A

TRAINING REPORT
ON
STEAM GENERATION & AMMONIA PLANT
NATIONAL FERTILIZER LIMITED
Submitted by:

YUDHVIR SINGH AHLAWAT

13001005057

Department of Chemical Engineering

Deenbandhu Chhotu Ram University of Science & Technology
Murthal, Sonipat 131039 (Haryana)
June 1 July 11, 2015

ACKNOWLEDGEMENT

I am glad to inform you that I have been provided with a golden opportunity to get my practical
training in National Fertilizers Limited, Panipat, Haryana and I express my deep sense of
indebtedness to Dr.D.P.Tiwari (Head of Chemical Engg. Department, DCRUST, Murthal,
Sonipat), Training & Placement Cell and to all officers who made me to get imparted with
valuable knowledge during the training period from 1 June 2015 to 11 July 2015.
I am very thankful to all officers of steam generation & ammonia plant who helped me directly or
indirectly during my training at NFL, Panipat.

Yudhvir Singh Ahlawat

13001005057

ABSTRACT
The training report of the working in NFL, PANIPAT is the part of professional training done
after B.TECH 2nd year. The report is completely based on the generation of steam & working of
Ammonia Plant. In the report the explanation of every process is given. In the Ammonia Plant
our main aim is to produce Ammonia which can be supplied to UREA Plant for the manufacture
of UREA.
In the plant, Ammonia is produced by HABERs process. The molecular formula of Ammonia is
NH3 which means we require one molecule of N2 and three molecules of H2 to produce two
Ammonia molecule.
For Ammonia synthesis, the required nitrogen is obtained from the atmospheric air through Air
Separation Unit and during this process we also get O 2 which is used for the partial oxidation of
Natural Gas in the shell gasification section then the gases evolved are taken to the
desulfurization section where H2s is removed and then remaining gases are send to Shift
Conversion Process to obtain CO 2 from CO. Now this generated CO 2 is removed in the
decarbonation section for the use in Urea plant. Now the gases are sent to Nitrogen wash unit
from which these finally reaches to Ammonia Synthesis Section where AMMONIA is produced.
This project report comprises of my 04 weeks industrial training here at NFL Panipat. The
vocational training was divided into two sections. For the first two weeks my training was done at
Ammonia Plant of NFL and for the remaining time the training was done at Urea Plant.
This report consists of brief introduction of the plant, the synthesis of various chemicals and their
usage in plant as well as for various purposes.
I would like to thank the staff here appointed for their commendable help in each and every stage
of my training. I learnt a lot from them. My training became successful because of them.

CONTENTS
S.No.

Title

Page no.

Acknowledgement

Abstract

ii

1. THE COMPANY
2. PANIPAT UNIT
3. STEAM GENERATION PLANT
4. AMMONIA & UREA PRODUCTION
5. AMMONIA PLANT
6. DETAILED PROCESS DESCRIPTION
7. RAW MATERIALS REQUIRED
8. HYRDROGEN PRODUCTION
9. DESULFURISATION
10. REFORMER
11. NITROGEN ADDITION
12. REMOVAL OF CARBON MONOXIDE
13. WATER REMOVAL
14. REMOVAL OF CARBON OXIDES
15. SYNTHESIS OF AMMONIA
16. CATALYST USED IN NFL, PANIPAT
17. AMMONIA STORAGE (HORTON SPHERES)
18. UTILITIES
19. THE ROLE OF THE LABORATORY
20. ENVIRONMENTAL IMPLICATIONS
21. ENVIRONMENT CONTROL
22. SAFETY & PRECAUTIONS
23. FIRE PROTECTION
24. CONCLUSION
References

1
1
2
6
7
9
10
11
11
11
12
13
13
13
13
15
16
17
17
18
18
19
21
22

1. NATIONAL FERTILIZERS LIMITED

National Fertilizers Limited (NFL) is a major Indian producer of inorganic and organic
fertilizers and industrial chemicals. National Fertilizers Limited was established in August,
1974 to set up two Fuel Oil based plants Bhatinda (Punjab) and Panipat (Haryana). Both of them
were commissioned in 1979. The Nangal Fertilizer Plant of Fertilizer Corporation of India (FCI)
IN 1978 on the reorganization of FCI and NFL group of companies. Later, NFL executed the
countrys 1st inland gas based plant at Vijaipur (MP) on HBJ gas pipeline. Vijaipur plant had gone
in commercial production in July, 1988. Subsequently, expansion was undertaken in 1997 for
doubling the capacity of Vijaipur Unit.

