Agritech LTD Internship Report

INTERNSHIP REPORT
Pak American Fertilizer Limited

Iskanderabad
Presented By
Muhammad Khuram
Zahid Mahmood
Aqeel Abbas
Nouman Asad
Arshad Naveed
Roman Bin Tariq
(M08-CE-47)
(M08-CE-06)
(M08-PG-01)
(E08-CE-40)
(E08-CE-40)
(E08-PG-19)
Department of Chemical Engineering and Technology
UNIVERSITY OF THE PUNJAB
Downloaded From : http://www.ICETStudentS.com
INTERNSHIP REPORT (Pak American Fertilizer Limited)
| University Of The Punjab
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ACKNOWLEDGEMENT
First of all, I would like to say Alhamdulillah, for giving me the strength and health to do
this internship work until it done We offer our heartily respects to the HOLY PROPHET
HAZRAT MUHAMMAD (SAW) who is, forever a torch of guidance and knowledge for
humankind as a whole.
Not forgotten to our families for providing everything, that is related to this internship
work and their advice, which is the most needed for this journey. They also supported us
and encouraged us to complete this task so that I will not procrastinate in doing it.
Wed like to thanks our respected teachers for their moral support, their guidance in time,
useful suggestions and their confidence on us that we can do this task efficiently as we are
representing our Institute.
Its not very easy for us to find the right words to express my gratefulness to our advisor
Mr. ABDUL HASEEB, his enthusiastic interest, continuous encouragement, and kind
behavior throughout my internship period.
Apart from our respectable advisor, there are many other people who have been very
helpful to me right from the beginning. We would warmly acknowledge the entire
management of Pak-American Fertilizer Limited who provided us this opportunity to
achieve this practical experience under their valuable supervision and helping suggestions
to complete this report.
Last but not least, my friends internship colleagues who were doing this project with me
and sharing our ideas. They were helpful that when we combined and discussed together,
we had this task done.
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EXECUTIVE SUMMARY
This report is based on our four weeks EXPERIENCE at PAK-AMERICAN
FERTILIZER LIMITED as an internee from 1st June to 29th June. THE
COMPANY IS a highly reputed organization. PAFL is one of the pioneers of
the fertilizer industry in Pakistan. It owns and operates urea plant located
at Daudkhel, Iskanderabad District Mianwali.
The salient features of this report are: Pak-American Fertilizer Limited
background, its vision, corporate values and goals. This report focuses its
overall marketing strategies, its production and operations, and its Human
Resource. The process description of the firm has been done in detail. The
flue gas Analysis, water treatment plant Analysis are really a fascinating
experience of mine.
This report accentuates the details of my learning and observation at PAFL.
It also includes the actual techniques that are used in this organization to
carry out basic processes. And we were sure that this report will provide
you a complete and clear image of organization.
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CONTENTS_________________________
HISTORY ................................................................................................6
AMMONIA SECTION............................................................................7
UREA SECTION.....................................................................................27
UTILITIES SECTION............................................................................34
ICET
Students
Digitally signed by ICET Students

DN: cn=ICET Students, o=ICET
Students, ou=Administrator,
email=admin@icetstudents.com,
c=PK
Date: 2011.06.11 12:27:19 +05'00'
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HISTORY
The Plant is located at Iskanderabad, District Mianwali. It was the first nitrogenous Plant built in
Pakistan. The project when commissioned in 1957 was designed to produce 40 metric tones per
day of Ammonia to be fully converted into 150 metric tones per day of Ammonium Sulphate.
The unit underwent expansion in 1968 when the capacity was increased to 273 metric tones per
day i.e. 90,000 metric tones per annum of Ammonium Sulphate.
The Ammonium Sulphate Plant was closed in June, 1997 and a new Ammonia /Urea Complex
having capacity of 600 metric tone per day of Ammonia and 1050 metric tone per day of Urea,
started commenced production in November, 1999.
The annual production capacity of the Plant is 346,500 metric tone of urea.
Total completion cost of the Project was Rs.9, 700.060 million, out of which Rs.6, 878.119
million was in foreign currency. The authorized and paid up capital of the Company is Rs.3, 000
million, which is subscribed by NFC.
The raw material used is Natural Gas from SNGPL Network.
Today the plant is running at 1176 tone per day which is the 112% of the designed capacity 1050
tone per day of Urea and 650 tones per day of Ammonia. Both plants have been designed by
TOYO Engineering Japan. Ammonia plant is under license from Kellogg International, USA,
while urea plant is TEC's own. The plants are latest in design and most modern. The company
possesses over 11,481 Kanals of land, comprising 6,432 for Factory, 2,818 for Housing Colony
and 2,230 for experimental farm.
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Ammonia Section
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GENERAL OVERVIEW
Ammonia is produced in a process in which nitrogen and hydrogen react in the presence of
an iron catalyst to form ammonia. The hydrogen is formed by reacting natural gas and
steam at high temperatures and the nitrogen is supplied from the air1.
Other gases (such as water and carbon dioxide) are removed from the gas stream and the
nitrogen and hydrogen passed over an iron catalyst at high temperature and pressure to
form the ammonia. The process is shown schematically in Figure 1.
The ammonia process is the low energy natural gas reforming process. Offered and
licensed by the M.W kellog company. The ammonia plant design is based on producing
6oomtd of anhydrous liquid ammonia.
Under normal operating conditions liquid ammonia is delivered to battery limits at 30 0c.
for uses feed to urea plant in the event that the urea plant is not working the ammonia
product can be delivered to the battery limits -33 0c. for offsite storage.
By product CO2 is delivered to the battery limits at 38 0c and 1.9 kg/cm2.
FEED STOCK SPECIFICATIONS:
Component gas
Mole %
CH4
82.6
C2H6
8.5
C3H8
3.3
C4+ higher
1.9
CO2
1.3
N2
2.4
TOTAL
100%
Pressure at battery limits:

