INTERNSHIP REPORT ON

PRODUCTION PROCESSES OF
AMMONIA AND UREA AT NFCL

Presented by:

R. Sitarama Chandra murthy.

Dasari nithin prabhakar.

AMMONIA PRODUCTION

Production steps:

The various steps involved in the production of synthesis gas and ammonia are:
1. Natural Gas Supply
2. Desulphurisation section
3. Reforming section
4. Primary Reformer
5. Secondary Reformer
6. CO conversion section
7. CO2 removal section
8. Methanation
9. Process condensate stripping section
10.Ammonia synthesis section
11.Refrigeration section
12.Ammonia absorption section

AMMONIA PLANT:

INTRODUCTION:N.F.C.L (Nagarjuna Fertilizers and Chemicals Limited)

manufactures the product Urea (NH2-CO-NH2).
The plant is based on the latest technology from M/s
Snamprogetti, Italy for the Urea process and Halder
topsoe(Denmark) for ammonia process, with an installed
capacity of 1500 Mt/day for each stream, later it has been
increased to 1800Mt/day for each stream through the
process of revamping.
The Industry has two Ammonia plants, two Urea plants,
Bagging Plant and Utilities & Power Plants.
The Raw materials used for manufacturing the Ammonia
and Urea are:1) Natural Gas - From Krishna Godavari basin through GAIL.
2) Natural air - Atmosphere.

TECHNICAL FEATURES:
Installed Capacity : 2 x 1500 MT Urea / Day
2 x 900 MT Ammonia / Day
Revamped Capacity :2 x 2325 MT Urea / Day
2 x 1325 MT Ammonia / Day

BAGGING PLANT:
1 BAG of urea contains = 50 Kg
Each empty bag weighs= 130gms
1 stream contains 250 tonnes of urea in 8hrs.
In NFCL they use 6 streams total which packs 1500 tonnes of
urea in 8hrs.
That is about 30000 bags of urea are packed in 8hrs and in
total 90000 bags in 1 day.

 Fig: Catalyst
used

NH3 MANUFACTURING PLANT

PRE-DESULPHURIZATION:
Natural gas contains sulfur compounds of types R-SH, R1-S-R, R-S-S-R1 etc
These compounds are removed by hydrogenation process where H2 is added.
The
reactionstothat
So, for liquid natural gas to react with hydrogen it is to be
converted
gaseous
state and thus it is sent to fired heater and then into HYDROGENATOR.
take place in

H2

PRE-HEATING FURNACE
(F-203)

hydrogenator are:
R-SH + H2 R-H +
H2S
R-S-RI + 2H2 R-H +
R1-H + H2S
R-S-S-RI + 4H2 R-H
+ R1-H + 2H2S
CATALYSTNIMOX(Nic
kel-Molybdenum)
HYDROGENATOR
(R-201) OPERATING
CONDITIONS:380OC &
24KSC

Fig:Total Desuphurization Section (Hydrogenator &

absorbers)

 FINAL DESULPHURIZATION:
So, S is removed to a large extent as H 2S, to strip off the H2S
present in the product, the stream is sent into the stripper where
product stream falls from the top and the steam from the bottom.
0.5 ppm of sulfur is present and thus is to be further removed
because S acts as a poison to the catalyst in the reforming section .
So, the product obtained is sent into the final desulphurization unit
for further removal of S.
So the H2S formed now is sent into the reactors where ZNO beds are
present. The sulfur removal inside the beds takes as follows:
ZNO + H2S -> ZNS + H2O
Zno

Zno

R202
A

R202
B

Catalyst: Ni based unreduced

catalyst R-67-7H at the bottom.
.

R-67-7H is unreduced and used in tubular

reformers downstream a prereformer or for
steam reforming of light feedstocks such as
natural gas. For reforming of feedstocks
ranging from heavy natural gas to LPG . R-677H is delivered in a prereduced version for
Prefast
reduced
start-up. catalyst R-67R-7H at top
By using the R-67R-7H in the top of the tubes,
the reforming process is initiated immediately
when exposed to process gas. The hydrogen
generated in the top layer rapidly activates
the catalyst in the lower part of the tube, and
this easy activation greatly minimizes the
start-up time.

