Hariom Report

A REPORT ON
TO CARRY OUT THE ENERGY BALANCE OF UREA PLANT & SIMULATION OF MEDIUM PRESSURE ABSORBER(C-01) BY Name of the Student Hariom Sharma ID No. 2009H101015P Discipline M.E Chemical Engineering
Prepared in Partial Fulfillment of the Practice School-II Course No. BITS G639 AT
TATA CHEMICALS LIMITED, BABRALA
A Practice School-II Station of
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI (June, 2011)
Birla Institute of Technology & Science, Pilani.
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI (RAJASTHAN)

Practice School Division Station: Tata chemicals Limited Duration: From: 06 Jan. 2011 Date of Submission: 13 June 2011 Title of the Project: To Carry out the energy balance of Urea plant & Simulation of Medium Pressure (MP) Absorber (C-01) in an Urea Plant. ID No.: 2009H101015P Name of Student: Hariom Sharma Discipline: M.E. Chemical Engineering Designation: Manager-Urea Plant Centre: Babrala To: 18 June 2010.
Name of Expert: Mr U.P .SINGH Name of the PS Faculty: Prof. R. K. Tiwary
Key Words: Study,Analysis,Calculation,Simulation,Aspen Project Areas: Designe Abstract: The first part of the report looks at one of the problem which was assigned to me. During the course of this assignment I done the energy balance of all section of Urea Plant. The second part of report deals with the simulation of Medium Pressure Absorber(C-01) of urea plant in aspen plus ,commercial process simulation software.The detailed results and the curves can be accessed by running the simulation files which are attached with the soft copy of this report. Signature of Student Date: Signature of PS Faculty Date:
BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE PILANI (RAJASTHAN) PRACTICE SCHOOL DIVISION Response Option Sheet
Station: Tata Chemicals Ltd. ID No: 2009H101015P Center: Babrala Name: Hariom Sharma
Title of the Project: To Carry out the energy balance of Urea plant & Simulation of Medium Pressure (MP) Absorber (C-01) in an Urea Plant. Usefulness of the project to the on-campus courses of study in various disciplines. Project should be scrutinized keeping in view the following response options. Write Course No. and Course Name against the option under which the project comes. Refer Bulletin for course no and course name. Code No. 1 2 3 Response Option A new course can be designed out of this project. The project can help modification of the course content of some of the existing courses. The project can be used directly in some of the existing Compulsory Discipline Courses (CDC)/ Discipline Courses Other than Compulsory (DCOC)/ Emerging Area (EA) etc. courses The project can be used in preparatory courses like Analysis and Application Oriented Courses (AAOC)/ Engineering Science (ES)/ Technical Art (TA) and Core courses. This project cannot come under any of the above mentioned options as it relates to the professional work of the host organization. Process Plant Simulation (CHE G541). Advanced Separation Processes (CHE G615). Course No. & Name
Signature of student Date:
Signature of Faculty Date:
ABSTRACT
The first part of the report looks at one of the problem which was assigned to me. During the course of this assignment I done the energy balance of all section of Urea Plant. The second part of report deals with the simulation of Medium Pressure Absorber(C-01) of urea plant in aspen plus ,commercial process simulation software.The detailed results and the curves can be accessed by running the simulation files which are attached with the soft copy of this report.
Signature of Student
Signature of PS Faculty
Signature of Guide
Signature of General Manager
Date: Place:
ACKNOWLEDGEMENTS
I would like to thank my mentor Mr. U.P. Singh for guiding me all through my project. I am overwhelmed in all humbleness and gratefulness to acknowledge my debt to Mr. Azaz Ali, Mr.Avineesh, Mr. Sanjay Kumar, Mr. Siva Prasad, Mr. Kamakhya and Mr. Adarsh for their support and timely help. A special thanks to Captain K. Santosh, Mr. Rajendra Singh and Mr. Thomas Varghese for taking care of us at TATA Chemicals Ltd. I would also like to thank Mr. C. K. S. Raman and Mr. Mahenderpal for providing us freedom to refer books and avail the software facilities in the Technical Library and Documentation Centre. I am also indebted to BITS, Pilani for providing me the opportunity in the form of practice school to enrich my practical knowledge. And of course, this project would never have been complete without the immense motivation by our PS Faculty Mr. R. K. Tiwary. Last but not the least; I would like to thank my parents for their blessings.
Hariom Sharma 2009H101015P
INDEX
Abstract i Acknowledgement Index List of Tables List of Figures ii iii v v
Name
1. Introduction 1.1) Introduction to Tata Chemicals Limited, Babrala
1.2) Credentials of Tata Chemicals Limited, Babrala. 1.3) TCL Babrala: The Nations Conceit
Page Number
1 1
2 3
1.4) Milestones of Tata Chemicals Limited, Babrala 1.5) Composition of Tata Chemicals Limited, Babrala 1.6) Salient Features of Tata Chemicals Limited, Babrala
3 4 6
2. Fire and Safety

2.1) Fire Chemistry 2.2) Fire Prevention 2.3) Classification of Fires 2.4) Fire fighting Gadgets and Appliances 2.5) Safety Programme at T.C.L 2.6) Safety Provisions
8 8 8 9 10 11 11
3. Brief Introduction of Urea Plant

