INDUSTRIAL INTERNSHIP REPORT

SUBMITTED BY : Group 3 (ROLL NO: 27,29,30,31,32,34,35,36,39,40)

B.Tech CHEMICAL [2ND YEAR, 4TH SEMESTER]

INTERNSHIP INSTITUTION : GSFC LTD

SUBMITTED TO : SCHOOL OF TECHNOLOGY GSFC UNIVERSITY

UNIVERSITY MENTOR : MRS KANGANA DESAI

(Chemical-Department)

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AKNOWLEDGEMENT

It has been my upmost privilege to work with Gujarat State Fertilizers and Chemicals Limited.
The opportunity of training here has given me an enriching learning experience, which is a
necessity in a modern growing world today. I have been fortunate enough to have trained under
immensely knowledgeable people and extremely hardworking staff.

I would like to give my pleasure to GSFC University for providing me such a great opportunity
and let myself to adopt this kind of environment at a very early stage. I would like to thank Mrs.
Kangana Desai for helping me out with orientation of my vocational training and their efforts to
make the whole process of my training at Gujarat State Fertilizers and Chemicals Limited
smooth and faithful experiences.

I would like to extend my thanks to Mr. M.N Shah , Mr. Jignesh Desai, Mr.Sitaram and
Mr. R.T Patel for guiding and helping me to solve all kind of queries regarding project work and
providing additional knowledge in the Melamine Plant.

I would like to extend my thanks to Mr. Satish Patel MR. Bipin Patel and Mr. Mehul Sir
for guiding and helping me to solve all kind of queries regarding project work and providing
additional knowledge in the Ammonia-IV Plant.

I would like to extend my thanks to Mr. K.A Darji for guiding and helping me to solve all
kind of queries regarding project work and providing additional knowledge in the Urea Plant.

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OBJECTIVE OF THE INTERNSHIP

The objective of the training is to acquire practical and field experience along with the
theoretical experience gained by us. Training of the students in the field of engineering is
necessary as it provides them with required knowledge of the industry and equips them to be
better prepared for work.

The technology is evolving day by day and the students in the field of engineering should be well
versed with the latest technology being used in the industries today. So to build a better
tomorrow, it is imperative that student youth must be trained in their respective fields of
education. This fact was literally reflected in the internship provided by GSFC Limited.

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Contents
AKNOWLEDGEMENT .............................................................................................................. 2
OBJECTIVE OF THE INTERNSHIP ....................................................................................... 3
List of Tables ................................................................................................................................. 8
List of Charts ................................................................................................................................. 8
Abbreviation .................................................................................................................................. 8
MELAMINE.................................................................................................................................. 9
1. Melamine ................................................................................................................................. 9
1.1 Melamine Specifications ............................................................................................................ 9
1.2 Hazards Identification ................................................................................................................ 9
1.3 First Aid Measures ..................................................................................................................... 9
1.4 Fire Fighting Measures .............................................................................................................. 9
1.5 Accidental Release Measures .................................................................................................... 9
1.6 Handling and Storage ................................................................................................................. 9
1.7 Exposure Controls, Personal Protection................................................................................... 10
1.8 Physical and Chemical Properties ............................................................................................ 10
1.9 Stability and Reactivity ............................................................................................................ 10
2. Plant Description................................................................................................................... 11
Flow Diagram ................................................................................................................................ 11
2.1 Melamine Synthesis- FIRST REACTOR ...................................................................................... 12
2.2 Melamine Synthesis- SECOND REACTOR ................................................................................. 12
2.3 Scrubbing ................................................................................................................................. 13
2.4 Finishing ................................................................................................................................... 14
2.5 Gas Treatment ......................................................................................................................... 15
3. Application and uses ............................................................................................................. 16
4. Critical Equipments .............................................................................................................. 17
4.1 Compressor .............................................................................................................................. 17
4.2 Pumps....................................................................................................................................... 17
EQUIPMENTS RELEATED TO FFO AND HEAT TRANFER .................................................................. 18
DIFFERENT TYPES OF VALVES......................................................................................................... 19
5. Safety Permit ......................................................................................................................... 20

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 5.1 Line Breaking Permit ................................................................................................................ 20
5.2 Hot Work Permit ...................................................................................................................... 20
5.3 Confined space Permit ............................................................................................................. 20
5.4 Work to start Permit ................................................................................................................ 20
5.5 Electrical Isolation Permit ........................................................................................................ 20
6. Important Questions Discussed ........................................................................................... 21
6.1 Why the Stack Temperature is kept around 1500 C. ................................................................ 21
6.2 Melamine Resin and APHA..................................................................................................... 21
6.3 Interlock and trips. ................................................................................................................... 21
6.4 Material of construction. .......................................................................................................... 21
6.5 Inconel Material ....................................................................................................................... 21
AMMONIA IV ............................................................................................................................ 22
1. Ammonia................................................................................................................................ 22
1.1 Ammonia Specification ........................................................................................................... 22
1.2 Hazards Identification .............................................................................................................. 22
1.3 First Aid Measures ................................................................................................................... 23
1.4 Fire Fighting Measures ............................................................................................................ 24
1.5 Handling and storage ............................................................................................................... 24
1.6 Physical and chemical properties ............................................................................................. 25
2. Plant Description................................................................................................................... 26
Flow sheet ...................................................................................................................................... 26
2.1 H2 production .......................................................................................................................... 27
2.3 Steam / Carbon Ratio: .............................................................................................................. 27
2.4 Carbon formation:.................................................................................................................... 27
2.5 N2 Production .......................................................................................................................... 29
2.6 Rectification: ............................................................................................................................ 29
2.7 Ammonia Synthesis Section: ................................................................................................... 30
2.7.1 Theoretical principal of process: ........................................................................................... 30
2.7.2 Ammonia converter general description: ............................................................................. 30
2.8 Cooling tower and pumps and compressor ............................................................................. 31
3. Application and uses .............................................................................................................. 32

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 Common Uses of Ammonia........................................................................................................... 32
4. Material Balance ..................................................................................................................... 33
UREA I & II ................................................................................................................................ 36
1. Urea (Properties & Hazards) ............................................................................................... 36
1.1 Urea Specification .................................................................................................................... 36
1.2 Hazards Identification .............................................................................................................. 36
1.3 First Aid Measures ................................................................................................................... 36
1.4 Fire Fighting Measures ............................................................................................................ 37
1.5 Accidental Release Measures .................................................................................................. 37
1.6 Handling and Storage ............................................................................................................... 37
1.7 Physical and Chemical Properties ............................................................................................ 37
2. Plant Description................................................................................................................... 38
Flow diagram ................................................................................................................................. 38
2.1 Introduction ........................................................................................................................... 39
2.2 Production Process ............................................................................................................... 40
2.3 Urea Reaction ........................................................................................................................ 42
2.4 Difference in Urea Plant I and Urea Plant II ..................................................................... 43
2.5 Process Description ............................................................................................................... 43
2.4.1 Synthesis Section .................................................................................................................. 44
2.4.2 Decomposition Section ......................................................................................................... 45
2.4.3 Concentration / Filtration ...................................................................................................... 45
2.4.4 Finishing Section – Crystallization / Centrifuge ................................................................... 45
2.4.5 Drying Melting & Prilling .................................................................................................... 45
2.4.6 Recovery Section .................................................................................................................. 46
2.4.7 Process Description.............................................................................................................. 46
3. Heat Exchanger Designs ....................................................................................................... 48
3.1 Data .......................................................................................................................................... 48
3.1.1 Chemical Data: ...................................................................................................................... 48
3.1.2 Mechanical Data: .................................................................................................................. 48
3.2 LMTD (logarithmic Mean Temperature Difference) ................................................................ 49
3.3 Heat duty (Q)............................................................................................................................ 49

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 3.4 Assuming the Heat transfer Coefficient `U` ............................................................................. 49
3.5 Tube Side Calculations: ............................................................................................................ 50
3.6 Shell Side Calculation: .............................................................................................................. 51
3.7 Overall heat transfer coefficient calculated: ........................................................................... 52
3.8 Percentage Over Design:.......................................................................................................... 53
3.9 Pressure Drop: ......................................................................................................................... 53
3.9.1 Tube side pressure Drop: ...................................................................................................... 53
3.9.2 Shell side pressure drop:....................................................................................................... 53
3.10 Area Required: ....................................................................................................................... 53
3.11 Calculated using Automated Excel Sheet .............................................................................. 54
4 Application and Uses ............................................................................................................ 54
References .................................................................................................................................... 55

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List of Tables:

1. Material Balance of Ammonia Page No:34

2. Properties of Urea Page No:37

List of Charts:

1. Flow Chart of Melamine. Page No:11

2. Flow Chart of Ammonia. Page No:26
3. Flow Chart of Urea. Page No:38

Abbreviation:

1. LMTD : logarithmic mean temperature difference

2. OSHA : Occupational Safety and Health Administration
3. APHA : American Public Health Association
4. DCS : Distributed control system
5. MTD : Metric Ton Per Day
6. DM : Distilled water

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 MELAMINE

1. Melamine

1.1 Melamine Specifications

 General Name : Melamine
 Chemical Name : 2,4,6-Triamino-s-triazine

1.2 Hazards Identification

 Health Effects
o Eyes : Cause mild irritation. Causes redness and pain.
o Skin : May cause skin irritation. Harmful if absorbed through skin.
o Ingestion : May cause irritation in digestive tract. May be harmful if swallowed.
o Inhalation : May cause respiratory tract irritation.