2. NATIONAL FERTILIZERS LIMITED-PANIPAT

The Panipat project was approved by the Govt. of India on 10 th February, 1975 for
implementation. Prime consultants for design, engineering, erection and commissioning of plants
were M/s Toyo Engineering Corporation of Japan and M/s Engineers of India Ltd. From the zero
date 30.04.75, the feed in was achieved 0n 01.09.78 i.e. within 40 months of the zero date. The
unit went in commercial production from 01.09.79. The total cost of project was rupees 221.33
crores
The performance of the unit in all areas has also been widely acknowledged. It has won number
of awards and recognitions in the fields of production, productivity, safety, welfare, innovation,
environment protection, skill etc. the unit is also well known for its commitment towards
environment protection and social welfare in the design.
Brand name of product is Kisan Urea.
Capacity of NH3 plant is 900 METRIC TPD
Capacity of NH2CONH2 is 1550 METRIC TPD

3. STEAM GENERATION PLANT

INTRODUCTION
The Steam Generation Plant comprises of three identical pulverized coal fired boilers with oil
support, having a maximum continuous rating (MCR) of 150 T/Hr steam at a pressure of
Kgs/cm2g and 4950C. The normal rate of steam generation (NCR) is 84T/Hr. The boilers are
tangentially fired, balanced draught, Natural circulation, radiant dry bottom and provided with
bow mills.
MAJOR EQUIPMENT:
Bowl Bills- 3 Nos per boller.
Fuel firing system
Furnance Ash hopper
Furnance chamber
Forced draft fan
Induced draft fan
Regenerative type of Air-heater
Steam/air pre-heater
Economiser
Electrostatic Precipitation for fly ash
Water drum, steam drum and boiler, tubes
Steam desuperheater and super-heater
A common chimney is provided for final disposal of flue gases for all the three boilers.
DESCRIPTION OF THE PROCESS
FEED WATER
Boiler feed water at a temperature of 131 0C and a pressure of 141Kg/cm2g is pumped
from the Deaerator by boiler feed water pumps AGA-701AB. This feed water passes through a
synthesis economizer and goes to boiler house at a temp of 200 0C. It boiler house it is
distributed to each boiler through an 8 individual feed water line.
FUEL AND ASH:
Coal is pulverized in the bowl mill and used as feed for the boilers under normal
operation. Ash which is formed as a result of burning of coal is collected in the bottom ash
hopper/fly ash hoppers is disposed off through the ash disposal system. Flue gases are discharged
out through the chimneys.
I.D. FAN & F.D. FAN:
Motor driven FD fan ID fan provide a draft for the furnance. FD fan supplies the combustion air
to the furnance after heating the air in tee regenerative type air pre-heater. The flue gases are
finally disposed off by the ID fan to the atmosphere via chimney.

STEAM SUPPLY AND DISTRIBUTION:

Super heated steam at 105 Kg/cm2g and 4950C is produced in boiler. A part of this steam is let
down to a pressure of 3 Kgs/cm2g in a de-superheater for use in fuel oil unloading system.
Rest of high pressure steam is carried to Ammonia Plant where steam from Ammonia Plant steam
superheaters ABA-701 at 103Kg/cm2 and 4950C is also mixed with it and the entire superheater
steam is distributed as under:1.

Synth compressor turbine

175.O T

2.

N2 Compressor turbine

80.O T

3.

O2 Compressor turbine

25.O T

4.

Air Compressor turbine

58.O T

Exhaust steam from Air Compressor, Oxygen compressor turbines and condensing

turbines

of synthesis is compressor is condensed in respective surface condensers and the condensate, thus
obtained is sent to the DM/Plant for treatment for re-use as boiler feed water.
The extraction steam from back pressure turbines of synthesis compressor and N 2 compressor
meets the entire demand for the process plants, utilities and off site area at various pressure levels
of 65,40,9 and 3 Kg/cm2g. The requirement of steam at different pressures for various plants are
given below:
Sr.

Plant

Steam Pre. &

Qty.

Source

No.
1.
2.
3.
4.
5.
6.
7.

Ammonia
Urea
NH3 Compressor
Ammonia
De-aerator
FO Storage Tank
Boiler FO day

temp.
65kg/cm2 430oC
40 Kg/cm2/370 oC
40 Kg/cm2
9 Kg/cm2/230 oC
3Kg/cm2/187 oC
3Kg/cm2/187 oC
3Kg/cm2/187 oC

60.0
80.0
70.0
15.0
20.0
8.0
0.1

N2 Compressor
Syn. Compressor
Syn. Compressor
NH3 Compressor
Ammonia
NH3 Plant
-do-

8.
9.
10.

Tank
LPG Vaporizer
Caustic Soda
Caustic soda

3 Kg/cm2/187oC
-do-do-

0.1
0.2
0.7

Ammonia
----do-------do----

11.

Unloading
Miscellaneous

-do-

3.0

----do----

STEAM FOR FURNACE OIL UNLOADING

Apart from the steam required for various plants, steam at a pressure of 3 Kg/cm 2g is also
required for fuel oil unloading facilities. The requirement may fluctuate from O T/hr to 21.7T/hr
depending on the ambient conditions, quantity and quality of oil being unloaded.