3.1) Raw Material Required for Urea Production 3.2) Manufacturing Procedure 3.3) Steam and Condensate Steam 3.4) Flushing Network
12 12 14 18 20 21 21 30
4. Project
4.1) To Carry Out The Energy Balance of Urea Plant 4.2) Simulation of Medium Pressure Absorber (C-01)
5. Conclusions and Recommendations 6. References
59 61
1. INTRODUCTION
1.1) INTRODUCTION TO TATA CHEMICALS LIMITED BABRALA
Tata Group, India's foremost business conglomerate. Tata Chemicals, by itself, is one of the largest inorganic complexes in the world beginning to TATA Group. Its first plant, which is also called inaugurated establishment of TATA. It is India's leading manufacturer and marketer of inorganic chemicals and fertilizers, with a turnover of over Rs. 4000 crores and is part of the Rs 65,000-crore ($14.25 billion) TCL's products and production processes are benchmarked with the best of global touchstones, and meet the most rigorous international specifications., Established in 1939. An ISO-9001/14001 OHSAS 18001 certified company, TCL has a varied user industry base comprising glass, paper, textiles, food additives, petroleum, refining, chemicals, dyes, pesticides, direct farm application etc. The products go into numerous end-use applications in a variety of industries: glass, detergents, paper, textiles, agriculture, photography, pharmaceuticals, food, tanning, rayon, pulp, paints, building and construction, and chemicals. Tata Chemicals is also one of India's leading manufacturers of urea and phosphatic fertilizers. With an export presence in South and Southeast Asia, the Middle East and Africa, it has set itself the objective of achieving global cost competitiveness in soda-ash. Its foray into phosphatic fertilizers follows the merger of Hind Lever Chemicals Limited into Tata Chemicals Limited. TCL's phosphatic fertilizer complex at Haldia in West Bengal is currently the only manufacturing unit for DAP/NPK complexes in West Bengal. The Haldia plant has production volumes exceeding 1.2 million tones per annum. Tata Chemicals makes urea at its fertilizer complex in Babrala. The complex has an installed capacity of 13, 14,000 metric tones per year, which constitutes nearly 12 per cent of the total urea produced by India's private sector. Tata Chemicals is among the world's largest producers of synthetic soda ash, with the largest domestic market share, produced at the company's integrated complex at Mithapur on the Gujarat coast in western India. The fertilizers, sold under the brand name 'Paras', lead the market in West Bengal, Bihar and Jharkhand. TCL is also a pioneer and market leader in the branded, iodized salt segment. Its salt has a purity percentage of 99.8 per cent, the highest in the country.
1.2)
CREDENTIALS OF TATA CHEMICALS LIMITED BABRALA
AWARDS: Prestigious Industry Award, Govt. of UP., 1995. National Energy Conservation Award, Ministry of Power, 1997. National Energy Conservation Award, Ministry of Power, 1998. Best Production Performance Award for Nitrogenous Fertilizers, Fertilizers Association of India. Second best productivity performance in Nitrogenous Fertilizers Industry, 1997-98. Yogyata Praman Patra Award, 1998. Jawaharlal Nehru memorial National Award for Pollution Control and Energy Conservation, 2000-01. Golden Peacock Environmental Management Award, World Environment Foundation, 200102. Best Technical Innovation Award, Fertilizer Association of India, Dec.2004. Excellence in Safety, Fertilizer Association of India, Dec.24. Commendation Certificate for Strong Commitment to TQM, CII-Exim Bank Award for Business Excellence, Nov.2004. 5 Star Rating in Safety, British Safety Council, UK, Safety Gold Awards, Greentech Foundation, Delhi. Indian Chemical Council (ICC) confers the ICC award for social responsibility 2005-06. NSCI safety award for 2006. ICC Aditya Birla Award for Best Responsible Care Committed Company and ICC Award for Social Responsibility for 2005-06. Fertilizers Association of India Award for the Best Technical Innovation 2007. Nine ABCI (Association of Business Communicators of India) Awards, 2008.
1.3)
TCL BABRALA: THE NATIONS CONCEIT
Substituting a part of the imports of Urea, TCL, Babrala is estimated to save the country about Rs. 500 crores in foreign exchange every year and provide the farmer with nitrogenous nutrient, which could help raise the food production about 4 million tones/year.
First major steps towards the fulfillment of a long standing TATA CHEMICALS commitment to provide the farmer with an optimal package of agriculture inputs to safe guard the food security of the company.
Produced more than 100% of the designated production during the first year of commercial production. Produced more than 8, 40,102.35 tons of Urea achieving a capacity of 113% in the year1995-96, and produced 9, 51,764 tones of Nitrogenous Urea in year 1996-97. Now produce capacity of 13, 14,000 metric tons of Urea per year, which constitutes nearly 12 per cent of the total urea produced by India's private sector. Total production of urea at Babrala is 3300 tons/day maximum and 2600 tons/day average. Current maximum capacity is 146%. The Babrala facility, among the best of its kind in India and comparable to the best in the world, has set new standards in technology, energy conservation, productivity and safety It is the only fertilizer plant in the country to use dual feedstock: natural gas or naphtha, or a combination of both.
10
1.4)
MILESTONES OF TATA CHEMICALS LIMITED, BABRALA December 21, 1994
Commercial Production Started on
AMMONIA UNIT First firing of Reformer Furnace for dry out of refractory First feed into Primary Reformer First Carbon Dioxide for making Urea First Ammonia production October 12, 1994 October 20, 1994 October 23, 1994 November 14, 1994
UREA UNIT Urea Prill Test conducted First Prill Test conducted through Unit 2 Second Prill Test conducted through Unit 2 October 04, 1994 November 05, 1994 December 09, 1994
ISO 14001 certificates obtained in October 2000. ISO 14001 certificate for Babrala township obtained in 2004.
11
1.5)
COMPOSITION OF TATA CHEMICALS LIMITED, BABRALA 1. AMMONIA PLANT
Capacity: 2000 MTPD Technology: HALDOR TOPSE Process, DENMARK Plant (Single Stream) Production: 2000 tons/ day of liquid Ammonia. Plant at TCL, Babrala is the first low energy plant in the country. Basic scheme involves the following steps: Desulphurization. Primary and Secondary Reforming. Carbon Dioxide Shift. Methanation. Synthesis and Chilling. Storage and supply to Urea unit
12
2.UREA PLANT Capacity: 2 X 1750 MTPD Technology: SNAMPROGETTI Process, ITALY Carbon Dioxide requirements supplied from ammonia plant. Two urea strings have a common Prilling section. Maximum Urea production: 3600 tons per day
Basic scheme involves the following steps: Urea Synthesis Waste Water Treatment section
3.OFFSITE AND UTILITIES S. N. 1. 2. 3. 4. 5. 6. 7. UNIT Ammonia Storage Tank Captive Power Plant Cooling Tower D. M. Water Plant Gas Turbine Generator Heat Recovery Unit Naptha Bulk Storage Tank CAPACITY 2X5000 MT 1X110 TPH 24000 M3/hr 3X450 M3 2X20 MW 2X90 TPH 3X6300 KL TECHNOLOGY M/S Kaveri Engineering THERMAX/ L&T M/S Paharpur Cooling Tower TCL, Mithapur THOMASSON, Holland L&T M/S Technofab Engg. Ltd.
13
1.6)
SALIENT FEATURES OF TATA CHEMICALS LIMITED, BABRALA Babrala, District Badaun, Rajpura block, Gunnor Tehsil, Uttar Pradesh. Approx. 160km. south-east of Delhi.
Location
Land Area
1519 acres Plant area:1,069 acres Township area:350 acres Green belt: 100 acres
Fuel
Natural gas (main) Naphtha (alternate)
Fuel Source
Natural gas supplied by GAIL (HBJ Pipeline) Naphtha from IOCL, Mathura
Consumptive water Six deep bore wells. source Present capacity installed Ammonia:2000 MTPD Urea: 3500 MTPD 1532 crores power Total 7,855,128 man-hours. Peak (month) 405,799 man-hours.
Project cost Man
Deployment (During Commissioning/ Erecting phase Beneficiary states
U.P., Bihar, West Bengal, Punjab, M.P., Assam.
14
UNIQUE FEATURES OF TATA CHEMICALS LIMITED, BABRALA An integrated energy network, which is the key, factor in achieving high energy efficiency. The flexible range of the ratio of natural gas and naphtha as a fuel/ feed is a major reason for this. The current low operating energy record is 5.055 Gcal/T of Urea. The second unique feature is common single central control room (CCR) for ammonia, Urea to captive power and steam generation plant (CPSSGP) and other offsite and utility plants. This provides a well coordinated and integrated control of the entire complex from one location and on line inters plant sharing of information. This has been found extremely beneficial especially during plant startups and upsets.
QUALITY POLICY OF TATA CHEMICALS LIMITED To provide customer satisfaction and timely delivery of quality products. Maintain good quality management systems and incorporate regular improvements to meet our customer changing needs. Continuously upgrade product quality by improvements in process technology. Develop and upgrade employee skills and provide an environment for their effective participation through teamwork to meet our customer expectations. Take adequate care to ensure safety at the work place, environmental preservations and to respond to the needs of the community.
2. FIRE AND SAFETY

