed to control the undesirable element in the liquid effluent
before discharging outside IFFCO premises.
Effluent discharge outside IFFCO should statutory requires norms imposed by state & central
pollution control boards.

Types of liquid effluents:

The total effluent generated within the plants is divided into two categories & treated
separately

Strong effluent : Having higher concentration of dissolved compounds.

Bulk effluent : Having comparatively less amount of concentrated dissolved s
Solids.

This effluent is collected either into strong effluent tanks or bulk effluent tanks. Water
from urea plant drains & washing is collected in separate tanks known as balancing ponds
diverted to bulk or strong effluent as per its analysis.

Strong effluent & disposal:

The concentrated effluent from water plant is collected in strong effluent tank &
discharged to solar evaporation lagoons inside IFFCO premise with the help of strong effluent
pumps. Nearly 600m3/day of strong effluent is generated, collected in strong effluent storage
tanks, mixed & then pumped to polythene lined solar evaporation lagoons having area about
15 hecters.

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Bulk effluent treatment & disposal:

Effluent water containing comparatively very low concentration of pollutant is called

bulk effluent. The effluent from following source is collected in bulk effluent storage tank.

 Water treatment plant with low concentration of salts

 Inert gas generation plants
 Cooling water blow down
 From hydrolyser system during upset condition
 Sand filter backwash oil separator
 Domestic effluent
 HCL fumes scrubber water

Open channels domestic water collected at effluent pit is diverted to bulk effluent.
Bulk effluent segregated from the water treatment plant is collected only in bulk effluent tank
B & allowed to mix into tank A for better neutralization effect.

Weak effluent collected & mixed in weak effluent storage tanks to form
bulk/combined effluent. Bulk effluent elements are controlled by adjusting the dilution water
flow in normal operation.

About 3000m3/day combined effluent is pumped outside IFFCO premise. The effluent
quality is continuously monitored within plant before final discharge to meet statutory
requirement of pollution control board.

The pH of the bulk effluent is continuously recorded by pH analyzer. pH is controlled

by dosing H2SO4 or 2% spent NaOH collected from regeneration of SBA units in water
treatment plant. Samples are also analyzed in laboratory at diff intervals. Bulk effluent is
discharge outside IFFCO premise once the analysis report confirm to the limits set by GPCB.

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