Training Report

ON
Ammonia Plant
AT
NATIONAL FERTILZERS LIMITED,NANGAL
In Partial fulfillment for Summer Training Programme
OF
Bachelor of Technology
IN
Chemical Engineering.
Submitted By: Submitted To:
ANMOL AGNIHOTRI DR.RAJESH KATIYAR
SR. NO. : 7/15 ASSOCIATE PROFESSOR
ROLL NO. : 1504551008 Ms. SHIVANGI MAM

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 PREFACE

As per the requirement of B – TECH degree course in Chemical Engineering industrial training
has to be undertaken after third year. To full-fill this requirement I took my training from NFL
NANGAL. During this period everything that I learned and study :

This report contain all the necessary information about the plant viz AMMONIA PLANT . it also
contain an overview of NFL. The information has been prepared to best of data available at my
knowledge and time.

It is pleasure to face the industrial life that helped me to convey my theoretical concepts into
practical knowledge.

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 ACKNOWLEDGEMENT
I have undergone training at NATIONAL FERTILIZER LIMITED , NANGAL. During this
training I have learned a lot for which I pay my heartiest gratitude to all the staff member of NFL,
NANGAL who helped me in all respects in full-filing my desired of getting a successful industrial
training in an esteemed organization.

I am very grateful to Mr. SHUBHANKAR MITRA ( ASSISTANT MANAGER –HRD) & Mr.
I.P. SINGH ( CHIEF MANAGER PRODUCTION ) & Mr. PRAVEEN KUMAR ( ASSISTANT
SHIFT MANAGER) who deputed me with senior engineers and provided me knowledge of
various chemical process and equipment‘s in detail that are used in industry . I pay my sincere
thanks to all supervisor and other official of the site for providing me the details of the respective
plant. I am very thankful to PROF. S.K. GUPTA ( HEAD OF CHEMICAL DEPARTMENT,
HBTI – KANPUR ) and all the professors of Chemical Engineering Department who guided and
support me time to time.

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INDEX.....................................................................................................PAGE NO.

1.History Of Organisation………………………………………………...1

2.NFL Nangal Unit………………………………………………………...2

3.Products of NFL…………………………………………………………3

4.Ammonia Plant…………………………………………………………..4

5.Process Steps……………………………………………………………..5

5.1Feed Gas Compression……………………………………………....6-7

Preheating , Desulfurization

5.2Primary Reforming…………………………………………………..7-8

5.3Process Air Compression…………………………………………….8-9

5.4Secondary Reforming………………………………………………...9-10

5.5Shift Conversion………………………………………………………10

5.6Carbondioxide Removal……………………………………………...11-12

5.7Methanation…………………………………………………………...12

5.8Drying………………………………………………………………….12-13

5.9Cryogenic purification………………………………………………..13

5.10Syn Gas Compression………………………………………………..13-14

5.11Ammonia Synthesis…………………………………………………..14

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 History Of Organisation

The rise in fertilizers consumption in India has been quite phenomenal during the past three
decades. To meet the rise of consumption of fertiliser the creation of additional capacity was also
planned.

It is in this context the National Fertilizers Limited (A public sector undertaking) was to implement
nitrogenous plant for demand of fertilisers in the region of India.

The NFL,Nangal consequent on the reorganisation of FCI group of plants. Nangal plant was
transferred to NFL and subsequent expansion plant of Nangal Unit was commissioned with an
installed capacity of 3.30 LMT. Further in order to sustain and enhance the company’s growth,
NFL successfully revamped urea plant of Nangal Unit and commercial Production was
commissioned after revamped w5.e.f first Feb 2001 thus enhances the annual installed capacity
from 3.30 LMT to 4.785 LMT. As per guidelines of government of India, in order to reduce the
subsidy burden and carbon footprint, NFL revamped the Nangal unit on LSTK basis for
changeover of feedstock from LSHS/FO to Natural gas and commercial production on gas was
commenced during April, 2013.