1.3 First Aid Measures

 Eyes : Flush eyes with plenty of water for at least 15 minutes, occasionally
lifting the upper and lower eyelids. Get medical aid.
 Skin : Get medical aid. Flush skin with plenty of water for at least 15 minutes
while removing contaminated clothing and shoes.
 Ingestion : Get medical aid. Wash mouth out with water.
 Inhalation : Remove from exposure and move to fresh air immediately. If not
breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical
aid.

1.4 Fire Fighting Measures

 General Information : As in any fire, wear a self-contained breathing apparatus in
pressure-demand, MSHA/NIOSH (approved or equivalent), and full protective gear. This
material in sufficient quantity and reduced particle size is capable of creating a dust
explosion. Containers may explode if exposed to fire. Risk of explosion if heated under
confinement.
 Extinguishing Media : Use water spray, dry chemical, carbon dioxide, or chemical foam.

1.5 Accidental Release Measures

 General Information : Use proper required personal protective equipment.
 Spills/Leaks : Vacuum or sweep up material and place into a suitable disposal
container.

1.6 Handling and Storage

 Handling : Use with adequate ventilation. Avoid breathing dust, vapor, mist, or gas.
Avoid contact with skin and eyes.

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  Storage : Store in a cool, dry place. Store in a tightly closed container.

1.7 Exposure Controls, Personal Protection

 Engineering Controls : Use adequate ventilation to keep airborne concentrations
low.
 Personal Protective Equipment
o Eyes : Wear chemical splash goggles.
o Skin : Wear appropriate protective gloves to prevent skin exposure.
o Clothing : Wear appropriate protective clothing to prevent skin exposure.

1.8 Physical and Chemical Properties

 Physical State : Crystalline powder
 Color : white – fine
 Odor : odorless pH: 8.4-8.9 (10% aq soln)
 Vapor Pressure : 0.204mbar @20 deg C
 Freezing/Melting Point : 354 deg C ( 669.20°F)
 Auto ignition Temperature : 658 deg C ( 1,216.40 deg F)
 Flash Point : > 280 deg C (> 536.00 deg F)
 Solubility in water : 3 g/l (20°C)
 Specific Gravity/Density : 1.573
 Molecular Formula : C3H6N6
 Molecular Weight : 126.12 grams/mole

1.9 Stability and Reactivity

 Chemical Stability : Stable under normal temperatures and pressures. When heated to
decomposition cyanide fumes are released.
 Conditions to Avoid : Incompatible materials, dust generation, temperatures above
300°C.
 Incompatibilities with Other Materials: Strong oxidizing agents, strong acids.
 Hazardous Decomposition Products : Carbon monoxide, carbon dioxide,
nitrogen oxides (NOx) and ammonia (NH3).
 Hazardous Polymerization : Will not occur.

Note: References are mentioned at the end of the report…

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 2. Plant Description

Flow Diagram

SALT FURNACE UREA FLUIDIZED BED REACTOR

DECOMPOSTION
REACTOR 1

SALT TANK

REACTOR 2 (Al2O3)
SUSPENSION MAIN
TANK SCRUBBER CONTACT FURNACE /
CATAYLTIC BED REACTOR

CRYSTALLIZATION VENTURI
TANK SCRUBBER

CENTRIFUGE HAMMER MILL

DRYER
FILTRATION

PNUEMATIC
BAGGING TRANSPORT

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2.1 Melamine Synthesis- FIRST REACTOR (Sand Bed)

The molten urea is injected into a hot fluidized sand bed by means of six urea injection nozzles.
The fluidized sand bed is maintained by preheated ammonia gas in the first reactor. The
necessary decomposition energy is transferred to the fluidized bed by means of salt melt heated
coils.

The ammonia gas to the first reactor is heated in two steps:

 In the ammonia preheater 1, by means of heat transfer medium diphyl preheated in the
second reactor (or in case of start up by ammonia preheater 3).
 In the ammonia preheater 2, which is heated with salt melt from salt heating unit.

A part of hot ammonia gas is bypassed around the decomposer and then blended with the
decomposition gas mixture.

Decomposition of urea is endothermic reaction which has to be carried out quickly, forming
isocyanic acid (HNCO) and ammonia.

The hot ammonia should contain as little water as possible, as water together with urea forms
ammonia and carbon dioxide, thus reducing the melamine yield.

2.2 Melamine Synthesis- SECOND REACTOR (Catalyst Bed)

The gas mix containing isocyanic acid and ammonia, coming from the decomposer, flows
through four aluminum oxide catalyst beds of the second reactor, arranged is parallel. Here the
isocyanic acid is transformed into melamine. The normal conversion efficiency is 92 to 92.5%.

The reaction takes place in a temperature range of 390 - 420°C. The heat generated during the
formation of melamine is transferred to the two rows of finned cooling tubes embedded in
catalyst, arranged in two rows one above the other.

Diphyl, which is simultaneously heated, is being used as cooling medium. The diphyl system
comprises the thermic fluid tank, from where the thermic fluid fill pump fills the system.

Moreover, the entire system may be emptied into this tank. The thermic fluid circulation pump
pumps the dyphyl through the cooling tubes and ammonia preheater.

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The thermic fluid expansion tank is charged with a nitrogen blanket of approx. 11 bar-g pressure,
keeps the pressure constant in case the volume of circulating diphyl quantity changes.

Compressed nitrogen is fed by reducing the pressure of HP- nitrogen in the manifold. Should
diphyl evaporate in the cooling tubes and blow down through the pressure relief valves in case of
malfunctions, the dyphyl vapor is condensed in water-cooled thermic fluid condenser and then
drained into the thermic fluid collecting tank.

2.3 Scrubbing

As the discharge gas of the second reactor contains a small quantity of isoscyanic acid which has
not been transformed, besides ammonia, melamine and carbon dioxide it has to be cooled down
as quickly as possible in order to avoid any side reactions. Isocyanic acid is partly transformed to
ammonium cyanate and then to urea, or hydrolyzed to ammonia and carbon dioxide.

The temperature of AC liquor (ammonium carbonate liquor) is about 77°C. When cooled down,
melamine passes from gaseous to solid state.

Melamine is quenched and washed out of the gas stream in the film scrubber, with ammonium
carbonate liquor (AC liquor). The heat contained in gas stream is eliminated by evaporation of
AC liquor; the melamine crystals form a suspension.

To discharge the small quantity of urea formed of isocyanic acid, a small quantity of mother
liquor is continuously drained off after filtration, fed to the mother liquor treatment, made up
with fresh liquor and vapor condensate from the ammonium carbonate liquor treatment.

Due to special design of the film scrubber and suitably conducted scrubbing liquid circuits all
surfaces of the film scrubber containing the gas flow will be wetted by scrubbing liquid.

A small quantity of ammonia gas to the top of the film scrubber prevents gaseous melamine to
diffuse to the top plate. Thus, there is no direct contact between the gas stream and cold main
scrubber and any formations of incrustations are avoided.

The scrubbing liquid circuits are maintained by two head circulation pump sand the central tube
indication pumps.

The pumps are always preceded by a stone separator (strainer). A part stream of central lube
circulation is branched off as melamine and is fed to further treatment.

The gas emanating from the film scrubber, which is now saturated with water vapors, is washed
one more time in the Venturi scrubber, to separate any residual melamine.

The venturi circulation pump circulates the liquid in the venturi scrubber.

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2.4 Finishing

The melamine suspension is fed to the suspension tank, which buffers the melamine suspension
as feed to the centrifuge.

The centrifuge filters the suspension batch wise. After the filtration the cake is washed with
process condensate from cake washing liquor tank.

The wet Filter cake which comes batch wise from centrifuge is collected in the metering hopper.

To prevent the residual layer in the centrifuge drum from becoming non diffusible, after every
batch, this layer is destroyed by back flushing with filtrate which is stored in the back flushing
liquor tank.

The filtrate, also called the mother liquor, flows back to the mother liquor tank. The mother
liquor is heated to about 60°C by the mother liquor pre-heater.

