VOCATIONAL

TRAINING REPORT
ON

UREA-2 PLANT

TRAINING DURATION:19th JUNE 2012 TO17th JULY 2013

SUBMITTED TO
Dr. KRISHNA KUMAR
D. G. M.-TRAINING
IFFCO PHULPUR
ALLAHABAD

SUBMITTED BY
ABHISHEK KUMAR PANDEY
4th B. Tech. (CHEMICAL ENGG.)
MEERUT INSTITUTE OF ENGG. & TECHNOLOGY
MEERUT

CERTIFICATE

This is to certify that the Training Report on UREA-2 plant has been prepared
By Abhishek Kumar Pandey s/o Sushil Pandey (4th B.Tech, Chemical Engineering) of
Meerut Institute Of Engg. & Technology,Meerut (M.T.U. Noida) and he has taken keen
interest in completion of his assignment under my guidance.

Mr. Krishna kumar

D.G.M. (Urea)
IFFCO, Phulpur,
Allahabad

Mr. Sanjay Bhandhari

Chief Manager (Ammonia)
IFFCO, Phulpur,
Allahabad

Mr. V.D. YADAV

Chief Manager (Urea)
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. Anurag Tiwari who provided me an
opportunity to do training. I wish sincerely thanks to Mr. Krishna Kumar 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. S.K.bhandhri, Mr. V.D. YADAV, and Mr. Rajan 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
S.No
(1)
(2)
(3)
(4)
(5)
(6)
(6.1)
(6.2)
(6.3)
(6.4)
(6.5)
(6.6)
(7)
(8)
(9)
(10)
(11)
(12)
(12.1)
(12.2)
(12.3)
(12.4)
(12.5)
(12.6)
(13)
(14)
(15)
(15.1)
(15.2)
(15.3)
(16)
(17)
(18)

Topics
Brief introduction of IFFCO
Brief description of Urea plant
Physical and chemical properties of urea
Uses of Urea
Ammonia -1 Plant
Brief description of process
Pre-desulphurization
Final desulphurization
Reforming
Shift conversion
CO2 removal
Regeneration of Benfield solution
Methanation
Ammonia synthesis section
Refrigeration system
Material balance and energy consumption
Process technology of urea
Process description of urea plant
Pressurization of CO2 gas
Urea synthesis and high pressure recory
Urea purification and low pressure recory
Urea concentration
Urea prilling
Waste water treatment
Effect of process variable in urea production
Corrosion in urea plant equipments
Offsite
Effluent treatment plant
Water softening plant
Reverse osmosis plant
Power distribution in factory
Distributed control system
Environmental pollution and control

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. 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 tonnes of Urea and NPK/DAP equivalent to 1.71
million tonnes. 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 fertilisers 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 Fertilisers 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 dot Coop Global Award for Cooperative Excellence

IBM Awards First Prize to IFFCO for Innovation

IFFCO Phulpur Unit-I bagged "First Prize" by FAI.

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)
Re-assessed Production Capacities
Ammonia- Urea Complex Commissioned in 1981
Ammonia - 0.824 million TPA
Urea - 1.416 million TPA
Total Area

1068 acres

Area Under plant

321 acres

Area under Township

Area under township,

cordet, agricultural farms,
green belt, ash ponds, roads,
open space : 747 acres.

Phulpur Unit - Milestones of Project Implementation

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

Commercial Production
Phulpur I
Urea
Phulpur II
Urea
Plant Reassessed Capacity in TPA
AMMONIA
823900
UREA
1415700

Date of Commencement
Oct. 10, 1980
Oct. 15, 1980
Date of Commencement
Dec. 18, 1997
Oct. 31, 1997

Mar. 28, 1981

Dec. 22, 1997

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)
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 tonne of Ammonia production have been achieved in a period of 1064 days
on 02.10.2007.
3. Fifteen million tonne of Urea Dispatch (By road & rail) achieved in a period of 568 days
on 20.07.2009.
Unit-II
1. Ten million tonne of Urea Production have been achieved in a period of 392 days on
07.08.2009.

