A TRAINING REPORT ON

UREA- PLANT

TRAINING DURATION: 6th JUNE 2011 TO 2nd JULY 2011

SUBMITTED TO Dr. D. N. VERMA D. G. M.-TRAINING IFFCO PHULPUR, ALLAHABAD 1

SUBMITTED BY SAUMYA TIWARI 3rd yr, B. Tech. (CHEMICAL ENGG.) H.B.T.I. KANPUR

CERTIFICATE

This is to certify that the Training Report on UREA-1 plant has been prepared by Saumya Tiwari d/o Rakesh Tewari ( 3rd yr B.Tech, Chemical Engineering) of HBTI Kanpur (G.B.T.U Lucknow) and she has taken keen interest in completion of her assignment under my guidance .

Mr. R.B. Rai D.G.M.(Urea-1) IFFCO ,Phulpur, Allahabad

Mr. A. K. Chaturvedi Chief manager(Urea-1) IFFCO,Phulpur, Allahabad

Mr. S.K. Mishra Sr. Manager(Urea-1) IFFCO, Phulpur, Allahabad

ACKNOWLEDGEMENT
Industrial training is a part of our academic activities and every student has to attach himself with any one of the leading industries for getting insight of this subject. The entire period of training, I wish to express my gratitude to the management of IFFCO Phulpur, Allahabad, especially its management and training department who gave me this opportunity by permitted to me to work under their kind supervision. I would like to express my thanks to Dr. D. N. Verma who provided me an opportunity to do training. I wish sincerely thanks to Mr. Rajan Singh for all outwork rendered to me for completing this training report. At the submission of this project we take the opportunity to express our deep sense of gratitude to Mr. R.B. Rai, Mr. A. K. Chaturvedi, Mr. S.K. Mishra and Mr. V. P. Singh for supporting and guiding us. We would also like to appreciate all the plant operators and engineers of this organization who helped us enough in quenching our thirst to smallest queries.

TABLE OF CONTENTS:
SR. NO. 1 2 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 5 6 7 8 BRIEF DESCRIPTION OF CONTENTS Introduction of IFFCO Introduction of IFFCO Phulpur unit Ammonia plant Brief description of ammonia plant Brief process description of ammonia plant Urea plant Brief description of urea plant Urea : physical and chemical properties Process technology Uses of urea Brief process description of urea plant Effect of process variable in urea plant Urea production performance Equipment details Corrosion in urea plant Offsite description Power distribution DCS System Environment and pollution control Fire and safety Conclusion References Pg. no. 5 7 10 11 13 18 19 20 21 22 23 29 31 32 36 37 42 42 43 44 46 48

INTRODUCTION
Indian Farmers Fertilizers Co-operative Limited (IFFCO) was registered on November 3, 1967 as a Multi-unit Co-operative Society. On the enactment of the Multistate Co-operative Societies act 1984 & 2002, the Society is deemed to be registered as a Multistate Co-operative Society. The Society is primarily engaged in production and distribution of fertilizers.

IFFCO commissioned an ammonia - urea complex at Kalol and the NPK/DAP plant at Kandla both in the state of Gujarat in 1975. Another ammonia - urea complex was set up at Phulpur in the state of Uttar Pradesh in 1981. As part of this vision, IFFCO has acquired fertilizer unit at Paradeep in Orissa in September 2005. As a result of these expansion projects and acquisition, IFFCO's annual capacity has been increased to 3.69 million tons of Urea and NPK/DAP equivalent to 1.71 million tones. In pursuit of its growth and development, IFFCO had embarked upon and successfully implemented its Corporate Plans, Mission 2005 and Vision 2010. These plans have resulted in IFFCO becoming one of the largest producer and marketer of Chemical fertilizers by expansion of its existing Units, setting up Joint Venture Companies Overseas and Diversification into new Sectors. IFFCO has now visualized a comprehensive plan titled Vision-2015 which is presently under implementation. IFFCO has made strategic investments in several joint ventures. Godavari 5

Fertilizers and Chemicals Ltd (GFCL) & Indian Potash Ltd (IPL) in India. As part of strategic diversification, IFFCO has entered into several key sectors. IFFCO-Tokio General Insurance Ltd (ITGI) is a foray into general insurance sector. Through ITGI, IFFCO has formulated new services of benefit to farmers. 'Sankat Haran Bima Yojana' provides free insurance cover to farmers along with each bag of IFFCO fertiliser purchased. IFFCO is also behind several other companies with the sole intention of benefitting farmers. The distribution of IFFCO's fertilizer is undertaken through over 39824 Co-operative Societies. In addition, essential agro-inputs for IFFCO has promoted several institutions and organizations to work for the welfare of farmers, strengthening cooperative movement, improve Indian agriculture. Indian Farm Forestry Development Cooperative Ltd (IFFDC), Cooperative Rural Development Trust (CORDET), IFFCO Foundation, Kisan Sewa Trust belong to this category. An ambitious project 'ICT Initiatives for Farmers and Cooperatives' is launched to promote e-culture in rural India. IFFCO obsessively nurtures its relations with farmers and undertakes a large number of agricultural extension activities for their benefit every year. At IFFCO, the thirst for ever improving the services to farmers and member co-operatives is greedy, commitment to quality is insurmountable and harnessing of mother earths' bounty to drive hunger away from India in an ecologically sustainable manner is the prime mission. IFFCO, today, is a leading player in India's fertilizer industry and is making substantial contribution to the efforts of Indian Government to increase food grain production in the country.

Awards & Milestones

Safety Innovation Award - 2010 Greentech Gold Award for Training Excellence ICWAI Award for Excellence in Cost Management - 2009 for IFFCO IFFCO Shines at Public Relation Society of India, Grabbed 2 prestigious awards IFFCO Aonla Wins "Gold Award - 10th Annual Greentech Environment Excellence Award 2009 IFFCO bagged First ever dotCoop Global Award for Cooperative Excellence IBM Awards First Prize to IFFCO for Innovation IFFCO Phulpur Unit-I bagged "First Prize" by FAI. 6

CIO 100 & IT Awards Microsoft Felicitates IFFCO National Energy Conservation 2008 - 1st Award Conferred on Phulpur Unit IFFCO bags three FAI Awards IFFCO bags Energy conservation award Phulpur Unit bags National Energy Award from Honorable President of India Best Managed Work Force Award for IFFCO

IFFCO PHULPUR UNIT

Head of the Unit: Mr. Surjit Singh (Sr. Executive Director)

Total Area Area Under plant Area under Township

1068 acres 321 acres Area under township, cordet, agricultural farms, green belt, ash ponds, roads, Open space: 747 acres.

