Industrial Training Report

On

Ammonia Synthesis Completed

At Indian Formers Fertilizers Co-operative Ltd. Unit: Phulpur Allahabad

By: Ravi Kumar Chaudhary 0605251015 Sandeep Kumar Verma 0605251016 Submitted To: Er. Isha Srivastava

Department Of Chemical Engineering Institute Of Engineering and Technology Lucknow

23

One Month Industrial Training Report

On

Ammonia Synthesis
Completed
At

Indian Formers Fertilizers Cooperative Ltd.

Submitted At Partial Fulfillment for Award of Degree in Bachelor of Technology in Chemical Engineering

Unit: Phulpur Allahabad

Submitted By: Sandeep Kumar Verma 0605251016 Ravi Kumar Chaudhary 0605251015
23

23

23

ACKNOWLEDGEMENT

I am indebted to many IFFCO employees and personnel who directly or indirectly helped me in giving valuable information and process knowledge of the plant. I greatly acknowledge Shri. DC VAISHYA under whose guidance I completed my training. I would like to thanks Dr.D.N.VERMA (training officer) who with utmost cooperation provided all the relevant text and reference material for sound grasping of the entire important features of IFFCO Phulpur Plant. He helped me in each moment of my training period in every possible ways to make my training period hassle free and fruitful.

23

CONTENTS

1. AN INTRODUCTION TO IFFCO 2. IFFCO PHULPUR UNIT AT GLANCE 3. ADVANTAGES OF USING RLNG 4. MARKETING IN IFFCO 5. AMMONIA PROCESS OVERVIEW 6. AMMONIA PLANT-1 PROCESS IN BRIEF 7. THERMODYNAMICS REACTION 8. SYNTHESIS CONVERTER 9. MISCELLANEOUS 10. HONOURS OF IFFCO ASPECTS OF AMMONIA SYNTHESIS

23

AN INTRODUCTION OF IFFCO IFFCO (Indian farmer fertilizers cooperative ltd.) was set on November 3. 1967 as a modest venture with an authorized capital of Rs.200 crore. It has over years emerged as the singularly successful enterprise with its total investment standing at Rs. 1150 crores as a cooperative institution it has grown into a biggest society in the whole of Asia as an industrial enterprise. IFFCO commissioned the ammonia urea complex at Kalol and the NPK/DAP plant at Kandla both in state of Gujarat in 1975. Ammonia urea complex was set up at Phulpur in Uttar Pradesh in 1981 the third ammonia urea unit at Aonla was commissioned in1988 the annual installed capacity of all the plants was 1.62 million tonne of urea and NPK/DAP Equivalent to 309 thousands of phosphates till 1993. In 1993 IFFCO had drawn up a major expansion program of all the four plants under overall aegis of IFFCO VISION 2000. The expansion projects at Aonla Kalol and Phulpur have been completed on schedule. The latest feather in the cap of IFFCO was completion of all the Kandla phase-2 on 5th August 1999 which has heralded realization of all the objectives set forth under vision 2000. as per the tradition of IFFCO the project was completed more than two months ahead of schedule as a result of these expansion projects IFFCOs annual installed capacity has been increased to 3.22 million tonne urea and NPK/DAP equivalent to 519.7 thousand tonne of phosphates the distribution of IFFCOs fertilizer is undertaken through over 35000, co operative societies, the entire activities of distribution, sales and promotion are coordinated by the marketing centre office(MKCO) at NEW DELHI assisted by the marketing offices in the field in addition to essential agro inputs for crop production are made available to the farmers through a chain of 167 farmers service centre (FSC) IFFCO obsessively nurtures its relation with farmers and undertakes a large number of agricultural extension activities for their benefit every year.

23

IFFCO today is a leading player in INDIA fertilizer industries and is making substantial contribution in the country. This organization is certified by ISO 9001 for quality management and ISO 14001 for environment management. Recently IFFCO has started a new project regarding insurance with the collaboration of Tokyo named IFFCO-TOKYO general insurance company and planned it through out the country. A new urea plant is also planned to open in OMAN with the help of another cooperative society KRIBHCO .All the product will be marketed by IFFCO in India to meet the countrys fertilizer need. The success of IFFCO has set up a pace for organizing another cooperative organization on the same pattern in 1980. IFFCO has promoted the KRISHAK BHARTI CO OPERATIVE LTD. (KRABHICO) with an authorized capital of 500 crore / with a contribution of 100 crore towards equity of this new venture. IFFCO along with government of ANDHRA PRADESH promoted a company in the joint sector namely GFCL (GODAVARI FERTILIZER CHEMICAL LIMITED) and established a plant at Kakinada at the cost of 108 crore IFFCO along with spice and GOVT.OF INDIA participated in a joint venture project executed by industries ICS OF SENEGAL and there is an agreement to supply 1.00 lakh tonnes of p205 annually to India from 1984 IFFCO had been receiving shipments of phosphoric acid from Senegal.

23

IFFCO PHULPUR UNIT AT A GLANCE Phulpur fertilizer unit is LNG (liquefied natural gas) based in which it is used as a fuel as well as a feed .It is being supplied from gas pipeline commonly known as HBJ by GAIL(GAS AUTHORITY OF INDIA LIMITED) from Thuledi near Jagdishpur to Phulpur distancing almost 140 km. Coal supplies for the power plant are received from central coal field ltd. through railway wagons. Raw water is pumped from bore wells located around the factory and township. Electricity meant for the plant is generated in the power plant for reliability. It also receive from UPSEB. Major inputs of this plant are as following. RLNG supplied at a pressure of 40.2 kg/cm2. COAL 1200 MTPD

WATER 2400 MTPD GENERATED POWER 12.5 MWPer hr PRODUCTION AT IFFCO PHULPUR : Urea production capacity of P-1= 2015 TPD Urea production capacity of P-2=3030 TPD

23

ADVANTAGES OF USING RLNG 1. RLNG consists of mostly lower hydrocarbons (mainly CH4 or methane as a major component) having higher percentage of hydrogen thus having increase in amount of hydrogen for syngas. 2. No need of desulphurization section as sulphur present in it is in traces. 3. Maximum yield is achieved in terms of steam reforming of hydrocarbon. No carbon formation takes place on reforming catalyst. 4. Transportation cost is very low as it is supplied through gas pipeline. 5. More savings with the use of RLNG as fuel. It is estimated that there shall be saving in government subsidy to the tune of Rs. 658 crore per year with the use of RLNG.