FUELS COMBUSTION :
Each boiler is designed for steaming with two mills supported with FO guns. Pulverized cool is
supplied to the furnance at the four corners of the boiler in three elevations A.B and C. Each mill
suppliers PF coal in all the four corners of one elevation only. There are two types of FO guns in
between elevation AB and BC in all the four corners of the boilers. As such, there are 12 Nos. of
pulverized cool burners and 8 Nos of FO guns. There is provision to burn HSD in lower tyre FO
guns as and when required.
The coal from unloading bay comes to the raw coal bunkers passing through crusher
houses conveyed by a system of conveyer belts. Coal coming from raw coal bunkers comes to
raw cola feeder and then supplied to the mill Quantity of coal supplied to the mill is controlled by
changing the speed of raw coal feeder. This coal is crushed in between bowl and bull ring
segments of mill. Hot air is introduced to mill, which is coming from RHS and LHS wind boxes
of the boiler. There is provision to supply cold air to maintain the temperature of coal dust and
air mixture from 70oC to 90oC. This coal dust and air mixture is passing via classifier vanes and
exhauster of the mills, supplied to all the four corners of the boiler furnance through distributor.
Size of the coal dust is 200 m of 70% passing Regulating of the fireness of grinding is done by
changing the angle of the vanes of classifier of the mill.
In order to ensure safety against explosion hazards are provided peepholes in furnace and
explosion diaphragms in flue gas path at different placed on flue gas ducts after Air Pre-heater.
This cola dust and air mixture burns in the furnace with the support of fuel oil. Adequate quantity
of secondary air supplied to the furnace to boost up ignitions by both side wind boxes, regulated
by aux.air dampers in each corner. Heat liberated due to combustion of fuel in furnace is
absorbed by water walls for steaming inside tube water and remaining heat goes with flue gas for
further use. This flue gas heat is used in superheaters to superheat steam temperature in bank
tubes and economizer for further heating up water temperature in air pre-heatet to raise the
temperature of air coming from FD fans.
70 to 80% of the ash particles are driven out with flue gas and remaining are collected in bottom
ash hoppers. More than 99% of ash particles are liberated in electro-static precipitators from flue
gas. This flue gas, temp, about 140oC goes to chimney through 2 Nos. of ID fans, and then to
atmosphere. The ashes of bottom ash hoppers and electrostatic precipitators hoppers transferred
to the ash ponds, out side of factory by ashing system equipment.
BASIC COMBUSTION REACTIONS
Carbon, Hydrogen and Sulphur in the fuel, Combine with oxygen in the air to form CO 2, H2O
vapours and SO2 and releasing heat as follows:-

-----

C+O2

CO2+8014 K.cals/Kg of Carbon

2C+O2 2CO+2430 K cals/Kg of Carbon

--- 2H2+O2 2H2O+28922K cals/Kg of Hydrogen

---

S+O2

SO2+2224 K.cals/kg of Sulphur

If excess air is used for combustion, Sulphur trioxide(SO 2) may also be formed as combustion
product.
TURN DOWN RATIO:
The relationship between the maximum and minimum fuel input without heating excess air level
is called Turn down Ration For example a burner whose maximum input is 250,000K cals and
minimum rate is 50,000K, cals has a turn down ration of 5 to 1.

3. AMMONIA AND UREA PRODUCTION

Urea (NH2CONH2) is of great importance to the agriculture industry as a nitrogen- rich fertiliser.
In Panipat, National Fertilizer Limited manufacture ammonia and then convert the majority of it
into urea. The remainder is sold for industrial use.
Ammonia synthesis
Ammonia is synthesised from hydrogen (from natural gas) and nitrogen (from the air). Natural
gas contains some sulfurous compounds which damage the catalysts used in this process. These
are removed by reacting them with zinc oxide, e.g.
ZnO + H2S ZnS + H2O
The methane from the natural gas is then converted to hydrogen:
CH4 + H2O 3H2 + CO
CH4 + 2H2O 4H2 + CO2
CO + H2O H2 + CO2
Air is mixed in with the gas stream to give a hydrogen:nitrogen ratio of 3:1.
Water, carbon monoxide and carbon dioxide (all of which poison the iron catalyst used in the
ammonia synthesis) are removed. The carbon monoxide is converted to carbon dioxide for use in
urea production, and the carbon dioxide removed:
CO + H2O CO2 + H2
The remaining traces of CO and CO2 are converted to methane and then the gases cooled until the
water becomes liquid and can be easily removed.
The nitrogen and hydrogen are then reacted at high temperature and pressure using an iron
catalyst to form ammonia:
N2 + 3H22NH3
Urea synthesis
Urea is made from ammonia and carbon dioxide. The ammonia and carbon dioxide are fed into
the reactor at high pressure and temperature, and the urea is formed in a two step reaction
2NH3

CO2NH2COONH4

(ammonium

carbamate)

NH2COONH4 H2O + NH2CONH2 (urea)

The urea contains unreacted NH3 and CO2 and ammonium carbamate. As the pressure is reduced
and heat applied the NH2COONH4 decomposes to NH3 and CO2. The ammonia and carbon
dioxide are recycled.
The urea solution is then concentrated to give 99.6% w/w molten urea, and granulated for use as
fertiliser and chemical feedstock.