2.1) FIRE CHEMISTRY The well known Fire triangle requires the three ingredients of fire namely fuel, oxygen and source of ignition. A fire is a combination of fuel, oxygen and source of ignition.
15
2.2) FIRE PREVENTION Fire prevention can be done in three ways: a.) Eliminate sources of ignition. b.) Eliminate combustible substances. c.) Eliminate air excess to combustible substances.
a.) FIRE PREVENTION THROUGH ELIMINATION OF IGNITION SOURCES: To prevent fire the first is to remove the cause of fire. Studies made by fire insurance company shows that majority of fires are caused by following general sources of ignition: Electrically limited fire: Improper earthing, short circuiting, loose electrical contacts, temporary direct connections without proper fittings, high current, over heating of electrical equipment are among the common cause of electrically initiative fires. Smoking ignited fire: Smoking or even carrying cigarettes/biddies/matches/lighter etc. in the following areas is a serious offence. All non-smoking areas should carry NO SMOKING signboards. Friction and overheated material: In flame proof areas, frictional fires can also be started by the friction of moving parts of machinery which are overheated due to excess friction. This is likely in non-lubricated and not well maintained machinery.
b.) FIRE
PREVENTION
THROUGH
ELIMINATION
OF
COMBUSTIBLE
MATERIALS: Waste and combustible materials: All combustible wastes and materials like waste paper, cotton waste etc. accumulated after a job should be transported to waste bins and is the responsibilities of the person doing the job that creates the wastes. Tins and cans of flammable materials like paints, oils, spirit etc.: These should b handled carefully ensuring that no undue spillages takes place during their uses and any spillages takes place during their use and any spillage should be cleaned immediately.
16
Fueling of vehicle tanks: Engine should be always switched off while fueling a vehicle. If diesel or petrol spills over during fueling, dry sand should covered over the spill immediately till only dry sand is visible on the spilled area.
Waste disposal: All combustible waste must be regarded in such a way that can be disposed off as such and not burnt.
c.) PREVENTION THROUGH ELIMINATION OXYGEN SUPPLY Smoothening: It is a process of covering the burning area with a non-combustible substance like asbestos or fire proof blanket, wet thick cotton blanket or sand.
2.3) CLASSIFICATION OF FIRES Fires are classified according to the nature of fuel burning and fire extinguishing methods that can be applied and the following is the fire classification under the Indian fire code. CLASS A FIRE CLASS B FIRE CLASS C FIRE CLASS D FIRE CLASS E FIRE
CLASS A FIRE: Fires where the burning fuel is a cellulosic material such as wood, clothing, paper etc. is called class A fire. It can be extinguished by the water and sand. Class A fires can also be extinguished by all the available means of extinguishing fires like foam, soda acid, dry chemical powder, carbon dioxide etc. CLASS B FIRE: Fires where the burning fuel is a flammable liquid Naphtha, petrol etc. are categorized as class B fire. Blanketing is a useful first aid fire control for B class fire. Water
17
is forbidden as a fire fighting means on class B fires. Foam, carbon dioxide, dry chemical powder extinguishers are the desired means of controlling B class fires.
CLASS C FIRE: Fire involving flammable like natural gases hydrogen are classified as class C fire. The best means of extinguishing C type fire is by stopping the gas supply to the leaking vessels or pipe lines if possible. This must be the intermediate and very first step. Dry chemical powder and carbon dioxide are useful in controlling C class fire. CLASS D FIRE: Fire involving material like magnesium, aluminum, zinc, potassium etc. are classified as class D fire. Sand buckets are useful in most cases of metallic fires. Special dry chemical powder also works on class D fires. CLASS E FIRE: Fires involving electrical equipments are classified as E class fires. Only carbon dioxide and D.C.P extinguishers are used on class E fires. 2.4) FIRE FIGHTING GADGETS AND APPLIANCES a) b) CO2:- It contain under pressurized liquid carbon dioxide. SODA ACID: - Contain a double container with sodium bicarbonate solution in outer container and dilute sulphuric acid in the inner container. After the inner container both react and produce a liquid of entrapped CO2. c) FOAM: - Contain aluminous sulphate in inner container and sodium bicarbonate in outer one. After cracking the container both reacts to produce carbon dioxide and the foam stabilizer makes stable form of carbon dioxide. d) DRY CHEMICAL POWDER: - It contains an inert dry chemical powder of sodium bicarbonate or potassium bicarbonate or potassium chloride and diammonium phosphate along with liquid carbon dioxide under pressure. e) HALON/ BROMOCHLOROFLUORO METHANE: - Halon is in the form of a liquid gas under pressure that is released on pressing the knob.
2.5) SAFETY PROGRAMME AT T.C.L
18
The company conducts regular programmes for safety measures, which not only creates awareness about safety but also maintains it; the fire and safety department of T.C.L organizes many programmes to motivate in this direction and to make the employees aware. National safety day 4th march is being celebrated each year with earnestness and includes various awareness programmes, competitions and includes various awareness programmes, competitions etc. some of these are listed below: 1. 2. 3. 4. 5. Training programmes on safety. Home safety. Use of safety equipments. Safety quiz. Safety slogan competition.
2.6) SAFETY PROVISIONS Personal protective equipment (PPEs ): The various types of PPEs are:Helmet for head protection. Goggles for eye protection. Ear plugs and muff for ear protection. Safety shoes for foot protection. Gloves for hand protection. Face shields foot protection. Full body protection suits. Hoods for head, neck, face, and, eye protection. Safety belts or life belts or harness. Breathing apparatus or respiratory protection equipment. Fencing of machinery. Devices for cutting of power. Hoists and lifts.
19
3. BRIEF INTRODUCTION OF UREA PLANT