23

]MARKETING IN IFFCO IFFCOs marketing is broad based and it strives to improve the socio economic status of rural people through more than 35000 cooperatives spread over in 22 states and 2 union territories IFFCO has strengthened its marketing by establishing more than 168 farmers service centres to provide essential agriculture inputs under one roof. The marketing division was awarded ISO 9002 certificate for marketing fertilizer strengthening cooperatives and providing services to farmers and rural community. The IFFCO Phulpur plant consists of following 1. Ammonia plant 2. Urea plant 3. Steam and power plant 4. Water treatment plant 5. Cooling towers 6. Inert gas plant 7. Instrument plant and air 8. Ammonia storage and bagging 9. Coal and ash handling 10. Urea storage and bagging 11. Reverse osmosis plant

23

AMMONIA PROCESS OVERVIEW Commercial synthetic ammonia production started in 1913 and has become a large industry by chemical standards; 2005 world production approached 143 million metric tons. Commercial ammonia synthesis chemistry and catalyst are still based directly on the original developments by Haber and Bosch; variations in reaction equipment, operating conditions, and process schemes, however, have proliferated through the years. Most of the worlds ammonia output is synthetic material manufactured by combining hydrogen and nitrogen over a catalyst according to the following equation:

The following sections summarize the feed stocks and methods commonly used in the preparation of synthesis gas (containing hydrogen and nitrogen in a 3:1 mole ratio), that is then fed to a converter where it is catalytically transformed into ammonia. Feed stocks for Ammonia Synthesis: Air is the ultimate source of nitrogen, and methane or heavier hydrocarbons are usually the main source of hydrogen. Of the hydrogen feedstock sources - natural gas, coal, and petroleum fractions - natural gas is the most often employed in commercial ammonia plants, representing about 90 percent of world production. A few commercial plants exist (one in Zimbabwe) that produce hydrogen for ammonia by electrolysis of water; this route requires extremely inexpensive electric power and is rarely used. Natural gas is favoured for several reasons: its availability and ease of delivery as an inexpensive feedstock, its high hydrogen content, and the simplicity and relative lack of expense of plants designed for natural gas. As inexpensive natural gas becomes more available in developing, export oriented regions, the percentage of natural gas based plants will rise even higher. Most ammonia is produced from gas, although other feed stocks are used, such as coal in China.
23

Hydrogen Production: Hydrogen is produced by steam reforming of natural gas (mainly methane) and is schematically represented by the following reaction:

A large amount of heat must be supplied to force reaction 1 in the desired direction. In the primary reformer, heat is externally supplied by burning fuel at an efficiency of about 30 to 40 percent in the radiant zone. In the secondary reformer, heat is generated by partial oxidation of reactants by mixing compressed air with the primary reformer effluent. The oxygen in the air burns some of the process gas and releases heat at efficiency close to 100 percent. At the same time, the nitrogen required for ammonia synthesis is introduced to the process with the air. As shown in equation 1, carbon monoxide is also produced. The next step in hydrogen production is to react carbon monoxide with water to produce hydrogen. This step is called the water/gas shift conversion and is represented by the following reaction:

The purpose of reactions 1 and 2 is to produce a synthesis gas (syngas) that contains hydrogen, nitrogen and carbon dioxide. However, neither equation 1 nor 2 ever goes completely to the products shown on the right hand side. So, there is always some unreacted methane and carbon monoxide left in the synthesis gas. The argon and other inerts that enter the secondary reformer with the air will also be present in the syngas produced.

23

Synthesis Gas Purification: The raw syngas leaving the hydrogen production section must be purified before it is suitable as feed to an ammonia synthesis reactor. The impurities in the syngas include carbon dioxide, carbon monoxide, water, methane, and argon. The first purification step is carbon dioxide removal. This step is accomplished through one of a variety of processes that are available, such as Benfield and activated MDEA. Typically, these processes reduce the carbon dioxide content of the syngas from about 20 percent to less than 0.1 percent. This is done by contacting the syngas with a liquid that either chemically reacts with, or physically dissolves, the carbon dioxide. The syngas leaving the carbon dioxide removal step contains traces of unreacted carbon monoxide from reaction 2 and residual carbon dioxide from the previous step. Since oxygen bearing compounds would poison the ammonia synthesis catalyst, they must be removed. The process step that removes the carbon oxides is methanation. This chemical reaction converts carbon oxides to methane via the two equations shown below:

At this point in the purification sequence, the remaining impurities in the syngas are methane, water, and argon. These impurities may be removed by a variety of techniques, such as by cryogenic treatment or purged out from the downstream ammonia synthesis section. Ammonia Synthesis: The synthesis gas leaving the purification section is compressed before feeding it to the ammonia synthesis loop where it is combined with recycle gas.This mixture is fed directly to the ammonia converter, where ammonia is formed according to the reaction:
23

The synthesis reaction is favoured by high pressure, but the conversion per pass is limited by reaction equilibrium constraints resulting in unreacted synthesis gas leaving the ammonia converter. The effluent from the ammonia converter is cooled to condense and separate liquid ammonia from unreacted syngas. Part of this cooling duty is supplied by either air or water cooling, and the balance is provided by a mechanical refrigeration system. The separated unreacted syngas is returned to the ammonia converter as the recycle gas referred to above. AMMONIA SYNTHESIS LOOP DETAILED DESCRIPTION

Syngas compression: The pure syngas is compressed in a turbine driven two case centrifugal compressors. Intercase cooling and chilling is provided for optimum volumetric efficiency and also to condense out water of saturation and simplifying the mechanical design of second case and reducing the horse power of the machine. A side stream from first case is sent to desulphuriser. Recycle gas from synthesis loop containing 12 vol. % of NH3 is admitted in the last wheel of second case and mixes with pure syngas and undergoes final stages of compression to approximately 155 kg/cm2. The compressor outlet gases at 68 C are cooled with cooling water in syngas compressor after cooling to 46 C. The syngas from compressor has following composition: Component H2 Mol% 58.27