REFORMING SECTION:
The process gas thus obtained is sent to the ADIABIATIC PRE-REFORMER
where high carbon chains of naphtha are broken into low carbon chains by
cracking and this gas is sent into REFORMING SECTION.
Reforming means conversion of hydrocarbons to CO 2 with the help of
steam. This takes place at high temperatures since it is a endothermic
reaction.
The reactions that take place are called as shift reactions.
CH4 + H2O -> CO + 3H2
CH4 + 2H20 -> CO2 + 4H2
CATALYST Ni based catalyst.
TEMPERATURE - The temperature required is nearly 950 oC & 30.5KSC.
Reaching this temperature at once is very difficult and thus it is done in 2 stages:
1.Primary Reforming
2.Secondary Reforming

PRIMARY REFORMER:
This reformer contains 190 tubes in 2 parallel sections.
Each section contains95tubes, divided into 5zones, i.e, each zone
contains 19tubes.
The furnace operates with side firing of fuel gas on both sides of
each row of tubes.
These tubes are filled with Ni catalyst.
Super heated steam along with natural gas is sent into small tubes.
Each
19
Nearly 86% conversion
takes place. Thus the product stream
tubes+CH +H 0.
contains C0+C0
2
4
2
z2

z3

z4

5z

z1

Firing inside Primary Reformer

SECONDARY REFORMER:

Product stream along with air is sent inside the reformer where it is
heated to 945oC for the rest 14% conversion of CH4.
The off gases that are evolved during the stripping of H 2S gas are
used as a fuel to secondary reformer for maintaining high
temperatures.
The product stream now contains only CO, CO 2, H2 and AIR. In order
to convert CO to CO2 it is sent into the CONVERTER via WASTE HEAT
BOILER.
This waste heat boiler recovers the heat from the product stream
and is used for rising temperature.

secondary reformer

HT CO(or SHIFT) CONVERTER:

From waste heat boiler the process gas enters High Temperature CO
converter. This is maintained at 360 oC.
Although CO conversion to CO 2 takes place at low temperatures this
converter is used in order to increase the speed of reaction.
CO + H2O

CO2 + H2 + Heat

Catalyst: copper promoted iron oxide

Operating conditions: 3600C& 29.8 Kg/cm2g

LT_CO(OR SHIFT) CONVERTER:

The stream from HT CONVERTER enters the LT CONVERTER and the CO
formed in the process is converted to CO2.
This is maintained at 140oC.
Catalyst: Catalyst consisting of oxides of copper, zinc and
aluminum.
Operating conditions: It will be operated between
200 to 2180C.

Fig: High temperature shift converter

Fig: Low temperature shift converter

CO2 REMOVAL SECTION:

CO2 that is present is to be separated and thus it is sent into a tower
where it is made to mix with a solution called GV SOLUTION .
GV SOLUTION (GIMMARCO VETRACOKE SOLUTION) whose
constituents are K2CO3, V2O5, DEA and GLYCINE.
V2O5 acts as the catalyst and DEA, GLYCINE are the initiators of the
reaction.
Lean
GV
The operating conditions are 2.5 KSC, 250 oC.
SEMI-LEAN
GVCO -> 2KHCO
reaction
that
takes
place
is:K
CO3
+
H
0
+
The
2
2
2
3
Components of GV Solution:
K2CO3
= Solvent
Glycine = Activator
V2O5
=corrosion Inhibitor
DEA
= promoter

SOLn

GV+ CO2

CO2 REMOVAL
SECTION

CO2 REGENERATOR and METHANATOR:

This KHCO3 is to be stripped for removing the CO 2 from the GV
SOLUTION.
This stripping is done both at high pressures and low pressures .
High pressure regeneration at 1 KSC is done where steam
is made to flow counter-currently to KHCO3 solution.
This helps in CO2 stripping off. Traces of CO2 that are present
are also to be stripped and thus they are sent into the
low pressure regenerator which is made to work at 0.1 KSC.
This process gas is now made to pass through the METHANATOR
so that traces of CO2 left out is converted into CH4 once again
and this is called as reverse shift reaction.