IFFCO Phulpur is a large scale modern fertilizer complex having two ammonia plants and two urea plants. A turbo generator set has been provided to insulate the plant operations from the effects of unreliable imported electric power. Coal handling, ash handling, inert gas generation plant naphtha fuel oil and diesel storage and handling facilities. 10000 tons capacity of atm ammonia storage and loading facility bagging and material handling etc are often auxiliary units of ammonia and urea complex. Consultants for ammonia, urea and offsite facilities were respectively Pullman Kellog, Snam Progetti and Development consultants. LOCATION: Unit is located in the heartland of gangetic zone which is Indias prime agriculture belt at Phulpur district Allahabad in the state of U.P. The site is located in U.P. highway no. 7 connecting Allahabad to Jaunpur and Gorakhpur Phulpur, which is a tehsil, is about 5 km. away from the site and linked with broad gauge line on the Varanasi- Allahabad railway route.

Phulpur I Ammonia Plant Urea Plant Phulpur II Ammonia Plant Urea Plant

Process Licensor MW Kellog, U.S.A Snamprogetti, Italy Process Licensor HTAS, Denmark Snamprogetti, Italy

Date of Commercial production 28th MAR 1981 Date of Commercial production DEC 22nd , 1997

PHULPUR PRODUCTION CAPACITY:

PLANT PHULPUR-1 AMMONIA UREA PHULPUR-2 AMMONIA UREA : : 1740 3030 : : 1215 2115 PRODUCTION IN MTPD

Phulpur Unit - Records & Achievements

Highlights of 2009-2010 of Phulpur Unit has Achieved Highest ever Yearly Production with Lowest ever Yearly Energy in All Plants. Longest Accident free period of 1721 days till March 31,10 is continuing since 15th July, 2005. Golden Jubilee Award in Recognition & Appreciation of Extraordinary Accomplishment and Contribution to the Nation from Chamber of Commerce & Industry, (Eastern U.P., Allahabad) 8

Phulpur Unit: Records & Achievements

Unit-I 1. Fifteen million tonne of Urea Production have been achieved in a period of 568 days on 20.07.2009. 2. Eight million tons of Ammonia production has been achieved in a period of 1064 days on 02.10.2007. 3. Fifteen million tons of Urea Dispatch (By road & rail) achieved in a period of 568 days on 20.07.2009. Unit-II 1. Ten million tons of Urea Production has been achieved in a period of 392 days on 07.08.2009. 2. Six million tons of Ammonia production has been achieved in a period of 717 days on 01.12.09. 3. Ten million tons of Urea Dispatch (By road & rail) achieved in a period of 387 days on 06.08.09.

AMMONIA- PLANT

Brief Description of Ammonia Plant

The Ammonia plant in Phulpur-I is based on MW Kellogs USA technology

having capacity of 1215 MTPD and in Phulpur-II plant is based on Haldor Topsoes Denmarks technology with a capacity of 1740 MTPD.

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 Phulpur-II.

The Ammonia Plant in Phulpur-I and Phulpur-II uses RLNG as raw material

for feed and fuel. But there is a provision of using Naphtha also as raw material in The main process steps for production of Ammonia in both the plants are

similar and are briefly described below:

Raw material:
RLNG is used as main raw material to produce ammonia which has the following composition: CH4 C2H6 N2 : : 98.77% 0.69% : 0.51% 0.03%

C3H8 :

BLOCK DIAGRAM FOR AMMONIA PROCESSING

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BRIEF PROCESS DESCRIPTION OF AMMONIA PRODUCTION: Desulphurisation

12

The Traces of sulphur present in RLNG are removed in the desulphurisation section before sending to the reforming section following hydrogenation reactions are as under: 1) RSH 2) COS + + H2 H2 4H2 = = = RH CO + + H2S H2S H2S

3) C4H4S +

C4H10 +

The desulphuriser reactor consists of Co, Mo based catalyst and ZnO based catalyst. The desulphurisation takes place in two steps. The first step is hydrogenation where organic sulphur is converted into Hydrogen sulphide over the hydrogenation catalyst in the HDS reactor. The second step is the absorption of the H2S formed which takes place in 2 nos. ZnO absorbers connected in series.

Reforming Section
In the reforming section consisting of Pre-reformer, Primary reformer & Secondary reformer, the sulphur free RLNG is reformed with steam and air into raw synthesis gas (process gas) at a pressure of 30 - 37 kg / cm2. The gas contains mainly hydrogen, nitrogen, carbon monoxide (CO) and carbon dioxide (CO2). The steam reforming process can be described by the following reaction: (i) Cn H2n+2H2O = Cn-1H2nCO2+3H2 (ii) CH4 +2H2O = CO2 = CO + 4H2 + H2O (iii)CO2 + H2 heat heat heat

Since the reaction is highly endothermic, RLNG is fired in furnace as fuel to maintain the temperature at about 800 deg C. The reformed process gas has a temperature of about 800 deg. C and contains about 9-11 mole% (dry basis) of methane and around 70 % hydrogen.

SECONDARY REFORMING
Secondary reforming, which including mixing and combustion of the reformed process gas with process air, takes place in the secondary reformer. Secondary reformer consists 13

of Ni based catalyst. The process gas (31.5 kg/cm2g, 800 deg C) enters the Secondary reformer at the top. The reaction between oxygen and process gas is a combustion where all the oxygen is utilized, raising the temperature to about 1200 deg C. When passing the catalyst bed, the temperature decreases to about 975 deg C and the pressure to 31 kg/cm2 g. The Outlet gas from Secondary Reformer contains about 56 % hydrogen.