23

N2 NH3 CH4 A

19.3 9.92 8.68 3.83

Chilling and ammonia separation: The makeup gas/recycle gas mixture under conditions mentioned above now flows to the NH3 synthesis loop through a motor operated block valve MOV-1. The gas is cooled successively to lower temperature to condense and separate the NH3 contained in the gas. The gas is split into two streams to reduce loop pressure drop and recover refrigeration. The major flow passes through the tube sides of feed and recycles gas first stage and second stage chillers in succession and is cooled to 22 C in first chiller and then to 1 C in second chiller. The minor stream flows to shell side of converter feed/ feed and recycle gas exchanger where it exchanges heat with cold stream of ammonia separator outlet gases. The gas cools down to -9 C. A hand control valve controls the flow through this exchanger. The gas stream again combines together and enters the tube side of feed and recycle gas third stage chiller here the gas is cooled to 23.3 C. Gas flow now enters ammonia separator. All the condensed NH3 in the gas is separated here. The NH3 separated here forms the main part of product NH3. Along with liquid NH3 the water vapours contained in syngas together with small traces of CO2 left after methanation are also removed in this separator. This serves as another purification step for the gas before entering the converter catalyst bed. Converter feed leaving NH3 separator enters the tube side of a converter feed/ feed recycle gas exchanger and gains heat from a part of the incoming feed. Gas temperature is around 24 C after this exchanger, the gas flows to converter effluent exchanger where temperature is raised to 140 C. Gas entering synthesis converter has following composition:

23

Component H2 N2 NH3 CH4 A Synthesis converter:

Mol% 63.34 20.98 2.08 9.43 4.17

Synthesis converter consists of a high pressure shell containing a catalyst section and a heat exchanger. The catalyst section is a cylindrical shell which fits inside a pressure shell and is called the basket. The basket contains four catalyst beds, each supported on screen covered grids. Top bed is the smallest with each succeeding bed containing greater volume to limit the exothermic heat of reaction which is sharpest in the upper beds. The catalyst basket leaves an annular space between basket and the pressure shell. The main inlet to the converter is at the bottom of the pressure shell and converter feed flows upward through the annular space to the shell side of converter interchanger at the top. It is recommended to have a flow through annular space always to reduce heat flux from the basket to shell so that converter shell is maintained within design temperature limit. In the converter interchanger gas picks up heat from the hot converter effluent stream while circulating around the exchanger tubes. For temperature control of the top bed at 410 C a part of the feed can be directly introduced to the top bed which by passes the exchanger and acts as quench for first bed. The combined stream passes into first catalyst bed at the prevailing pressure of 141 kg/cm2 and 410 C, the ammonia synthesis reaction takes off and proceeds in the catalyst bed with a sharp temperature rise to 497 C. The gases pass through the grid supporting the next bed.

23

In order to maintain catalyst temperature at desired levels and thereby achieve maximum yield, provision is made to inject to feed gas as quench in the space between each catalyst bed. These quench flows; by passing the converter interchanger can be conveniently controlled. Inter bed quenching has additional advantages is that it provides for exceptionally good temperature control and operating flexibility which promotes maximum formation of product, eliminate catalyst hot spots, and thus contributes to long catalyst life. There are temperature recorders and indicators for every bed. The gas flows downward through all the bed at optimum temperature. The outlet temperature of 2nd, 3rd, 4th bed is likely to vary between 460 470 C. Hot gases after reaction at about 470 C leave the bottom catalyst bed and passes up through a centre return pipe into the tubes of converter interchanger to give up heat to the incoming feed. The gas leaves the converter at a pressure of 141 atm. and temperature of 287 C with nearly the following composition. Component H2 N2 NH3 CH4 A Mol% 54.93 18.16 12.00 10.34 4.57

NH3 synthesis reaction is not a once through process. The conversion rate is hardly 21% so the H2: N2 mixture contained in the gas is again recycled back to converter after removing product ammonia and making up the pressure. Converter effluent from interchanger exchanges heat with boiler feed water (from deaerator) and gets cooled to 165 C in ammonia converter boiler feed water heater.

23

It then flows to ammonia converter feed/ effluent exchanger and exchanges heat with the incoming feed and gets cooled to 43 C. The gas called recycle gas goes to the last wheel of second case of synthesis gas compressor. The whole process as mentioned above, from synthesis gas compressor discharge to the suction of the recycle gas stage in closed circuit system is termed as ammonia synthesis loop.

AMMONIA PLANT-1 PROCESS IN BRIEF This single stream plant is based on the Kellog Process with Reliquified Natural Gas as a raw material. The manufacture of Ammonia involves the following 6 basic steps: 1. Primary Reforming 2. Secondary Reforming 3. CO conversion 4. CO2 Absorption And Removal Of CO2 5. Methanation 6. Ammonia Synthesis 7.Refrigeration 1.PRIMARY REFORMING: Primary reformer furnace is a rectangular box structure lined internally with refractory from all the sides to serve the radiant section and a refractory lined rectangular duct as the convection section.

23

The Primary Reformer consists of a 336 tubes suspended in 8 rows of 42 parallel tubes each,in the radiant section.Each row of tubes terminates in a manifold placed within the radiant section of furnace.There are 8 centrally located risers one on each of these manifolds.These risers lead the gas flow to a water jacketed transfer line located over the top of the Primary Reformer furnace. As the reforming reaction is endothermic, heat is supplied externally to the tubes.There are 9 row of top gas fired with 18 burners in each row in the Primary Reformer radiant section.There are 9 tunnels at the floor level with holes on the sides for the hot flue gas to enter.These 9 tunnel burners are also provided so as to raise the flue gas temperature going to the convection section as per requirement. RLNG is mixed with superheated steam and is preheated with the flue gas of primary reformer furnace and is sent to the primary reformer catalyst tubes packed with nickel based catalyst and operating elevated temperature 800-812C and pressure of 31.6kg/cm2 at the outlet of the primary reformer.The hydrocarbon and steam react to form H2, CO, CO2 and residual CH4.The reaction being endothermic,heat is supplied to the catalyst tubes by burning RLNG externally outside the tubes. Since the reforming reaction is endothermic,an increase in reforming temperature will favour the reforming reaction there by reducing the CH4 content and CO2 content in the outlet gas.The expected design outlet temperature is 812C. The steam reforming of gas is a very complex reaction.Some of the gas compounds are broken down by the thermal catalytic cracking into simpler hydrocarbon such as CH4.These simpler hydrocarbons are further reformed through the steam CH4 reaction. Catalyst: - Nickel Temperature: - 800-812 C Pressure: - 31.6 kg/cm2