2. Six million tonne of Ammonia production have been achieved in a period of 717 days on
01.12.09.
3. Ten million ton of Urea Dispatch (By road & rail) achieved in a period of 387 days on
06.08.09.
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
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 described below:

Desulphurisation

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
+
H2
=
RH
+
H2S
2) COS
+
H2
=
CO
+
H2S
3) C4H4S +
4H2 =
C4H10 +
H2S

The de-sulphurizers reactor consists of Co, Mo based catalyst and ZnO

based catalyst. The desulphurization 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)
(ii)
(iii)

Cn H2n+2H2O = Cn+1 H2n+CO2+3H2

CH4 +2H2O = CO2
+ 4H2
CO2 + H2 = CO
+ H2O

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, which including mixing and combustion of the reformed
process gas with process air, takes place in the secondary reformer. Secondary
reformer consists of 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.
Gas Purification System
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
CO-converters 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 of the gas is about 424 deg. The oulet 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.
Methanation Section
Following reactions take place in methanator.
(i) CO
+
3H2 =
CH4 + H2O + Heat
(ii) CO2 +
4H2 =
CH4 + 2H2O + Heat
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 oulet gas from Methanator contains around 73 % H2, 25 % N2 ,0.7 % CH4.
Ammonia Synthesis Section
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.
Reaction:

3H2 + N2 = 2NH3 + Heat

Since the reaction is highly exothermic the waste heat is utilised for generating steam
and Boiler feed water heating. The 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.

Brief Description of Urea Plant

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.

UREA PLANT
O
H

H
N

N
H

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

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

Specific heat at

200 C

98.40 C120.50 C

160.30 C

2200 C

(Cal/gm0C)

0.321

0.158

0.194

0.224

Solubility in at00C
Water (wt%) 67

200C
105

400C
163

600C
240

800C
396

0.288
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.

WHY UREA???
Plants take nitrogen in form of nitrates. This is the reason why we manufacture urea in
IFFCO plant to feed agriculture field. Urea nitrogen content (46.6%) is quickly converted
into nitrate in the presence of catalyst presents in agricultural field.
PROCESS TECHNOLOGY:
Urea is produced by synthesis from liquid NH 3 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 NH 3 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 occours.
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 CO 2 and NH3. Decomposition
pressure is a function of NH3 concentration in the feed and solution temperature and
increases if either temps. 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 occour. 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 extreamly corrosive
in nature.

BRIEF PROCESS DESCRIPTION OF UREA PLANT

Urea is commercially manufactured by direct synthesis of gaseous CO 2 and liquid NH3. Urea
production process consists of the following main operations:

1: UREA SYNTHESIS
Liquid ammonia (through reciprocating and centrifugal pump; here we only use
reciprocating pump due to low cost) along with recycle Carbamate and gaseous
carbon dioxide at high pressure (through compressor) enter the Reactor (R-1) and react to
form ammonium Carbamate. This Carbamate then dehydrates to form Urea and Water.
Liquid Ammonia from HP Ammonia Feed Pumps P-1 A /B / C at ~ 240 Ata and
350 C serves as the motive fluid in Ejector EJ -1 and drives the Carbamate from HP
Carbamate separator MV-1 to the Reactor R-1 .
On mixing with Ammonia from Pump P-1 A/B/C the mixture enters Reactor R-1 at
the bottom at ~160 Ata and 1200C . Carbamate recycle ejector EJ-1 is steam jacketed
to avoid crystallization of Carbamate.
MAIN REACTION
2 NH3 + CO2 =
AMMONIA

CARBONDIOXIDE

NH2COONH4 +38.1Kcal/gm mol.

AMM. CARBAMATE

NH2COO NH4 = NH2CONH2 +H2O +7.1Kcal/gm mol.

