FFBL

Submitted By:

Name: Ahtasham Ghani

University: Quaid-e-Awam University of Engineering
Sciences & Technology Nawabshah

Field: Electronic Engineering.

Submitted to: The Technical Training Centre

FAUJI FERTILIZER BIN QASIM LIMITED

Date of Submission: July 5-2019

 Table of Contents

Introduction
Safety
Plant Utilities
Orientation Di-ammonium Phosphate
Ammonia Plant
Study and Orientation of DISTRIBUTED CONTROL
Machinery of Urea, Dap and Ammonia Plant
Bagging and shipment
Tool Shop
 AN INTRODUCTION

OF
FAUJI FERTILIZER BIN QASIM
LIMITED

FFBL is one of the largest granular Urea and Dap fertilizer complex in Pakistan,
built at the cost of US$469 Million in November 1993, located in Eastern Zone of
Bin Qasim. The plant is approximately 45km south east to Karachi City and it is
connected to National High way.

FFBL is only fertilizer company in Pakistan which is producing DAP (DIAMONIUM

PHOSPHATE) .It is the soul producer of Urea and Dap in the country and forms
part of Fauji group, one of the largest conglomerates of Pakistan. FFBL and FFC
jointly holds 63% of Urea and 51% of DAP share of Pakistani fertilizer market.

FFBL increases its product capacity which is higher than the designed parameters.
There are many features of FFBL that make it distinct from any other Fertilizer
complex in Pakistan. It is the first granulated Urea plant and the first generating
60 HZ 110v power. Most modern state of the art instrumentation system like
Distributed Control system (DCS) and Programmable logic Control (PLC) are
applied on plant site.

FFBL also have membership of industry association and trade bodies;

 Rawalpindi Chamber of Commerce

 International Fertilizer Association

In 1993 incorporation of the company initially named as FFC-Jordan Fertilizer

Company.

Renamed as fauji Fertilizer Bin Qasim Ltd., as Jordan Phosphate Mines Co. had
sold its entire rquity in the company.

Achieved ISO Certification

 QMS (9001:2000)
 EMS (14001:2004)
 OHSAS (18001:1999)

Successful completion of Ammonia BMR resulting in increased production of

Ammonia by 23% from 1,270MT to 1,570 MT and Urea by 15% from 1,67o MT
to 1,920 MT per day

Incorporation of FFBL Power Company Limited

Received two awards in Corporate Social Responsibility

Bronze Medal in ERP from SAP, Germany

 Highest ever Dap production of 72,390 MT in a month

Yearly DAP production 768,004 MT

4th in Chemical sector forbest corporate report award by ICAP and ICAMP

Investment in Noon Pakistan Ltd

Safety

Safety is the first priority in the FFBL. Safety is a measure of success in any work.
In FFBL, safety is considered equal to the production.

The FFBL is registered with company named “OSHA”. The Occupational Safety
and Health Administration (OSHA) is an agency of the United States Department of
Labor.

Safety means constant evaluation of thing we do and how we go about doing

them so that we would not get hurt that our equipment’s condition will not contribute
to an accident, and that our fellow operators would not get hurt.

Safety Precautions

 Safety helmets, shoes should be worn at plant site during working and other
activity.
 Googols for protection against liquid and gases.
 Gloves for protection against acid and alkaline solution
 Ear plugs for protection against higher frequency of noise.
 Respiration Mask with filters for duct and poisonous gases.
 Compressed air mask for protection against CO.
Plant Utilities

Utility plant provides the facilities to other plant to operate well and continuously.

 For that purpose it is included of following equipment’s.

 Cooling tower
 Power generation
 Filtration of water
 Supply of water and steam for the whole plant
 Chillers and hvac
 Compressed air for whole plant
 Dimin water, hot water
 Natural gas distribution
 Raw water storage
 Fire water
 Portable water
 Now we will discuss major areas of utilities in description
Orientation Di-ammonium Phosphate (DAP)

Inputs:

1) Ammonia
2) Sulphuric acid
3) Phosphoric acid
4) Sand

Output  DAP granules

Procedure:

All these steps are being carried out simultaneously. All the procedure can be
Summarized in a few steps:-

 Ammonia, sulphuric acid and phosphoric acid added in the pre neutralizer.
This forms the slurry.

 The slurry is added along with sand to the granulator. Here grains are
 Formed by simple mixing.

 The grains are then moved to the dryer where it is dried at 90oC for 2 minutes.

 The heat is provided by the hot gas generator which maintains the temperature.
 Then with the help of belts this is fed to the vibratory feeder for screening.

 Only 1/3rd are on size and are moved to the de dusting section De dusting is
done to remove large lumps.

 Scrubbing is also done to absorb ammonia by water.

 The oversize grain, undersize grain and ammonia water are all recycled.