23

Reaction: -

CH4

H2O + heat = CO + 3H2 = CO2 + H2 + heat H2,CO,CO2,CH4&N2

CO + H2O Effluent:-

2.SECONDARY REFORMING: Partially reformed gas from the water jacketed transfer line is directed to the refractory lined and water jacketed secondary reformer tangentially.The compressed process air supplied by the process air compressor at a pressure of 33kg/cm2 and 176C is preheated to 482C in the steam preheater coil located at the primary reformer convection zone to recover the heat in the flue gas.The air is added to furnish the N2 requirement for ammonia synthesis in the secondary reformer. The purpose of the secondary reformer is to reform the unconverted CH4 coming out of the primary reformer as well as to introduce the necessary quantity of N2 to the process stream.Reformed gas is partially burnt with oxygen in the air and the heat of combustion is utilized for the endothermic methane reforming reaction,at the sane time supplying required quantity of nitrogen to make synthesis gas containing H2,CO,CO2,N2 and a small quantity of CH4 is obtained. Reformed gas from the primary reformer enters the secondary reformer top portion through transfer line.The gas enters at 812C and 31.3kg/cm2 and flows down through the annular space of process air inlet pipe and the top heat liner.Preheated air at 468C is introduced to the process through a mixer burner below passing straightening vanes through the air inlet pipe.After the ignition,the hot gases at a temperature of 1238C pass through the catalyst beds. Catalyst: - Chromia at top and nickel at bottom Temperature: - 1238 C
23

Reaction: - 2H2 + AIR (O2 + 3.8N2) =2H2O + 3.8N2 + heat CH4+5AIR (O2+3.8N2) =CO2+2CO+6H2O + 19N2 + heat 2CH4 +3H2O + heat = CO + CO2 +7H2

Effluent: - H2, N2, A, CO, CO2, CH4

3.CO CONVERSION: HIGH TEMPERATURE SHIFT CONVERSION: Hot reformed gases from the secondary reformer are cooled by heat recovery in three waste boilers producing HP stream.Then it enters High Temperature Shift Converter at about 30.5kg/cm2 and temperature 371C through the catalyst bed.In the presence of iron-chromium catalyst,CO reacts with steam to form CO2 and H2.The temperature rises as the reaction is exothermic. Catalyst: - Iron-Chromium Temperature: - 371C Pressure: - 30.5 kg/cm2 Reaction:CO + H2O = CO2 + H2 + heat

LOW TEMPERATURE SHIFT CONVERSION: After heat recovery gas at a comparatively lower temperature 200C is introduced in Low Temperature Shift Converter where in the presence of copper-zinc catalyst the water gas shift reaction proceeds and CO content in gas mixture brought down fron 3.3% to around 0.3% by volume. Catalyst: - Copper Zinc Temperature: -236 C
23

Pressure: - 28.2 kg/cm2 Effluent:- H2,N2,A,CO,CO2,CH4 The gas comes out of LTS at following approximate conditions: Pressure=28.2kg/cm2, Temperature=236C 4.CO2 ABSORPTION: The gas leaving the CO conversion section,consist mainly H2,N2,CO2 and steam.This is cooled in exchangers and condensate from gas is separated out.The raw synthesis gas at pressure of 27.5kg/cm2 and 82C containing 22.7%dry volume CO2 is introduced at the bottom of CO2 absorber tower where a counter current stream of benefield solution absorbs CO2 from the gas.The raw synthesis gas free from CO leaves the absorber.The absorber of CO2 by benefield solution involves the following reaction: K2CO3+H2O+CO2=2KHCO3 A 27% Potassium Carbonate solution enriched with 3% of diethanolamine as an activator and 0.3 to 0.5% of vanadium pentaoxide as corrosion inhibitor is called the Benefield solution and is a good reagent for CO2 absorption and the process is known as Benefield Process. REGENERATION OF BENEFIELD SOLUTION: The purpose of CO2 stripppers is to regenerate Benefield solution for reuse in the CO2 absorber.The Benefield solution which has absorbed the CO2 is regenerated in a pair of CO2 stripper tower.The strippers operate at 0.9kg/cm2 pressure and at 125C at bottom.Reboiling heat is supplied by two sets of reboilers namely the gas boilers and the steam boilers.The solution from the strippers is heated to 125C and by thermo siphoning the vapour solution mixture returns to the strippers from the top of reboilers. In the first three beds from the top the down coming rich solution comes in intimate contact with hot liberated CO2 and water

23

flowing upwards and bicarbonate gets converted to carbonate under the action of heat and low CO2 partial pressure: 2KHCO3=K2CO3+CO2+H2O The remainder of the partially regenerated Benefield solution flows downward to the stripper bottoms through the 4th bed and gets regenerated to lean solution and collects at the strippers bottom and is cooled to 117C in the tubeside of lean solution BFW exchanger 107C. A major portion of partially regenerated solution is withdrawn from the level hold up maintained below the third bed of CO2 stripper and is pumped to the middle of CO2 absorber as semi lean solution at a temperature of 116C with the help of two semi lean solution pumps. Semi lean partially regenerated solution is taken from an intermediate point of the CO2 strippper by the semi lean carbonate circulating pumps and fed to distributor provided on the top of the third bed of the absorber. The partially cooled lean carbonate solution is withdrawn from the CO2 strippers bottom by lean carbonate solution circulating pumps and is directed through a distributor over the top bed of absorber at a temperature of 70C.The flow rate is 261M3/hr gas leaving absorber top contains 0.05% CO2. A portion of semi lean carbonate solution is withdrawn from a trapout pan below the third bed of packing by circulating pump and returned to the absorber mid section.The balance of the carbonate solution continues down through a bed of 25mm packing in each stripper tower. Solution moves to the bottom of this solution where it accumulates on a trap out pan from which it flows into the CO2 stripper reboilers for regeneration. The stripped CO2 saturated with water vapours at 107C leaves the top of the stripper and flows to the CO2 stripper condenser and is cooled with cooling water to 40C.The condensed water vapours in
23

the gas is separated in the CO2 stripper reflux drum.The CO2 saturated with waters vapours is sent to Urea Plant.