Tata Chemicals owns fertilizer complex at Babrala. It has adopted Snapgrogetti NH3 stripping process for the production of urea. It has two identical units (11 and 21) of the same nameplate capacity 1750 MTPD each, so the total capacity is 3500 MTPD. 3.1) RAW MATERIAL REQUIRED FOR UREA PRODUCTION The raw material condition at the battery limit is as under: Ammonia: NH3 min Oil Water - 99.5%wt - 10 ppm max 0.5% wt
Carbon dioxide: CO2 (dry basis) - 98.76% vol. min H2 H2O - 0.3% vol min Saturated
Utilities characteristics Cooling water: Pressure (norm/design) Inlet temperature Outlet temperature Fouling factor - 3.5/6.0 kg/cm2g
- 35 C 45 C 0.0004 m2 h C/kcal
Electric power:
20
Alternating current
- 11KV 50 Hz 3ph 3.3 KV 50 Hz 3ph 415 V 50 Hz 3ph
Direct Current Service air: Moister
115 V 1Ph
- saturated 7/11 kg/cm2
Pressure (norm/degn) Temperature Instrument air: Pressure Temperature Type Dew Point Polished water: Conductivity Silica (reactive) Fe TDS Oil pH -
- 40 C
- 7/11 kg/cm2 - 40 C - Oil free - -20 C max at 7 kg/cm2
0.2 s/cm 0.02 s/cm 0.01 ppm 0.1 ppm 0.5 ppm 7
21
Nitrogen: Nitrogen plus noble gas CO2 99.6 % vol 20 ppm max
Water Oxygen Pressure (min/ norm) Temperature
20 ppm max 200 ppm max 5/7 kg/cm2 ambient
3.2) MANUFACTURING PROCEDURE Urea is commercially manufactured by direct synthesis of gaseous CO2 and liq. NH3. The urea production involves following steps: 1. 2. 3. Urea synthesis and pressure recovery. Urea purification and medium low pressure recovery. Urea concentration - pre vacuum concentration - Vacuum concentration 4. 5. Urea prilling Waste water treatment
1. UREA SYNTHESIS AND HIGH PRESSURE RECOVERY For urea production raw materials (liquid ammonia and gaseous carbon dioxide) are supplied by ammonia Plant. The liquid ammonia is pumped at high pressure through an ejector in to the reactor. The ejector serves as drive less pump to recycle back ammonia and CO2 mixture at high pressure known as carbamate into the Synthesis loop.CO2 mixed with small but measured quantity of air is compressed in a fourstage compressor up to synthesis pressure. CO2 from the
22
compressor outlet is fed to the reactor. The NH3 and CO2 react in the reactor to form an intermediate product, ammonium carbamate (NH4 COONH 2). This intermediate product dehydrates to form urea and water. The oxygen in the air forms a passive oxide layer on the inner surface of the vessel to prevent corrosion by carbamate and urea.
The reaction products from the reactor overflow to the stripper where the unconverted carbamate is decomposed back in to the constituents with the help of the heat supplied by MP steam. The stripper is basically a falling film exchanger with urea solution on the tube side and MP steam on the shell side. The Urea solution obtained at the bottom flows to MP section through a level control valve. The vapours from the stripper top enter the HP carbamate condenser along with the carbamate solution Again and in the process releasing a large amount of heat of condensation, which is utilized to generate the low-pressure steam on the shell side. Vapours consisting mainly of inerts are sent from the carbamate separator to the bottom of the MP decomposer to passivate the MP section.
2. UREA PURIFICATION Urea purification takes places in two stages. One is known as MP section and the other is known as LP Section. MEDIUM PRESSURE SECTION Urea solution from the bottom of the stripper enters the MP decomposer. During the expansion most of the remaining carbamate flashes forming the NH3 and CO2 vapours, thereby concentrating the urea solution. The vapours from the MP decomposer top flow to pre vacuum concentrator shell side and from pre vacuum Concentrator to MP condenser shell side. Prior to the entry of the vapours in the pre vacuum concentrator the vapours get mixed with the low concentration carbamate solution from the LP section. The partly condensed gas mixture from MP condenser outlet goes to MP absorber where the CO2 is stripped from the NH3 vapors and the pure NH3 vapors from the MP absorber flow to ammonia condenser. The solution at the
23
bottom of the MP absorber provides the suction for the HP carbamate pump. Ammonia condenser has cooling water on tube side. From ammonia condenser both vapour and liquid flow to the ammonia receiver tank. The receiver tank receives fresh ammonia from the ammonia plant. The inert gases saturated leaving the receiver enter the ammonia recovery tower. Here ammonia is further condensed by direct contact with cold ammonia from the battery limit.The inert with residual ammonia from the tower are sent to MP inert wash tower via a condenser. The ammoniacal solution collected at the bottom is recycled back to the MP absorber. LOW PRESSURE RECOVERY The urea solution from MP decomposer bottom enters the LP decomposer after expansion through a level controller. Consequently most of the residual carbamate is decomposed and in the process urea solution gets concentrated. The remaining carbamate is decomposed in falling film exchanger, which is a part of LP decomposer. The vapours from the LP decomposer enter the LP condenser where they get cooled and liquefied. Prior to entry of LP off gases in LP condenser the vapours get mixed with aqueous solution from wastewater section. The vapours thus formed get condensed in LP condenser goes to carbonate solution tank from where it is sent back to MP condenser. The inert gases in the tank contain considerable amount of ammonia and thus are absorbed in cool condensate before being sent to the vent stack. The urea solution at the bottom of LP decomposer is sent to pre vacuum concentrator through a level controller valve.
3. UREA CONCENTRATION PRE VACUUM CONCENTRATOR The urea solution from LP decomposer enters the pre vacuum concentrator, which is an exchanger with urea solution from the LP section on tube side and MP decomposer off-gases on the shell side. The MP decomposer off-gases give their heat and the urea solution gets concentrated in the process. The pre vacuum concentrator operates under vacuum and the
24
vapours from the top are condensed in the pre vacuum condenser. The vapours condensing in the pre vacuum condenser are collected at the bottom in vacuum system tank and the liquid is sent to the wastewater section. The concentrated urea solution at the bottom is sent to the vacuum concentrated section.