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 NFL NANGAL UNIT

• SALIENT FEATURES:

Installed Capacity: 478500 MTPA

Capital Investment Rupees: 229.19 Crores
Commencement of Production: November 1, 1978

• PROCESS:

Ammonia: KBR SMR(Steam Methane Reforming) with purifier technology

Urea: Technimont Total Recycle Process
Raw materials: Coal, LNG/RLNG, Power, Water

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 PRODUCTS OF NFL

 PRODUCTS:

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1. NEEM COATED UREA
2. KISAN UREA
3. BIO-FERTILIZER
3.1 RHIZOBIUM
3.2 AZETOBACTOR
3.3 P.S.B. PHOSPHATE SOLUBILISING BACTERIA
4 NITRIC ACID
5 AMMONIUM NITRATE
6 ANHYDROUS AMMONIA
7 SODIUM NITRATE
8 SODIUM NITRITE
9 AGROCHEMICALS
10 BENTONITE SULPHUR
11 CERTIFIED SEEDS

AMMONIA PLANT
(NFL, NANGAL UNIT)

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PROCESS DESCRIPTION:

The front end of Ammonia Plant is based on KBR purifier TM technology which is a low energy
Natural Gas steam reforming process i.e. offered and licensed by the KBR. The New front end is
combined with the existing synthesis loop to produce 950 MTPD of Ammonia. The Plant design
and performance is based on the lean Natural Gas composition which is controlling case. However,
the plant will also operate and achieve the name plate capacity with the rich Natural Gas
composition.

Composition(dry mole %) Lean Gas Rich Gas

CH4 97.97 84.50
C2H6 1.79 9.00
C3H8 0.14 3.00
C4H10 0.00 2.00
C5H12 0.00 0.25
CO2 0.00 0.00
N2 0.10 0.25
LHV(Kcal/Kg) 11908 11515
Total Sulfur, ppmv <10 <10
Pressure Kg/cm2 40.5 40.5
Temperature (K) 30 30

 The main process steps are as follows:

• Feed gas compression, Preheating and Desulfurization

• Primary Reforming
• Process air Compression

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• Secondary Reforming

• Shift Conversion
• Carbon Dioxide Removal

• Methanation
• Drying

• Cryogenic Purification

• Syn-Gas compression
• Ammonia Synthesis

 FEED GAS COMPRESSION , PREHEATING &

DESULFURIZATION

Natural gas for feed and fuel is supplied at the plant battery limit at 300 0C and 40.5 kg /cm2 natural
gas is initially directed to a Feed Gas Knockout Drum , where any entrained liquid are removed.

10
Part of the natural gas from the outlet of Feed gas knockout drum is sent to the primary reformer
furnace as fuel.

The remaining natural gas is compressed to 57.3 kg/cm2 in the Feed Gas compressor, which is
driven by an electric motor. To allow the compressor to operate over a wide range of operating
conditions without going into surge, it is provided with Kickback line with a Kickback cooler. This
allows some of the compressor discharge gas to be recycled back to the compressor suction through
Feed gas knockout drum. This is typically required during plant start-up and turn down conditions
when the feed gas flow is much lower than normal.

After compression in feed gas compressor , natural gas feed is mixed with a small amount of sy-
ngas recycled from the synthesis loop which provides the required hydrogen for the downstream
hydrotreater. If the synthesis loop is not in operation, the hydrogen recycle stream can be taken
from the Methanator Effluent Separator overhead, and added at the suction to Feed gas
compressor. There is also a provision to generate hydrogen via ammonia cracking in the primary
reformer during initial plant start-up.

The mixture of natural gas and hydrogen is heated to 3710C, first using condensing LP steam in
the LP steam/Feed Gas Preheater , and then in the Feed Gas Coil located in the convection section
of the primary reformer . The hot gas then enters a two-step desulfurization system. In the first
step, the hot gas passes through Hydrotreater, which contains cobalt/molybdenum (CoMo)
catalyst. The catalyst ensures hydrogenation of organic sulphur compounds, if present in the feed
gas, such as mercaptans (RSH), carbonyl sulfide (COS), to hydrogen sulfide.