5.METHANATION: In the methanation step final traces of carbon oxides present in the process gas leaving the absorber is converted into CH4 by reacting with H2 present in process gas in presence of a nickel catalyst at a temperature of around 300C.The oxides of carbon are poisons for the ammonia synthesis catalyst and are therefore required to be eliminated.At the exit of methanator a pure synthesis of H2:N2 mole ratio of 3:1 is obtained with less than 1%CH4, which is eventually purged from the synthesis loop. Catalyst: - Nickel Temperature: - 300 C Reaction: - CO + 3H2 = CH4 + H2O + heat CO2 + 4H2 = CH4 + 2H2O + heat Effluent: - H2, N2, CH4, A, CO+CO2 (in traces) The hot methanator outlet gas is cooled in two steps in Methanator BFW Heater,where it is cooled to 134C and then by cooling water in Methanator Effulent Cooler to 38C.The gas then flows to synthesis gas compressor suction drum.The condensate collected in compressor suction drum and the purified synthesis gas leaving the drum is sent to synthesis gas compressor.

6.COMPRESSION AND AMMONIA SYNTHESIS: The pure synthesis is compressed in a two case centrifugal compressor driven by a back pressure condensing steam turbine to a final pressure 155kg/cm2.Recycle gas(12%vol % of ammonia)

23

from synthesis convertor outlet is introduced at the last stage of compression. The compressor outlet gas at 68C is cooled with cooling water in synthesis gas compressor after cooler to 46C. The synthesis gas from compressor discharge has approximately the following composition: Component H2 N2 CH4 NH3 Mol% 58.27 19.30 8.68 9.92

The make up gas/recycle gas mixture under the conditions mentioned above now flows to the ammonia synthesis loop.The compressed gas mixture is cooled,chilled successively in three ammonia refrigerated chillers operating at successfully lowered temperature to condense and separate the ammonia contained in the gas. The gas is split into two streams to reduce loop pressure drop and recover refrigeration. The major flow passes through the tube sides of feed and recycles gas first stage and second stage chillers in succession and is cooled to 22 C in first chiller and then to 1 C in second chiller. The minor stream flows to shell side of converter feed/ feed and recycle gas exchanger where it exchanges heat with cold stream of ammonia separator outlet gases. The gas cools down to -9 C. A hand control valve controls the flow through this exchanger. The gas stream again combines together and enters the tube side of feed and recycle gas third stage chiller here the gas is cooled to 23.3 C. Gas flow now enters ammonia separator. All the condensed NH3 in the gas is separated here. The NH3 separated here forms the main part of product NH3. Along with liquid NH3 the water
23

vapours contained in syngas together with small traces of CO2 left after methanation are also removed in this separator. This serves as another purification step for the gas before entering the converter catalyst bed. Converter feed leaving NH3 separator enters the tube side of a converter feed/ feed recycle gas exchanger and gains heat from a part of the incoming feed. Gas temperature is around 24 C after this exchanger, the gas flows to converter effluent exchanger where temperature is raised to 140 C. Gas entering synthesis converter has following composition: Component H2 N2 NH3 CH4 SYNTHESIS CONVERTER: Synthesis converter consists of a high pressure shell containing a catalyst section and a heat exchanger. The catalyst section is a cylindrical shell which fits inside a pressure shell and is called the basket. The basket contains four catalyst beds, each supported on screen covered grids. Top bed is the smallest with each succeeding bed containing greater volume to limit the exothermic heat of reaction which is sharpest in the upper beds. The catalyst basket leaves an annular space between basket and the pressure shell. The main inlet to the converter is at the bottom of the pressure shell and converter feed flows upward through the annular space to the shell side of converter interchanger at the top. It is recommended to have a flow through annular space always to reduce heat flux from the basket to shell so that converter shell is maintained within design temperature limit. In the converter interchanger gas picks up heat from the hot converter effluent stream while circulating around the exchanger tubes. For temperature control of the top bed at 410 C a part of the feed can
23

Mol% 63.34 20.98 2.08 9.43

be directly introduced to the top bed which by passes the exchanger and acts as quench for first bed. The combined stream passes into first catalyst bed at the prevailing pressure of 141 kg/cm2 and 410 C, the ammonia synthesis reaction takes off and proceeds in the catalyst bed with a sharp temperature rise to 497 C. The gases pass through the grid supporting the next bed. In order to maintain catalyst temperature at desired levels and thereby achieve maximum yield, provision is made to inject to feed gas as quench in the space between each catalyst bed. These quench flows; by passing the converter interchanger can be conveniently controlled. Inter bed quenching has additional advantages is that it provides for exceptionally good temperature control and operating flexibility which promotes maximum formation of product, eliminate catalyst hot spots, and thus contributes to long catalyst life. There are temperature recorders and indicators for every bed. The gas flows downward through all the bed at optimum temperature. The outlet temperature of 2nd, 3rd, 4th bed is likely to vary between 460 470 C. Hot gases after reaction at about 470 C leave the bottom catalyst bed and passes up through a centre return pipe into the tubes of converter interchanger to give up heat to the incoming feed. The gas leaves the converter at a pressure of 141 atm. and temperature of 287 C with nearly the following composition. Component H2 N2 NH3 CH4 Mol% 54.93 18.16 12.00 10.34

NH3 synthesis reaction is not a once through process. The conversion rate is hardly 21% so the H2: N2 mixture contained in the gas is again recycled back to converter after removing product ammonia and making up the pressure. Converter effluent from interchanger exchanges heat with boiler feed water (from
23

deaerator) and gets cooled to 165 C in ammonia converter boiler feed water heater. It then flows to ammonia converter feed/ effluent exchanger and exchanges heat with the incoming feed and gets cooled to 43 C. The gas called recycle gas goes to the last wheel of second case of synthesis gas compressor. The whole process as mentioned above, from synthesis gas compressor discharge to the suction of the recycle gas stage in closed circuit system is termed as ammonia synthesis loop. The ammonia synthesis reaction taking place at elevated temperature and pressure in presence of a promoted iron catalyst can be depicted as below: N2+3H2=2NH3+Heat As the reaction is exothermic,a rise in temperature lowers the equilibrium % of ammonia and at the same time accelerate the reaction.If reaction is near equilibrium,rise in temperature will lead to decrease in conversion and viceversa.