VACUUM CONCENTRATION The urea solution from the pre vacuum section bottom gets further concentrated up to the concentration required for prilling in two vacuum concentrators in series. The heat for concentrating the urea solution is supplied by low-pressure steam. The vacuum is maintained in both the stages with the help of ejectors and condensers. The urea solution from the outlet of second vacuum concentrator has 99.7 % (w/w) concentrations and is pumped to prilling section. The vapours from both the stages get condensed in the condensers and are sent to the wastewater section. 4. UREA PRILLING The urea melt from the second vacuum concentrator is sent to the prilling bucket. The urea melt comes out from the bucket in the form of liquid drops and they fall along the prilling tower. The drops get solidified and cooled by the countercurrent flow of air from the bottom of prilling tower. The solidified urea melt drops known as urea prills, fall on the prilling tower bottom. These prills are collected by a rotating scrapper and are sent to the bagging plant with the help of belt conveyors. The heated air containing few ppm of NH3 is released from the top in to the atmosphere. 5. WASTE WATER TREATMENT The liquid waste containing water, urea, ammonia and carbon dioxide from the process, the condensate from vacuum and pre vacuum concentration ejector/condensers are collected in a wastewater tank. From here it is transferred to the distillation tower where it is fed in the upper portion of the distillation tower. The stripping medium is low-pressure steam fed at the bottom of the tower. The ammonia stripped wastewater is then pumped to the hydrolyser where the urea in the wastewater is hydrolyser to be converted back in to ammonia and carbon dioxide. The hydrolyzation takes place with the help of the superheated steam. The wastewater from the
25
hydrolyser outlet contains only few ppm of urea but still has ammonia in it. So the wastewater from the hydrolyser outlet is again fed to the lower portion of the distillation column where the remaining ammonia is stripped off and the wastewater at the distillation tower at the bottom contains only few ppm of ammonia and urea. This treated water is sent to O&U plant for reuse. The vapours from the distillation tower and hydrolyser get condensed in the overhead condenser and are recycled back to the LP section and a part of it is used as reflux for distillation column. The distillation column is a tray column PROCESS FLOW DIAGRAM
Fig.3.2.1. Process Flow Diagram of Urea Plant
3.3) STEAM AND CONDENSATE SYSTEM The steam networks provided in the urea plant are: 1. Superheated steam (KS) network at P = 110 kg /cm2 g & T = 510C
26
2. Superheated steam (HS) network at P = 37 kg /cm2 g & T = 381C 3. Saturated steam (MS) network at P = 22 kg /cm2 g & T = 219C 4. Saturated steam (LS) network at P = 3.5 kg /cm2 g & T = 147C
5. Saturated steam (KS) network at P = 4.7 kg /cm2 g & T = 160C KS NETWORK: The steam is available at urea plant battery limit and is utilized to drive the CO2 compressor turbine. It may be used to provide the MS steam in case of failure of turbine extraction steam. HS NETWORK This steam is available at the point battery limit and is utilized in hydrolyzer. MS NETWORK This steam is extracted from the carbon dioxide compressor turbine and is the superheated to make it saturated. This steam is utilized in the stripper and MP decomposer. LS NETWORK This steam is produced in the HP carbamate condenser shell & is used in the following equipment / systems: 1. 2. 3. 4. 5. 6. 7. 8. 9. LP decomposer First vacuum concentrator Second vacuum concentrator distillation tower bottom Prevacuum / vacuum system ejectors Steam tracing Steam jackets MP start up lines MP inert gas wash tower vent line
27
10. 11. 12. 13. 14.
Steam condensate collector tank Blow down vents, ME-14,ME-15, ME-21 PSV flushing Mechanical seal / jacket flushing of P-08, P-09, & P-20 utilities points
LMS NETWORK: This steam is produced by boosting LS pressure with the help of an ejector with MS as motive fluid. The steam is utilized in the MP decomposer. CONDENSATE COLLECTION Turbine condensate is exported to O&U for steam generation. MS & HS condensate known as MC & HC respectively is utilized for LS generation in HP carbamate condenser shell. LS condensate known as LC from all the sources in the plant is collected in a common tank as steam condensate tank. From where it is used for flushing purpose and the excess condensate is exported to O&U.
3.4) FLUSHING NETWORK Condensate in the steam condensate tank is utilized to provide flushing water requirement in all the section of the plant. There are three types of network: KW Network: Flushing water at pressure of about 180 kg /cm2 a HW Network: Flushing water at pressure of about 25 kg /cm2 a LW Network: Flushing water at pressure of about 10 kg /cm2 a
28
29
4) PROJECT 4.1) To Carry out the energy balance of Urea plant
30
TO CARRY OUT THE ENERGY BALANCE OF UREA PLANT PROJECT SUMMARY The project assigned to me is To Carry Out The Energy Balance of Urea Plant.I was assigned this project by Mr.Azaz Ali, the head of department of urea plant.Now the urea plant here at Tata Chemicals Limited has two exactly identical units viz. 11 and 21 within the plant.Both the units work on the same load of raw materials and energy and have the same installations.Therefore it is prudent to surmise that both the units would have the same or nearly same concentration of gases in the flows analogus to both the sister units. The process used here for urea manufacturing is Snamprogetti process. The urea production involves following steps: 1 2 3 4 Urea synthesis and pressure recovery. Urea purification and medium low pressure recovery. Urea concentration pre vacuum concentration Vacuum concentration 5 6 Urea prilling Waste water treatment
The material balance of every section has already done in detail manner.Now the task was to Carry Out The Energy Balance of Urea Plant.
31
Approach: The way forward for tackling this problem was to first get a design data sheet of the plant.Since the plant was updated to a new capacity of 2*1750 MTPD as against the old 2*1225 MTPD it was imperative only to work with the new design data sheet.The idea was to first find the design flowrates of various components at various points and then to find out the temperature at various points. FLOWRATES OF PROCESS FLUID The flowrates of process fluids were obtained from the Control room as well as from the PROCESS FLOW DIAGRAMS(PFD). TEMPERATURE MEASUREMENTS The temperature of process fluids were obtained from the Control room as well as from the PROCESS FLOW DIAGRAMS(PFD). SPECIFIC HEAT DATA The specific heats of various components were obtained from the data sheets in the technical library.Since there is a small variation in Cp value with temperature.I assume Cp of any component at three diff. temperature ,then I get three variable with three equations and after solving them I get the value of a,b.and c . Hence,although this approach may not be entirely accurate ,it will still be within an extremely small range of error of the actual value. PROCEDURE The heat exchanged by the process side is calculated by the formulae: Q = mcp(Tin Tout) [mass flowrate*specific heat *temp.difference]
32
Material Balance Of Urea Plant.