Temp at battery limits:
Lower heating value (LHV)
7.5 kg/cm2
28 0c
9609 K cal/nm3
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The process is described in the following sections:

Raw synthesis gas preparation:
Synthesis gas purification:
Purified synthesis gas compression and ammonia synthesis:
Ammonia refrigeration system:
Process condensate stripper:
Steam system:
Other utilities:
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RAW SYNTHESIS GAS PREPARATION

The raw synthesis gas is produced from natural gas is produced from N.G in four major
steps.
Compression.
Partial reforming.
Final reforming.
Conversion of carbon mono oxide and steam in the reformed gas.
N.G is used for feed stock and fuel. The N.G at 7.5 kg/cm2 passes through the feed gas
knock out drum to remove suspended liquids and solids. The N.G is split up in to two
streams feed gas and fuel. The fuel gas portion is combined with recovered gas from
synthesis to provide the ammonia plant net firing requirements. The feed gas portion is
compressed to 46 kg/cm2 in a steam turbine driven two stage centrifugal natural as
compressor. A N.G pressure gas cooler and n N.G knock out drum are provided in order
to provide 2 % hydrogen level in the natural gas stream. A recycle stream of hydrogen rich
synthesis gas from 104 j pump is added to the second stage suction and a start up hydrogen
rich stream from A-103 F pump can be added to the first conditions. A-135-c is also
utilized for spill back from operation which allows all or part of the discharge gas to be
recycled back to the a-102-j first discharge line.
DESULFURIZATION
The sulphur compounds contained in small amounts in the feed gas are removed by
catalytic reaction with the hydrogen in the gas over a Como catalyst followed by absorption
with ZnO. The compressed natural gas is heated to 399 0c. in the convection section of the
primary reformer A-101-B. The natural gas and hydrogen combined streams then flow
down through the hydrotreator.
A-101-D hydrogenating the organic sulfur compounds to H2S over a bed of Como catalyst.
The reacted gas then flows through the desulfurizers A-102-DA/B where zone absorbs the
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H2S producing an effluent stream containing less then 0.1 ppm by volume of hydrogen
sulfide.
PRIMARY REFORMING
The 3880C desulfrized gas is mixed with 44 kg/cm2 and 3900C high pressure steams, a part
of which was used to strip the process condensate before hand. The steam is added in a
ratio of 3.5 moles of steam per mole of organic carbon. The feed gas/steam mixture is then
preheated to 621 0c in the convection of the primary reformer, A-101-B, recovering heat
from the furnace flue gas. After pre heating, the mixture is distributed to the catalyst tubes
suspended in the radiant section of the primary reformer furnace and passes down through
the nickel reforming catalyst. The heat from the endothermic reforming reaction is
supplied by fuel gas burners located b/w the row of the tubes. The pressure at the outlet of
the catalyst tubes is 37.2 kg/cm2 .
The reforming furnace incorporates the use of
internal man folding at the outlet of the catalyst
section for heat conversion of the reformed gas.
The reformed gas continues to pick up the heat
in these risers and collector headers while
exciting the radiant section. This raises the gas
temp aprox to 8330C.
The reforming furnace is designed to attain
maximum thermal efficiency by recovering heat
in the convection section from the flue gases. Flue gases consist of combustion products
from the radiant section of the reformer and the auxiliary boiler.
The convection heat is used for the following services.
Process air.
Steam
Natural gas feed preheat for desulphurization.
Steam super heating.
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Reformer fuel preheats.
Combustion air preheats for the reformer burners.
The super heat burners in the compression section and the boiler together with the
reformed gas waste heat boiler, A-101-C and the high pressure steam super heater will
maintain the plant in steam balance and generate export stream for the urea and utility
plants.
CH4 + H2O 3H2 + CO

CH4 + 2H2O 4H2 + CO2
CO + H2O H2 + CO2
SECONDARY REFORMING
The reformed gas flows from the outlet of the primary reformer through the primary
reformer effluent transfer line A-107-D to the secondary reformer A-103-D there it is
mixed with the quantity of heat and air to provide the N2 requirements of ammonia
synthesis reaction the heat librated by combustion of the part of partially reformed gas
supplies the energy needed to complete the reforming action the reformed gas temp leaving
the secondary reformer is about 1013 0C.
CO + H2O CO2 + H2
O2 + 2CH4 2CO + 4H2
O2 + CH4 CO2 + 2H2
2O2 + CH4 2H2O + CO2
The secondary reformer effluents passes directly to the reformed gas waste heat boiler
where SHP steam is generated by by hot gasses passing through the tube side. The partially
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cooled gas then passes through the SHP super heater A-102-C and cooled to high temp shift
inlet temp. of 3710C this super heater provides part of steam super heat requirements with
the remaining portion fulfilled by coils in the reformer convection section a process by pass
is provided b/w these two exchangers to various steam balance requirements.
SHIFT CONVERTERS
Down stream of A-102-C are high temp, and low temp. Shift converters. A-104-DA and A104-DB, in shift conversion step, CO reacts with steam to form equivalent amount of H2
and CO the shift reaction is reversible and exothermic. The reaction rate id favored by
high temp and maximal conversion by low temp. Two stages of shift conversion are
provided with HP boiler feed water heating between them to moderate heating the gas
temp.
CO + H2O CO2 + H2
CO + 3H2 CH4 + H2O
CO2 + 4H2 CH4 + 2H2O
The heat from the HTS A-104-DA is recovered by heating high pressure boiler feed water
in the shell sides in series of HTS effluents BFW preheaters, A-103-C1 and A-103-C2.
The low temp. shift effluents provides energy for CO2 removal system with the remaining
use full heat utilized to preheat boilers feed water for the plant steam system in LTS
effluents /BFW pre heaters located down stream of the benfield exchanger in the A-106-C,
Demineralized water is pre heated before it is sent to the dearator A-101-U.
The benfield system utilizes the LTS effluents waste heat as follows:
Steam generation in the CO2 stripper over head condensate reboiler A-113-C,
Benfiled system sol. Reboilng in the CO2 stripper gas reboiler A-105-C.
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The process gas is cooled below its dew point in the process gas exchanger and condensate
generated is removed from the gas in the CO2 absorber feed gas separator A-103-F. The
raw condensate is pumped to condensate stripper A-103-E to removed dissolve gasses and
any shift reaction by products so the water is reused and boiler feed make up after
treatment in the offsite polisher.
After condensate removal raw synthesis gas at 75 0C and 32.5 kg/cm2 enters the bottom of
the CO2 absorber A-103-E in the benfield system to begin the purification setup.
SYNTHESIS GAS PURIFICATION