By mother liquor pump a smaller part is fed to mother liquor treatment, the main part is recycled
to the scrubbing unit to the venturi scrubber.

For metering hopper the wet melamine filter cake falls continuous into the steam heated multi
coil dryer.

The melamine dryer has two sections:

1. A drying zone where the product is heated with the steam and dried

2. A cooling zone, where it is cooled with a separate cooling circuit. It comprises of a

cooling water tank, a cooling water pump, and a cooling water cooler.

Drying air is conveyed to the dryer via suction filter and the air fan.

The dried and cooled melamine runs directly into the hammer mill to crush any lumps and then
fed to a rotary valve, which doses the melamine into a pneumatic conveying system to storage
section.

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2.5 Gas Treatment

After scrubbing unit the carbon dioxide, formed in the synthesis part of the process is washed out
of the ammonia gas by two absorber columns. These columns contain of four cooled absorption
circuits. The first absorption circuits has to condense part of the water, evaporated in the
scrubbing section. The excess water of this section is discharged towards the scrubbing section.

The gas discharged from the venture scrubber is fed to the part of first absorption column,
together with ammonia enriched vapors from the mother liquor stripper. This column is divided
into three sections.

At the head of second absorber column ammonia gas with water content of 4-5% is discharged.
In the liquid separator, this gas is separated from entrained liquid droplets, in ammonia preheater
it is slightly preheated with compressed, hot ammonia gas, so that no solid ammonium carbonate
may precipitate in case of malfunction and finally fed to ammonia compressor via suction
strainer.

On the suction side of the compressor the pressure is about 0.1 bar-g and it is compressed to the
pressure of about 1 bar-g and the temperature rises. The hot ammonia gas is fed to final
intercooler. As a result of gas cooling, ammonia water condenses. At the after-cooler there is a
drain which drains the condensate.

The ammonia gas formed in the melamine synthesis and from the liquid ammonia evaporated in
the deep cooler will be liquefied in the ammonia liquefaction unit.

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 3. Application and uses

 Laminates : For table tops, kitchen shelves, platforms, wall cladding, bus bodies,
interior of railway coaches, counters, deckings, instrument panels.
 Consumer Moulded Goods : Bowls, trays, spatulas, mixer's base, crockery, cutlery
items, launderable buttons, and lamp shades.
 Industrial Moulded Goods : Circuit breakers, television tube support, automotive
ignition components, washing machine, agitators, soda fountain parts, switch gears,
switch housings, connector plus inserts, wattmeter terminal block, junction boxes, fuse
carriers, plating tanks.
 Treatment Resin for Paper : For currencies, toilet paper, facial tissues, shopping and
shipping bags, map papers, food wrappers, photographic paper.
 Resin for Lacquer Paints : For motorcars, refrigerator cabinets, washing machines,
kitchen equipment, typewriters, water heaters.
 Adhesives : Melamine adhesives from Melamine resins are extra strong, extra tough,
highly water resistant and colorless (veneered doors).
 Melamine Resin for Textile Auxiliaries: For providing anti-crease treatment to cotton
and other fabrics.
 Leather Chemical : MF resins act as pre-tanning agents.
 Coating : Textile, paints, art paper, currency paper, photography.

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 4. Critical Equipments
4.1 Compressor

 Compressor is the most critical equipment of the plant.

 It is also called the heart of the plant.

Centrifugal Compressor

 This is German made (Demake) Compressor.

 Specially is used for maintaining the flow of ammonia in sand-bed reactor for
fluidization.
 This compressor is having high speed of about 14000 RPM.
 After power cut-off it takes around 12min to come to rest at 0 RPM.
 So to avoid wear and tear for continuous lubrication oil pump is provided.
 Two main parts are:
o Anti-Surge Valve: used to prevent surging.
o Guide-Vane: Used to provide continuous flow in the compressor through nozzles.

Reciprocating Compressor

 This is 2 stage double acting compressor.

 Specially used for liquefaction of ammonia gas

4.2 Pumps
 Mostly centrifugal pumps are used in whole plant.
 Two critical pump used are:
o 502-A Pump
 It is Japan made vertical pump.
 With very high speed of about 10000RPM.
 And specialty is that it is single stage pump
o Hermetic pump
 It used for pumping of diphyl.
 No sound is heard very silent pump.
 Even motor and shaft are internally connected.
 It has two impellers one is for main operation while other is
Used for cooling purpose.

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EQUIPMENTS RELEATED TO FFO AND HEAT TRANFER
1) Harmetic pump –
This pump is used to transport diphyl to second reactor for cooling purpose. This pump has
internal connection of motor and shaft which avoid leakage of diphly. Speciality of this pump
is, it do not make sound. In this lube oil is not used as lube oil work is done by diphyl itself.
If the bearing gets heated, diphyl takes away the heat and make the pump cool down and also
it do not required any lubrication.
Material of construction of this pump is:-
 Casing – cast steel
 Impeller – cast iron
 Shaft – chrome steel
 Gaskets – graphite
 Rotor – stainless steel

2) Vertical centrifugal pump (502-A) –

This pump is used for AC liquor transport. This vertical centrifugal pump of single stage
gives high pressure at the discharge due to its high rotation. It has a small impeller which
rotates at a speed of 10,000 rpm and converts 0.6 kg pressure to 25kg pressure. This can also
be done in horizontal pump but it requires multiple stages to obtain that pressure. In
melamine 1 plant, it has 5 stages to obtain such a high pressure.
Its material of construction is basically cast iron and stainless steel.
3) Spiral type heat exchanger –
This type of heat exchanger is used to cool down melamine suspension which comes from
the suspension tank. This equipment cools the melamine with the help of cooling water. The
outlet of melamine from this heat exchanger is appr. 35°C which is send to crystallization
tank. The advantage of this type of heat exchanger over shell and tube is: 1) The cleaning of
spiral heat exchanger is easy as compared to shell and tube, 2) heat transfer coefficient is
more than that of shell and tube. 3)compact size gives large heat transfer area and low
pressure drop.

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DIFFERENT TYPES OF VALVES

1) Gate valve - Gate valve is the most common type of valve in any process plant. It is a linear
motion valve used to start or stop fluid flow. In service, these valves are either in fully open
or fully closed position. Gate valves are used in almost all fluid services such as air, fuel gas,
feed water, steam, lube oil, and all most any services. Gate valve provides good shutoff.

2) Globe valve - Globe valve is used to stop, start, and regulate the fluid flow. Globe Valves are
used in the systems where flow control is required and leak tightness is also necessary. Globe
valve provides better shut off as compared to gate valve and it is costlier than gate valve.

3) 3 – way valve – The purpose of a 3-way control valve is to shut off flow in one pipe while
opening flow in another pipe, to mix liquid from two different pipes into one pipe, or to
separate liquid from one pipe into two different pipes. In melamine plant it is used for two
fluid i.e. urea and steam.

4) Butterfly valve - A Butterfly valve is a quarter-turn rotary motion valve, which is used to
stop, regulate, and start the flow. Butterfly valve has a short circular body. Butterfly Valve is
suitable for large valve applications due to compact, lightweight design that requires
considerably less space, as compared to other valves. Mostly in melamine plant butterfly
valve is used because of high flow inlet.

5) Needle valves - are similar to a globe valve in design with the biggest difference is the sharp
needle like a disk. Needle valves are designed to give very accurate control of flow in small
diameter piping systems. They get their name from their sharp-pointed conical disc.

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 5. Safety Permit
5.1 Line Breaking Permit

OSHA: Occupational Safety and Health Administration

 Line breaking is the intentional opening of a pipe, line, or duct that contains or has
contained material capable of causing injury. OSHA requires that all members of a line
breaking team understand the hazards related to the material and equipment involved
 Color-code : Yellow

5.2 Hot Work Permit

 Generally used for hot works like cutting, welding, soldering and brazing operations for
construction, demolition, maintenance or repair activities.
 Color-code : Red

5.3 Confined space Permit

 Generally used when an person needs to enter the vessel and operate.
 Oxygen is checked should be more than 20%.
 Nitrogen gas should be cut-off in plant because it affects in breathing.
 Color-code : Green

5.4 Work to start Permit

 Most basic permit.

 Generally used when work is to be started.
 To keep track on who is doing which work etc.
 Color-code : Blue

5.5 Electrical Isolation Permit

 Generally taken when a power cutoff is required.

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 6. Important Questions Discussed
6.1 Why the Stack Temperature is kept around 1500 C.
 Stack Temperature is kept above 1500C and never kept below 1000c because below 1000c
Water vapor will get condensed at atmospheric pressure.
 And also condensed vapor will react with present gases like SOx & NOx and forms acidic
content which will help in corrosion and the stack will start corroding.