2H2 + Air (O2 + 3.8 N2 ) CH4 + 5 Air (O2 + 3.8 N2) Gas Purification System

2H2O + 3.8 N2 + Heat CO2+2CO + 6H2O + 19 N2 +Heat

The gas purification section comprises three main process steps: 1) CO conversion 2) CO2 Removal 3) Process Condensate Stripping 4) Methanation

CO-Conversion Section
The reformed process gas enters into CO-conversion section comprising the two COconverters and equipment for process gas cooling and condensate separation. The main part of the carbon monoxide is converted into carbon dioxide by the shift reaction: CO + H2O = CO2 + H2 + Heat The heat evolved is primarily used for steam production and boiler feed water preheating.

High Temperature CO-Conversion

The high temperature CO-converter comprises two catalyst beds. The process gas enters the top of the converter and passes the two beds the normal outlet temperature 14

of the gas is about 424 deg. The outlet gas from HT Shift Converter contains around 3% CO.

Low Temperature CO conversion

The gas leaving the high temperature CO-converter is cooled in HP waste heat boiler, in the trim heater and in the boiler feed water preheater. Process gas entering the low temperature CO converter has a content of 2.98 mole% carbon monoxide. The gas leaves the converter at about 219 deg C and 29.1 kg/cm2 g.The process gas is cooled in the boiler feed water preheater. Before entering the CO2 removal section. The process condensate is separated in the separator inlet reboiler.The outlet gas from LTshift converter contains around 0.12 % CO

Carbon dioxide Removal Section

Basically, the CO2 removal section comprises of Absorber, where the CO2 content in the process gas will be absorbed in liquid phase at high pressure. The liquid containing the CO2 is transferred to tower regeneration unit. Consisting of two Strippers operating at different pressure. In these two towers the pressure is low and thereby, due to equilibrium, the CO2 again will be transferred into the gas phase. Carbondioxide is removed by absorption in hot potassium carbonate solution containing approx. 27 wt% potassium carbonate. The solution also contains glycine and diethanol amine as activators and vanadium pentaoxide as corrosion inhibitor. The gas passes the separator OH absorber and enters the methanation section. The solution enters the top of 1st regenerator column. The solution passes down through the packed beds in the column in counter current with steam. The steam strips off the carbon dioxide, and a mixture of steam and carbon dioxide leaves the top of the column the CO2 thus evolved is sent to urea plant and regenerated solution is recirculated back to CO2 absorber. K2 CO3 + H2O + CO2 2KHCO3 2 KHCO3 (ABSORPTION) K2CO3 + CO2 + H2O (STRIPPING)

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Methanation Section
Following reactions take place in methanator. (i) CO + 3H2 4H2 = = CH4 + H2O + Heat CH4 + 2H2O + Heat (ii) CO2 +

The process gas from carbon dioxide removal section still contains about 0.05 vol% CO2 and 0.30 vol % CO As the carbon dioxides are poisonous to the ammonia synthesis catalyst, it is converted in the methanator by use of hydrogen. The outlet gas from Methanator contains around 73 % H2, 25 % N2, and 0.7 % CH4.

Ammonia Synthesis Section

COMPOSITION OF SYN GASES: H2 N2 Ar CH4 : : : : 73.78% 25.39% 0.31% 0.59%

The gases after the methanator outlet are sent to synthesis loop for conversion of N2& H2 into NH3. The gases are introduced in synthesis gas compressor where the pressure is increased to around 180 Kg/cm2. since ammonia reaction take place at elevated pressure.

Ammonia Conversion
The ammonia conversion is carried out in two converters installed in series. One original converter and another (S-50) installed during Energy Saving Project (ESP). Ammonia converter catalyst is promoted Iron. 16

Reaction: 3H2 + N2 = 2NH3 + Heat Since the reaction is highly exothermic the waste heat is utilised for generating steam and Boiler feed water heating. TThe gases are cooled in a series of Chillers and the ammonia get condensed a series of chillers and the ammonia get condensed and is separated. The uncondensed gases are recycled back to Synthesis Gas Compressor. The liquid NH3 separated out in a high pressure separator is taken to a lower pressure separator where the inerts are separated out. This liquid NH3 is taken to Another flash drum for removal of inerts and liquid NH3 is sent to Urea plant or Ammonia Storage Tanks.

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UREA-1 PLANT

Brief Description of Urea Plant

18

The Urea Plant is based on Snamprogettis Ammonia stripping process. The Phulpur-I plant is having capacity of 2115 MTPD while in Phulpur-II there are two units with a capacity each of 1515 MTPD. The process of manufacturing of urea in both the units is same except for Phulpur-II where all the sections are separate for two streams except for Prilling and waste water treatment section which are common for both the units. RECORDS: PRODUCTION IN UREA-1 PLANT HIGHEST PRODUCTION: DAILY MONTHLY YEARLY : : : 2401.00 MT (14/06/2010) 70105.80 MT (OCT 2009) 745131 MT (2010-2011)

LOWEST ENERGY CONSUMPTION: MONTHLY YEARLY : : 6.4677 GCAL/MT (2010-11) 6.6698 GCAL/MT (MARCH2011)

LOWEST SP. STEAM CONSUMPTION: MONTH YEAR : : 1.0700 MT/MT (DEC2010) 1.0908 MT/MT (2010-11)

UREA

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PHYSICAL AND CHEMICAL PROPERTIES OF UREA

Molecular weight Melting point Boiling point Specific Gravity (Crystal) at 200 C Heat of combustion Heat of solution in water Critical Humidity Viscosity at 1500 C Crystallization heat Fusion Heat Thermal conductivity Specific heat at (Cal/gm0C) 200 C 0.321

: : : : : : : : : : :

60.05 132.600 C Decomposes at atm. press. Before boiling. 1.355 2531 Cal/g -57.8 Cal/g 70.1% 2.16 CPS 47 Kcal / kg. 59.95 Kcal/kg. 0.191 K.cal/cm0 C 160.30 C 0.224 2200 C 0.288

98.40 C120.50 C 0.158 0.194

Solubility in at Water (wt%)

00C 67

200C 105

400C 163

600C 240

800C 396

1000C 725

Urea is a white crystalline chemical product and is readily soluble in water. On heating beyond its m.p. It decomposes leaving CO2, NH3 and other complex compounds of C, N2O. At 1600 C, it decomposes to yield NH3, biuret and higher condensation product and longer the Urea is held above its m.p. further the reaction process.