In this section synthesis gas is proceed to remove CO2 and CO, yielding a high purity H2
and N2. Bulk removal of carbon dioxide is accomplished by the use of an improved benfield
low heat process which uses the four stage flash of the semi lean sol. to minimize external
heat requirements. Final removal of residual CO2 and CO. is accomplished by catalytically
converting the CO2 to methane and water in the methenator using hydrogen.
The benfield low heat process circulates an aqueous sol. containing a nominal 30%
potassium carbonate
This potassium carbonate chemically combines with CO2 on the process gas but not
significantly with the other constituents. Additives are injected into the solvent to enhance
the CO2 absorption rate, inhibit corrosion and to control foaming.
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ABSORPTION OF CO2
In the packed absorber A-101-E, removal of CO2 from the synthesis gas is carried out in
two absorption stages by counter currently
contacting the gas with the benfield sol. raw
synthesis gas enters the lower
Section of the absorber where the major
portion of CO2 in the gas is removed by
contact with partially regenerated semi
lean sol. In the upper section of the absorber
the process gas leaving the lower section is
contacted again but with more thoroughly
regenerated lean sol. resulting in an exit
gas CO2 level of 1000ppmv.
In the upper section of stripper the rich benfield sol. Is the partially stripped of CO2 . A
major portion of the sol. Is then with drawn and fed to A-117-F.
The exiting semi lean sol. is returned to the lower section of the absorber via the semi lean
sol. Circulation pumps. A-107-J, JA.
The reminder of the partially regenerated sol. is further regenerated in the stripper lower
section, where most of the remaining CO2 is removed from the solvent. The resulting
lean sol. is with drawn from the bottom of the stripper cooled to 70 0C. by preheating de
aerator feed water in the lean sol. /BFW preheater, A 107 C and by cooling in the lean
solution cooler A-108 C and then pumped by the lean solution circulation pump A-108J,JA to the top of the absorber.
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STRIPPER
The stripper is operated at conditions of 128 0C and 2.1kg/cm2 at the bottom of the column.
Heat required for stripping, available from low temp. Shift effluent, is obtained by
reboilng, benfield sol. In A-105-C by reboilng reflux condensate in A-113-C, flash cooling
of the semi lean in A-117-F lowers the required heat input to the stripper and enables the
process to operate with out need of sources except during start up. This system maximizes
reboiler heat recovery from the low temp. Shift conversion effluents by taking advantage of
the lower boiling point of the condensate compared to carbonate sol. Blow down from A113-C is required to the system by injection in to the lean sol flow through A-105-C.
After separation from the benfield sol. The CO2 product vapor is cooled to 38 0C, by direct
contact cooling with quench or reflux water in a packed bed above the benfield stripping
section of the tower quench water is circulated by the CO2 stripper quench pump. To the
CO2 stripper quench cooler. In this exchanger the quench water is heat is rejected to the
cooling water, water condensed from the CO2 product vapor during cooling is removed
from the cooling circuit to satisfy the water make up requirements. After being cooled the
99% CO2 product passes through the demising pad, exists the tower and is exported for use
in urea.
The absorber over head gas containing approx 1000ppmv CO2, is designed of an entrained
liquid in the CO2 absorber over head knock out drum A-103-F, and preheated to about 326
0
C by the methenator effluent in the methenator feed exchanger A-190-C a by pass is
provided around the exchanger to control the inlet temp. A line is provided from A-103-F
exit to the suction of A-102-J to provide H2 for start up and low temp shift reduction.
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METHANATOR
The metahntorA-106-D contains a bed of nickel catalyst that promotes the reaction of CO2
and CO with H2 to form methane and water. The total carbon oxides leaving the
methanator.
Will be less than 5 ppm by vol. due to highly exothermic nature of the methanation
reactions the synthesis gas temp increase from 316 at the inlet to about 347 0C at the out let.
The heat energy in the methanator efffulent is recovered by the heat exchange against the
feed gas the purified synthesis gas is then cooled to 41 0C on the methanator effluent cooler
A-115-c and delivered to the synthesis gas compressor suction drum A-104-F to separate
condensate water a small flow is taken from
A-104-F exit to the second stage suction of A-102-J to provide the H2 for desulprization.
SYNTHESIS GAS COMPRESSION AND AMMONIA