6.2 Melamine Resin and APHA.

 Melamine resin is prepared for quality check.
 Resin is prepared as a mixture of melamine and formaldehyde heated at 900 C.
 Check is done on basis of clarity and color.
 APHA – American Pharma health Association
 APHA=20 is consider as almost clear.

6.3 Interlock and trips.

 It is a feature that makes the state of two mechanisms of functions mutually dependent.
 It may be used to prevent undesired states in a finite-state machine and may consist of any
electrical, electronic or mechanical devices or system.
 Generally set between 2 valves to set upper and lower limit for control.

6.4 Material of construction.

 Two main factors are taken into consideration while selecting MOC.
(Material of construction)
I. Coasting
II. Chemical/Physical properties like corrosiveness and hazards of fluid.

6.5 Inconel Material

 A special type of inconel material alloy is used for making the 8 shaped salt coil used for heating
in reactor 1 (i.e. Sand Bed Reactor) .
 Its cost is around 2 Crore rupees for a coil.
 Specialty is that it has high friction and corrosion resistant properties.
 And main part is it has high heat transfer coefficient.
 Life-period is considered around 10 Years.

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 AMMONIA IV

1. Ammonia
1.1 Ammonia Specification
 Product Name : Ammonia
 Chemical Formula : NH3
 Trade name : Ammonia

1.2 Hazards Identification

 Main Hazards : Irritating or corrosive to exposed tissues. Inhalation of
vapors may result in pulmonary oedema and chemical pneumonitis. Contact with liquid
product may cause frostbite or freeze burns, in exposed tissues. All cylinders are portable
gas containers and must be regarded as pressure vessels at all times.
 Adverse Health Effects : Inhalation of high concentrations produces violent
coughing due to the local action on the respiratory tract. If rapid escape is not possible,
severe lung irritation, pulmonary oedema and death can result. Lower concentrations
cause eye irritation, laryngitis and bronchitis.
 Biological Hazards : Because of its alkaline properties, long-term exposure to flora can
cause damage. Aquatic fauna can also be affected should the pH of their environment
change due to long-term exposure to high concentrations of ammonia.
 Vapor Inhalation : Ammonia acts principally on the upper respiratory tract, where it
exerts an alkaline, caustic action. It produces respiratory reflexes such as coughing and
arrest of respiration. It affects the conjunctiva and cornea immediately.
o Inhalation causes acute inflammation of the respiratory organs, coughing, oedema
of the lungs, chronic bronchial catarrh, and secretion of saliva and retention of
urine.
 Eye Contact : Exposure to high gas concentrations may cause temporary
blindness and severe eye damage. Direct contact of the eyes with liquid anhydrous
ammonia will produce serious eye burns.
 Skin Contact : Liquid anhydrous ammonia produces skin burns on contact.
 Ingestion : swallowing of the liquid results in severe corrosive action of the
mouth, throat, and stomach.
 CONTAINS GAS UNDER PRESSURE; MAY EXPLODE IF HEATED
 HARMFUL IF INHALED
 CAUSES SEVERE SKIN BURNS AND EYE DAMAGE

Group 3 Page 22
 1.3 First Aid Measures

 Prompt medical attention is mandatory in all cases of overexposure. Rescue personnel should
be equipped with self-contained breathing apparatus. Any conscious person who has inhaled
ammonia causing irritation should be assisted to an uncontaminated area and inhale fresh air. A
person overcome by ammonia should immediately be carried to an uncontaminated area. If
breathing has ceased, artificial respiration must be started immediately, preferably by trained
personnel. If breathing is weak or has been restored by artificial respiration, oxygen may be
administered. Summon a physician immediately for anyone who has been burned or overcome
by ammonia. Until a physician arrives, and after having accomplished a thorough removal of
ammonia as possible, keep the patient warm and quiet, and take such specific action as may be
indicated.
 Eye Contact : Persons with potential exposure to ammonia should not wear contact lenses.
Call a physician at once. Immediately begin irrigation of the eyes with copious amounts of clean
water while holding the eyelids apart. Continue irrigation for 15 minutes. Repeat this procedure
every 10 minutes for an hour, each time irrigating for a period of 5 minutes. If readily available,
a 5% boric acid solution may be used instead of water, but irrigation must not be delayed while
such a solution is sought or prepared. Prompt and thorough irrigation is of primary importance.
Any standard anaesthetic solution for ophthalmic use ordered by the physician may be instilled
for control of severe pain, but only after the 15 minute period of irrigation has been completed.
 Skin Contact : If skin contact is extensive and emergency showers available, the victim should
get under the emergency shower immediately. Contaminated clothing and shoes should be
removed under the shower. In other cases, the affected areas should be washed thoroughly
with large amounts of running water for at least 15 minutes. Do not apply salves or ointments or
cover burns with dressing; however, protect the injured area with a clean cloth prior to medical
care. Do not attempt to neutralise the ammonia. Subsequent medical treatment is otherwise
the same as for thermal burns .
 Inhalation : The conscious person who has inhaled a concentration of ammonia which
causes irritation effects should go to an uncontaminated area and inhale fresh air or oxygen.
Eye, nose and throat irritation should be treated as described below for more serious exposures.
However, if the exposure has been to minor concentrations for a limited time, usually no
treatment will be required. A worker overcome by ammonia must be carried to an
uncontaminated atmosphere and, if breathing is labored or has ceased, given artificial
respiration (back-pressure, arm lift, or mouth-to-mouth resuscitation) immediately, preferably
by trained personnel. When breathing has been restored, 100% oxygen is administered, but not
for more than 1 hour of continuous treatment at one time. Oxygen therapy may be interrupted
after 1 hour, and reinstituted as the clinical condition indicates. Observe for laryngeal spasm and
perform tracheotomy if indicated. In case of severe exposure, the patient should breathe 100%
oxygen under positive exhalation pressure (4cm) for one-half hour periods every hour.
Treatment may be continued in this way until symptoms subside or other clinical indications for
interruption appear.

Group 3 Page 23
  Contact with nose & throat : Irrigate the nose and mouth continuously for 15 minutes. If the
patient can swallow, encourage him to drink large quantities of 0.5% citric acid solution or
lemonade. Never give anything by mouth to an unconscious person.
 Ingestion : If liquid anhydrous ammonia has been swallowed, call a physician immediately.
If the patient is conscious and able, he should drink large amounts of water to dilute the
chemical. Do not induce vomiting if the patient is in shock, extreme pain or is unconscious. If
vomiting begins, place the patient face down with head lower than hips; this prevents vomit
from entering the lungs and causing further injury

1.4 Fire Fighting Measures

 Extinguishing media : Fog-water spray. (In the absence of fog equipment, a fine spray of
water may be used.) Use media suitable for surrounding fire. Although ammonia does not
represent a serious flammability hazard, mixtures of air and ammonia containing from 15% to
28% ammonia vapor by volume will ignite when sparked, or exposed to temperatures exceeding
651°C.
 Specific Hazards : High levels of ammonia can produce corrosive effects on tissues and
can cause laryngeal and bronchial spasm and oedema so as to obstruct breathing.
 Emergency Actions. Rescue personnel should be equipped with self-contained breathing
apparatus. If possible, stop the flow of gas. Since ammonia is soluble in water, it is the best
extinguishing media - not only in extinguishing the fire, but also absorbing the escaped ammonia
gas. Evacuate the area. All cylinders should be removed from the vicinity of the fire. Cylinders
that cannot be removed should be cooled with water from a safe distance. Cylinders which have
been exposed to excessive heat should be clearly identified and returned to the supplier.
CONTACT THE NEAREST AFROX BRANCH.
 Protective Clothing : Self-contained breathing apparatus. Safety gloves, Goggles and shoes,
or boots, should be worn when handling cylinders.
 Environmental precautions : As the gas is lighter than air, ensure that it is not trapped in
confined spaces. Knock down pockets of gas with fog water spray, and ventilate the area using
forced-draft if necessary. Prevent from entering sewers and drains.

1.5 Handling and storage

 Always store full cylinders in upright position. Avoid dragging, rolling or sliding cylinders. Use
trolleys for handling.
 Cylinders should be stored in a well ventilated area on a hard dry surface. Ventilation inlets
should be at ceiling and floor level.
 Cylinders must be used on a "first in - first out" basis.
 Keep cylinders away from sources of heat.
 Keep away from children.