PROCESS TECHNOLOGY :
20

Urea is produced by synthesis from liquid NH3 and gaseous CO2. NH3 & CO2 react to form ammonium carbamate, a portion of which is dehydrated to form Urea and water. The fraction of ammonium carbamate that dehydrates is determined by the ratio of the various reactants, the operating temperature and the residence lime in the reactor. The reaction to produce Urea from NH3 and CO2 takes place in two stages at elevated pressure & temperature. 2NH3 + CO2 NH2 COONH4 = = NH2COO NH4 + 38.1 K.cal/g.mole (1) NH2CONH2 + H2O -7.1 K.cal/g.mole (2)

The first reaction is strongly exothermic, therefore heat is liberated as this reaction occurs. With excess NH3, the CO2 conversion to carbamate is almost 100%, provided solution pressure is greater than decomposition pressure of carbamate. The decomposition pressure is the pressure at which carbamate will decompose back into CO2 and NH3. Decomposition pressure is a function of NH3 concentration in the feed and solution temperature and increases if either temp. of NH3 recycle is increased. It is desirable to operate at high temperature and high ratio of NH3 to CO2 provided reactor pressure is high enough to prevent carbamate from decomposing into CO2 and NH3. This will maximize CO2 conversion to Urea as shown in the reaction (2) The 2nd reaction is endothermic, therefore heat is required for this reaction to occur. The heat for this reaction comes from the formation of carbamate. This reaction is a function of temp. and NH3 concern in feed. The solution effluent from the reactor being a mixture of Urea solution, ammonium carbamate, unreacted NH3, water and CO2 is extremely corrosive in nature. USES OF UREA:

1. As Fertilizer in agriculture; Due to high N-content of Urea demand of Fertilizer

grade Urea is rising rapidly. Nitrogenous Fertilizer. Urea today accounts for a large percentage of

21

2. As cattle Feed: Urea is used as cattle feed in western countries sheep and cattle
are capable of digesting Urea upto about 40% of their protein requirement.

3. As raw material for various industrial products: Urea also is used extensively in
preparation of adhesives, textile, anti-shrink compound, ion-exchange and as an intermediate in the preparation of pigments.

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BRIEF PROCESS DESCRIPTION OF UREA PLANT

Urea is commercially manufactured by direct synthesis of gaseous CO2 and liquid NH3. Urea production process consists of the following main operations: Process Technology The Urea production process takes place through the following main operations: a) Urea synthesis and high pressure recovery. b) Urea purification and low pressure recovery. c) Urea concentration. d) Urea prilling e) Waste Water treatment a) Urea synthesis and high pressure recovery CO2 gas mixed with a small measured quantity of air is compressed in a turbine driven four stage centrifugal compressor to about 160 Ata and fed to the reactor. The liquid ammonia is pumped at high pressure pumps to a pressure of about 240 Ata through an ejector which drives the carbamate from carbamate separator into the reactor In the Urea reactor operating at 150 kg/cm2 and 190 deg.c. Ammonia along with recycle Carbamate, reacts with compressed CO2 to form Ammonia carbamate, a part of which dehydrates to Urea and water. The oxygen in the air 23

forms a passive oxide layer on the surface of the vessel to prevent corrosion by carbamate and urea. The reaction products from the reactor overflow to HP stripper where most of the un reacted carbamate get stripped off as gaseous Ammonia and CO2. Heat of decomposition is supplied by MP steam, admitted into Stripper shell side. Urea solution thus obtained flows out to the MP section. The vapours produced on decomposition of carbamate in HP stripper enter the HP carbamate condenser, along with weak carbamate solution from MP section through a mixer. Gases condensed to form carbamate again and flow to the HP carbamate separator. During this condensation, LP steam is generated in the HP carbamate condenser shell side. Condensate required for generating steam is supplied from shell side of MP decomposer. b) Urea purification and low pressure recovery Medium Pressure Section Urea solution from the bottom of the HP Stripper now enters the bottom of PreDecomposer and then to MP Decomposer for further decomposition. During expansion much of the remaining Carbamate flashes forming NH3 and CO2 vapours, thereby concentrating urea in the solution. This urea solution is further let down through a level control valve and enters the LP section. The vapours from the MP Decomposer are condensed in MP condenser using ammonium carbonate solution from the LP section, with tempered cooling water in the tube side. The carbamate solution overflows from the MP Condenser into MP Absorber where the excess Ammonia and inerts are separated in form the vapours. These vapours are further purified in the top section of the Absorber with reflux ammonia. Ammonia with inert gases leaving the top of MP Absorber is mostly condensed in Ammonia Condenser, with cooling water in tube side. From Ammonia Condenser both liquid and gas phases are sent to Ammonia receiver along with incoming liquid Ammonia. The inert gases, saturated with Ammonia, leaving the receiver enter the Ammonia Recovery Tower, Here Ammonia is 24

further condensed by direct contact with cold Ammonia from the Battery limit and flows down the Ammonia Receiver. The inerts with residual ammonia vapours from the Tower are sent to MP Ammonia Absorber where later gets absorbed with cold condensate in inert washing tower and recycled to MP Absorber as ammonia water. The inerts are released to vent stack.

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26

Low Pressure Section :

The Urea solution from MP Decomposer bottom enters the LP Decomposer after let down through a level control valve. As a result of expansion, most of the remaining carbamate undergoes decomposition. Thus Urea solution is further concentrated and is then sent to the vacuum concentrators through a level control valve. The vapours enter the LP condenser shell and get absorbed in a weak Carbamate solution. LP condenser has cooling water in tube side. The liquid thus formed goes to the Carbonate Solution Tank from where it is recycled back to MP Condenser. The inert gases from the Tank containing ammonia vapours are absorbed with cold condensate in LP Ammonia Absorber and sent to vent stack. The liquid flows down to the Tank. The concentration of urea is approx. 70% at the outlet.