COS + H2 CO + H2S

RSH + H2 RH + H2S

In the second step, hydrogen sulfide in the feed gas is removed in two desulfurizers. Each
desulfurizer contains a bed of zinc oxide. Hydrogen sulfide reacts with the zinc oxide and is
retained as zinc sulfide, thereby producing an effluent stream containing less than 0.1 ppmv of
sulphur.

H2S + ZnO ZnS + H2O

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The two desulfurizer vessels are arranged in series, in a lead-lag configuration such that either
vessel can be taken out of service to replace the zinc oxide while the other vessel remains in service
and plant operation is not interrupted. Each vessel contains enough zinc oxide to last for at least
one year of continuous service at the design inlet sulfur concentration of 10 ppmv hydrogen sulfide
in the feed gas.

 PRIMARY REFORMING

Desulfurized feed gas is mixed with process steam from the overhead of the Process Condensate
Stripper to give a steam to organic carbon molar ratio of 2.7:1. The feed gas flow is controlled by
ratio to the process steam flow. This feature protects the reforming catalysts in case of loss of
process steam. The mixture is preheated to about 495 0 C in the convection section of the Primary
Reformer . The preheated mixed feed is distributed over tubes packed with reforming catalyst and
suspended in the radiant section of Primary reformer. Steam Reforming reactions takes place over
the Nickel based reforming catalyst in the radiant tubes to form carbon monoxide, carbon dioxide
and hydrogen. Steam reforming reaction for any hydrocarbon can be written as

CnHm + nH2O nCO + (2n+m)/2 H2

For methane the above reaction becomes:

CH4 + H2O CO + 3H2

The water gas shift reaction converts carbon monoxide to carbon dioxide and additional hydrogen:

CO + H2O CO2 + H2

The Primary reformer effluent gas at 48.0kg/cm2 (a) and 72loC contains about 29.9 mole% (dry
basis) of unreacted methane. The Primary reformer effluent is sent to the Secondary Reformer via
the Primary Reformer Effluent Transfer line .

Heat for the endothermic steam reforming reactions in Primary reformer is supplied by the
combustion of fuel gas in burners located at the top of the furnace. The burners are located between
rows of catalyst tubes and operate with downward firing. Thus, the heat flux is highest at the top
of tubes, where the process temperatures are the lowest and most of the reforming reaction is being
done. The outlet manifolds and riser tubes are located inside the radiant box, for heat conservation.
The primary reformer uses the latest refractory and insulation technology.

12
Ceramic fiber lining in the radiant section provides rapid thermal response due to low heat storage.
Super duty hard factory is used where flames may contact the sidewalls. The reformer is designed
with 2% oxygen (dry basis) in the flue gas at the outlet of the radiant section. This ensures complete
combustion of the fuel in the burners.

The Purifier process uses excess air in the secondary reformer. This feature reduces the size of the
primary reformer furnace by about one third, and lowers the process gas outlet temperature from
the reformer substantially, as compared to a conventional ammonia plant. The lower outlet
temperature results in longer tube and catalyst life.

The primary reformer is designed to obtain maximum thermal efficiency by recovering heat from
the flue gas in the convection section. The heat recovered is used for the following services:

 Mixed Feed Preheating

 Process Air Preheating
 Steam Superheating
 Feed Gas Preheating
 Combustion Air Preheating

 PROCESS AIR COMPRESSION

Process air is drawn in through an Air Filter which removes any dust particles. Process air is then
compressed in an integrally geared Process Air Compressor to a pressure of 50.8kg/cm2 (a). Inter
Stage cooling and condensate separation is provided in process air compressor. Process air
compressor is controlled to maintain a constant pressure drop across the downstream process air
control valve. During plant startup or turndown operation, enough compressed air is vented to
maintain the minimum load on the compressor to prevent it from going into surge. Compressed
process air is then preheated to about 5100C in Air preheat Coil located in the convection section
of Primary reformer, and sent to the secondary reformer. Steam is continuously added to the
process air to the inlet of the coil. This feature prevents backflow of hot gas from the secondary
Reformer in the event of Process air compressor trip. Process air compressor also provides plant
and instrument air which is required for the entire plant from one of the intermediate stages of the
compressor.