Group 3 Page 24
 1.6 Physical and chemical properties
PHYSICAL DATA
 Chemical Symbol : NH3
 Molecular Weight : 17.031 g/mol
 Specific Volume @ 20°C & 101,325 kPa 1405.6 ml/g
 Boiling point @ 101,325 kPa -33,4°C R
 elative density (Air = 1) @ 101,325 kPa 0,599
 Flammability levels in air 16 - 25% (by vol.)
 Auto ignition temperature : 651°C
 Taste : Alkaline
 Odour : Pungent

Group 3 Page 25
 2. Plant Description

Flow sheet

Sections:
 100 : Steam Reforming
 200 : CO Water-shift reaction
 300 : CO2 Removal
 400 : Pressure Swing Adsorption (PSA)
 500 : Ammonia Synthesis Unit
 600 : Refrigeration unit
 700 : Air Separation Unit
 800 : Steam Condensate BFW System
 900 : Turbo Generation
 1100 : Cooling Water System

Group 3 Page 26
2.1 H2 production

 Ammonia-4 plant produces hydrogen gas using natural gas which is supplied by reliance
or Gail.
 First the NG is reduced to operating pressure of about 32barg and then pre heater, where
it is heated by the flue gases of reformer.
 Then it goes to de sulphursier to remove Sulfur from the NG which acts as catalyst
poison in the reforming reaction.
 In the desulphurisier it consist of two columns in the first column consist of 2 bed of 70%
comox and 30% ZnO, and other section of ZnO bed.
 ZnO bed gives outlet Sulfur upto < 0.1 ppm

 H2S ZnO + H2S = ZnS + H2O (exothermic)

 After the Sulfur is removed the NG goes to super heater, which is been heated by the flue
gases.
 Then it goes to the reformer section, in which there are 408 tubes with 8 rows and 51
tubes in each row and 12 burners in each row which make total of 108 burner, with
induced draft fans and forced draft fans to provide vacuum in the reformer so for proper
heating and for safety purpose.
 The burner is burned by NG and preheated air.
 The tube contains nickel based catalyst.
 The steam reforming of saturated hydrocarbon can be represented by

 CnH2n+2 + H2O = n CO + (2n+1)H2

2.3 Steam / Carbon Ratio:

Since increase in temperature makes it difficult for the reformer tube to resist the pressure
the steam / carbon ratio can be increased to help offset the effect of high pressure.

The usual range is 3.5 to 4 miles of steam per miles of carbon.

A lower ratio could be used but the higher one not only improves conservation but also helps
supply the steam need in the Co conversion step. Moreover, excess steam in the reformer is a
good insurance against “C” formation on the catalyst.

2.4 Carbon formation:

Under normal condition there should be sufficient “C” formation to interfere with plant

Group 3 Page 27
 operation complete loss of reaction steam, however, may result in massive deposition of
carbon and a rapid increase in pressure drop complete catalyst replacement with then be
required operation with a small steam deficiency can result in slow carbon deposition from
a number of carbon forming reactions.

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

 At temperature between 540 to 650c all the four “C” forming reactions are capable
of producing carbon then only a few seconds in this condition are sufficient to plug
tube and break up the catalyst.

 The flue gas are used to produce High Pressure and Medium Pressure steam and
released from the stack.
After that the process gas goes to ISR section, in which further conversion of h2 gas take
place

 Reaction: CO + H2O = CO2 + H2

 The water gas shift reaction plays a major role in hydrogen plant design and operation.
Good performance of the Cu based catalyst system is critical to the efficient and
economic operation of the plant to maximize H2 production form the hydrocarbon
feedstock.
 Here for maintaining constant pressure water is feed in tube side and catalyst and process
gas and steam in shell side.
 After this the process gas is used to recover MDEA semi lean solution by giving up its
heat to semi lean by means of reboiler.
 Then it is sent to absorption tower where the process gas is feeded from the bottom and
the MDEA solution is feeded from the top, this tower has a reflux of semi lean
somewhere in the middle of the tower, Hence CO2 gas is absorbed.
 For the regeneration of the MDEA solution it is send to reboiler as discussed above and
series of heat exchangers to increase its temperature so the absorbed CO2 is removed, by
using flash column and stripper.
 After removing CO2 from the process gas it contains majority of H2 gas, which is further
purified in the PSA section where it has 12 column system containing Mole sieves to get
99.99% pure H2 gas.

Group 3 Page 28
2.5 N2 Production
 N2 is produced by separating N2 from air, since air contains 79% N2, 20 %O2 and
093%Ar.
 First the air is compressed and cooled using cooling water with direct contact so Sox and
Cox get removed then its sent to absorber containing mole sieves, which removes
moisture from air , then it goes to expansion turbine in which due to sudden expansion it
cools down to -190oC.
 After that it is send to rectification unit.

2.6 Rectification:
 This process of separation ensures a high degree of purity and simultaneously a good
output.
 Air rectification consists of an oxygen nitrogen exchange between liquid and gaseous
phases, the liquid being posed in the counter current to the ascending gaseous O2 - N2
mixture so called rectification plates (Perforated trays) are mostly used for this
exchange. When in equilibrium, the vapor immediately above the liquid mixture
(liquid air) has a higher N2 content, due to nitrogen’s lower boiling points, than the
liquid. The vapor and the liquid fractions passing respectively through and ever the
rectification trays attempt to remain in equilibrium by exchanging oxygen and
nitrogen when in contact a process which at the same time involves heat exchangers
(condensation of oxygen and evaporation of nitrogen). The ascending gaseous mixture
will steadily become richer in nitrogen and the descending liquid I oxygen.
 That a separation effect must take place when an ascending gaseous fraction is in
contact with a descending liquid fraction of a binary mixture can be understood from
the following:
 Imagine that gaseous air is saturated with its liquid components (O2 and N2) rising in
a column is completely liquefied at the upper end (eg. By the condenser) and then
flow back to the sieves trays without change of composition. According to the
diagram, a small volume of vapor at the point A is at a higher temperature than the
boiling liquid at B of the same composition. The subsequence equilibrium will result
in a temperature T3 between T1 and T2 at that point C on the same vertical line.
However, at this temperature T3 only a liquid E with a higher oxygen content than in
B and a vapor D with a lower oxygen concentrates in the down flowing liquid and
nitrogen in the ascending vapor. Finally the liquid reaches the condenser in the form
of pure oxygen while a gas consisting mainly of nitrogen escapes at the top of the
column.
 Ar is removed in the crude argon and pure Ar section using reflux of liquid oxygen
and liquid air to liquefy the Ar.

Group 3 Page 29
2.7 Ammonia Synthesis Section:

2.7.1 Theoretical principal of process:

The synthesis of H2 and N2 takes place in presence of ion catalyst at H2:N2 ratio of 3:1 and
at a high temperature and pressure as per following reaction.

N2 + 3H2 = 2NH3

The synthesis of ammonia from gaseous hydrogen and nitrogen is an exothermic reaction,
which is accompanied by considerable volume decreases at constant pressure. Equilibrium
consideration dictates that the synthesis reaction must be carried out at high pressure to obtain
an economic yield. According to Le Chateliers principles, thermodynamic equilibrium data
show that the highest yield is obtain at low temperature. As the synthesis reaction proceeds,
the exothermic reaction causes the temperature to rise which increase rate of reaction. But at
the same time the equilibrium becomes less favorable and the synthesized ammonia increased
the rate of the reversed-reaction.

2.7.2 Ammonia converter general description:

 N2 and H2 is compressed in 4 stage compressor which compresses to

143barg and send to get pre heated by the produced NH3 after that it
enters the reactor with Fe based catalyst with intercooler since it is an
exothermic reaction. After that the hit NH3 is cooled down by producing
hp steam using heat exchanger, followed by H2 and N2 gas
 Further it is cooled by using cooling water, after it is liquefied using 2
ammonia chillers.
 Then it is flashed in a drum where the unreacted N2 and H2 is used to
cool the NH3 as discussed above then this N2 and H2 is recycled and
compressed in the 4th stage compressor.
 The NH3 liquid is separated in another storage tank.

Group 3 Page 30
2.8 Cooling tower and pumps and compressor

 We have seen cooling tower which have induced draft fan to create
counter flow of air with water.
 We have seen many single and multi stage centrifugal pumps motor
driven or turbine driven to supply steam and BFW or cooling water in the
plant.
 We have seen compressor like syn gas compressor and Air compressor.