5. AMMONIA PLANT
Introduction to plant:AMMONIA: Ammonia is the key intermediate product for manufacture of urea.
The primary use of ammonia is the nitrogen source in fertilizers. Until the turn of this century, the
nitrogen supply in farm soils was entirely dependent upon natural sources of nitrogen, mainly
mineral deposits and animal and vegetable wastes. Most of these were from industries other than
agriculture.
Today ammonia is primarily produced by the direct synthesis of hydrogen and nitrogen. The
manufacturing technology stems from Haber-Bosch process of synthesizing ammonia,
commercialized first in 1913.The commercial development of ammonia synthesis is rightly
considered as one of the most significant technological advanced benefiting all mankind. For this
achievement, Haber & Bosch were awarded noble prize in the year 1818 & 1931.Their
achievement makes increased supplies of food available for a growing world population.
Ammonia storage is major potential hazard at NFL Panipat as quantity stored and handled is very
high. The spread out ammonia may lead to atmospheric as well as water pollution due to its high
solubility in water. It may affect the site as well as population around works. Though ammonia is
lighter than air, it forms mixture with air which is heavier than air when stored at conditions of
higher pressure and low temperature.
Ammonia release can be instantaneous(puff) or continuous or steady(plum).In case of
instantaneous, release total material will escape quickly forming flat cylindrical cloud which is
then carried down by wind becoming larger and more dilute during its passage by means of air
entrainment .
In continuous release, gas is released steadily over long period of time Gas cloud forms a plume in
which time averaged concentration at given point remains constant throughout duration of release.

CHARACTERISTICS

o
o
o
o

Color/odor: colorless/pungent
TLV (8 hrs. exposure): 25 PPM
Explosive Range (%v/v in air): 16-25
Mode of Entrance: inhalation - skin contact

Ammonia is a colorless, alkaline gas, lighter than air and possesses a unique, penetrating odor
.The flammable limits of ammonia in air are 16 & 25 volume%, in oxygen the range is 15 to 70

volume%. Ammonia is comparatively stable at ordinary temperatures but decomposes into

hydrogen and nitrogen at elevated temperatures.
Initially in India, the ammonia was produced only based on coke even gas and electric power.
However, we have changed over to other feedstock, namely naphtha, lignite natural gas, coal
&Natural Gas.
At NFL Panipat, Natural Gas is used as feedstock for making ammonia. At NFL PANIPAT,
ammonia is produced as an intermediate product during process of manufacturing urea. Release
may occur from pipelines carrying ammonia or storage vessels including Horton spheres. Affected
range of ammonia depends on the relative humidity, wind velocity, ambient temperature and
quantity of ammonia stored and rate of release. Worst case is during stable atmosphere in which
ammonia moves up as vertical column.

Process used for manufacture of ammonia is "Partial Oxidation" of Natural Gas with steam
and oxygen .
Process: Feedstock is partially oxidized and gasifies with steam and oxygen at 55Kg/cm2G and 1370oC
temperatures.
Raw gas produced in gasification contains mainly the gases like CO, H 2, CO2, H2S and CH4.
H2S is removed from gas stream at 48kg/cm2Gpressure and -33oC, by physical absorption in
circulating methanol in Rectisol section.
The CO from desulfurized gas is converted to CO 2& H2 by CO shift reaction at
46kg/cm2Gpressure of Fe catalyst in CO conversion section.
The CO2 from shifted gas is physically absorbed in circulating methanol at 42kg/cm2G pressure
and -66oC temperatures in second stage of rectisol Section.
Decarbonated gas containing small proportions of CO, CO 2& CH4 is scrubbed with liquid nitrogen
in Nitrogen Wash Unit at -195oC.
The gas from NWU is mainly hydrogen and nitrogen. Thereafter, N2 is mixed to maintain H2 to N2
ratio 3:1.
Gas is compressed to 220Kg/cm2G and sent to ammonia synthesis converter where ammonia is
produced in presence of catalyst at 500oC.