Catalyst: - Iron Temperature: - 420-480 C Pressure: - 145-150 kg/cm2 Reaction: - N2 + 3H2 = 2NH3 Effluents: - H2, N2, NH3 7.REFRIGERATION: The primary purpose of the refrigeration system is to condense product ammonia for separating it from the converter feed.Further it is applied to cool makeup gas for separation of water to condense and recover liquid ammonia from purge gas and flash

23

gases and to cool the product run down to -33C and degassing inerts. Liquid ammonia separated in ammonia separator operating at 147kg/cm2 and purge separator operating at 140 kg/cm2 are letdown to Letdown Drum operating at 17kg/cm2.This letdown in pressure helps to flash most of the dissolved gases in the ammonia product.Flashed gases from letdown drum combines with the gases from gas chiller.These two flash gas streams then go to the fuel gas knock outdrum. Approximate composition of flashed gases from Letdown Drum is: Component H2 N2 CH4 NH3 Mol% 47.45 18.25 18.98 10.21

Liquid ammonia from letdown drum is letdown further through level control valve to third stage Refrigerant Flash Drum operating at a pressure of 0.014kg/cm2.pressure being controlled by Refrigerant Compressor.Here temperature is around -330C. Liquid ammonia is letdown to second stage Refrigerant Flash Drum also when necessary,to maintain level due to varying refrigerant load in ammonia plant.It is combined with flashed gases from second stage refrigerant flash drum before being sent to the second case of compressor.After three stages of compression in the second case the gases are sent to refrigerant compressor intercooler where it is cooled 106C to 43C with cooling water to remove the heat of compression.The pressure of the gas leaving the cooler is 6.2kg/cm2.The flashed gases from first stage Refrigerant Flash Drum join the gas from intercooler and again compressed to a final pressure 17kg/cm2 in the last four wheels of compressor.The compressed flash gases are condensed by cooling

23

water in Refrigerant Receiver.The overhead from the receiver is chilled with ammonia in flash gas chiller to a temperature of 1C. The approximate composition of flash gases from flash gas chiller is: Component H2 N2 CH4 NH3 Mol% 25.92 14.82 29.64 25.92

The three drums are combined in one single vessel with partitions with operating pressure of 6kg/cm2,2.3kg/cm2 and 0.01kg/cm2 respectively.These pressures are controlled by Refrigerant Compressor at different stages.These drum receive flashed ammonia from refrigerant receiver by successive letdown.These drums serve as Head Drums for the various refrigerant ammonia chillers used un synthesis loop.The refrigerant ammonia while taking up the heat gets vaporized and is compressed by refrigerant compressor condensed and received in refrigerant receiver and then again sent back to these drums for refrigeration.The whole refrigeration cycle is a closed circuit. Product ammonia from flash drum at -33C is pumped to atmospheric ammonia storage tank.The atmospheric storage tank is having capacity of 10,000tonnes.The urea plant uses ammonia at 4C.

23

OFFSITE: Offsite is a very sophisticated unit which is necessary to run the main plant properly and efficiently. Offsite contain various different utilities which are as follows:
o o o o o o

Demineralization water plant Water softening plant Cooling water plant Inert gas plant Reverse osmosis plant Ammonia storage tank

Demineralization water plant: The ion exchange reactions that take place here are: Cation : 2ReH + Ca(HCO3)2 +H2 = H2CO3 +ReH + NaCl + H2O = ReNa + HCl + H2O Degasser: H2CO3 = H2O + CO2 Anion: ReOH + HCl + H2O = ReCl + 2H2O ReOH + H2SiO3 + H2O = ReHSiO3 + 2H2O Regeneration Medium: Cation HCl Anion NaOH Cation : Re2Ca + 2HCK + H2O = 2ReH + CaCl2 + H2O Anion: ReCl + NaOH + H2 = NaCl +ReOH

23

The plant consists of following

1.

Pressure sand filter:

It generally consists of a steel pressure vessel filled with the filter media sand. Out of the 4 unit 2 are normally in service one is under back wash and one is available already for change over. When pressure drop of the units is increased the bed is air blown and back washed for removing the deposits.
2.

Cation unit

Primary cation unit The raw water after filtration enters the weak acidic cation unit in which in which the cations with alkaline water are exchanged with hydrogen ions imported to resin by regeneration with HCl .The eater coming from this cation unit contains neutral salts and carbonic acid corresponding to the alkalinity in raw water . The cation units are mild steel rubber lined vessel and contains weakly acidic cation resin. Method adopted for regeneration is through fuse technique where in the acid from strong acid cation unit going to the drain, out of 4 units 2 normally remain in service. Secondary cation unit This is similar to primary cation unit but charged with strong acidic cation resin (Indana 255) When the capacity of resin to exchange cation has been exhausted between the units has to be regenerated. Backwash is not recommended after each regeneration in order to maintain always a fully regenerated resin bed at the bottom of the column hence double quantity of acid is injected after every backwash operation.
3.

Degasser towers

23

This is mild steel rubber lined vessel packed with raschig rings. It is fitted with a top tray, which distributed water evenly over the degasser tower area, and provide an outlet for CO2 enriched air. Water from cation or weak base anion exchanger which frees CO2 or carbonic acid flows down the column against a current of low pressure air supplied by a motorized blower at the bottom of the tower. CO2 is stripped off and vented degassed water is collected in a sump. Out of the two units only one remain in service, other is kept as standby.
4.

Anion units

Primary anion unit This is similar to the cation unit, but charged with De Acidite resin instead. Internally it is fitted with distributors for water and regenerate and a collecting system for collection of his anion exchange resin, the strong acids like HCl and H2SO4 are readily absorbed while the weak carbonic and silica acids pass through unaffected. The resulting treated water has acidic ph. When the resin is saturated and cannot absorb acids any further it is regenerated to OH by caustic soda adopting through base anion exchanger. Total 4 weak anion vessels are installed.

Secondary anion unit The secondary anion exchanger is similar to primary anion exchanger but contains De acidite Ff, a strong base resin present in the degassed demineralised water are taken up by the resin yielding a DM water which is very low in silica. When capacity of resin bed is exhausted the unit is regenerated with caustic soda. Three exchanger are utilized out of four exchangers installed.
5.

Mixed bed units

The anion treated water enters the mixed bed exchanger contains mixture of cation and anion rings, which are used in a state. Total

23

4 vessels are installed out of which normally two always remain in service. This is considered to be final stages of purification of high grade of DM water.