Group 3 Page 31
3. Application and uses

Common Uses of Ammonia

 Talking about the uses of ammonia, it is the most important or building-block chemical
and in the manufacture of products that people make use of every day. So let’s see where
it is used.
 Ammonia in Industries
o Ammonia is used extensively in several industries. It is used either as a stabilizer,
neutralizer or as a source of nitrogen to carry out several functions. Ammonia is used in
wastewater treatment, leather, rubber, paper, food and beverage industries. It also is
used cold storage or refrigeration systems and in the production of pharmaceuticals.
Ammonia is used in the printing as well as cosmetics industries. It is also used in
fermentation.
 Agriculture
o Ammonia is used mainly in Agricultural industries. About 90 percent of all ammonia
produced is used in this field. Since, ammonia acts as a rich source of nitrogen and other
elements; it is used in fertilizers to basically sustain food production. It is also used in
the production of liquid fertilizer solutions consisting of compounds like ammonium
nitrate, salts, urea and others. And there’s more. Ammonia is often used as an
antifungal agent on certain fruits and as preservatives.
 Household Products
o Ammonia is one of the main ingredients in a lot of household cleaning products. It is
used as a cleaning agent and can be used to remove stains or clean mirrors, tubs, sinks,
windows and more. Some of the other uses include antimicrobial agent or an antiseptic,
and ammonia is also used as a fuel.
 For Manufacturing Various Compounds
o We find uses of Ammonia in the manufacturing of a number of compounds like nitric
acid, Hydrogen cyanide, Ammonium carbonate, Phenol, Urea, Amino acids, and a whole
lot of other items.
 Metal Treating
o Here dissociated ammonia is used in operations like carbonitriding, nitriding, furnace
brazing, bright annealing, sintering, atomic hydrogen welding and other operations.
 Petroleum and Mining
o In the petroleum industry ammonia is utilized in counterbalancing the acid constituents
of oil which is in crude form. It also helps to keeps equipment free from corrosion.
Additionally, Ammonia is used in the mining industry for extraction of several metals.

 These are some of the popular uses of Ammonia.

Group 3 Page 32
4. Material Balance

*Data is taken from DCS panel.

DATA:

Ammonia Converter

Feed:

 H2 = 37000 (m3/hr)
 N2 = 113000 (m3/hr)

Total Feed = 150000 (m3/hr)

Theoretical Production: 1350 M.Ton/Day

Calculations

Reaction:

N2 + 3H2 = 2NH3

Production : 1350 M.Ton/Day

: 56.25 M.Ton/hour

: 3308.82 moles/hour

From the stoichiometry of the above reaction.

 1654.41 moles/hour Nitrogen will be required.

 4963.23 moles/hour Hydrogen will be required.
 Total = 1654.41 + 4963.23 = 6617.64 moles/hr is required.

Actual Data:

 H2 = 37000 (m3/hr)
 N2 = 113000 (m3/hr)
 Total = 150000 (m3/hr)

= 6696.42 moles/hr

Group 3 Page 33
Material Balance using Per Pass Conversion @17 %

Feed Converted
3
Hour (m /hr) (@17% per Pass)
(m3/hr)
1 150000 25500
2 124500 21165
3 103335 17566.95
4 85768.05 14580.5685
5 71187.482 12101.87186
6 59085.61 10044.55364
7 49041.056 8336.979521
8 40704.076 6919.693002
9 33784.383 5743.345192
10 28041.038 4766.976509
11 23274.062 3956.590503
12 19317.471 3283.970117
13 16033.501 2725.695197
14 13307.806 2262.327014
15 11045.479 1877.731421
16 9167.7475 1558.51708
17 7609.2304 1293.569176
18 6315.6613 1073.662416
19 5241.9989 891.1398055
20 4350.8591 739.6460386
21 3611.213 613.906212
22 2997.3068 509.542156
23 2487.7646 422.9199895
24 2064.8447 351.0235912
Total 148286.179

Group 3 Page 34
PSA (Pressure Swing Adsorption) – Unit Material Balance

Purge Gas:-

 H2 = 59.12 %
 N2 = 0.64 %
 CO2 = 2.07 %
 CH4 = 36.1 %
 CO = 2.07 %

PSA Inlet:-

 H2 = 91.43 %
 N2 = 0.16 %
 CO2 = 0.2 %
 CH4 = 7.75 %
 CO = 0.46 %

Purge
1361.60 Kmol / hr
Pressure
6250 Kmol / hr Swing
Adsorption
H2 (99.9 %)
X Kmol / hr

Inlet Flow Rate = 140000 Nm3/hr = 6250 Kmol/hr

H2 Flow Rate = 109000 Nm3/hr = 4866.071 Kmol/hr

Purge Gas Flow rate = 30500 Nm3/hr = 1361.607 Kmol/hr

Mass Balance of Hydrogen:

6250*(0.9143) = 1361.60*(0.5912) + 0.99*(X)

4909.397 = 0.99*X

X = 4958.98 Kmol/hr (Theoretical) = 111081 Nm3/hr

Group 3 Page 35
 UREA I & II

1. Urea (Properties & Hazards)

1.1 Urea Specification

PRODUCT NAME : Urea

CHEMICAL NAMES : Carbamide resin, Isourea, Carbony diamide, Carbonyldiamine

CHEMICAL FORMULA : NH 2 CO NH 2

1.2 Hazards Identification

 Eye : May cause eye irritation. Causes redness and pain.

 Skin : May cause skin irritation. Causes redness and pain. May be harmful if
absorbed through the skin.
 Ingestion : Causes gastrointestinal irritation with nausea, vomiting and diarrhea.
May cause cardiac disturbances. May be harmful if swallowed.
 Inhalation : May cause respiratory tract irritation. May be harmful if inhaled.
 Chronic : Prolonged or repeated exposure may cause adverse reproductive effects.

1.3 First Aid Measures

 Eyes : Immediately flush eyes with plenty of water for at least 15

minutes, occasionally lifting the upper and lower eyelids. Get medical aid.
 Skin : Get medical aid. Immediately flush skin with plenty of water for
at least 15 minutes while removing contaminated clothing and shoes.
 Ingestion : Get medical aid. Do NOT induce vomiting. If conscious and
alert, rinse mouth and drink 2-4 cupfuls of milk or water.
 Inhalation : Remove from exposure and move to fresh air immediately. If not
breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical
aid.
 Notes to Physician : Treat symptomatically and supportively.

Group 3 Page 36
1.4 Fire Fighting Measures

 General Information : As in any fire, wear a self-contained breathing apparatus in

pressure-demand, MSHA/NIOSH (approved or equivalent), and full protective gear.
 Extinguishing Media : Use water spray, dry chemical, carbon dioxide, or chemical foam.

1.5 Accidental Release Measures

 General Information : Use proper personal protective equipment as required.

 Spills/Leaks : Vacuum or sweep up material and place into a suitable disposal
container. Avoid generating dusty conditions. Provide ventilation.

1.6 Handling and Storage

 Handling : Use with adequate ventilation. Minimize dust generation and

accumulation. Avoid breathing dust, mist, or vapor. Avoid contact with eyes, skin, and
clothing. Avoid ingestion and inhalation.
 Storage : Store in a cool, dry place. Store in a tightly closed container.
 Storage Temperature : Room Temperature
 Disposal : Observe all national, state, and local regulations regarding disposal.

1.7 Physical and Chemical Properties

Sr. No. Properties Values

1 Physical State Solid
2 Appearance White
3 Odor Ammonia like
4 pH 7.5-9.5
5 Vapor Pressure 1.25 mm Hg @25 deg C
6 Freezing/Melting Point 131-135 deg C
7 Solubility Soluble
8 Specific Gravity/Density 1.335
9 Molecular Formula NH 2 CO NH 2
10 Molecular Weight 60.06 grams/mole

Group 3 Page 37
 2. Plant Description
Flow diagram
UREA PLANT BLOCK DIAGRAM

CO2 Recycle Liq. NH3

comp. Pump Pump
Recovery Column

NH3 cond. NH3 free

A,B,C,D,E Ammonical vent gases
194 oC UREA vent
220 kg/cm2g REACTOR Gases
NH3 reservoir
from
Fress NH3 Enviro-
Make up UREA-I nment

HIGH UREA-II control

155 oC HIGH PRESS. Ammonium Sulphate
17 kg/cm2g PRESS. ABSORB. MEL-I Scheme Solu. to AS - II Plant
DECOMP. & COOLER
MEL-II (ECS)

130 oC LOW LOW

1.5 kg/cm2g PRESS. PRESS. Sulfuric Acid
DECOMP. ABSORB.
Urea-I Urea-II Urea Total
CO2 NH3/hr 5300 13200 18500
NH3 MT/hr 8.1 20.1 28.2
STEAM MT/hr 20.2 50 70.2
115 oC GAS GAS POWER KWH 2625 6500 9125
0.3 kg/cm2g SEP. COND. Gases to ECS Plant Capacity MT/D 323 800 1123

Ammonical
DM WATER effluent
110 oC OXIDIZIN from
atm. Press COLUMN UREA-I Effluent
To
UREA-II pumping Urea Lagoon
at Chalk Pond
MEL-I system OR
Gypsum Pond for
R
ZE

MEL-II Level make up &

LI
AL

pH control
ST
CY

E
G

PRILLING
U
IF

DRYER MELTER UREA PRODUCT

TR

TOWER
EN

UREA-I 323 MTPD

C

UREA-II 800 MTPD

TO MELAMINE PLANT

Group 3 Page 38
2.1 Introduction

Urea was first prepared synthetically in 1828 by Wobler from ammonia and cyanuric acid
and urea became the first organic compound prepared by synthesis from inorganic material. The
present method of synthesizing urea from ammonia carbon dioxide has been known in principle
since 1968 but commercial production by this method started in 1922 in Germany & in 1932 in
United States.