Urea production per day CO2 conversion CO2 requirement per day NH3 requirement per day = 3800 MTPD = 64% = 57954 kg/hr = 127804 kg/hr
Compound Ammonia Carbon di oxide Ammonium Carbamate Water Urea
Chemical formula NH3 CO2 NH2COONH4 H2O NH2COONH2
Molecular Weight(kg/kmol) 17 44 78 18 60
Table 1 Compound in Urea Manufacturing Input ratio to reactor Molar ratio Weight ratio NH3:CO2 4: 1 68: 44
Reactions involved in the process 2 NH3 + CO2 NH2COONH4 + HEAT
33
Sch
1 44 0.564
1 78 1.000
Mass 34 Wt% 0.436
NH2COONH4 + HEAT NH2CONH2 + H2O Sch Mass Wt% 1 78 1.000 1 60 0.769 1 18 0.230
5.0 Heat Balance Calculation

5.1 Main Process Energy Balance
2 NH3 + CO2 NH2COONH4 + HEAT NH2COONH4 + HEAT NH2CONH2 + H2O 2NH3 + CO2 NH2CONH2 + H2O -84 KJ/mol +23 KJ/mol -60 KJ/mol
Ammonia Liquid
T (C) Cp (KJ/KgK) 60 5.6 80 5.87 112 8.6
Ammonia Vapour
T (C) Cp (KJ/KgK)
87 2.2
127 2.3
167 2.37
207 2.44
34
CO2(g) T (C) Cp (KJ/KgK)
27 0.84
127 0.94
227 1.01
Urea Vapour T (C) Cp (KJ/KgK)
80 1.26
120 1.36
200 1.56
Urea Liquid T (C) Cp (KJ/KgK)
80 1.4
120 1.6
200 2.1
Urea Solid T (C) Cp (KJ/KgK) 27 1.56 77 1.8 127 2.04
Water Liquid T (C) Cp (KJ/KgK) 27 4.18 127 4.26 177 4.39
Cp of the Carbamate = 2.3 KJ/KgK
35
For NH3 liquid Cp = a + bT + cT2 5.6 = a + 333b + 3332 c 5.87 = a + 353b + 3532 c 8.6 = a + 385b + 3852 c From (1), (2) & (3) a = 163.44 b = - 0.9338 c = 1.38*10For NH3 gas Cp = a + bT + cT
2
(1) (2) (3)
2.2 = a + 360b + 3602 c 2.3 = a + 400b + 4002 c 2.44 = a + 480b + 4802 c From (4), (5) & (6)
(4) (5) (6)
a = 0.4 b = 7.25*10 c = -6.25*10 For CO2 gas Cp = a + bT + Ct2 0.84 = a + 300b + 3002 c 0.94 = a + 400b + 4002 c 1.01 = a + 500b + 5002 c From (7), (8) & (9) a = 0.36 b = 2.05*10 c = -1.5*10 For Urea Cp = a + bT + cT2 1.4 = a + 353b + 3532 c 1.6 = a + 393b + 3932 c 2.1 = a + 473b + 4732 c (10) (11) (12)
-3
-3
-6
(7) (8) (9)
-6
36
From (10), (11) & (12) a = 1.08 b = -2.77*10 c = 1.04*10

-3 -5
Reactor (R-01)
Urea formation heat by decomposing Ammonium Carbamate Hf = 79279 *
= 30390.28 kJ/hr
Ammonium Carbamate production in the reactor = *79279
= 103,062.7 Kj/hr Ammonium Carbamate formation heat Hf = 103062.7*
= -110990.6 KJ/hr
Heat required to increase raw material from 178C to 188C = (12,7804)*[ (163.44 0.9338T + 1.38 * 10-3T2)dT ] +(23333)*(461-451) + (57954 + 42,284)*[(0.36 + 2.05*10-3T 1.5*10-6T2)dT] = 3818763.96 KJ/hr Energy required to reactor = 30390.28 110990.6 + 3818763.96 = 3738163.66 KJ/hr
Stripper (E-01) Decomposition energy of Ammonium Carbamate (251373 )*
270,709.38 Kj/hr
Heat absorbed by Carbamate by temp.increase from 461K to 477K
37
= (79,279)*[(1.08 2.77*10-3T + 1.04 *10-5T2)dT ]+ (45,665)*[ (163.44 0.9338T + 1.38 * 10-3T2)dT] + 43,007*4.4*(477-461) + (12,843)*[ (0.36 + 2.05*10-3T 1.5*10-6T2)dT] = 79,279*32.5 + 45,665*390.7 + 3,027,692.8 + 204,414.58 = 2577186.6 + 206852657.8 + 3,027,692.8 + 204,414.58 = 212,661,951.8 Kj/hr Heat absorbed by carbon Dioxide by increasing the temp. from 461C to 463C = (12843)*10.36(463-461) + 2.05*0.001*0.5*(4632 4612) 1.5 *10*-6*(4633 -4613)*0.333 = 12843*21.98 =282,289.14 Kj/hr Heat absorbed for Ammonia Vapourisation = 37214*160 = 5954240 Kj/hr. Energy required for stripper = 270,709.38 + 212,661,951.8 + 282,289.14 + 5954240 = 219,169,190.3 Kj/hr
Carbamate Condenser:(E-05) Heat absorbed by Carbamate by temp.increase from 368K to 428K (13169)*(0.36 + 2.05*0.001T 1.5 *10-6 T2)dT + (28138)*[(163.44 0.9338T + 1.38*103 2 T )dT] + 19283*4.4*(428-368) = 742,731.6 + 42,550,976.92 +50,90,7 12
Heat released by CO2 = 29257*(0.36 + 2.05*0.001T 1.5 *10-6 T2)dT = -1001871.7 Kj/hr
38
Heat released by water = 19263*4.4*(428-463) = -2969,582 Kj/hr Condensation heat & Sensible heat released by NH3 = 37,214*760 + 37,214*[(0.4+(7.25*10-3)T-1.5*10-6T2)dT] = 37214*760 + 37,214*-116.72 = 23,939,021.92 Kj/hr. Heat released from water = 4,110*4.4*(428-463) = -632,940 kj/hr. Heat released from Carbamate condenser = 742,731.6 +42,550,976.92 + 5090,712 -1001871.7 -2,969,582 +23,939,021.92-632,940 = 67,719,048.72 Kj/hr.
Carbamate Separator(MV-O1) : Heat released from up flow (190C to 155C) = 4501*[(163.44 0.9338T + 1.38*10-3T2)dT] = -5,934,540.99 Kj/hr Heat released from down flow (190C to 155C) 60,581*[(163.44 0.9338T + 1.38*10-3T2)dT] + 42,284*[*(0.36 + 2.05*0.001T 1.5 *10-6 T2)dT +23,251*4.4*(428-463) = - 85,345,693.06 Kj/hr
Energy loss = -5,934,540.99 - 85,345,693.06
= -91,280,234.05 Kj/hr
39
Low pressure Decomposer (E-03): Decomposition energy of Ammonium Carbamate = 123723*84/78 = 133,240.15 KJ/hr Heat absorbed for Ammonia Vapourization = 6006 *210 = 1261260 KJ/hr Heat released from Urea (160C - 142C) = (79279)*[(1.08 2.77*10-3T + 1.04 *10-5T2)dT ] = 79,279*-31.62 = - 2506,951.85 KJ/hr Heat released by Ammonia (160C - 142C) = 7849*[(163.44-0.9338T + 1.38*10-3 T2)dT] = -2080,640.037 KJ/hr Heat released from water (160C - 142C) = 34459*4.3*(415-433) = - 2,667,126.6 KJ/hr Heat released from carbon di-oxide (160C - 142C). = 2136*[(0.36 + 2.05*10-3T 1.5*10-6T2)dT] = -36,179.28 KJ/hr Heat released by LPD = 133,240.15 +1261260 - 2506,951.85 -2080,640.037 - 2,667,126.6 -36,179.28 = -5,896,397.61 KJ/hr
40
MP Decomposer (E-02 A/B): Decomposition energy of Ammonium Carbamate = (180794 123723)*
= 61,461.07 KJ/hr.
Heat absorbed for Ammonia vapourisation = 42317*210 = 8886570 KJ/hr Heat released from Urea (204C - 160C) = (79279)*[(1.08 2.77*10-3T + 1.04 *10-5T2)dT ] = 79,279*-117.54 = -9318998.45 KJ/hr Heat released from water (204C - 160C) = 43007*4.3*(160-204) = -8136924.4 KJ/hr Heat released by Ammonia (204C - 160C) = 45665*[(163.44-0.9338T + 1.38*10-3 T2)dT] = 45665*-1808.4 = -8258104.39 KJ/hr. Energy loss = 61,461.07 + 8886570 9318998.45 8136924.4 8258104.39 = -16,765,996.17 KJ/hr
41
M.P.Absorber(C-01): Condensation heat released by NH3 = (50308-29713)*(-200) = -4119000 kj/hr Energy loss due to reduce temperature from 85c to 80c = 28138*[(163.44 0.938T + 1.4*10-3T2)dT] + 13169[(0.36+ 2.05*10-3T -1.5*10-6T2)dT ] + 17783*4.4*(80-85) = 28138*-22.18 +13169*-8.15 + 17783*4.4*(80-85) = -1122,654.19 Kj/hr. Energy released from M.P.ABSORBER(C-01) = -4119000 -1122,654.19 = -5,241,654.19 Kj/hr Prevacuum Separator(MV-29/E-29) Heat released from UREA = 79279*1.96*(102-142) = -6,215,473.6 KJ/hr Heat released from Water = (29745+8690)*4.25*(102-142) = -6,533,950 KJ/hr Heat absorbed by water Vapourisation = 15856*2,258 = 35,802,848 KJ/hr Total Heat gain = -6215,473.6-6,533,950 + 35,802,848 = 23,053,424.4 KJ/hr M.P Steam load S6 *1972 = 23,053,424.4 S6 = 11,690.38 KJ/hr
42
1st Vacuum Separator (MV-06/E-14):