CO + 4H -> CH + 2H 0

NH3 SYNTHESIS SECTION:

the reaction is exothermic , so low temperature is favorable.

Since the no. of moles decreases high pressure is favorable.
H2/N2 ratio is maintained at 2.78:1 .
The output of absorber section i.e; from final separator ,it is
passed to 4 stage compressor.
Then purge is taken, and is passed to 8heat exchangers connected
in series and to ammonia reactor.
And the formed ammonia is collected in V-502 , we get pure
ammonia.
4 STAGE COMPRESSOR

Fig: Ammonia Synthesis Reactor

Reaction:
N2 + 3H2 2NH3
+Heat
H2 / N2 ratio is maintained
at 2.78:1
Catalyst: First bed
KM1R catalyst
Second bed KM1
catalyst.
Operating conditions:
131-141 Kg/Cm2g & 360
- 5200C

KM1R
Ammonia synthesis catalyst
It is a prereduced iron-based ammonia synthesis catalyst containing a number of

carefully selected promoters.

Application.
itis used in the majority of the worlds ammonia converters to convert synthesis gas

containing hydrogen and nitrogen into ammonia.

To produce ammonia from a variety of hydrocarbon feedstocks ranging

from natural gas to heavy naphtha using

Topses low energy

AMMONIA SEPERATION

Purpose: Toseparatetheammoniafromtheunconvertedprocessgas. It
included2sections.

1) AmmoniaRefrigeration2)Ammoniaabsorption
Ammonia Refrigeration:

TherefrigerationsectionisusedtoliquefygaseousAmmoniaandconsistsofacompressorunit,
acondenser,anaccumulatorandnumberofchillers.LiquidNH3flowsfromtheNH3
accumulator,totheNH3heater,whichservestoheatAmmoniasenttotheUreaPlant.
Ammonia Absorption:

AmmoniaproducedintheAmmoniaSynthesisConverterseparatedfromunreactedgas
mixtureinAmmoniaSeparator.

Fig: Ammonia separation

Purge Gas Recovery Unit:

Purpose: TorecovertheH2 fromthepurgegas

Fig: purge
gas recovery
unit

Production of UREA

Properties of urea
Urea is a white, odorless, hygroscopic solid. It
is non-corrosive.

The Urea production takes place through

the following main operations:
Urea Synthesis and High Pressure Recovery
Urea purification in the medium, low and pre-vacuum pressure
recoveries.
Urea concentration
Urea Prilling
Bagging

UREA SYNTHESIS AND HIGH PRESSURE RECOVERY:

Purpose: synthesis of urea

2NH3 + CO2 NH2COONH4 (Ammonium carbamate)

NH2COONH4 NH2CONH2 (Urea)+ H2O

CO2 and NH3 obtained in ammonia plant are sent into UREA PLANT. Since
the reaction requires high pressures both the reactants are compressed.

Urea is produced by the synthesis of liquid ammonia(240 KSC, 135c) and

gaseous carbon dioxide. The first reaction occurs rapidly and is completed,
while the second reaction occurs slowly and determines the reactor volume.
The fraction of ammonium carbamate that dehydrates is determined by the
ratio of the various reactants, the operating temperature and the residence
time in the reactor.

The molar ratio of ammonia to carbondioxide is in the range of 3.33.6 to 1. The molar ratio of water to carbondioxide is in the range
of 0.50-0.70 to 1.