AMM. CARBAMATE

UREA

WATER

Here carbon dioxide is limiting agent. The total conversion is decided by this only. Carbon
dioxide converted only 60% in process feed remaining feed are recycled again to get better
conversion. Here any inconvenient will manage by NH3 flow rate

2:UREA FORMATION IN HIGH PRESSURE SECTION:

Flow sheet

Process description: (High pressure means 135kg/cm2)

Liquid Ammonia and gaseous CO2 along with recycled liquid Carbamate from HP
Carbamate Separator MV-1, rise in the Reactor from bottom to top. Liquid ammonia
and gaseous carbon dioxide react to form liquid Carbamate.
The reaction products coming out of the Reactor (R-1)
overflow pipe flow to the HP stripper (E-1).

through the

Carbon dioxide from CO2 compressor ( K-1 ) enters the bottom of Reactor
(R-1) through a separate nozzle at ~160 Ata and ~1300 C.
Unconverted Carbamate, present in Reactor (R-1) outlet urea solution, is
decomposed and stripped off in the HP Stripper ( E-1).

Stripped Urea solution from the bottom of the Stripper (E-1) goes out to MP Pre
decomposer (E-53) / Separator/Decomposer (MV-2/E-2).

3:MP SECTION
Urea solution from the HP stripper enters the MP pre-decomposer /MP decomposer.
Unconverted Carbamate decomposes to ammonia and co2 vapors, there by
concentrating urea in solution.
This urea solution is fur

their let down.

The vapors from the MP decomposer are condensed in Pre Conc. / MP

condenser using Ammonium Carbamate solution from the LP section.

The Carbamate solution overflows from the Pre Conc./ MP condenser into MP
Absorber where the excess ammonia and inert are separated in form of the vapors
These vapors 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

Receiver along with incoming liquid Ammonia.

are

sent

to Ammonia

The inert gases, saturated with Ammonia, leaving the receiver enter the
Ammonia Recovery Tower. Here Ammonia is further condensed by direct contact
with cold Ammonia from the Battery limit and flows down the Ammonia Receiver.
Inert with residual ammonia vapors 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 inert are released to vent stack.
4:Low pressure section (3-4kg/cm2)
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 vapors enter the LP Condenser shell and get absorbed in an 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 vapors are absorbed
with cold
condensate in LP Ammonia Absorber and sent to vent stack.
The liquid flows down to the Tank.
Vacuum concentrator:
The liquid from the bottom of LP Decomposer is further concentrated in a vacuum
pre-conc. & two vacuum concentrators in series.
With the help of MP gases/low pressure steam, Urea solution is concentrated from
70% to 99.7% by wt.
The vacuum is created and maintained by three vacuum systems consisting of a set
of steam ejectors and condensers.
1: at 1kg/cm2.
2: at 0.1kg/cm2.
3: at 0.04kg/cm2 respectively.
Urea melt thus obtained is then pumped to the prilling tower top.

The vapors from the vacuum separators are condensed in the condensers
and sent to the waste water tank.

5:Urea Prilling
By using property of liquid urea we converted liquid urea into crystallized form with desired
shape and size. This important property of the fluid is when liquid urea is at temperature
below 133Oc at atm pressure its crystallization occurred. (if by any reason we cant achieve
this situation we recycled the whole fed before enters into the prilling tower)This property is
used in prilling tower for crystallization of urea. And desired shape and size is given out
through the bucket holes specification and by controlling speed of rotation of the bucket.
Generally we placed 214 rpm for desire size of 1.74mm of urea particle through bucket. Rpm
will depend upon the load and size of the product obtained.

Process description:
The molten urea thus obtained from the 2nd vacuum separator holder is pumped to
the top of prill tower and fed into a prill bucket . The Urea comes out through
the holes of the rotating prill bucket and falls down the prill tower.
Air by natural

draught flow upwards counters current.

Urea prills are then transported to the bagging plant through belt conveyor.

(FIG: Schematic view of urea)

By product of the urea plant:

The one and only one byproduct of urea plant is BIURATE.

WHY BIURATE FORM???

Biurate were formed due to following four factors:
1: high temperature.
2: high pressure.
3: high concentration of ammonia feed.
4: high residence time in vacuum section.

What is biurate???
When two molecules of urea is joined together at high temperature and with high residence
time in vacuum section biurate formation were occurred.