DM water storage There are two tanks of mild steel rubber construction for storing DM water DM WATER QUALITY PH at 25 C 6.8-7.3

Silica<0.01 ppm as SiO2 Conductivity: < 0.01 micro mho Total dissolved solid: Nil Water softening plant: The heated water is cooled in the towers and utilized for cooling purposes which is the basic necessity in a fertilizer industry. The temporary hardness present in raw water and cooling water cause severe scale formation. This hardness is precipitated with time in softener and removed and the clear water is used in cooling towers. Ca(OH3)2 + Ca(OH)2 = 2CaCO3 + 2H2O Mg(OH3)2+ 2Ca(OH)2= 2CaCO3 + 2H2O + Mg(OH)2 Alum acts as a coagulation agent who helps in combining all the precipitate in groups to form a proper blanket and also to reduce turbidity in the softened water.
23

Physical description There are big open tanks where solution of lime mixes and form other tank raw water comes in the clarifier tank where both mixes and some alum is also mixed through small pipe , and arrangement of recycling is also done. From outlet fresh water is collected in the other tank and from there it goes to the cooling water plant.

Cooling water system: Chemical process industries produce low level heat usually in the form of hot water, as requirement of water is very high; hot water is cooled and reused in plant. Cooling tower plays an important role in total energy balance of chemical process industries with respect to total water conservation. Cooling water treatment is of vital importance for all chemical process industries. Any treatment failure will result in poor performance of plant due to fouling/choking of heat exchanger. If the treatment program fails to provide adequate corrosion protection, it may result in failure of heat exchanger and their replacement may turn out to be a costly proposition. Corrosion, scale and growth of micro organism in circulating cooling tower stand heat transfer damage equipment, tower wood and result in stoppage of production. To safe guard against this cooling water is chemically treated. Chromate water treatment is employed at phulpur. Cooling water is employed to contact hot water allowing its reuse in the process of cooling media. Cooling is mainly done by latent heat transfer and not is sensible heat transfer between hot water and comparatively cool water and air. By evaporation loss of water by the salt concentration is increase which is removed by blow down and by make up water we maintain the level of the water in the basin.

23

Inert gas plant: A 600 Nm3/hr nitrogen producing plant serves the requirement of inert gas. Ammonia cracks on catalyst tubes at 580 C into nitrogen and hydrogen, hydrogen is removed by combustion with air and nitrogen so produced is cooled and compressed to 10-12 Kg/cm2 and distributed to usage terminals. Plant can also produce 900Nm3/hr. Nitrogen and hydrogen gas mixture on demand of ammonia plant for desulphurization and catalyst reduction etc.

Reverse osmosis plant: It is plant to reuse the wastewater and to control pollution generated from plant to environment. The rejected waste from the R.O. unit is send to ash pond which is situated 4 km. from the plant where waste is diluted. Process description: R.O. Pit It contains various nets to filter to solid sludge. Clarifier: It is cylindrical column having filter in the centre here chemicals are added through different pipes. Polyelectrolyte for flocculation Na2CO3 for removal of hardness Lime/Dolomite to maintain the pH and for removal of silica. Soda Hexamite Phosphate (SHMP) is added as antecedent. Continuous filter:

23

They are four in number of which one is on stand by condition. Continuous filter consist of a vertical tube, the sludge is collected at the bottom with the sand and is ejected by creating vacuum pressure a form clarifier, it passed through sand bed and the filtered water is pumped to clarify water shortage tank. (CWST) sludge is taken out from back wash outlet. CWST (Clarified water storage tank) - In this tank, chlorine is added to remove bacteria and other impurities.

MFG (Multi Grade Filter) First it was named as activated filter because activated carbon was used with sand and gravel. But as bacteria rapidly destroy activated carbon, therefore it was replaced by sand. New thought sand is easily skipped with fresh water but further treated with chlorine and thus oil and grease. Ammonia storage area: There are two storage tanks for NH3 .One is of 10,000 m3 another is of capacity 5,000 m3. In both these tanks NH3 comes in the form of liquid from the NH3 plant and is stored in the form of liquid only. The temperature is maintained at -33 C. Both the tanks are of double wall type. In one of the tank, parallite is filled which acts as an insulator and in the other tank, vapour is filled in between the walls. When this liquid NH3 falls into the tank, it first fall on a plate, which spreads this liquid NH3 all around the tank. Certain pressure is maintained in the tank and some of the NH3 vapour is sent to the NH3 plant for conversion of it into the liquid form. From this storage, NH3 goes to the urea plant for the production of urea

23

MISCELLANEOUS
1.

Power distribution and emergency power

The captive power plant is designed to produce 12.5 Mw of power. The total power requirement of the factory is 11.5 Mw. But IFFCO has to take just 8.95 Mw and the rest 2.5 Mw comes from UPSEB(Uttar Pradesh State Electricity Board). Two feeders of UPSEB powers to IFFCOs 132 KV substation where it is stepped to 11 KV. The power distribution in the factory is divided into two parts one critical and other is non-critical. Critical power requirement is 8.95 Mw and this is met by the captive power supply. Non critical power requirement is 2.5 Mw and this is met by the UPSEB supply. Critical power supply This consists of: NH3 plant Urea plant Steam power plant and ash handling
23

Offsite, cooling water pumps & compressors Non-critical power supply This consists of: Coal handling Water treatment plant Bagging plant handling Emergency power There are certain pumps and machinery which are required to run during a shutdown due to power failure. These machineries are so sensitive that a small dip in power supply will lead to their destruction. So there is an automatic system which supplies uninterrupted power whenever there is a dip. The following services get the emergency power supply failure. 1. 2. 3. 4. 5. 6. 7. 8. 9. Emergency lighting Prilling tower lift Condensate pump HP flushing water pump NH3 booster pump Stripper DP cell flushing pump Lube oil pump for Co121 compressor Emergency lube oil pump for compressor section Barring device for CO2 compressor