Ammonia Plant

Ammonia Plant is the heart of FFBL or any other fertilizer company because this
plant is responsible for Ammonia production and also Carbon Dioxide which is
used in the manufacturing of Urea or in other words a shutdown of ammonia
plant means a shutdown of whole fertilizer company. Following are the names of
someof the major equipment under ammonia plant.

 Furnace (Primary Reformer).

 Secondary Reformer.
 Heat Exchangers (Shell & Tube, Flat Plate, Finned Type).
 Boiler
 Start up Furnace
 Start up Heater and many more.

Inputs:

1) Natural gas
2) Air
3) Steam

Outputs:

1) Ammonia
2) Carbon dioxide
Procedure

 Desulphurization of natural gas.

 Crack natural gas in steam to produce hydrogen.
 Remove oxygen from air to give nitrogen in secondary reformer.
 Cool nitrogen and hydrogen in heat exchanger.
 Steam is removed and temperature elevated to 400-600oC.
 2N2+3H2=2NH3
 Liquid ammonia is produced.
 Goes to Urea if storage is full.
Study and Orientation of DISTRIBUTED CONTROL SYSTEM

Basically There are four types of signals on which the DCS system is working i.e.

 Analog Input – Transmitters (4ma to 20ma).

 Analog Output – Control Valves (INPUT/OUTPUT).
 Digital Input – Switches.
 Digital Output – (Solenoid Operated Valve ).

There are many junction boxes nearby in plant site, in-which all the wires are
combined related to DCS.
After this junction boxes are wired through the Marshalling panel which is found
in CONTROL SYSTEM ROOM. Furthermore these wires passes from CTU
(conditioning termination Units) in these signals of 4ma to 20ma converted to 1 to
5volts accordingly. Then forwarded to I/O Slaves and then to Multi-functioning
Processor, in-which the signal of 1 to 5 volts converted to binary values and moved
towards NPM (Network processing module) and then to NIS (network interface
slave).

Machinery of Urea, Dap and Ammonia Plant

This includes the moving parts of the plant. Their summary is as follows:
 Compressors (screw type mainly)
 Pumps
 Steam turbines
 Gas turbines

Two types of pumps are used:

1) positive displacement (plunger and piston types)

2) centrifugal type (mostly used)

3) The types of pump impellers are open impeller, partially closed impeller
and closed impeller. In pumps there are steam turbine pumps which are
run by steam turbines.

 Couplings

The two types of coupling are mechanical and hydraulic. The advantage of
hydraulic coupling over mechanical is that there are no jerks. Thermal plug
and fuse plug are two methods for the safety of the coupling.

 Seals

Gland seal and mechanical seal are used.

 Bearings
 Feeder
 Elevator (pulley and belt)

Bagging And Shipping Area

Urea and DAP have to autonomous networks, entirely separated which can work
perfectly independen of each other. Urea and DAP are weighed and transforred
from the production plants to dicharge belt conveyors. The goal of these belt
conveyors is to take the final product to the stockyard or storage building where it
is either stored or directly transferred to the shiping section.

Shipping Section

In shipping section the final product from storage building is packed seprately in
50 kg bags by modern techniques. Shipping sectio contains 11 bagging hoppers of
which 6 hoppers are assigned to urea bagging and 5 oppers to DAP. The prduct
isdespatched to these hoppers by means of movable belt conveyors respectively.

Each bagging line includes

 The hopper to store the bagging product over correspondin bagging machne
 The electronic weighing unit for separation of 50 kg product.
 The autometic sewing machine for the simultaneous sweing of the ineer PE
liner and outer cotton bag
 The wooden salttype conveyors below the bagging machine for continos
conveying of filled bags.

Equipment used in bagging and shipping

 Scraper
 Reclaimer
 Sewing machine
 Tripper
 Delumper
 Bucket elevator
 Hopper

FOUR SECTION OF PRODUCT HANDLING AND SHIPPING

 1. Production to stockyard
2. Storage and products
3. Screening and conveyer network to bagging
4. Products to bagging and shipping

Conveyer Belt

The belt conveyer is essentially a very simple piece of equipmen . It consists of an

endless belt on which the solids are conveyed horizontally or at small angles to the
horizontal. The main elements of the belt conveyor are the belt itself drive the
support and the tightened. Power required to drive a belt conveyor is made up of
five components. Power to drive the empty belt, to move the load against friction
of the rotating part , to raise or lower the load , to overcome inertia in putting
material into motion , and to operate a belt driven tripper if required.

TOOL SHOP

Some of the tools are as follows:

 Argon set
 Baby grinder
 Angle grinder
 Cutting set(gas cutting)
 Plasma cutter (for CS)
 Eye bolt
 Crow bad
 Pneumatic gun
 Rubber hammer
 Pump set
 Ladder
 Jack
MISSION

FFBL is committed to remain amongst the best companies by maintaining the

spirit of excellence through sustained growth rate in all activities, competitive
price, equity fertilizer and providing safe and conducive working environment for
the employees.