6. Process Description
This report describes the process for plant of National fertilizer Limited(NFL).The name plate
capacity of plant is 900 MTPD of Ammonia. The plant is based on steam reforming of natural
gas and is located at Panipat,Haryana.
The report consists of information on chemical reactions, catalysts and an overview of the
process in each of the main sections:

Desulphurization
Reforming
CO conversion
CO2 removal
Methanation and compression
Drying
Compression
Ammonia synthesis and refrigeration
Process condensate stripping

THE AMMONIA MANUFACTURING PROCESS

Ammonia is produced in a process known as the Haber process, in which nitrogen and hydrogen
react in the presence of an iron catalyst to form ammonia. The hydrogen is formed by reacting
natural gas and steam at high temperatures and the nitrogen is supplied from the air 1 . Other gases
(such as water and carbon dioxide) are removed from the gas stream and the nitrogen and
hydrogen passed over an iron catalyst at high temperature and pressure to form the ammonia. The
process is shown schematically in Figure 1.

7. RAW MATERIALS REQUIRED

For the production of 900 metric tons/day of ammonia and 1550 metric tons/day of urea,
following raw materials are required;

Natural Gas
COAL
WATER
ELECTRICITY

910 metric tons/day

1650 metric tons/day
17 metric tons/day
26MWH

Feed stock (Natural Gas) is obtained from refineries like IOCL, Panipat and IOCL Mathura.

FIGURE 2: SKECH OF AMMONIA PLANT

8. STEP 1 - HYDROGEN PRODUCTION

9.DESULFURISATION
Hydrogen is produced by the reaction of methane with water. However, before this can be
carried out, all sulfurous compounds must be removed from the natural gas to prevent catalyst
o
poisoning. These are removed by heating the gas to 400 C and reacting it with zinc oxide:
ZnO + H2S ZnS + H2O

FIGURE 3: DESULFURISATION SECTION

10. REFORMER
Following this, the gas is sent to the primary reformer for steam reforming, where super-heated
steam is fed into the reformer with the methane. The gas mixture heated with natural gas and
o

purge gas to 770 C in the presence of a nickel catalyst. At this temperature the following
equilibrium reactions are driven to the right, converting the methane to hydrogen, carbon
dioxide and small quantities of carbon monoxide:
CH4 + H2O > 3H2 + CO
CH4 + 2H2O > 4H2 + CO2

CO + H2O > H2 + CO2

This gaseous mixture is known as synthesis gas.

FIGURE 4: PRIMARY AND SECONDARY REFORMER

11. STEP 2 - NITROGEN ADDITION

o

The synthesis gas is cooled slightly to 735 C. It then flows to the secondary reformer where it is
mixed with a calculated amount of air. The highly exothermic reaction between oxygen and
methane produces more hydrogen. Important reactions are:
CO + H2O > CO2 + H2
O2 + 2CH4> 2CO + 4H2
O2 + CH4> CO2 + 2H2
2O2 + CH4> 2H2O + CO2

In addition, the necessary nitrogen is added in the secondary reformer.

As the catalyst that is used to form the ammonia is pure iron, water, carbon dioxide and carbon
monoxide must be removed from the gas stream to prevent oxidation of the iron. This is carried
out in the next three steps.

12. STEP 3 - REMOVAL OF CARBON MONOXIDE

Here the carbon monoxide is converted to carbon dioxide (which is used later in the synthesis of
urea) in a reaction known as the water gas shift reaction:
CO + H2O > CO2 + H2
o

This is achieved in two steps. Firstly, the gas stream is passed over a Cr/Fe 3O4 catalyst at 360 C
o

and then over a Cu/ZnO/Cr catalyst at 210 C. The same reaction occurs in both steps, but using
the two steps maximises conversion.

13. STEP 4 - WATER REMOVAL

o

The gas mixture is further cooled to 40 C, at which temperature the water condenses out and is
removed.

14. STEP 5 - REMOVAL OF CARBON OXIDES

The gases are then pumped up through a counter-current of UCARSOL solution (an MDEA
solution, ). Carbon dioxide is highly soluble in UCARSOL, and more than 99.9% of the CO 2 in
the mixture dissolves in it. The remaining CO2 (as well as any CO that was not converted to
o

CO2 in Step 3) is converted to methane (methanation) using a Ni/Al 2O3 catalyst at 325 C:

CO + 3H2 > CH4 + H2O

CO2 + 4H2> CH4 + 2H2O
o

The water which is produced in these reactions is removed by condensation at 40 C as above.

The carbon dioxide is stripped from the UCARSOL and used in urea manufacture. The
UCARSOL is cooled and reused for carbon dioxide removal.