SYNTHESIS
The synthesis gas is compressed in a turbine driven centrifugal synthesis gas compressor A103-J.the compressor consists of two casings with inter cooling , condensate removal and
molecular sieve purification b/w cases and a integral recycle wheel in the second case, after
compression in the first case to approximately 78.06 kg/cm2 the synthesis gas is cooled to 41
0c in the syn gas compressor interstage cooler A-1116-C,and then cooled to 4.4 0c with
ammonia refrigeration in the syn gas compressor inter stage chiller A-129-C,condenste is
separated from the synthesis make up gas in the syn gas compressor first stage separator,
A-105-F.
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MOLECULER SEIVES
following the condensate removal , the synthesis gas passes, through one of the two
molecular sieve driers A-109-DA/DB the driers use molecular sieve absorbents which
remove water and trace amounts of CO2 to less than 1ppm by vol. while one molecular
sieve unit is in use the other is being regenerated on an 8-12 hour cycle or on stand by.
Dried gas exit the on line drier is used to regenerate the molecular sieve vessel not in
service during regeneration of the molecular sieves, the dry synthesis gas is first heated by
super high pressure steam in the molecular sieve regeneration heater, A-173-C, after
passing upward through the molecular sieve bed the refrigeration gas is recycled to the
methenator feed.
The purified synthesis gas leaving the molecular sieve unit is further compressed in the
make up gas section of the high pressure compressor case the fresh synthesis gas is mixed
with recycle gas from the synthesis lope internally with the compressor case before entering
the recycle wheel. Of the compressor, the combined flow to the synthesis lope leaves the
compressor at about 146 kg/cm2.
A syn gas kick back cooler A-175-C, is provided to protect the compressor over a vide
range of operating conditions. A A-103-J, discharge seal oil separator, A-111-L, is provide
at he compressor discharge to trap only oil from the compressor during an upset.
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AMMONIA REACTOR
Before going directly to the ammonia reactor synthesis gas leaving A-111-L, is preheated in
the ammonia converter feed exchanger , A-121-C, to 253 0c and sent directly to the
converter provisions has been made for by pass of the exchanger to control the temp. of the
converter feed.
N2 + 3H2 2NH3
The horizontal ammonia synthesis converter consists of a pressure shell, a removable
catalyst basket, and a ammonia converter interchangers. The converter contains 31.6m3 of
synthesis catalyst divided into three thermodynamics beds and four physical beds, each
supported on profile wire screens. The catalyst beds are arranged so that the first bed is the
smallest to limit the temperature rise. The feed gas to the converter is split into two
streams. The first feed split stream passes through an annular space between the shell and
converter basket. This helps to cool the shell and keeps the converter basket at a uniform
temperature. This feed gas stream receives some preheat prior to interchanger tube side
where it is preheated to the desired first bed temperature. The second feed split stream is
heated in the second interchanger tube side before mixing with the first preheated split
feed stream. The preheated total converter feed stream passes down through the first
catalyst bed where over 50% of the total ammonia conversion occurs. The first bed effluent
is cooled by passing through first interchanger shell side and flows to the second bed.
The cooled first bed effluent passes down through the second catalyst bed where more
ammonia conversion and temperature rise take place. The effluent from the second bed is
cooled passing through the shell side of the second interchanger before flowing down over
the third beds. The third catalyst bed is divided into two physical beds in series flow
configuration. This is to ensure uniform flow over the catalyst. Further reaction in the
third catalyst beds raises the converter outlet temperature to about 454 0C and the
ammonia concentration to 15.8 mol %.
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The design feature of an intercooler horizontal ammonia converter has the advantage of
producing a relatively high ammonia concentration per pass and making the heat available
in the converter effluent at a sufficiently high temperature for high pressure steam
generation. The horizontal arrangement of the converter produces a lower pressure drop
through the catalyst beds then a vertical, axial-flow type and enables removal of the basket
and interchanger
by using a diameter that is within the fabricating limitations of full closure.
The heat of reaction from the ammonia synthesis is recovered from gas leaving the
converter by cooling it to 278 0C in the ammonia converter effluent BFW preheaters.
The cooled converter effluent is further condensed in the ammonia converter effluent
recycle exchanger. This specially designed chilled further provides for cooling of the
converter effluent through interchange of the heat with ammonia vapors returning from
the ammonia product separator and boiling ammonia liquid at four different temperature
levels ( 20.6 0C, 0 0C, -17.9 0C, -33.3 0C).
This unitized chiller consists of multiple co centric tubes which run through the boiling
ammonia compartments. Synthesis gas recycle vapors pass counter currently through the
center tube and the converter effluent flows through the annular tube. Thus, the converter
effluent is being cooled from the outside by ammonia refrigeration and from the inside by
vapor from the ammonia separator. The converter effluent is condensed at -17.8 0C in the
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unitized chiller and the liquid product disengaged immediately downstream in the
ammonia product separator.
Recycle vapor from the ammonia separator, containing near 2.79 vol% ammonia, is
reheated in the unitized chiller as described above. After leaving the exchanger, a small
portion of the gas is split off to the ammonia absorber, to prevent inert gas accumulation in
the loop and recover the remaining
ammonia in the purge gas. The remainder of the recycle vapor is directed to the synthesis
gas compressor, mixed with fresh synthesis loop feed, and compressed for reuse as feed to
the converter.
Liquid from the ammonia separator is flashed into the ammonia letdown drum. The
flashed vapor, primarily inert, is mixed with the refrigeration system purge gas and sent to
the ammonia absorber. The liquid ammonia product is then split into several streams
leading to the refrigeration system and to the purge gas cooler section of the refrigerant
receiver.
AMMONIA REFRIGERATION SYSTEM