Harmful effect:
According to F.C.O. the minimum biurate concentration in urea is 1.5%. If it will exceed
from this level it would be harmful for the plants in agriculture field. (Biurate burns the
newly growing plant seeds.)
6)

WASTE WATER TREATMENT:

Vapour containing water and little NH3 and CO2 from process and steam of ejectors from
vacuum system are condensed and collected in waste water tank. It is thus pumped to a

better waster water tank and thus to a distillation tower where after stripping of NH 3 in the
upper part, the solution is contaminated with urea is sent to hydrolyser. Here urea is
hydrolyzed at high pressure by 38 atm. superheated steam.
Vapors being sent to the distillation tower overhead condenser. Solution from hydrolyser
goes back to the distillation tower for further NH 3 removal. Vapors from the top of
distillation tower goes to overhead condenser with vapors from the hydrolyser. One part of
this solution is recycled to the distillation tower top as reflux and the remaining portion to the
L.P. condenser. Liquid from bottom of distillation towers called the effluent or purified
waste water which can be used as B.F.W. or as cooling tower make up.
EFFECT OF PROCESS VARIABLE IN UREA PRODUCTION
The equilibrium conversion to Urea will be favored under the following process variables :
I)
Higher ammonia concentration.
II)
Less H2O concentration.
III)
Higher temperature.
IV)
Higher pressure.
V)
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 NH 3 / 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 CO 2 is changed from 0-300%,
Urea yield will increase only from 43.44% to 46%. The effect of excess CO 2 is very small.
More over, in the CO 2 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 H 2O 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 H 2O. 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:
As per Le-chaterliers principal higher pressure favored carbamate formation. At the
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.

In case of Urea formation, higher temperature is favorable, 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 Fertiliser control order. It is produced
when Urea is heated in the absence of free NH3.
2 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.
USES OF UREA:
1. As Fertiliser in agriculture; Due to high N-content of Urea demand of Fertiliser grade
Urea is rising rapidly. Urea today accounts for a large percentage of Nitrogenous
Fertiliser.
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, and ion-exchange and as an
intermediate in the preparation of pigments.

CORROSION IN UREA PLANT EQUIPMENTS :

Studies of corrosion in urea plant have led to the identification of the following type of
corrosion:
1)
Stress corrosion.
2)
Inter granular corrosion.
3)
Galvanic corrosion.
4)
Crevice corrosion.
5)
Pitting corrosion.
6)
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 NH 3, CO2 and ammonium carbamate are
introduced. In view of higher pressure, temperature, cone and two phase 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.
2.
Cooling Tower.
3.
DM and CPU Units.
4.
Effluent Treatment Plant
5.
Water Softening plant
6.
Air compressor ELLIOTT
7.
Instrument Air Drier Split Flow
8.
P.S.A. Unit
9.
Naphtha Storage & Handling System
10.
Diesel Generator set
11.
Instrument Air Drier HOC
12.
Air compressor IR.

EFFLUENT TREATMENT PLANT

INTRODUCTION:
Removal & control of nitrogenous compounds such as NH 3 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 NH 3 present in effluent water is
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 occours and the treated water obtained is transferred to softening plant . The
ammonia effluent treatment plant consists of following components :
a) Two numbers of effluent collection pits and transfer pumps for storage and feeding
the ammoniacal effluent to stripper.
b) A preheater for heating the raw effluent going to steam stripper by outgoing hot
treated water.
c) Stream stripper for removal of ammonia by stripping process.
d) A stripper sump where treated effluent collects.
DESIGNED EFFLUENT QUALITY OF INLET :
Ammonia
Urea
Suspended solute
T.D.S.
Flow rate

2000 ppm
2000 ppm
Nil
50 ppm
30 M3/hr. (continuous)

50 ppm
225 KW / day
10.6 T/hr. at pressure 4 Kg/cm2
and temperature 1500 C

TREATED WATER QUALITY :