• Properties of Urea : NH 2 CO NH 2

• Mol wt. : 60.06

• Nitrogen Content : 46.6

• Color : White

• Specific Gravity : 1.335

• Melting Point : 132.7 Degree Celcius

• Angle of Repose : 23

• Bulk Density : 0.672 (gm / cm³)

Group 3 Page 39
2.2 Production Process

 All commercial production of urea is from CO2 and NH3 and the different method for
production of urea were adopted as follows:

o Once through process

o Partial recycle process

o Total recycle process

o Stripping process

 Mitsui Toatsu Total Recycle Process:

o GSFC – BARODA, ICI – KANPUR, ZUARI – GOA, NFL – PANIPAT –

BHATINDA, SPIC – TUTICORIN

 D.S.M. Total Recycle Process:

o DCM – KOTA

 Monti Adison Total Recycle Process:

o HFC – SINDRI, HFL – NANGAL

 CPI Allied Total Recycle Process:

o COROMANDAL FERTILIZERS

 Chemico Total Recycle Process:

o RCF-TROMBAY, MADRAS FERTILIZER

 DSM CO2 Stripping Process:

o IFFCO-KALOL & MANGLORE CHEMICAL

 Snampragetti NH3 Stripping Process:

o GNFC-BHARUCH, IFFCO-AONLA, IFFCO-PHULPUR, NFL-GUNA,

o KRIBHCO-HAZIRA, RCF-THAL-MUMBAI, INDOGULF-JAGDISHPUR

Group 3 Page 40
 Urea-I Urea-II

------------------------------------------------------------------------

 MT/Day MT/Year MT/Day MT/Year

 Capacity 323 1,03,000 800 2,64,000

 Process Know How: Mitsui Toatsu Toyo Koatsu, Japan

 Total Recycle “C” Process

 Detailed Engineering By: Toyo Engineering Corporation, Japan

 Product Specifications:

 Nitrogen By Wt. (Min.) 46.20 % 46.20 %

 Moisture By Wt. (Max.) 00.5 % 00.4 %

 Biuret By Wt. At 90 % load (Max.) 0.75 % 0.36 %

 Biuret By Wt. At 50 % load (Max.) 1.00 % 1.00 %

 pH of 10 % Solution 7 to 9 7 to 9

 Screen Analysis Min. (8-24 US Mesh) 95 % 95 %

 Raw Material And Utility Consumption Per MT of Urea:

 Ammonia Kg 585 580

 CO2 Kg 770 770

 Power KWH 180 165

 (excluding C.T. & Bagging Lighting)

 Steam MT 1.8 1.4

 Cooling Water in Circulation 137 MT at 31.7 0C 137 MT at 31.7 0C

Group 3 Page 41
2.3 Urea Reaction

NH2

CO

NH2

• 2 NH3+ CO 2  NH2COO NH4 + 38000 Cal

•  Ammonium Carbamate

• NH2 CO2 NH4  NH2 CO NH2 + H20 – 7700 Cal

• 

• 2 NH3+ CO2  NH2 CO NH2 + H20 + 30300 Cal / M

• B I U R E T (C2 O2 N3 H5 )

• NH2 CO NH2 + H HN CO NH2 _____ NH2 CO HN CO NH2 + NH3

• BIURET AMMONIA

– H

– N

• / \

• O=C C = O BIURET + 2H20  2CO2 + 3NH3

• \ /

• NH2 NH2

• NH2 CO NH2 + H HN CO NH2 _____ NH2 CO HN CO NH2 + NH3

• NH2 CO NH CO NH2 + H H N CO NH2 __ NH2 CO NH CO NH CO NH2 + NH3

• TRIURET

Group 3 Page 42
2.4 Difference in Urea Plant I and Urea Plant II

1. UREA-I

1.1 DRYING OF CRYSTALS IN ROTARY DRYER

1.2 MELTER AT GROUND FLOOR
1.3 LESS FLEXIBILITY DUE TO ONE CO2 COMPRESSOR
1.4 A-1 COOLING TOWER IS USED
1.5 PRILLING TOWER NOZZLES ARE HAVING 0.55 mm SIZE (SIEVE SIZE LIMITATION)
1.6 POWER & STEAM CONSUMPTION HIGHER THAN UREA-2 PLANT DUE TO CAPACITY
LIMITATION

2. UREA-II

1.1 DRYING OF CRYSTALS IN PNEUMATIC DRYER

1.2 MELTER AT PRILLNIG TOWER TOP
1.3 MCRE FLEXIBILITY DUE TO TWO CO2 COMPRESSORS AND ONE UREA-1 CO2
COMPRESSOR
1.4 UREA-II OWN COOLING TOWER
1.5 PRILLING TOWER NOZZLES ARE HAVING 0.60 mm SIZE (SIEVE SIZE)
1.6 POWER AND STEAM CONSUMPTION LOWER THAN UREA-1 DUE TO HIGH
CAPACITY

2.5 Process Description

In the G.S.F.C Limited there are two Urea Plants producing prilled fertilizer grade Urea
having capacity of 323 MT and 800 MT of Urea Per Day. Both the Urea Plants are engineered,
supplied and commissioned by M/s. Toyo Engineering Corporation – Japan, using MTC (Mitsui
Toatsue Corporation) total recycle “C” process.

The first Urea Plant No.1 (323 MTD) was commissioned in May-1967 and the 2nd Urea
Plant No.2 (800 MTD) in June-1969. The total Annual Capacity of Both Urea Plants are
3,67,200 MT.

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 The raw material required for the production of Urea is ammonia and carbon dioxide,
which is available from Ammonia group of plants. Ammonia is received at a pressure of 20
Kg/cm2 in liquid form while CO2 in gaseous form at a pressure 0.2 kg/ cm2. The Urea
Plant can be divided into four sections.

Process description of Urea-II Plant:

1. Synthesis Section
2. Decomposition Section
3. Concentration / Filtration
4. Finishing Section – Crystallization / Centrifuge
5. Drying, Melting & Prilling.
6. Recovery Section
7. Emission Control

2.4.1 Synthesis Section

Both the Reactants, ammonia and carbon dioxide are pressurised to 210 kg / cm2 With the help
of liquid ammonia high pressure reciprocating pumps and carbon dioxide reciprocating CO 2
compressor respectively & fed to the Reactor. The reactor is vertical, multi-layered Carbon
Steel & Titanium lined. The reaction between ammonia and carbon dioxide is carried out in
the reactor at temp. of 193 0C and at pressure of 210 kg/cm2 as follows:

(i) Carbamate Formation: 2 NH3 + CO2  NH2 COO NH4 + 38500 Cal.
(ii) Dehydration of Carbamate: NH2 CO NH4  NH2 CO NH2+H2O Urea

The first reaction of formation of ammonium carbamate is exothermic and is complete at reaction
condition but the second reaction of dehydration of carbamate to form urea is endothermic and
doesn’t go completion under all practical conditions.

Excess liquid NH3 is fed in the ratio of 4:1 to control the reaction condition and to increase the
conversion. The maximum conversion of CO2 to urea can be achieved 67 % only in this process.

Group 3 Page 44
 2.4.2 Decomposition Section

The liquid effluent from the reactor contains 29 % of urea only and rest is water, ammonia and
unreacted carbamate, biuret. To recover urea from the solution, the excess ammonia and
unconverted carbamate is reverted back to carbon dioxide and ammonia from the reactor
products. The decomposition of ammonium carbamate takes place in two stages at a pressure of
16 kg/cm2 in high pressure decomposer and 1.5 kg/cm2 in low pressure decomposer.

2.4.3 Concentration / Filtration

The urea solution from low pressure decomposer flows to the concentrator upper part
operating at a pressure of 0.3 kg/cm2g where last traces of ammonia and carbon dioxide are
removed and then flows down to the lower part.
In the lower part of the concentrator air is blown to remove moisture and oxidized
metallic impurities. The separated gas from the top of concentrator upper part goes to gas
condenser.

The urea solution from the concentrator is passed through pressure leaf filter coated with
diatomaceous earth to remove oil and metallic impurities.

2.4.4 Finishing Section – Crystallization / Centrifuge

The urea solution coming from filter enters the upper part of crystallizer. The crystallizer is
divided into two parts.
(1) The upper part is a vacuum evaporator with vacuum generator.
(2) The lower part is crystallizer where urea crystals are suspended in urea slurry. The vacuum
evaporator operate at 90 mm Hg absolute pressure and 60 0C. Temp.
Almost entire water in the supplied urea solution is vaporized at this condition. Urea slurry
(supersaturated urea solution) comes down from evaporator through barometric leg to
crystallizer which is operated at atmospheric pressure and 60 0C Temp.
And crystal growth takes place. Crystal’s farms are separated from the mother liquor by pusher
type centrifuges. A part of the circulation urea slurry is sent to the cooler of high pressure
absorber for heat recovery and from this cooler, it again come back to evaporator.