A four stage ammonia refrigeration system provides refrigeration for ammonia
condensation in the synthesis loop, recovery of ammonia from vented gas, and synthesis gas
compressor make-up gas chilling. The four refrigeration levels operate at approximately
20.6 0C, 0 0C, -17.9 0Cand -33.3 0C.
The refrigeration system consists of a two-case centrifugal compressor with two
intercoolers, a refrigerant condenser, a refrigerant receiver, evaporator and a four stage
flash drum which forms an integral part of the unitized exchanger. Provision is made for
contact chilling and venting of any inert gases dissolved in the warm liquid ammonia
product.
Additional provision is made to recover a small amount of ammonia vented from
atmospheric storage to the first stage suction of the refrigeration compressor.
Ammonia vapor from the second case of the ammonia refrigerant compressor is cooled,
condensed at 38.2 0C in the refrigerant condenser and then sent to the refrigerant receiver.
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Inert and uncondensed ammonia vapor from the refrigerant receiver and the refrigerant
condenser enter the contact chiller section on the top of the receiver where it is washed with
cold ammonia from the ammonia letdown drum condensing the ammonia to drain back to
the vessel. The inert gases containing ammonia vapor from---along with the flash gases
from ---- are sent to the ammonia absorber.
A major portion of the liquid ammonia from the refrigerant receiver after mixing with a
small amount of the cold ammonia from the letdown drum leaves as warm ammonia
product from the plant. It is pumped by the hot ammonia product pump to the urea plant.
The remaining liquid is flashed into the fourth stage refrigerant flash drum at 20.6 0C and
8.9 kg/cm2a. Liquid in the fourth stage drum provides refrigeration to the fourth stage
chiller section of the unitized exchanger.
Liquid from the fourth stage drum is flashed by letdown into the third stage refrigerant
flash drum at 00C and 4.4 kg/cm2. a portion of the liquid from the fourth stage refrigerant
flash drum is routed to the synthesis gas compressor interstage chiller with the vapors
delivered to the third stage flash drum. Liquid in the third stage drum provides
refrigeration directly to the third stage chiller section of the unitized exchanger.
Liquid from the third stage drum is flashed into the second stage refrigerant flash drum at
-17.9 0C and 2.1 kg/cm2a. liquid in the second stage drum provides refrigeration directly to
the second stage chiller section of the unitized exchanger. The net liquid from the second
stage drum is flashed into the first stage refrigerant flash drum at -33.3 0C and 1.0kg/cm2a.
Liquid in the first stage drum provides refrigeration directly to the first stage chiller
section of the unitized exchanger and can also be sent to the atmospheric storage tank via
the cold ammonia transfer pump.
The vapor generated in the four refrigeration drums are fed to the appropriate stage of the
two case, steam turbine driven centrifugal ammonia refrigerant compressor. The heat of
the compression is rejected to the refrigerant compressor 2nd stage intercooler and to the
refrigerant compressor 3rd stage intercooler. The vapors are compressed, condensed, and
returned to the refrigerant receiver, thus completing the refrigerant cycle.
| 22
PROCESS CONDENSATE STRIPPER

Process condensate from the carbon dioxide absorber feed gas separator is recovered and
reused in the ammonia plant after treatment.
Process condensate can contain up to 1000 ppm (by weight) ammonia, 3000 ppm (by
weight) carbon dioxide, and 1000 ppm (by weight) methanol and higher alcohols. Before its
reuse, the condensate is stripped by steam in the process condensate stripper to reduce the
ammonia content to about 10 ppm (by weight) , carbon dioxide content to less than 10 ppm
(by weight) , and the combined methanol and higher alcohol content to approximately 25
ppm (by weight) . The stripped condensate may also contain up to 2.5 ppm (by weight) of
metals.
The treatment of the process condensate is carried out by steam stripping in a packed
column using a portion of the high pressure process steam. The process condensate is
preheated by the stripper effluent in the condensate stripper solution exchanger, and then
distributed to the top of stripper packing. The process condensate is stripped by the rising
counter current flow of steam. The stripper overhead is mixed with the remaining process
steam and combined with the desulphurized process natural gas and enters the primary
reformer mixed feed coil. The stripped condensate, after partial cooling in the condensate
stripper solution exchanger, is further cooled with cooling water in the stripped condensate
effluent cooler at 41 0C before being sent to water treatment plant.
AMMONIA RECOVERY SYSTEM