Ammoniacal N
Power consumption
Steam consumption

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,
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 forms 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 m 3/hr. of raw water
and the other design basis are :
pH
Total hardness
Ca hardness
Mg hardness
M alkalinity
P alkalinity
Sulphate
Chloride
Sodium
Total anion
Permanent Hardness
Silica
TDS

7.2 to 7.8
348 ppm as CaCO3
160 ppm as CaCO3
180 ppm as CaCO3
424 ppm as CaCO3
0
65 ppm as CaCO3
57 ppm as CaCO3
198 ppm as CaCO3
546 ppm as CaCO3
0
33 ppm (max.) as SiO2
650 ppm

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

The water softening plant is designed to treat 800 m 3/hr. water of given raw water
characteristics to produce soft water of the following components.
1.
Parshal Flume.
2.
Reactor Clarifier
3.
Sludge Basin & Disposal.

4.
Chemical Dogging System.
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.
Permeate stream (low in dissolved solid content)
2.
Reject stream (very high in dissolved solid content)
PROCESS DESCRIPTION:
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 catridge
filter. The cartridge filter removes suspended particles from water. When the differential
pressure across the catridge 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.)
Flow Rate : (m3/hr.)
Stage
1
2
3

Input
150
75
40

Product
75
35
15

Reject
75
40
25

Hence total product water is (75+35+15) = 125 m 3/hr. and reject is 150 m3/hr. The
maximum load can be handled by this R.O. unit is 165 m3/hr.
R.O. membrane modules are interconnected inside the pressure tubes with push fit type of
interconnecters. This R.O. unit consists of 2 sacrificial pressure enters the pressure tubes
and passes through the R.O. membrane elements. The purified water (permeate) travels
through the product header and gets collected.
A cleaning system provides means to remove foulness from the membrane elements and to
fill up pressure tubes with these infactant solutions. The cleaning system comprises of a
cleaning solution tank, a pump and a cartridge filter.
Cleaning Solution : (for 1000 lit. of water)
*
Solution I (for inorganic fouling) :
1.
Citric acid - 20 Kg
2.
Liquid non ionic detergent
(triton x 100 or tergitol 8 ) 1 lit.
Adjust to pH 4 with NH4OH.
*

Solution II (for CaSO4 and Organic )

1.
Sodium tri polyphosphate - 20 Kg.
2.
Sodium salt of EDTA 2.4 Kg
3.
Detergent 1 lit.
Adjust to pH 7.5 with H2SO4

Solution III (for high Organic fouling )

1
Detergent - 1 lit.
2
Sodium perborate - 5 Kg
3
Formaldehyde (37%) 13.5 Kg
Adjust to pH-8 with H2SO4 .

The product water is stored in product water tank and from there supplied to different
plants, such as DM plant and softening plant inlet. Once the recirculation is completed for the
desired time, pump is switched off and all the flexible hoses are disconnected, the blanks are
removed from feed and permeate headers and the blank is put on the stages, where the
flexible hoses are fixed, the system is started and flushed for 15 to 20 mins till the permeate
quality is within the desired limit and the system is taken into line.

Power Distribution:
T.G.1
12.5 MW
T.G.2
18 MW
Total power required 25.17 M
Urea1
3.7 MW
Urea 2
6.5 MW
For
Ammonia pump 01,P1/A/B/C
Carbamate pump - P2/A/B/C
C.T.P.
02,P1/A/B/C/D C.T.F.
ME,A/B/C/D/E
Needs total power 3.24 M.W.
DISTRIBUTED CONTROL SYSTEM (DCS)
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)
Geographical Distribution.
b)
Functional Distribution
c)
Safety Distribution
d)
DCS is more accurate, fast in operation, more user 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.
Control and monitoring of various process parameters.
2.
Data acquisition and storage.
3.
Data management , manipulations and report generation etc.
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.

Utilisation 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.

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 alongwith DM plant
effluent segregation scheme. The segregated DM plant effluent will be first
treated in pretreatment plant to remove this impurities. Treated H 2O 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 accoured 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 speak 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 m 3/h capacity. 1
Motor driven pump of 10m3/h capacity.

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.

References

IFFCO manuals