15. STEP 6 - SYNTHESIS OF AMMONIA

The gas mixture is now cooled, compressed and fed into the ammonia synthesis loop (see
Figure 1). A mixture of ammonia and unreacted gases which have already been around theloop
o

are mixed with the incoming gas stream and cooled to 5 C. The ammonia present is removed
o

and the unreacted gases heated to 400 C at a pressure of 330 barg and passed over an iron
catalyst. Under these conditions 26% of the hydrogen and nitrogen are converted to ammonia.
o

The outlet gas from the ammonia converter is cooled from 220 C to 30 C. This cooling process
condenses more the half the ammonia, which is then separated out.
(These reactions are the reverse of the primary reformer reactions seen in Step 1. The catalyst in
both cases is nickel, illustrating the fact that a catalyst accelerates both the forward and back
reactions of an equilibrium system. At reforming temperatures (~850oC) the methane is almost
completely converted to carbon oxides and hydrogen as the reaction is endothermic and favoured

by the high temperature. However, at the much lower temperature used for methanation
(~325oC), the equilibrium lies to the right and practically complete conversion of the carbon
oxides to methane is obtained.The remaining gas is mixed with more cooled, compressed
incoming gas. The reaction occuring in the ammonia converter is:
N2 + 3H2> 2NH3
The ammonia is rapidly decompressed to 24 barg. At this pressure, impurities such as methane
and hydrogen become gases. The gas mixture above the liquid ammonia (which also contains
significant levels of ammonia) is removed and sent to the ammonia recovery unit. This is an
absorber-stripper system using water as solvent. The remaining gas (purge gas) is used as fuel for
the heating of the primary reformer. The pure ammonia remaining is mixed with the pure
ammonia from the initial condensation above and is ready for use in urea production, for storage
or for direct sale. Ammonia product specifications are given in
Table 1 - Composition of the gas stream after each process step
Feed gas

Step 1

Step 2

Step 3

0.8

21.7

Step 5

Ideal

19.9

24.7

25

N2

2.9

H2

68.3

56.5

60.1

74

75

CO

6.2

8.9

0.1

CO2

4.1

14.5

11.8

18.9

CH4

83.4

10.2

0.7

0.7

1.0

Ar

0.3

0.3

0.3

other
9.6

hydrocarbons

Water is not listed among the gases considered because its levels are highly variable. All
water is eliminated after step 4.

All figures are given in mol % (i.e. the percentage of the total number of moles of gas present
that are due to this gas).
*
The gaseous composition after Step 4 is the same as that after Step 3 as Step 4 is simply the
removal of water.
Table 2 - Ammonia specifications
Component

Composition

Ammonia

98 % minimum

Moisture

1500 g T maximum

Oil

85 g T maximum

-1

-1

-1

Iron

1.0 g T maximum

16.CATALYST USED IN NFL, PANIPAT

11.3.1 Type :

KMIR

VOLUME
o 1st BED 7.6m3
o 2nd BED 16.2m3
o Size BED 1.5-3mm
11.3.3 Age
o 1st bed 24 months
o 2nd bed 84 months
Concentration
o FeO: 31%
o Fe2O3: 66%
o K2O: 1%
o Al2O3: 1.8%
o Impurity: .2%
Catalyst Poisoning
o O2, CO, CO2, H2O, temperature poisoning
o Cl2 compounds
o Arsenic compounds
o Some heavy metal compounds (permanent poisoning)

At low temperature reaction low, but equilibrium favored

At high temperature shifts backward.
Optimum temperature increases the life of catalyst .temperature is maintained 10oC higher than

the temperature at which reaction stops.

Catalyst temperature is controlled by TRC -602(COLD SHOT) and flow of gas by pass valve.

Catalyst hot spot temperature limits 522oC. Converter temperature allowed 320oC.
Ratio should be maintained 3:1.less than 2.5:1 or greater than 3:1, reaction speed decreases,

temperature decreases and pressure of loop increases. Gas must be purged to maintain the ratio.
High Inert (>1.26%) increases the loop pressure but effective pressure decreases and reaction

velocity decreases.
Ammonia concentration at conversion inlet: increase of ammonia concentration in the converter

reduces the reaction rate and decrease in concentration increase the rate.
Circulating rate: increase of circulating rate reduces the pressure of loop.
Pressure: increase in pressure forwards the reaction but pressure increases due to:
a) Increase of makeup gas

b)
c)
d)
e)

Decrease of circulating rate

Increase of inert
H2/N2 ratio below 2.5:1 or greater than 3:1
Reduction of catalyst activity
Increase in pressure due to make up gas favors reaction others do not.

17. AMMONIA STORAGE (HORTON SPHERES)

Two number of spheres of 1500 MT capacity are provided for ammonia storage but normally not
more than 750 MT of ammonia is stored at any time in each of Horton spheres.
a. Spheres are sited at a place away from main plant building and can be reached by the vehicles
from two directions.
b. Spheres have been designed as per standard codes to ensure safety even under extreme
conditions.
c. Two numbers of adequately designed relief valves with in di visual
d.
e.
f.
g.

isolations have been

provided on each Horton sphere.