The high pressure purge gas from the synthesis loop along with the flashed gases from A109-f and A-107-F are sent to the ammonia absorber via the purge gas ejector. In the
packed tower at 60.7kg/cm2a/ ammonia is absorbed by the water wash. The absorber
overhead gas is used as fuel in the primary reformer.
The solution leaving the absorber with the ammonia concentration of about is heated
about in the ammonia solution exchanger,against hot water from the ammonia rectifier,
| 23
bottoms. The heated aqueous solution enters the ammonia stripping column below the
reflux section of packing. Liquid ammonia reflux to the top of the stripper.
Column is provided from the refrigeration system via a side stream at the discharge of the
hot ammonia product pumps. The ammonia vapor from the top of the column is fed to the
refrigerant condenser, -- where it is condensed.
Stripping heat is provided by the ammonia rectifier reboiler, which uses high pressure
steam. The ammonia solution exchanger cools the rectifier bottoms which contain (weight)
to and the ammonia solution cooler, cools the stripper water to -- . a small amount of
condensate from is added to the rectifier as needed to make up for water losses in the
absorber overhead. A scrub water pump is used to pump the cooled water to the top of the
absorber.
STEAM SYSTEM
There are three principle steam system in the ammonia plant. In order to effectively
recover heat efficiently from the process, a super high pressure superheated steam
system is used to drive the major movers in the plant. This super high pressure steam is
generated in the auxiliary boiler and in the reformed gas waste heat boiler and is used to
drive the synthesis gas compressor, -- and refrigerant compressor, -- turbines. Boiler feed
water for this generation system is pumped by the h. p. blew pump through the boiler feed
water heaters, --and to the steam drum. the super high pressure steam is also used in the
mathanator start up heater, and the molecular sieve regeneration heater and is let down as
well to the high pressure header when any of the above turbines is down.
The high pressure header at 44.0kg/cm2a, 390 0C is the principle distribution system in the
plant. It is supplied by the extraction steam from A-103-JT AND A-105-JT and by letdown
when the plant is not in full operation. The motive steam for the air compressor , natural
gas compressor, H.P. BFW pumps, condensate pump for A-101-JC, forced draft and
induced draft fan, semi lean solution circulation pump, and lube oil and seal oil pump
turbines is supplied from this system along with the process steam for the condensate
| 24
stripper and for the primary reformer, and the reformer air coil. High pressure steam is
also exported to the urea plant.
The low pressure header (4.5kg/cm2a, 282 0C) is the distribution system for the low energy
level users in the plant. It is supplied by the exhaust steam from the condensate pump,
forced draft and induced fans, the seal oil and lube oil pumps turbines, the seal leak-off
steam from A-103-JT and A-105JT, and also the exhaust steam from the steam blow down
drum. It supplies part of the
motive steam for the air compressor turbine and surface condenser ejectors, and the
heating steam for the dearator and various small process users.
The surface condenser is used to provide low level exhaust conditions (99 mmHga, 50 0C)
for the process major prime movers. The capability of this unit to condense steam at very
low energy conditions bears directly on the efficiency and economic success of the plant.
This condenser receives vapor from the exhaust of the synthesis gas compressor, air
compressor, natural gas compressor, and the H.P. BFW turbines and also from the urea
plant. The collected condensate is pumped out of the condenser by the condensate pump(s)
send to the secondary reformer water jackets and to water treating for reuse in the plant.
| 25
| 26
Urea Section
| 27
GENERAL OVERVIEW
Urea [CO (NH2)2], also known as carbamide or carbonyl diamide, is marketed as a
solution or in solid form. Most urea solution produced is used in fertilizer mixtures,
with a small amount going to animal feed supplements. Most solids are produced as
prills or granules, for use as fertilizer or protein supplement in animal feed, and in
plastics manufacturing. Five U. S. plants produce solid urea in crystalline form.
About 7.3 million mega grams (Mg) (8 million tons) of urea were produced in the U. S
in 1991. About 85 percent was used in fertilizers (both solid and solution forms), 3
percent in animal feed supplements, and the remaining 12 percent in plastics and
other uses.
UREA MANUFACTURING PROCESS

The process for manufacturing urea involves a combination of up to 6 major unit
operations.
Urea plant is generally divided into following sections.
1- Compressor
2- Synthesis Section & high pressure recovery.
3- Purification & Recovery Section.
4- Concentration Section.
5- Prilling Section.
6- Waste Water Treatment Section.
| 28
PROCESS DESCRIPTION
SYNTHESIS SECTION & HIGH PRESSURE RECOVERY
In the solution synthesis operation, ammonia (NH3) and carbon dioxide (CO2) are
reacted to form ammonium carbamate (NH2CO2NH4).
Typical operating conditions include temperatures from 180 to200C (356 to 392F),
pressures from 140 to 250 atmospheres (14,185 to 25,331 kilopascals) NH3:CO2 molar
ratios from 3:1 to 4:1, and a retention time of 20 to 30 minutes. The carbamate is then
dehydrated to yield 70 to 77 percent aqueous urea solution. These reactions are as
follows:
ACES21 process synthesis section consists of a

reactor, a stripper and a carbamate condenser.
Liquid ammonia is fed to the reactor via the HP
Carbamate Ejector which provides the driving
force for circulation in the synthesis loop
instead of the gravity system of the original
ACES. The reactor is operated at an N/C ratio of
3.7, 182 C and 152 bar. The CO2 conversion to
urea is as high as 63% at the exit of the reactor.
Urea synthesis solution leaving the reactor is
fed
to
the
stripper
where
unconverted
carbamate is thermally decomposed and excess

ammonia and CO2 are efficiently separated by
CO2 stripping. The stripped off gas from the stripper is fed to the Vertical
| 29
Submerged Carbamate Condenser (VSCC), operated at an N/C ratio of 3.0,180C and

152 bar.Ammonia and CO2 gas condense to form ammonium carbamate and
subsequently urea is formed by dehydration of the carbamate in the shell side.
Reaction heat of carbamate formation is recovered to generate 5 bar steam in the tube
side. A packed bed is provided at the top of the VSCC to absorb uncondensed
ammonia and CO2 gas into a recycle carbamate solution from the MP absorption
stage. Inert gas from the top of the packed bed is sent to the MP absorption stage.
PURIFICATION & RECOVERY SECTION