13
  SECONDARY REFORMING

Hot compressed process air and primary reformer effluent are sent to the top section of the
Secondary Reformer where spontaneous combustion occurs. The resulting hot gas mixture then
flows down through a bed of Nickel based reforming catalyst in the lower section of Secondary
reformer. The heat released from the combustion reactions in the upper section supplies the heat
for the steam reforming reactions in the lower section, converting methane to more carbon oxides
and hydrogen. The unreacted methane content in the gas leaving Secondary reformer is about
1.8mole% (dry basis).

In a conventional ammonia plant, the amount of process air introduced in the secondary reformer
is controlled carefully to produce a stoichiometric 3:1 molar ratio of hydrogen to nitrogen at the
inlet to the ammonia converter.

In the Purifier process, about 50 percent excess air is used in the secondary reformer with the
excess nitrogen being removed in the Purifier Cold box. The excess air produces additional
combustion heat for the reforming reactions in the Secondary reformer. Thus the reforming load
is shifted from the primary reformer to the secondary reformer. This feature lowers the primary
reformer outlet temperature and furnace duty. In addition, the methane leakage from the reforming
section is relaxed as the unreacted methane is removed in the Purifier Cold box. This reduces the
overall reforming severity and lowers the secondary outlet temperature to about 906 0C. The lower
reformer results in milder conditions for the downstream waste heat boiler as compared to
conventional plants.

The heat in the Secondary reformer effluent is recovered by generating HP steam (104kg/cm2 (g))
in the Secondary Reformer Waste Heat Boiler is a KBR proprietary design. It is vertical water
tube, themosyphon boiler.

For safety reasons, Secondary reformer, Primary Reformer Effluent Transfer line and waste heat
boiler are provided with water jackets. The water jackets keep the metal walls cooler, and provide
an early warning system against any possible refractory failure which allows an orderly shutdown
of the plant in such a scenario.

 SHIFT CONVERSION

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The cooled secondary reformer effluent is sent to high Temperature shifter (HTS) Converter
reactor. Here , the gas flows over a bed of HTS catalyst (Fe based catalyst ) and carbon monoxide
reacts with steam to form carbon dioxide and hydrogen via the water gas shift reaction.

CO + H2O ---- CO2+ H2

About 72% of the carbon monoxide is shifted to carbon dioxide in HTS converter. The carbon
monoxide content in the HTS effluent is about 2.9% (dry basis). The water gas shift reaction is
exothermic. The gas leaving the HTS converter is cooled by generating high pressure steam in the
HTS effluent and by heating high pressure boiler feed water in the HTS effluent.

The gas then passes through a LTS guard bed which is packed with LTS catalyst. Catalyst volume
is based on 2.5 years of catalyst life. LTS guard effluent is cooled by the BFW in the LTS guard
bed effluent and is then sent to LTS shift converter at about 208 degree celcius. Most of the
remaining carbon monoxide is carbon dioxide in LTS, leaving a residual carbon monoxide content
about .25 mole% (dry basis) in the LTS effluent. LTS effluent is cooled against BFW in the LTS
effluent and by raising low pressure steam in the LTS effluent low pressure steam generator. The
gas is then sent to CO2 stripper and further cooled in LTS effluent to about 70 degree celcius. The
overhead of raw gas separator is sent to carbon dioxide removal unit.