Heat absorbed by water vapourisation = 9720*2702.4 = 26,267,328 KJ/hr Heat absorbed by Urea & Water = 79,279*2*(128-102) + 13,889*4.25*(128-102) = 4,122,508 + 1,534,734.5 = 5,657,242.5 KJ/hr Energy loss = (26,267,328 + 5,657,242.5)*0.01 = 319,245.71 KJ/hr Total energy requirement = (26,267,328 + 5,657,242.5 + 319,245.71) KJ/hr = 32,243,816.21 KJ/hr 3.5 kg/cm2 LS steam load S7 * 2109 = 32,243,816.21 S7 = 15,288.68 KJ/hr
2nd Vacuum Separator (MV-07/E-15):

Heat absorbed by water vapourisation = 5115*2706.28 = 13,842,622.2 KJ/hr Heat absorbed by Urea & Water = 79,329*2*(138-128) + 5,313*4.25*(138-128) = 1,586,580 + 225,802.5 = 1,812,382.5 KJ/hr Energy loss = (13,842,622.2+ 1,812,382.5)*0.01 = 156,550.047 KJ/hr Total energy requirement = (13,842,622.2+ 1,812,382.5 + 156,550.047) KJ/hr = 15,811,554.75 KJ/hr 3.5 kg/cm2 LS steam load S8* 2109 = 32,243,816.21
43
S8 = 7,497.18 KJ/hr
Prilling Tower (ME-06) Heat removed from Prilling Tower = 79,329*2*(128 138) + 5,313*4.25*(128 138) = -1,586,580 225,802.5 = - 1,812,382.5 KJ/hr Process Waste water treatment unit. Heat requirement of waste water treatment unit = 58396 * 4.2*(147-128) + 58,396*2258 = 63,000.5 + 131,858,168 = 131,921,168.5 KJ/hr
44
8.0 Tabulated heat balance Input Energy Heat supplied to reactor Heat supplied to stripper Heat out from Carbamate Condenser Heat supplied to HPD Heat supplied to prevacuum separator Heat supplied to 1st vacuum separator Heat supplied to 2nd vacuum separator Total input energy 23,053,424.4 32,243,816.21 15,811,554.75 340,735,198 KJ/hr 3738163.66 219,169,190.3 67,719,048.72
Output Energy Heat out from Separator Heat out from Carbamate Condenser Heat out from MPD Heat out from Absorber Heat out from prilling tower Heat out from waste water Heat out from LPD Total output energy
KJ/hr 91,280,234.05
16,765,996.17 5,241,654.19 1,812,382.5 131,921,168.5 5,896,397.61 251,286,689
Difference between input and output energy = 89,448,508.98 Total heat input is greater than total heat output.So this difference is due to heat generated in the reaction.But the amount of theoretical heat generated in the reaction is much higher than this value.That difference between actual and theoretical value is happens because of heat losses ocuured during the reaction.
45
5) CONCLUSIONS AND RECOMMENDATIONS
46
4.1) SIMULATION OF MEDIUM PRESSURE ABSORBER(C-01): This project deals with the steady state simulation of Medium Pressure Absorber(C-01) of the urea plant using Aspen plus simulator. Aspen plus is a process modeling tool for conceptual design, simulation, optimization and performance monitoring for chemical, polymer, specialty chemical, metals and minerals, and coal power industries. The unique combination of sequentialmodular and equation-oriented solution technologies in Aspen plus facilitate simulation of widescale, integrated chemical processes. Aspen plus can predict the output conditions based on the given input and process conditions and hence we can use it as a tool in process improvisation. We can also optimize a process using Aspen Plus's various in-built optimization algorithms. Using these optimization techniques we can improve the performance of various processes by manipulating the operating variables. The purpose of the simulating this absorber is to calculate the amount of absorption of carbon dioxide and water contained in the vapors of mixed stream coming from medium pressure condenser (E-07) outlet enter into the medium pressure absorption column (C-01), so as to increase recovery of ammonia from the process. In this project, the simulations are carried out based on design conditions. The saved aspen simulation files can be used by anyone to predict the behavior of the simulated sections The first step in simulation is to build the process flow diagram in the user interface. Fig. 4. 1.1 shows the process flow diagram of the medium pressure absorber (C-01). The process mixed stream from medium pressure condenser (E-07) outlet enters the absorber, from the middle of the column. The vapors containing ammonia, carbon dioxide, water and inerts are separated out from liquid and rises towards top of the column. Fresh ammonia and ammonia solution are entered on tray 1 and 2 resp. from top of the column. Whenever reflux gets contacted with rising vapors, it absorbs carbon dioxide and water. Vapors are drawn from the top of column containing ammonia, inerts and few ppm of carbon dioxide and water. Liquid solution is drawn from bottom of the column containing ammonia, carbon dioxide and water. In this case the equilibrium steady state simulation of medium pressure absorber (C-01) is carried out. The RADFRAC ABSORBER model from the steady-state simulator ASPEN PLUS, version 2006 was taken to simulate the process. RADFRAC is based on a rigorous equilibrium-stage model for solving the MESH (Material balance, vapor liquid Equilibrium, mass fraction Summations and Heat balance) equations.
47
Simulation of the design data on Absorber Column (C-01): The input data for the components entering from shell side of Pre Vacuum Column (E-29) shell side: Temperature = 85C Pressure = 18.22 kg/cm2g Ammonia flow rate = 78996 kg/hr Carbon di-oxide flow rate = 13169 kg/hr Water flow rate = 16917 kg/hr The input data from the M.P Ammonia absorber (E-11) Temperature = 37C Pressure = 23.00 kg/cm2g Ammonia flow rate = 5837 kg/hr The input data from the Ammonia Solution Temperature = 50C Pressure = 18.00 kg/cm2g Ammonia flow rate = 1385 kg/hr The M.P absorber input is : Height : 9 m Dia. : 1.74 m