The major impurities in the mixture at this stage are water from the urea production
reaction and unconsumed reactants (ammonia, carbon dioxide and ammonium
carbamate). The unconsumed reactants are removed in three stages3. Firstly, the
pressure is reduced from 240 to 17 barg and the solution is heated, which causes the
ammonium carbamate to decompose to ammonia and carbon dioxide:
At the same time, some of the ammonia and carbon dioxide flash off. The pressure is
then reduced to 2.0 barg and finally to -0.35 barg, with more ammonia and carbon
dioxide being lost at each stage. By the time the mixture is at -0.35 barg a solution of
urea dissolved in water and free of other impurities remains. At each stage the
unconsumed reactants are absorbed into a water solution which is recycled to the
secondary reactor. The excess ammonia is purified and used as feedstock to the
primary reactor.
CONCENTRATION SECTION
75% of the urea solution is heated under vacuum, which evaporates off some of the
water, increasing the urea concentration from 68% w/w to 80% w/w. At this stage
some urea crystals also form. The solution is then heated from 80 to 110oC to
redissolve these crystals prior to evaporation. In the evaporation stage molten urea
| 30
(99% w/w) is produced at 140oC.The remaining 25% of the 68% w/w urea solution is
processed under vacuum at 135oC in a two series evaporator-separator arrangement.
PRILLING SECTION.
There are 2 types of prill towers: fluidized bed and non fluidized bed. The major
difference is that a separate solid cooling operation may be required to produce
agricultural grade prills in a non fluidized bed prill tower.
The solids screening operation removes off size product from solid urea. The off size
material may be returned to the process in the solid phase or be redissolved in water
and returned to the solution concentration process.
Urea is sold for fertilizer as 2 - 4 mm diameter granules. These granules are formed
by spraying molten urea onto seed granules which are supported on a bed of air. This
occurs in a granulator which receives the seed granules at one end and discharges
enlarged granules at the other as molten urea is sprayed through nozzles. Dry, cool
granules are classified using screens.
Oversized granules are crushed and combined with undersized ones for use as seed.
All dust and air from the granulator is removed by a fan into a dust scrubber, which
removes the urea with a water solution then discharges the air to the atmosphere. The
final product is cooled in air, weighed and conveyed to bulk storage ready for sale.
| 31
| 32
A
Apppprrooxxiim
maattee ppeerrcceennttaaggee ooff pprriinncciippaall eelleem
meennttss iinn ddiiffffeerreenntt
FFeerrttiilliizzeerrss
| 33
Utility section
| 34
GENERAL OVERVIEW
Utilities include the following sections
Water intake facility
Water treatment plant
Cooling tower
IGG (Inert gas generation)
G.T(Gas Turbine), HRSG (Heat recovery and steam generation)
Package Boiler
Mitsui Boiler
WATER INTAKE FACILITY

For the supply of raw water, PAFL has its own water pumping station near Indus River
(Banian Tree site/area.). The Raw water coming from Banian Tree area is used for the
following purposes:
Make up water for Cooling Tower (old +new).Normal raw water use=3000m3
Potable water at Plants.
Potable water at PAFL Housing colony.
Water Treatment plant to produce DM water.
As cooling water during emergencies.
As fire water, 1100m3.
Water intake facility comprises on the following:
TUBE WELLS
06 tube wells are in operative condition, designed capacity of these tube wells is 3.0 cusec
but due to continuous operation, capacity of old pumps (installed in 1997and before)has
dropped to 2.0 ~ 2.5 Cusec.
1. No of Tube Wells in operative condition, installed before 1997 .01
2. No of Tube Wells in operative condition, installed in 1997 .03
| 35
3. No of Tube Wells in operative condition, installed in 2004 .02

(For these two tube wells, new bores were drilled; one new pump and one old pump were
installed)
PIPE LINE
1. 24 and 3948 meters length Pipe Line from Banian Tree to PAFL plants.
12 ~ 08 and 1500 meters length Pipe Line from PAFL plants to Housing Colony.
RAW WATER ANALYSIS

pH
7.5-7.6
M. Alkalinity
120-130 ppm CaCO3
Calcium
112-125 ppm CaCO3
Magnesium
40-50
Total hardness 1
60-170
Chlori de
10-17 ppm
Sulphate
40-50
Silica
12-16
WATER TREATMENT PLANT:

For the production of de-mineralized water, required for steam generation PAFL has a
water treatment plant of El-Car Company of Italy having 85-tons/hr capacity. This plant
comprises on three sand filters and two Ion Exchange Lines, each line comprising on
Cationic exchangers, de-gasifier, and Anionic exchangers, mixed bed and Auxiliaries for
the regeneration of these Ion exchangers.
Operating hours of each line/train are:
Cation exchanger/Anion Exchanger = 1020 m3
Mixed Bed
= 168 hrs
Following resins are being used at Water treatment Plant

a) Strong Cation resin (for Mixed bed exchanger)
b) Strong Anion resin (for Mixed bed exchanger)
Amber jet 1200 Na