A 6size vent line remote operated valve has been provided to release any over pressure.
Two number of refrigeration compressors have been provided.
Spheres are earthed, insulated and fenced.
Latest safety provisions have been made in new Horton spheres by providing single nozzle at

bottom.
h. Continuous ammonia monitoring sensors have been provided at strategic location around both
Horton spheres with indication cum alarm in urea control room.
i. Excess flow valves have been provided at five locations.

18. UTILITIES
The ammonia manufacturing has its own utilites. These are listed below.

Ammonia manufacture
Heat recovery
The heat of the gas from the primary reformer (Step 1) is used to produce steam for the primary
reformer using a boiler. The gas is then discharged. Heat from the process gas from the

secondary reformer (Step 2) is used to produce steam for a turbogenerator.

Water recycling
Excess water from the water gas shift converter, the methanator and the ammonia synthesis
loop is used for boiler feed water and as the absorbing water for ammonia recovery.
Carbon dioxide stripper
The used UCARSOL is sent to the carbon dioxide stripper. Here the UCARSOL is heated to
remove a mixture of CO2 and water, cooled and reused. The water is removed from the CO 2 by
condensation and the pure CO2 sent directly to the urea plant for compression and use in urea
synthesis.
Ammonia recovery
Gases purged from the ammonia synthesis loop and gases collected during ammonia
decompression are mixed and sent to the ammonia recovery system. Here the gas mixture is
introduced at the bottom of a column and passes up through a counter-current of cold water.
96% of the ammonia in the gas is absorbed into the water, leaving a gas mixture that is used as a
fuel gas to heat the primary reformer. The ammonia is distilled out of the ammonia-water
mixture, condensed and pumped to join the rest of the ammonia from the ammonia synthesiser.

19. THE ROLE OF THE LABORATORY

In Ammonia production

The laboratory monitors the gaseous mixture exiting each vessel at each stage in the
process using gas chromatography. The concentration of each component during the
process is kept at a precalculated design figure and laboratory results are compared to
these figures. Adjustments are made to the process based on the laboratory results to bring
the process back to the design figures.
The UCARSOL solution is analysed daily to determine the solution strength. The solution
strength must be kept within a defined range and additions to the system are made
according to laboratory results.
Liquid ammonia product is analysed to ensure that impurity concentrations are below
maximum levels set.

20. ENVIRONMENTAL IMPLICATIONS

The ammonia and urea complex is operated in accordance with stringent safety and
environmental standards. The National Fertilizer Limited complex produces effluent in the form
of storm water and waste water from the manufacturing process. All effluent is directed to large
holding ponds where it is treated and carefully checked as to its composition prior to discharge.
The effluent is spray irrigated onto National Fertilizer Limiteds pastures surrounding the

complex. Many waste minimisation measures are carried out during the process, resulting in the
plant having little effect on the environment.

21. ENVIRONMENT CONTROL

To keep the pollutants with in prescribed with in prescribed standard, highly innovative schemes
have been adopted right from the design stage itself. Many measures have been taken for
controlling pollution of water, air, soil and noise.
The liquid effluent is treated by biological treatment, one of the most sophisticated schemes
based on latest technology. It is the Asias best treating plant.
The treated effluent water is tested every hour to meet ISO:2490 specifications. This water is
normally reused for flushing. The ash from boilers sent to the ash pond.
Modern sophisticated electrostatic precipitators are employed to remove the find suspended
particles from stack gases disposed to atmosphere through a chimney at a height of 80m. For
gaseous effluent many tall stacks 50-80m height has been provided to vent the gases high up into
the atmosphere, so that ground level concentrations are not affected.
The only effluents are treated in oil separators and treated oil is reused in the plant.Oil free water
is sent to effluent treatment plant.
Even fire urea dust is eliminated from top of 84m high prilling tower by scrubbing it with
water,so that urea dust is not allowed to escape the surrounding.
Trees have been planted around the plant and township to improve the atmospheric conditions as
well as to remove the suspended dust in atmosphere.
NFL is still finding out ways and means to reduce the generation of pollutants and improve the
efficiency of plants.