 CARBONDIOXIDE REMOVAL
The carbon dioxide removal unit uses two stage aMDEA process licensed BASF. The process gas
enters the bottom of CO2 absorber at 70 degree celcius. It is contacted counter-currently with the
semi-lean aMDEA solution. The gas then flows upward into top section of CO2 absorber tower
where it is contacted with lean aMDEA solution. The gas is then passed through a water wash
section,a demister pad and is sent to CO2 absorber overhead knockout drum to remove traces of
entertained aMDEA solution.

Rich aMDEA solution from the bottom of CO2 absorber is first Passed through a power recovery
hydraulic turbine. The power recovered in the hydraulic turbine is used to drive one of the semi-

15
lean solution pump. The rich aMDEA solution is then sent to high pressure flash where most of
the dissolved inert are flashed out from the rich solution.

As the flash gas from the high pressure flash contain a fair amount of the carbon dioxide .this gas
is further scrubbed with the slipstream of lean aMDEA solution in the high pressure gas scrubber
to recover almost all of the carbon dioxide.

The high pressure gas scrubber bottoms are mixed with the high pressure flash bottom and sent to
the CO2 low pressure flash. The low pressure flash operates about 1.8kg/cm2 .at this low pressure
most of the carbon dioxide from the rich aMDEA solution is flashed. The solution flows down
through the packed bed where it is contacted with rising vapor from CO2 stripper.condensate is
separated from the CO2 low pressure flash overhead knockout drum and pumped by the CO2 low
pressure reflux pump to provide wash water for CO2 absorber. CO2 low pressure flash and high
pressure flash gas scrubber . the makeup water required for the CO2 removal unit is also added to
the suction of reflux pump.

Semi lean aMDEA solution is drawn from the bottom of the low pressure flash. Most of the semi-
lean solution is pumped by the pumps to the bottom section of CO2 absorber about 17% of the
semi-lean solution is pumped by the semi lean solution circulating pump heated to about 111
degree celcius in the lean/semi-lean solution exchanger and then sent to CO2 stripper. LTS effluent
gas supplied heat to the CO2 stripper which is used to strip carbon dioxide from the aMDEA
solution. The stripped carbon dioxide flows up to the stripper and is then sent to low pressure flash.
Lean aMDEA solution is drawn from the bottom of CO2 stripper .the lean solution is cooled by
the exchanging heat with the semi-lean solution is then pumped by the lean solution pump to the
top section of CO2 absorber.

The carbon dioxide removal unit is designed with a slightly negative water balance to maintain the
concentration of aMDEA solution in the system , a continuous make-up of about 220kg/hr of
demineralized water is required. This design eliminate the discharge of any aMDEA solution loss.
Given the composition of natural gas , the steam reforming front end does not produce sufficient
amount of carbon dioxide ,when producing syn-gas sufficient for 950 MTPD of ammonia. hence
additional feed gas to be reformed and passed through to meet requirement of the carbon dioxide.

 METHANATION
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The vapor CO2 absorber Overheated Knockout Drum is preheated to methanation reaction
temperature .using the methanator effluent in the Feed/Effluent ex-changer and using condensing
high pressure start-up heater. The preheated gas then flows through the methanator where carbon
dioxides converted to methane by reaction with hydrogen over Ni catalyst .Residual carbon oxides
leaving the methanator are less than 5ppmv(dry basis)

CO2 +4H2 ------------- CH4 + 2H2O

CO + 3H2 -------------- CH4 + H2O

The methanation reactions above are slightly exothermic and could potentially over heated in
methanator. This could occur if an upset in the shift (LTS/HTS) or carbon dioxide to methanator
an automatic shutdown system is provided to prevent overheating

 DRYING
In prepration for drying the methanator effluent is cooled by heat exchange with methanator feed
ex-changer to 79C and against cooling water in methanator effluent cooled to 38C the methanator
effluent then combines with recycle synthesis loop purge gasfrom high pressure ammonia scrubber
and the mixture is chilled using ammonia refrigerant in the methanator effluent chiller to about 4C
.The chilled gas is sent to methanator effluent separator where the process condensate is separated
out

The overhead from Methanator effluent separator is then sent to Molecular sieve dryers