Urea concentration section

The liquid from the bottom of LP decomposer is further concentrated in Preconcentrator and then goes for further in two Vacuum concentrators in series. Here with the help of Low pressure steam, urea solution is concentrated from 70% to 99.7%. The vacuum is created and maintained by two vacuum systems consisting of a set of steam ejectors and condensers. Urea melt thus obtained is then pumped to the prilling tower. The vapours from the vacuum separators are condensed in the condensers and sent to the waste water tank.

d) Urea prilling
The melted Urea leaving the second vacuum separator is pumped to the top of 104 meter high natural draft prilling tower and sprayed by means of rotating prill bucket. The fine droplets, while descending through the tower come into contract with cold air and solidify to from prills. These prills are conveyed to bagging plant for bagging or to Urea silo for storage. 27

e) Waste water treatment

Traces of gases present in the condensate from vacuum section are removed in a Hydrolyser stripper system. Waste water from the Hydrolyser section is sent to the effluent system. The recovered Ammonia solution is recycled back to the LP recovery section and Ammonium carbamate from LP section is recycled back to the MP recovery section. FCO LIMIT 46 1.0 1.5 PHULPUR UREA 46.6 0.45 1.0

Total N% (min on dry basis) Moisture % ( max.) Biuret % (max.)

FIG: Schematic view of urea

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EFFECT OF PROCESS VARIABLE IN UREA PRODUCTION

The equilibrium conversion to Urea will be favored under the following process variables : I) II) III) IV) V) Higher ammonia concentration. Less H2O concentration. Higher temperature. Higher pressure. Increased residence time.

I)

EFFECT OF NH3 / CO2 RATIO:

Theoretical ratio of NH3 / CO2 is two. But in this condition Urea yield is only around 43.44% at 170 atm. and 1550 C. This low yield can be improved by changing NH3 / CO2 ratio when the excess ratio of NH3 is increased to 279%, Urea yield will change from 43.44% to 85.2%. On the other hand when the excess ratio of CO2 is changed from 0-300%, Urea yield will increase only from 43.44% to 46%. The effect of excess CO2 is very small. More over, in the CO2 rich condition the soln becomes very corrosive. In general, most all the Urea plants are operated under NH3/CO2 ratio around 2.5 to 5.0.

II)

EFFECT OF H2O/CO2 RATIO:

Water is a product of Urea formation, presence of excess H2O shifts the equilibrium reaction in reverse direction and yield of urea is poor. However water has to be added for recycling unconverted NH3 and CO2 back to the reactor. Lower the amount of water in reactor higher is the yield of Urea. Excess H2O in reactor also reduces effective volume for urea formation and additional energy is required to get rid of this H2O. Study shows that presence of one mole of excess H2O per mole of carbamate reduces equilibrium yield of urea to half.

III)

EFFECT OF PRESSURE AND TEMPERATURE :

At the

As per Le-chaterliers principal higher pressure favoured carbamate formation.

operating condition carbamate formation is almost instantaneous and reaction tends to completion provided reaction heat is removed simultaneously. Lower temperature favoured carbamate formation, being an exothermic reaction. 29

In case of Urea formation, higher temperature is favourable, because the reaction is endothermic. The relation is such that when temperature increases, the conversion increases proportion only, maximum equilibrium conversion is achieved at around 196-2000 C. Reactants are highly corrosive at higher temperature. Operating pressure is totally dependent on the temperature at which conversion takes place. Urea conversion takes place in liquid phase, so equilibrium pressure becomes increasingly higher when the temperature rises.

IV)

RESIDENCE TIME:

Urea conversion reaction is slow and takes 20 mins. To attain equilibrium. Higher residence time favoured equilibrium. Conversion and normally reactors are designed for residence time of 30 mins to one hour depending upon there operating parameters. Residence time in Urea reactor plays an important part on equilibrium conversion. Where operating parameters including mole ratio are not favourable for a good yield, higher residence time compensates to some extent to achieve a better yield. But this is done by providing higher reactor volume which increases capital investment.

BIURET IN UREA:
The formation of biuret during Urea production is not desirable as it is toxic to the plants and it should not exceeds more than 1.5% in Urea as per Fertilizer control order. It is produced when Urea is heated in the absence of free NH3. NH2CONH2 + NH2CONH2 (Urea) NH2 CO NH CO NH2 + NH3 (Biuret )

The formation of biuret is favoured by higher temperature, higher concentration of urea solution, low NH3 content and higher residence time.

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EQUIPMENTS DETAILS: REACTOR

31

SUPPLIER: MITSUBISHI HEAVY INDUSTRIES LTD., JAPAN The liquid mixture of NH3 & carbamate and gaseous CO2 are fed in reactor where these react to form ammonium carbamae, a portion of which dehydrates to form Urea & Water. The reactor is vertically mounted and made of carbon steel. It is internally lined with 5 mm thick stainless steel liner 316-L (Modified). The reactor has 14 nos. sieve trays numbered from top over a length of 35 meter. Serve trays are provided to avoid back mixing & for improvement of contact between gaseous & liquid phase. The liquid & gases flow from bottom top via these sieve plates. Reaction products after leaving the reactor are sent to stripper. OPERATING DETAILS: Units Operating Pressure Operating Temperature Design Pressure Design Temperature MECHANICAL DETAILS: Length I.D. O.D. Internal lining Total nos. of sieve trays MATERIAL OF CONSTURCTION Shell Sieve trays All internal walls & liner In contact with fluid Composition of 316 L (Modified) Cr Ni Mo N C -> > < < 22% 12% 2.2% 0.2% .03% : : : Carbon steel SS 316-L (Modified) SS 316-L (Modified) mm mm mm mm Nos. 36,000 (Tan to tan) 2,305 2494 5 mm thick 316-L (Modified) 14 Kg/cm2a 0 C Kg/cm2a 0 C 151 185 166 195

MP DECOMPOSER
32

SUPPLIED BY

LARSEN AND TOUBRO LTD. BOMBAY

Solution from the stripper is flashed in MP separator (MV-2) at 18 Ata pressure. Due to flashing some Ammonia and CO2 is released from the solution. The rest of the solution is heated in MP decomposer E-2 to decompose carbamate into Ammonia CO2 and water at 18 Ata pressure. MP decomposer is a falling film type heat exchanger. The solution containing Urea, Water, Unconverted cabamate and Ammonia is fed over the tube sheet. The solution enters the decomposer tubes through a set of four holes.The tube sheet at the top and bottom both have a 10 mm thick overlay of SS-3316-L. Shell side fluid is 26 ata steam condensate (from stripper shell side) as heating medium. Expansion belows are provided for the shell. OPERATING DETAILS: Units Fluid Handled Shell Steam Condensate Tube Urea + Carb+ Water + ammonia 22 185 17