No.of Trays : 4 Type of Trays :Bubble cap Properties Specified : ELECNRTL (Electrolytic Non Random Two Liquid)
48
Simulation was run on the above input data and the following results were obtained.The results are tabulated on the following page.
Fig. 4. 1. 1. Medium Pressure Absorber (C-01)
49
Table 4. 1. 1: Streams Results
50
Table 4. 1. 2: Mass and Energy Balance
Table 4. 1. 3: Top stage parameters
Table 4. 1. 4: Bottom stage parameters
Table 4. 1. 5: Split fraction of components
51
Table 4. 1. 6: Temperature, Pressure and Flow rate Profiles
Table 4. 1. 7: Vapor Compositions of Components
Table 4. 1. 8: Liquid Compositions of Components
52
Table 4. 1. 9: K-Value Profiles
53
Some of the plots for various simulation results are as follows:
Fig. 4. 1. 2. Variation of temperature with stages
54
Fig. 4. 1. 3. Variation of column pressure with stages
Fig. 4. 1. 4. Variation of total liquid flow rate with stages
55
Fig. 4. 1. 5. Variation of total vapor flow rate with stages
56
Fig. 4. 1. 6. Liquid composition profiles
Fig. 4. 1. 7. Vapor composition profiles
57
5) CONCLUSIONS AND RECOMMENDATIONS
For 3500 MTPD capacity; ranges are found for column pressure would be 17 to 18 kg/cm2 a. P5NH3 flowrate would be 5500 to 6500 kg/hr and C1mixin temperature would be 84C to 87 C. Output of C1vapor temperature would be in the ranges of 42.4C to 44.5C and corresponding C1vapor flow rate would be in the ranges of 31100 to 31700 kg/hr. Output of C1liquid temperature would be in the 78C to 81C and corresponding C1 liquid flow rate would be in the ranges of 55600 to 56500 kg/hr.
58
6) REFERENCES 1) Urea Manual, TATA Chemicals Ltd, Babrala, 1999. 2) Fire and Safety manual of TCL, Babrala. 3) ASPEN plus Manual 2006. 4) McCabe Warren L., Smith Julian C., Harriott Peter, Unit Operations of Chemical Engineering, 6th Edition, McGraw-Hill Book Co.-Singapore, International Edition, 2001. 5) Richardson, J. F.; Harker, J. H.; Buckhurst, J. R., Particle Technology and Separations Processes, Vol. 2, 5th Edition, Butterworth-Heinemann, Elsevier, 2006. 6) Perry, R.H., and Green, D.W., Perrys Chemical Engineering Handbook, 7th Edition, Tata McGraw-Hill, 1999 7) Treybal, R.E., Mass Transfer Operations, 3rd Edition, Tata McGraw-Hill, 1980 8) Smith, J.M., Abbott, M.M., Vanhess, H.C., Chemical Engineering Thermodynamics, 6th Edition, Tata McGraw-Hill, 2003. 9) MARTYN S. RAY;DAVID W. JOHNSTON Chemical engineering Design Project: A Case Study Approach
59
60

Hariom Report

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Hariom Report

Caricato da

Copyright:

Formati disponibili

A REPORT ON

TATA CHEMICALS LIMITED, BABRALA

A Practice School-II Station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI (June, 2011)

Birla Institute of Technology & Science, Pilani.

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI (RAJASTHAN)

Name of Expert: Mr U.P .SINGH Name of the PS Faculty: Prof. R. K. Tiwary

Birla Institute of Technology & Science, Pilani.

Signature of student Date:

Signature of Faculty Date:

Birla Institute of Technology & Science, Pilani.

Signature of General Manager

Birla Institute of Technology & Science, Pilani.

Hariom Sharma 2009H101015P

Birla Institute of Technology & Science, Pilani.

2. Fire and Safety

Birla Institute of Technology & Science, Pilani.

3. Brief Introduction of Urea Plant

5. Conclusions and Recommendations 6. References

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

CREDENTIALS OF TATA CHEMICALS LIMITED BABRALA

Birla Institute of Technology & Science, Pilani.

TCL BABRALA: THE NATIONS CONCEIT

Birla Institute of Technology & Science, Pilani.

MILESTONES OF TATA CHEMICALS LIMITED, BABRALA December 21, 1994

Commercial Production Started on

Birla Institute of Technology & Science, Pilani.

COMPOSITION OF TATA CHEMICALS LIMITED, BABRALA 1. AMMONIA PLANT

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

Natural gas (main) Naphtha (alternate)

Project cost Man

Deployment (During Commissioning/ Erecting phase Beneficiary states

U.P., Bihar, West Bengal, Punjab, M.P., Assam.

Birla Institute of Technology & Science, Pilani.

2. FIRE AND SAFETY

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

2.5) SAFETY PROGRAMME AT T.C.L

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

3. BRIEF INTRODUCTION OF UREA PLANT

Birla Institute of Technology & Science, Pilani.

- 11KV 50 Hz 3ph 3.3 KV 50 Hz 3ph 415 V 50 Hz 3ph

Direct Current Service air: Moister

- saturated 7/11 kg/cm2

- 7/11 kg/cm2 - 40 C - Oil free - -20 C max at 7 kg/cm2

Birla Institute of Technology & Science, Pilani.

Water Oxygen Pressure (min/ norm) Temperature

20 ppm max 200 ppm max 5/7 kg/cm2 ambient

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

Fig.3.2.1. Process Flow Diagram of Urea Plant

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

10. 11. 12. 13. 14.

Birla Institute of Technology & Science, Pilani.

Birla Institute of Technology & Science, Pilani.

4) PROJECT 4.1) To Carry out the energy balance of Urea plant

From (10), (11) & (12) a = 1.08 b = -2.7710 c = 1.0410