Then two dryers the packed with zeolites based dessicant and operate cyclically .Each dryer sized
to remove traces of ammonia. Residual carbon dioxide and the water in 24-hours drying cycle

The dryer regeneration facilities are designed for a 20hrs heating and cooling cycle to provide a
comfortable safely margin of 4 hours of stand-by time .Regeneration and cooling of driers are done
using waste gas from the purifier .During dryer regeneration the waste gas is heated to 265C in the
molecular sieve Regeneration heater by condensing steam from the 63kg/cm2 steam heater

 CRYOGENIC PURIFICATION

17
Dried raw synthesis gas is then sent to cryogenic purification section. The gas is cooled by heat
exchange with make-up synthesis gas and with purifier waste gas is the top section of the purifier
Feed/Effluent ex-changer .The gas then flows through the purifier expander where work is remove
to provide net refrigeration duty required for purifier .THE expander effluent is further cooled and
partially condensed in bottom section of effluent ex-changer and enter the purifier rectifier at 171C
.Liquid from the bottom of rectifier is partially evaporated at reduced pressure in the shell side of
purifier rectifier condenser and provides cooling for condenser and re-flux for the column. the
rectifier contain nitrogen ,methane and some of hydrogen.

The partially evaporated liquid leaving the shell side of purifier rectifier condenser is reheated and
the vaporize ineffluent exchanger and leave as purified waste gas, the waste gas is used as carrier
gas to regenerate the molecular sieve drier and then sent to fuel system, the makeup syn-gas from
the top of purifier rectifier is heated ineffluent exchanger and send to the synthesis gas compressor
at 1.8 degree celcius, the operation of purifier to maintain and control the exact molar ratio of
hydrogen and nitrogen of 3:1 the other impurities in make-up gas is 32% argon and less then
50ppmv of methane .

 SYNGAS COMPRESSION
The process for syn-gas compression and ammonia synthesis section of the plant are identical,
except for new mechanical refrigeration system and purge gas ammonia recovery system all the
existing equipment in the syn-gas compression and ammonia synthesis sections will be reused.

The purified syn-gas is compressed in four stages, steam turbine driven synthesis gas compressor,
recycle gas is added to the syn-gas before the fourth stagesuction , and the combined flow leaves
the compressor at about 197.2kg/cm2.

The syn-gas compressor is driven by turbine that is rotated with the help of 91 ata steam pressure.

 AMMONIA SYNTHESIS
Ammonia is produced in fixed – bed , vertical converter. Effluent in the hot exchanger. It then
flow to the ammonia converter. Ammonia concentration in the feed to the converter is about 2.7

18
mole %. Ammonia is synthesized in two adiabatic beds provided with an inter cooler and after
cooloer.

The converter effluent containing about 17.70 mole% ammonia at 726 K . it is cooled by generating
high pressure steam in the syn – loop Waste heat Boiler and by heating boiler feed water in the
converter effluent BFW Preheater. After recovery of heat, the converter effluent is cooled to 311
K by cooling water in the converter effluent cooler. The converter effluent is then sent to the cold
Ex – changer where it is chilled by heat exchangerwith the recycle gas. The gas is finally chilled
to 269 K against the ammonia refrigerant in the ammonia chiller.

Liquid ammonia is separated out from the converter by the separator while the vapor is recycled
to the last stage of compression by line. A small fraction of the vapor stream from purged from the
synthesis loop is control the inerts (methane or argon) concentration inlet to the ammonia converter
at 3.20 mole% liquid ammonia is depressurized to about 37.0kg/cm2 in a flash drum. This
reduction in pressure dissolve most of the gas in liquid ammonia. Than this recovery ammonia is
sent to the Horton Sphere as product of capacity 2500m3. The expected purity of the ammonia is
99.85wt% ammonia. The Horton Sphere is operate about 4.2kg/cm2 pressure and it is used to
pump ammonia to Urea Plant at 283 K which passes through the ex-changer.

19