Design Pressure Design Temperature Operating Pressure Operating Temperature In Out Heat Duty

Kg/cm2
0

28 225 25

Kg/cm2

C C

225 161 4.2

129 155

MK Cals/hr

MECHANICAL DETAILS: Units Material of construction 33 SS 316L and 10mm thick overlay of SS 316L on tube

sheets. No. of Tubes Tube O.D. Tube I.D. Heat Transfer Area Effective length Nos. mm mm M2 mm 543 38 34.8 390 6,000

LP DECOMPOSER
SUPPLIER BY: Larsen and Toubro Ltd., Bombay LP decomposer is a falling film heat exchanger which decomposes carbamate present in Urea solution. Solution is distributed into the decomposer tubes through the ferrules fitted on them. Each ferrule is provided with 4 holes through which liquid flows down to tubes. The 4 holes are essentially on the same plane and are tangential to the surface of the ferrule. The tangential entry ensures that liquid is in the form of a film flowing along the wall of the tubes. Vapors of water, ammonia and CO2 leave the decomposer tubes top. The heating medium is 4.5 Ata steam. The shell side has an expansion joint for differential expansion. OPERATING DETAILS: UNITS Fluid Handled ---

SHELL Steam

TUBE Urea + Water some carbamate 5.5 170

Designed: Pressure Temperature Operating: Pressure Temperature: In Out No. of passes Heat Duty

Kg/cm2g 0 C

5.5 180

Kg/cm2g

3.5

3.5

C C No MKCal/hr. 34

147 147 1 3.1

95 138 1

MECHANICAL DETAILS FOR TUBES Units Material of construction No. of rubes O.D. I.D. Effective length --Nos. mm mm m SS 316-L 785 38.0 34.8 6

MECHANICAL DETAILS FOR SHEEL: Material of construction I.D. MM Steam inlet Nozzle dia Inches 8 Condensate outlet nozzle dia Inches Carbon steel 1,500 3

PRILLING TOWER:
ERECTOR: M/s E.C.C., BOMBAY This is a concrete structure of 96 meter height. The urea melt enters the rotating prill bucket situated just below the prill tower ceiling. Melt enters at a temperature of about 1400C and is distributed in fine droplets over the cross section of the tower of 22 meter diameter and having free falling height of 72.5 meters. It is a natural draft tower where ambient air enters through bottom lower openings having total area 57 M2.During the fall through bucket, the droplets of urea first solidify and then cooled to a temperature of about 600C-650C. Hot air outlet windows are provided at the top having total area 153 M2. The prill are scraped by a rotating straight double arm scraper and fed to the prill tower conveyor through openings in the rake floor. The inside wall of the tower is painted with epoxy painting & bottom floor where prills fall are coated with FRP coating to resist corrosion. 1,000 mm x 1,000 mm inspection windows with light are provided every four flights of external stairway. One elevator runs parallel to the prill tower structure. Over & above the elevator, external staircase is also provided.

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CORROSION IN UREA PLANT EQUIPMENTS: Studies of corrosion in urea plant have led to the identification of the following type of corrosion: 1) 2) 3) 4) 5) 6) Stress corrosion. Inter granular corrosion. Galvanic corrosion. Crevice corrosion. Pitting corrosion. Condensation corrosion.

Most severe corrosion in urea plant occurs at location where urea and carbamate solution are handled at high temperature and pressure. Studies have shown that major attack occurs at the bottom. 3 to 10 of the reactor directly; above where NH3, CO2 and ammonium carbamate are introduced. In view of higher pressure, temperature, cone and two phases mixture in urea reactor a liner of stainless steel 31 GL is used in the construction. Ti, Zr, and stainless steel are used as liner material. As to selection of material, corrosion resistance is not the only factor that determines the choice of material, other factor such as mechanical properties, workability weld ability and economic consideration are taken into consideration.

OFFSITES:
SECTIONS: 1. Borewells and Raw Water Distribution System. 36

2. 3. 4. 5. 6. 7. 8.

Cooling Tower. DM and CPU Units. Effluent Treatment Plant Water Softening plant AMF Plant RO Plant IG Plant

EFFLUENT TREATMENT PLANT INTRODUCTION: Removal & control of nitrogenous compounds such as NH3 that is present in waste being discharged from ammonia plant and urea plant is very essential in view of pollution control and water reuse philosophy. As water is one of the precious natural resources for running any industry its reuse and conservation is essential for environmental pollution control and to reduce operating cost of the industry. To overcome problems associated with disposal of ammonia effluent and making it fit for reuse the effluent treatment plant is installed in which NH3 present reduced by stripping process. BRIEF PROCESS DESCRIPTION To carry out the stripping process a packed column called steam stripper is provided in which the raw effluent is fed from the top and the LP steam is introduced from the bottom. The stripping occurs and the treated water obtained is transferred to softening plant. in effluent water is

WATER SOFTENING PLANT

Water source of raw water required for the plant is underground sub-soil water containing salts of sodium, magnesium and calcium, together with bicarbonate, carbonate, sulphates, 37

chlorides and silica (Major constituents) and Nitrate, Phosphate, Iron, Organic matter and dissolved gases (Minor constituents). On using the raw water having high hardness as cooling water make up, these salts break during heat transfer process inside the heat exchangers and thereby form scales. To bring down the concentration of calcium and magnesium hardness and also silica in cooling tower make up water, cold lime softening process is adopted. The raw containing high HCO3 alkalinity is reduced during treatment with lime solution and the treated water becomes suitable for cooling water make up. The capacity of the water softening plant under Phase-II is to treat 800 m3/hr. of raw water and the other design basis is: Design treated water quality and softening plant Phase-II outlet is following: pH Total hardness Ca hardness Turbidity < < < 10.4 to 10.7 50 ppm as CaCO3 40 ppm as CaCO3 12 NTU