Bagging plant Urea bagging and material handling equipments have been designed and supplied by ELECON Engg. CO. Urea is a low concrete structure of precast member. It has 40 m width, 230 m length and 20 m height. Its capacity is 30,000 tonnes. The urea silo has specially designed portal scrapper of 150 TPD capacities with covers the entire length and breadth of silo. This
23

design facilitates urea reclaiming to the extent of complete sweeping of the slopped floor of the silo. Usual belt conveyers affect the urea transfer in the bagging plant. A bucket elevator, vibrating screen and delumper are provided in the reclaimed urea circuit. The function of bagging machine is to feed correct quantity of material in the bags. They are installed under the urea bankers. The automatic scale words as a principle of continuous flow of urea to the bucket. The main parts of a bagging machine are: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Equal armed beam scale Main feed gates Fine feed gates Feeding chute Geared motor with agitator Air cylinder Weighing receptacle Discharge flip gate Solenoids Weighing box along with weights

There are two types of begs used- jute type & HDPE type. Cost of an HDPE bag is about Rs.8 while that of a jute bag is Rs.14 the government has specified that each plant should use 50% jute and 50% HDPE bags. The capacity of each bag is 50 kg. SEWAGE TREATMENT PLANT The residential colony at IFFCO Phulpur consists of about 820 families. The domestic sewage water generated from the colony if discharged untreated, would contaminate the natural receiving body of water causing problems of dissolved oxygen depletion apart from nuisance of water odours, colours and taste. Therefore the treatment of raw sewage water is a necessity for safe discharge or some other uses. The sewage treatment cum recycle plant (Capacity 3000 m3/day) at Phulpur involves a series of unit process, physical, biological and chemical. This treatment plant consists of bar screen, grit removal chamber, partially flume indicator, raw sewage collection sump, aeration tank, secondary
23

clarifier, filter feed sump, pressure sand filter, activated carbon filter and chemicals dosing system. Treated water is used for either irrigation of farm land or recycled to water softening plant for process use. Process description The removal of pollutant from waste water can be achieved by a wide variety of equipment and process. The choice of these is dictated by techno economic considerations. For the sewage treatment plant supplied a three stage treatment turn to be suitable. The first step comprises of primary treatment consisting of bar screen grit chamber, the second stage consist of activated sludge process for removal of dissolved organics and the third stage consists of polisher unit like filter etc. for polishing the treated water up to desired quality.

1.

Bar screen

It is an important unit in any waste treatment facilities. Waste more than often contain large floating materials which can be detrimental to the operation of downstream equipments. The bar spacing depends on the size of material to be criminated.
2.

Grit removal

Domestic sewage invariable contains some amount of grit particles. These are inert and abrasive in nature. Hence removal of these particle is an important pre-treatment step in prevent damage to the downstream equipment. The grit particles are removed manually which is sealed at the bottom of grit channel.
3.

Parshall flume

23

The sewage from the frit channel parts through parshall flume. The flow indicator is provided in the parshall flume to measure the flow.
4.

Raw water collection sump

The raw sewage is them collection into Raw sewage collection sump. The Raw sewage transfer pump provided will transfer sewage to the biological system.
5.

Biological treatment

The activated slued process has been envisaged for removal of non settable, colloidal and dissolved organic matte. The process is characterized by a suspension of aerobic microorganism maintained in a homogeneous state. These microorganisms need oxygen which is provided by the surface aerators. During operation the aerator throws liquid into the air as a spray. Due to high surface area of liquid exposed to the air, large quantities of oxygen for their respiration while consuming the organics as food, to provide adequate oxygen to maintain the biological reactions, as well as to provide sufficient mixing to keep activated sludge in suspension. Twenty HP surface aerator have been installed in the aerations tank. 6. Secondary clarifier

The waste discharge from the area on tank needs to be classified for two reasons. First these solids contain active bacteria which can be used for further degrading the pollmans. Secondary, unless these solids are removed the treated waste is disposable. This dual purpose is achieved in sedimentation basic, named as clarifier, circular in shape. Here the biomass solids sealed to the tank floor while the clear treated water overflows into the pretty hand lauder. The settled solids are taken to the tank centre. As these biomass solids are critical to proper operation of the aeration system, they are pumped back to the aeration tank

23

in order to maintain the level of motivated sludge.

7.

Filtration

The clarified sewage collected in the filter feed sump contains nominal amount of fine suspended solids. Removals of these solid can be done by pressure sand filter and activated carbon filter. Pressure sand filter They are three in number each of 2.6 media x 1.4 ht. In MS construction having dished ends with two coats of bituminous paints internally and complete with: 1. 2. 3. 4. 5. 6. 7. Frontal pipe work and requisite valves and flanging etc. Inlet and discharge nozzles for feed Under drain system 1. in No. Rota meter 2. in No. pressure gauges 1. in No. Differential pressure gauges 2. in No. sampling points on the vessel

Chemical dosing system Bleaching powder is added in treated water sump for bacteria killing purposes

23

THERMODYNAMICS ASPECTS OF AMMONIA SYNTHESIS REACTION Thus it can be inferred from above that low temperature and high pressure favours the reaction. From kinetics aspects equilibrium is maximum at 400-460 C

23

SYNTHESIS CONVERTER In IFFCO PHULPUR P-1 two reactors are being used in order to enhance the percentage conversion to ammonia. One of the older reactor is being designed by KELLOGG and the newer one is by HALDOR TOPSOE, they are installed in succession one after the other. The following reactor represents four bed axial flow converter with quench gas cooling (i.e. Kellogg Brown and Root) and two bed radial flow converter (i.e. Haldor Topsoe)
o

23

. HONOURS OF IFFCO 1. National safety award to IFFCO Aonla as Runner-up during the year 2004 based on Longest Accident Free year. 2. Golden Peacock Environment Management Award 2005 to IFFCO Aonla (Certificate of commendation) 3. National Award of Excellence in Emergency management- 2005 to IFFCO Phulpur by confederation of India Industry (CII). 4. National Energy Conservation Award 2005 to IFFCO Phulpur( certificate of merit in fertilizer sector). 5. National Award for Excellence in Water Management 2005 and innovative project award to IFFCO Phulpur by confederation of India Industry (CII).
23

6. Certificate of Honour for working more than one million Man-hours accident free and lowest disabling injury index for IFFCO Kalol and for working more than one million Manhours accident free during 2004 from Gujarat Safety Council for Kandla. 7. First position for the Best Horticulture Maintained Plant to IFFCO Kalol from Gujarat Horticulture Association. 8. FAIs Best Overall Production Performance Award for year 2004-05 for complex fertilizer plant of Kandla

23