2.4.5 Drying Melting & Prilling

The urea crystal from centrifuges are conveyed and fed to the bottom of a fluidized bed
dryer-cum-pneumatic conveyor. Here urea crystal are dried and pneumatically conveyed (with

Group 3 Page 45
the help of induced draft fan) to the top of prilling tower where air and urea crystal are separated
in cyclones. The cyclone outlet air is washed and let into atmosphere.

The dry urea crystal are melted in steam heated melter (melting point of urea 133 0C) at
temp of 137 0C. The molten urea from the melter is sprayed inside the prilling tower with the
help of prilling nozzles which have numbers of holes of 0.6 mm diameter to form prills.
The prills are cooled down after travelling downwards distance of about 40 meters.
Through prilling tower with the help of ascending air. The final cooling temperature of 45 0C. Is
achieved at fluidized bed cooler (CFD). The prilled product is sent to Bagging Plant for bagging.

2.4.6 Recovery Section

In the recovery section, the gases from gas separator, upper part of ammonia recovery
column and ammonia feed pump are absorbed by urea mother liquor, dust chamber solution,
dissolving tank solution, ammonium carbamate (KT) solution and D. M. Water (or condensate)
in gas condenser.
The liquor from gas condenser is utilized to absorbed gases from low pressure
decomposer in the low pressure absorber. The liquor from the low pressure absorber cooler
(HAC) by spraying it over the lower packed section of the high pressure absorber.
The top section of high pressure absorber is having bubble cap trays & here the gases
CO2 and water vapours are absorbed in liquid ammonia and aqua ammonia.
The vapour from the top of high pressure absorber is essentially pure ammonia and goes
to ammonia condenser. The carbamate liquor from the bottom of the high pressure absorber goes
to cooler for high pressure absorber where it absorbs the incoming gases from the high pressure
decomposer.
The heat of absorption in gas condenser and low pressure absorber is removed by cooling
water and in case of high pressure absorber cooler, the heat of absorption is removed by
circulation of urea solution from crystallizer and cooling water. The solution from high pressure
absorber cooler is pumped to carbamate recycle pump and then it pumped to reactor.

2.4.7 Process Description

• Vent gases from oxidization column and gas condensers from both Urea Plants and off
gases from Melamine – 1 & 2 plants are joined together and pass through knockout drum
to separate the ammonical condensate.
• The condensate is transferred to vapour liquid separator by gravity with liquid seal to
prevent back flow of gas.
• The vent gases at pressure of 0.1 kg/ cm2 and 100 degC temperature enter shell side of
off gas condenser in which part of water vapour is condensed with cooling water in
tube side.
• The outlet gas temperature is maintained at 65~70 0C. temperature to prevent choking
due to urea entrainment from the process.

Group 3 Page 46
 • The vent gases from off-gas condenser enter the vapour liquid separator where
ammonical condensate having 3~4 % ammonia is separated from vent gases.
• This ammonical condensate is further recycled in scrubber circulation loop for utilization.
There is also provision to use this ammonical condensate in process for emergency
disposal.
• The vent gases from vapour liquid separator fed to scrubber.
• The scrubber has two zones. Bottom zone is packed with PP poll rings to a height of 3
mtr and top zone is having bubble caps for final scrubbing with DM water.
• The scrubber solution from bottom of scrubber is neutralized with 98 % H2SO4 in an
acid mixing tee and then pumped through circulation pump to scrubber liquor circulation
cooler.
• The cooled solution at temperature of 40 degC. is recycled in scrubber at top of packing.
A part of scrubber liquor is exported to A.S. Plant through auto level controller of
scrubber.
• pH of circulating liquor is maintained in acidic range (3.5~4.5) to have best scrubbing of
ammonia.
• The concentration of A.S. solution is maintained by addition of DM Water at scrubber
top.

Group 3 Page 47
 3. Heat Exchanger Designs

3.1 Data
3.1.1 Chemical Data:
Tube Side:

 Cold Fluid : Cooling water

 µ (viscosity) : 0.734 Centi Poise
 Cp (Heat Capacity) : 4.178 Kj / Kg K
 K (Conductivity) : 0.628 W / m2 K
 Inlet Temperature (Tin) : 320 C
 Outlet Temperature (Tout) : 370 C
 Average Temperature (Tavg) : 34.50 C
 Density : 994.43 Kg / m3
 Flow Rate : 74.2855 Kg / Sec
 Pr no : 4.88320

Shell Side:

 Hot Fluid : DM water

 µ (viscosity) : 0.576 Centi Poise
 Cp (Heat Capacity) : 4.18 Kj / Kg K
 K (Conductivity) : 0.628 W / m2 K
 Inlet Temperature (Tin) : 550 C
 Outlet Temperature (Tout) : 400 C
 Average Temperature (Tavg) : 47.50 C
 Density : 989.36 Kg / m3
 Flow Rate : 24.75 Kg / Sec
 Pr no : 3.83388

3.1.2 Mechanical Data:

 Outer Diameter (Do) : 31.75 mm
 Inner Diameter (Di) : 25.4 mm
 No of Tubes (Nt) : 278
 Length of Pipe (Lp) : 16-ft i.e.(4.876 meters)

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3.2 LMTD (logarithmic Mean Temperature Difference)

–
 –

–


 0
C = 12.33 0 C

 Therefore Correction factor ( Ft = 0.93 )

o ΔTm = LMTD * Ft = 11.498 0 C

3.3 Heat duty (Q)

Q = mCpΔT

Q = 24.75 * 4.18 * (55-40)

Q = 1551825 K / Joules

3.4 Assuming the Heat transfer Coefficient `U`

 U for water can be assumed between 900 – 1100 W / m2 K
 Assuming the U for above calculation to be 1000 W / m2 K

Group 3 Page 49
3.5 Tube Side Calculations:
Area:




Mass Velocity:




Reynolds No:



 Re > 4000 i.e. Turbulent flow

Nussle Number:





Heat Transfer Coefficient [ Hi ]:





Group 3 Page 50
3.6 Shell Side Calculation:
Considering the Triangular Pitch.





Tube Bundle Diameter:




Where K = 0.0743, n = 2.44 Constants taken from the design charts.

Shell Diameter:





Baffle Spacing:





Area:





Group 3 Page 51
 Mass Velocity:




Equivalent Shell Diameter:



 22.8933 mm

Reynolds No:




Nussle Number:

(Jh = 0.022) From graph





Heat Transfer Coefficient [ Ho ]:





3.7 Overall heat transfer coefficient calculated:


Ucal = + + + * + *


Ucal = 1104.52

Group 3 Page 52
3.8 Percentage Over Design:
 Uassume = 1000 W / m2 K
 Ucalculated = 1104.54 W / m2 K



3.9 Pressure Drop:

3.9.1 Tube side pressure Drop:




3.9.2 Shell side pressure drop:
ΔPs = 8*Jh*( *( *(

ΔPs = 10.95 Kpa

1.58 PSI

3.10 Area Required:


Δ



Thus this Design is calculated using the classical methods of chemical engineering mention
above.

Group 3 Page 53
3.11 Calculated using Automated Excel Sheet

4 Application and Uses

Use of Urea:

 Major use as a fertilizer

 For the cattle feed as a source of protein
 In the manufacturing of urea-formaldehyde resin
 A cloud seeding agent, along with salts, to expedite the condensation of
water in clouds, producing precipitation
 In the manufacturing of potassium cyanate
 Raw material for the production of melamine
 A stabilizer in nitrocellulose explosives

Group 3 Page 54
References

o https://www.gsfclimited.com/urea.asp?mnuid=3
o https://lakeland.edu/PDFs/MSDS/1273/Urea%20(Fisher).pdf
o http://www.ich.co.za/MSDS%20-%20Urea.pdf
o https://en.wikipedia.org/wiki/Urea
o https://pubchem.ncbi.nlm.nih.gov/compound/Urea
o http://www.afrox.co.za/en/images/Ammonia%20%28Rev%203%29_tcm266-27591.pdf
o http://www.igs-cymaco.be/pdf/4_en.pdf
o https://byjus.com/chemistry/uses-of-ammonia/
o https://www.osha.gov/Publications/osha3138.html
o https://ehs.fiu.edu/_assets/docs/industrial-safety/what-is-a-hot-work-permit.pdf
o https://www.convergencetraining.com/line-breaking-safety.html
o https://www.gsfclimited.com/melamine.asp?mnuid=3
o www.gsfclimited.com
o http://www.melamin.si
o www.forbesmarshall.com

Group 3 Page 55