REVERSE OSMOSIS PLANT

Normally when 2 solutions are separated by means of semi permeable membrane, the solvent flows from dilute solution to concentrated solution. If pressure is applied to concentrated side and if the pressure is greater than osmotic pressure, then solvent flow is reversed, i.e., it flow from concentrated solution side. This process is called reverse osmosis. It is advantageously used to extract water from concentrated solution. During R.O. process, pressure is continuously applied to the feed stream by a high pressure pump. Consequently feed stream gets divided into two parts. 1. 2. Permeate stream (low in dissolved solid content) Reject stream (very high in dissolved solid content)

PROCESS DESCRIPTION: 38

The water is fed to the R.O. plant from R.O. feed pit. In the feed some chlorine is introduced in concentration of 1 ppm. This chlorine kills bacteria and algae, which is harmful to membrane. From feed pit the water is entered into solid catalyst classifier. In this classifier dolomite and lime is introduced in solid form (not in fully powdered form). Here 0.1% of a polymer solution is also added. This polymer coagulates the silica, which is deposited on dolomite and lime, into large size. Hence the effluent from classifier is reduced in silica and turbidity from that of water in feed. To the classifier effluent 10% sodium hexa-meta phosphate (SHMP) is added. The solution acts as an anti scalar. The effluent then enters into 4 continuous filters. These filters are actually sand filters having sands of uniform size. The effluent from these fitters is maintained at pH 6.5 by addition of 30% HCl and stored in clarified water storage tank. The rejects from solid contact classifier and 4 continuous filters are sent to sludge pit where it is poured and dried. The dried solid material was then sent into ash pond. This classified water is used as power water and in chemical tanks (dolomite, lime etc). Introducing it in multigrade filters, in which different sizes of sand layers are used as filter, further purifies this water. The effluent from multigrade filters then passes through a basket type cartridge filter. The cartridge filter removes suspended particles from water. When the differential pressure across the cartridge filter reaches 1 kg/cm2 when the flow rate through cartridge filter reduces, the cartridge filter must be replaced. The effluent from this filter then enters into 2 micron cartridge filters, removes suspended particles upto 5 micron. The effluent from micron cartridge filter then enters into R.O. skid. The R.O. unit consists of single stream 3 stages. There are total 37 pressure tubes each containing 6 No. of membrane modules:The 1st stage contains 20 pressure tubes. The 2nd stage contains 11 pressure tubes. The 3rd stage contains 6 pressure tubes. The membrane elements mainly made of polyamide films, imported from USA. The total input flow rate to this R.O. unit is 150 m3/hr. the flow rate through each pressure tube is 7 m2 / hr. (approx.) Hence total product water is (75+35+15) = 125 m3/hr. and reject is 150 m3/hr. The maximum load can be handled by this R.O. unit is 165 m3/hr. 39

The product water is stored in product water tank and from there supplied to different plants, such as DM plant and softening plant inlet.

D.M. PLANT
In the D.M. Plant the deep bore raw water containing various impurities is demineralized i.e. freed from the various minerals present in it to make it 100% free from particulate matter for its further usage as the boiler feed water and process water. The recommended quality of D.M. water being used in high pressure boiler is: Conductivity (mho/cm) Silica SiO2 hardness Electrical char. due to electrolyte pH : : : : : Less than 0.3 micron Less than 0.01 ppm Nil Nil 6.8-7.5

Raw water is passed to first sand filter to remove suspended impurities then to SAC (strong acid cation). In SAC cation resin is used to remove cationic part of impurities like NaCl, CaHCO3 etc. Re-H + NaCl Re-Na + HCl Re-Ca + H2CO3 Re-H + CaHCO3 by stripping it using air. H2CO3 H2O + CO2

From SAC the process stream is passed to degasser where CO2 is removed from water

Then the stream is passed to weak base anion exchanger (WBA). Here the weak base resin removes basic ion impurities. Re-OH + HCl Re-Cl + H2O

Then the stream is passed through SBA (strong base anion). Where strong base resin is used to remove remaining anion impurities. From this the stream is passed through mixed bed. It contains both anionic and cationic resins to remove both cation and anion impurities. Finally this demineralized water stream is passed to D.M. water tank. 40

Power Distribution in Urea Plants:

T.G.1 T.G.2 Urea1 Urea 2 12.5 MW 18 MW 25.17 M 3.75 MW 6.5 MW

Total power required

DISTRIBUTED CONTROL SYSTEM (DCS) 41

BRIEF DESCRIPTION OF DCS: Computer based Distributed Control Systems have been used in large quantities instead of pneumatic control or electronic analogue control system. In D.C.S. system, three types of distribution exists: a) b) c) Geographical Distribution. Functional Distribution Safety Distribution

DCS is more accurate, fast in operation, more users friendly more informatics and equipped to take care of start up and shutdown of plants. In Urea plant of IFFCO Phulpur expansion, DCS model is CENTUM-CS, supplied by M/s Yokogawa Blue Star Ltd. India. DCS collects the database from various section of the plant directly for open loop tags for monitoring, recording and control of process parameters. There are six information and command station comprising of six CRT screens and one engineering station for maintenance and configuration purpose. One PC is provided for loop drawing. One PC is provided with HART maintenance system for maintaining field instrument working with HART protocol. A transient data Manager (TDM) is also a part of DCS used for monitoring temperature and vibration of bearing of turbines, compressor and high pressure carbamate pumps. One PC is also provided along with TDM for storing, monitoring and analysis of the temperature and vibration. Main Function of DCS Are: 1. 2. 3. Control and monitoring of various process parameters. Data acquisition and storage. Data management, manipulations and report generation etc.

42

ENVIRONMENT AND POLLUTION CONTROL At IFFCO Phulpur Unit there has been an emphasis on keeping the environment clean and safe. Due to a continuous and dedicated efforts in this direction goal of zero discharge of effluent has been achieved. Strategy: Regular monitoring of effluent. Reduction of effluent generation. Reuse of liquid effluent generated. Using the solid waste for useful purpose.

Measures Taken: Natural draft prill tower of 96 M height for reduced dust emission. 100 M high chimney and ESP in boiler to reduce dust emission. Cooling tower blow down reduction. Reuse of steam condensate from ammonia and urea plant in steam generation plant. Reuse of inert gas plant effluent in softening plant. Reuse of waste water from urea plant in cooling tower after treating in Hydrolyser System. Reuse of Jacket cooling water of ammonia plant in cooling tower. Reuse of impure condensate from power plant in cooling tower. Reuse of raw water pump house ejector water softening plant.