22. SAFETY AND PRECAUTION

GENERAL:
1. The purpose of these safety instructions is to prevent any possible accident in the urea plant to
minimize the damage for employees and plant equipments. So operating personnel should
always follow instructions keeping in mind that SAFETY IS THE PRIMARY CONCERN.
2. Safety Training Programmes are organised throughout the year to assure safety awareness in
the mind of employees. Company provides safety equipments such as breathing apparatus, gas
masks, asbestos helmets (fire proof),goggles, gloves, ear plugs etc. free of cost. Safety and fire
fighting training is imparted to employees through various techniques. CO and H2S monitoring
system have been installed with indication in Ammonia Control Room.
3.Wide publicity is given to safety through Safety Committee, Exhibitions, training programs,
banners, holding stickers, pep talks etc.
4.Due to the cooperation of employees ,the effort of management and the C.I.S.F., the accident
rate has been dropped considerably. The unit has been awarded by National Safety Council with
three Awards of Honour besides a no. of state national level Awards.
The following rules should be carefully followed as neglect of these may result in damage
to personnel/and or equipment. However, attention should be paid to that these rules may not
cover all necessary items for safe operation of urea plant.
1. Smoking shall allow only in designated areas. Lighters and matches shall not be carried within
an operating plant handling inflammables.
2. All personnel must know the location and use of all fire hoses and hydrants. Fire blanks, gas
masks and respirators and other protective equipments such as hard hats, rubber gloves.
3. Intoxicants of any kind shall not be allowed to bring into or use in the plant.
4. Pass only the specified sidewalks in the plant unless necessary.
5. Do not walk under cranes, booms, or loads being hosted.
6. Do not jump from platforms, ladders etc.

7. Operatingequipments should be checked frequently for any leakage, overheating, corrosion

etc., so that corrective measures may be taken before these results in any serious damage to
personnel and or equipments. Usual conditions should be reported immediately.
8. Never disassemble any equipment or piping unless it is sure that no harmful substance such as
ammonia etc. is present and it is depressurized.
9. Without a work permit, no hot work should be allowed. All conditions should be properly kept
seal off leakage of any inflammable material.
10. Always flush with water and or steam, whenever flow of urea solution or carbamate solution
is interrupted.
11. Before starting operation check as to whether all the safety equipments are functioning
properly.
12. Always observe start-up and safe operating precautions for pumps and compressor as regards
safely.
13. Always ensure that steam is flowing through jacket tracing of safety valve etc.
14. Never run a pump dry. Always keep suction strainer clean and maintain sufficient level in the
equipment concerned to pump suction.
15. Never stand directly facing safety valves, rupture disc, sight glass sampling valves etc.
16. Isolation valve of safety valves are in open conditions.
17. Do not allow water containing solid contaminants in system as otherwise they will damage
valves and pumps.
18. Do not pull vacuum on equipments unless it is design to withstand such a stress set up under
such conditions.
19. Switch pump regularly when spares are available. This will ensure that spares are ready
whenever needed.
20. Always wear proper dress while operating any machine.
21. Never wear any loose clothes while operating in the plant.
22. Never allow water containing more than 50 ppm of chlorine ion to come in contact with
stainless steel either inside or outside equipment.
23. Check that all the bleed valves are in open conditions.

23. FIRE PROTECTION

1. From types extinguishers and water must not be used in fires around electrical equipment,
carbon dioxide or dry powder extinguishers may be used safety.
2. The carbon tetra chloride extinguishers which liberates poisonous fumes must not be used.
3. Carbon dioxide, dry chemical or foam type extinguishers are suitable for oil fires,
4. Do not use light distillates such as gasoline or naphtha to clean machinery or for any other
cleaning purpose. Use kerosene or heavy oil instead.
5. Keep all area free of waste paper and trash, especially oily rags and clothes should not be left
in locker or tool boxes.
6. Lighting fixtures and electrical equipment should be vapour proof.
7. Fire and explosive hazards in urea plant.
8. Ammonia is capable of forming flammable and explosive mixtures with air within certain
range (16-28% by volume). Such concentrations are seldom encountered in practical handling;
accordingly, the relative fire and explosion hazards are small. The presence of oil, or a ammonia
with other combustible material will increase the fire hazard. The explosive range of ammonia of
broadened by the following factors:
9. Admixture of hydrogen or oxygen replacing air.
10. Higher temperature and pressure.

24. CONCLUSION
Industrial training is one of the most important components in the fulfillment of any engineering
course conducted at any level and at any college. It is a bold attempt to bridge the gap between
the world of work and studies being imparted to students. Training makes the trainee use the
theoretical knowledge being imparted in the college for practical purposes. The students are
made aware of rapid development taking place in the industrial scenario. It is essential that the
students of technical institutes should be as near to the world of work as possible. The main
objective of industrial training is to enable the students to:
Exposure themselves to the industrial environment, which cannot be simulated in the
classrooms.
Apply theoretical knowledge to practical purposes.
Appreciate the importance of discipline, punctuality, teamwork, sense of responsibility,
value of time, money and dignity of labour.
Appreciate research and development, innovation and improvement, expansion, diversification
and moderation being carried out and planned in the industry

25. BIBLIOGRAPHY
NFL manual
NFL library

Websites
www.google.com
www.wikipedia.com
ywfdcrustm.blogspot.com

Books
Unit operations in chemical engineering (By McCabe & Smith)
Unit process (P.H.Groggins)
Outline of Chemical technology (By Dryden)

Fertilizers Magazines