UREA PURIFICATION IN THE MEDIUM, LOW

AND PRE-VACUUM PRESSURE RECOVERIES:

Urea purification takes place in three stages at decreasing pressures as

follows:

1st stage at 18.0 kg/cm2 pressure

2nd stage at 4.50 kg/cm2 pressure

3rd stage at 0.35 kg/cm2 pressure

M.P Decomposition and separation:

Purpose: To increase the concentration.

Description: The solution with a low residual CO2 content,

leaving the bottom of the stripper is expanded to a pressure of
18 kg/cm2 and enters the medium pressure decomposer
which is a falling film type.

L.P. Decomposition and separation:

Purpose: To increase the urea concentration in the solution.

Description: The solution leaving the bottom of medium

pressure decomposer is expanded to 4.5 ksca pressure and
enters the low-pressure decomposer at 4 KSC, 145C, which is
also a falling film type. Where 72% urea is obtained.

Pre vacuum concentrator:

Purpose: To increase the urea concentration. Water will be
evaporated from the urea solution.
Description: The solution leaving the bottom of low-pressure
decomposer is expanded to 0.35KSCg pressure and enters
the vacuum pre-concentrator which is also a falling film type.

permits to concentrate the urea solution from about 70-75%

to about 85-88 % by weight

UREA CONCENTRATION SECTION:

It is necessary to concentrate the Urea solution up to 99.8 % wt in order to prill
Urea. A vacuum concentration section in two stages is provided to accomplish
this concentration.

 The urea solution is sent to the first vacuum concentrator,

operating at a pressure of 0.35ksca.
The mixed phase coming out enters the gas liquid
separator, from where vapors are extracted by the first
vacuum system, while the solution enters the second
vacuum concentrator, operating at a pressure of 0.03ksca.
The two concentrators are fed by LP steam. The mixed
phase coming out enters the gas liquid separator, from
where vapors are extracted by the second vacuum
system.
Water obtained is condensed and then sent into waste
water tank. It contains 5% Ammonia and 1% Urea. Molten
urea is sent to the prillin tower.

PRILLING SECTION:

The height of the urea prilling tower is 100 meters and 22 meters in diameter.
The molten urea leaving the second vacuum separator holder, is sent to the prilling bucket, by means of
centrifugal pump.
The Urea coming out of the bucket in the form of drops fall along the prilling tower, and encounters a
cold air flow which causes its solidification. The heated air along with a few ppm of urea dust comes
out of the prilling tower top to atmosphere.
The solid prills falling to the bottom of the prilling tower are sent by the rotary scraper, to the belt
conveyor, and then to the belt conveyor, from where Urea can be taken either for bagging or to the
Silo.

Snam Progetti (Italy) Process

This process is based on the principle of the internal
carbamate recycle technique and is commonly called
the Snam NH3 stripping process.
The basic difference between the Snam process & the
conventional carbamate solution recycle urea
processes is the fact that in this case the unconverted
carbamate is stripped and recovered from the urea
synthesis reactor effluent solution at reactor pressure,
condensed to an aqueous solution in a steam
producing high pressure condenser, & recycle back to
the reactor by gravity.
Part of the liquid NH3 reactor feed, vaporized in a
steam heated exchanger, is used as inert gas to
decompose & strip ammonium carbamate in the
steam heated high pressure stripper.

 The

reactor operates at about 130 atm

& 180-1900C. The stripper operates at
130 atm & 180-1900C.

The

stripper off-gas is condensed in a

vertical shell & tube condenser,
operating at about 130 atm & 1481600C.

Low

pressure steam is produced in the

high pressure carbamate condenser.
The urea product solution, leaving the
stripper & still containing 2-3 % of
residual unreacted carbamate, is

Snamprogetti process

USES OF UREA
About

56 % of Urea manufactured is used in solid

fertilizer.

About

31 % of Urea manufactured is used in liquid

fertilizer.

Urea-formaldehyde

resins have large use as a

plywood adhesive.
Melamine-formaldehyde

resins are used as

dinnerware & for making extra hard surfaces.

THANK YOU

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