Utilization of Effluent for: Deashing operation in steam generation plant. Irrigation in farm land, green belt etc. Dust suppression in ash pond and coal yard.

Use of fly ash for making bricks. Fly ash being supplied to cement manufacturing plant.

43

ACTIONS IN HAND: In order to reduce the data water consumption further and also to take care of effluent to be generated in expansion plant, following two major schemes are being implemented. 1) Sewage Treatment Plant is being installed to treat township sewage. This water after treatment will be used in plant and raw water consumption is expected to reduce by about 3000 m3/day. It is expected to be completed by June 1997. 2) Reverse Osmosis Plant will be put up with its pretreatment along with DM plant effluent segregation scheme. The segregated DM plant effluent will be first treated in pretreatment plant to remove these impurities. Treated H2O from pretreatment section will be finally treated with the help of R.O. membranes to get the water quality fit for reuse in the plant. Total cost of the plant is expected to be Rs. 8.51 crores. Plant completion is expected by March 1998. FIRE & SAFETY: IFFCO Phulpur believes in the philosophy of prevention is better than cure. All necessary steps are being taken to avoid accidents. All employees are being given training to avoid accidents. However, to handle any eventualities a team of qualified and trained personnel with necessary modern facilities are available round the clock. An incident occurred on 04.05.96 when Naphtha caught fire in ammonia plant and it could have caused severe damage to the ammonia plant, being a major fire ancient, however the fire was brought under control within 25 mins. This speaks volumes about the preparedness of fire fighting staff.

Facilities Available: 10 Kms length of fire hydrant line ring with 13 single heated and 13 double heated ground hydrant and 23 single headed fire escape and internal hydrants. 3 fire tenders equipped with latest fire fighting facilities. 16000 m3 total water storage out of which 8000 m3 water exclusively reversed for fire fighting only. 3 Motor driven and 2 diesel driven water pumps. Each of 410 m3/h capacity. 1 Motor driven pump of 10m3/h capacity. 44

Fixed foam system for Naphtha storage area. Fire jeep and rescue van. Breathing apparatus 15 Explosive meter - 10 Gas detectors, O2 meters and smoke detectors.

CONCLUSION
IFFCO is the worlds largest cooperative sector in production of fertilizers. It was registered on November 3, 1967 as a Multi-unit Co-operative Society. IFFCO has production units in the following places Kalol, Kandla, Phulpur, Aonla, Paradeep in India. Ammonia - urea complex was set up at Phulpur in the state of Uttar Pradesh in 1981.

45

In Phulpur IFFCO has two ammonia and two urea plants, a power plant and other offsite planst like DM plant RO plant water softening plant, cooling tower, ammonia and naphtha storage. Other useful sites are production and quality control, material handling and bagging. The Ammonia plant in Phulpur-I is based on MW Kellogs USA technology having capacity of 1215 MTPD and in Phulpur-II plant is based on Haldor Topsoes Denmarks technology with a capacity of 1740 MTPD. The Ammonia Plant in Phulpur-I and Phulpur-II uses RLNG as raw material for feed and fuel. But there is a provision of using Naphtha also as raw material in Phulpur-II. The main process steps for production of Ammonia in both the plants are similar and are briefly: desulphurisation, reforming, shift conversion, CO2 removal by absorption, methanation and ammonia conversion. Following main reaction takes place in ammonia conversion. 3H2 + 2N2 2NH3 The Urea Plant is based on Snamprogettis Ammonia stripping process. The PhulpurI plant is having capacity of 2115 MTPD while in Phulpur-II there are two units with a capacity each of 1515 MTPD. The process of manufacturing of urea in both the units is same except for Phulpur-II where all the sections are separate for two streams except for Prilling and waste water treatment section which are common for both the units. The reaction of Ammonia and Carbon dioxide to produce urea takes place in two stages at elevated pressure and temperature. 1) 2NH3 + CO2 = NH2COONH4+ 38.1 Kcal/gm.mole carbamate 2) NH2COONH4 carbamate = NH2CONH2 + H2O -7.1 Kcal/gm.mole Urea Water

The Urea production process takes place through the following main operations: Urea synthesis and high pressure recovery. Urea purification and low pressure recovery. Urea concentration. Urea prilling. Waste Water treatment. Offsite contains all the auxiliary units supporting the main process units which are ammonia and urea plants. Offsite comprises of AMF set, IG plant, RO plant, DM plant, Cooling tower plant, water softening plant etc. Power plant has two sets of turbo generators: TG1 and TG2. TG 1 has capacity of 12.5 MW and TG2 has capacity of 18 MW. Total requirement of power is 25.17 MW for the whole 46

campus. Computer based Distributed Control Systems have been used in large quantities instead of pneumatic control or electronic analogue control system. DCS is more accurate, fast in operation, more users friendly more informatics and equipped to take care of start up and shutdown of plants. In Urea plant of IFFCO Phulpur expansion, DCS model is CENTUM-CS, supplied by M/s Yokogawa Blue Star Ltd. India. The plant is totally echo friendly and has got many recycling processes such as energy management unit for minimizing the consumption of energy, water treatment plant, manufacturing of ash bricks etc. Many features of it had got self dependent factors and thus are responsible for higher order of recycling and award getting performance thus had got many awards in this field. IFFCO Phulpur believes in the philosophy of prevention is better than cure. All necessary steps are being taken to avoid accidents. All employees are being given training to avoid accidents. However, to handle any

eventualities a team of qualified and trained personnel with necessary modern facilities are available round the clock. Thus IFFCO is one of the best examples of modernized industry in the world.

REFERENCES: INTERNET:
WWW.GOOGLE.COM WWW.WIKIPEDIA.COM WWW.IFFCO.NIC.IN 47

BOOKS AND MANUALS: BASIC TRAINING MANUAL, IFFCO PHULPUR UREA-1 MANUAL, IFFCO PHULPUR AMMONIA -2 MANUAL, IFFCO PHULPUR DRYDENS OUTLINES FOR CHEMICAL ENGINEERING.

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