Amber jet 4200 Cl
| 36
c) Weak Acid Cation resin (for Cationic exchanger)
D 113/ Dilute C 433
d) Strong Acid Cation resin (for Cationic exchanger)
Amber jet 1200 Na
e) Strong base Anion resin (for Anionic exchanger) Amber jet 4200 Na
For the regeneration of Cationic resins 98% H2SO4 is used and for the regeneration of
Anionic resins 50% NaOH is used.
COOLING TOWER
Purpose:
Cooling water is used at a plant for condensing steam, for cooling product feed gases, and
also for equipment cooling. It is considered, to beWATER and the WET BULB
temperature of the air surrounding it.
Brief Description:
PAFL cooling tower is an
induced draft type-cooling
tower with Counter Flow
design. The air enter the
tower through the louvers at
the
tower base, pulled upward
and
comes in contact with falling

droplets of water.
In the counter flow towers,
the
drift eliminators are located at the top. The eliminators are placed just ahead the fans to
prevent windage losses.
These types of towers are specially designed to minimize windage and drift losses which are
controlled at 0.005 % and 0.3 % of the water circulation rate.
The main component of a cooling water cell is.
1. A frame work i.c. outer structure of a cooling tower cell.
2. A system of fluid distribution and dispersion above the fill (fill: packing).
| 37
3. A film pack fill, which acts as a heat exchanger between the liquid and air.
4. A catchments pond or bay which provides the recooled water to various consumers.
5. A fan which induces the draught.
6. A drift eliminator is to catch the water droplets practically going out with air.
Design Data:
Item No.
C-EF-3301 A-F
Service
Cooling Tower
Quantity
One (1) with six cells.
Type
Mechanical draft - Counter flow
Design and Operating Conditions:

Circulating water flow
15000 M3 / hr.
Hot (Inlet) water temperature
43 oC
Cold (Outlet) water temperature
33 oC
Wet bulb temperature
30 oC
Tower pump head
9.76 M
Total fan B.H.P
777 KW
Drift losses
0.01 % (of circulated capacity)
Evaporation losses
1.66 % (of circulating
Design wind load
44.4 m / Sec.
Design seismic load

Tower site
cap)
0.12 % G.
Ground level (Tower will be constructed above
ground level).
Elevation above sea level
228.5 m
Tower exposure
Open
Structural Details:
Number of cells
Six (6)
Fan per cell
One (1)
| 38
Total number of cell
Six (6)
Nominal cell dimension
12.85 x 13.60 M
Over all tower dimension
78.76 x 13.96 M
Height of fan deck
12. 18 M
Fan stack height
3.2 M
Over all tower height
15.38 M
Inside basin dimension
78.16 x 15.60 M
Hot water inlet pipe points
Six (6)
Nominal dia.
32 (24)
Height of inlet pipe
9.26 M
Access to top of water
Stairway and cage ladder
Material Of Construction:
Frame work
Reinforced concrete (RC.)
Casing
RC
Filling
Poly propylene (PP) Grid
Supports
304 SS
Drift eliminators
PVC
Spacer
PP
Fan stacks
FRP
Louvers
RC
Partitions
RC
Water distribution
Channel
Material
RC / HD4 Steel Pipe
Splashers of spray Nozzles
Poly propylene (PP)
Bolts, Nuts, washer
304 SS
Mechanical equipment support
HDG steel (Supplied by Hamon)
Anchor Bolts material
HDG Steel
Cold water basin
RC
| 39
First Time Water Filling / Cleaning:
First clean the basin toughly and fill it with raw water.
The feed valves to the cells are closed and only open flushing valve.
Pump the water round the circuit for some time, in order to clean the circuit. Under
no circumstance the water from the first start up be fed to the cells since this water
being dirty and is likely to block the nozzles.
Once the circuit has been properly flushed, the pumps are to be stopped, the basin
emptied and cleaned out.
Fill the basin / bay again with water and start operation.
Start-up the pump, to avoid water hammering open the cell feed valves slowly.
Check the equilibrium of water distribution between the cells.
Check the water level of each cell under normal condition. Check the flow to ensure
that the design flow is not exceeded. The Bay, Nozzles, Fill all are designed to
tolerate only 15-20 % of increased flows then design condition.
OPERATION
FIRST START-UP
Checks Before The First Start Up:

1.
First check fan shaft alignment maximum tolerance is 0.05 mm.
2.
Check the fan pitch.
3.
Check oil level in the gear box.
4.
Manual check of rotation of motor / fan unit.
5.
Ensure that no stray material like boards, ladders and tools are present their.
6.
Check the rotational direction of motor, if not correct reverse the terminal
connection.
| 40
Start Up Of Fans:
The first start up of fan is done with no water flow.
Check that power is available.
Check the power requirement of fan and adjust its Pitch in accordance to power
demand / ambient temperature.
Point:
It is to be noted that more power is required when fan is running without load (with no
water)
Check the bearing vibration / noise.
This process of fan operation should continue far one
Stop after one (1) hr of running and check all bearings / oil temperature.
If no overheating is found, then run for another 4 hour and check temperatures of
hour.
oil and bearings again.

No over heating of bearing is said to occur when temperature less than 40 oC.
RESTARTING AFTER A STOPPAGE
Preliminary Checks:
Check gear box oil level.
Check rotation of motor.
Check water level in Bay.
Check that vibration switch is on.
Check that no other material is present in the Bay, which can cause problem during
operation.
| 41
IGG (INERT GAS GENERATION)

Purpose:
The linde-PSA (Pressure swing adsorption) plant works according to the principle of
Adsorptive separation of air. The use of the adsorption technique in the recovery of gases
is based on the ability of porous adsorption material. The loading capacity of gases depends
on pressure and temperature and these two parameters are used to separate gases.
About
98 % is removed from air (nitrogen) and remaining 2% oxygen is removed by
reacting with hydrogen in pressure of noble catalyst.
DESCRIPTION OF PROCESS
Compression
Ambient air will be compressed to a working pressure of 10 kg/cm2 by an oil free screw
compressor. The moisture in air will be drained automatically in the shape of condensate.
Adsorption
Water and CO2 will be adsorbed preferentially in the inlet zone after which O2 is
adsorbed. The product N2 flows from the absorber out let to the N2 buffer vessel and then
to the deoxo system.
Adsorption
After the adsorption of water, CO2 and O2, the desorption of these gasses will be done to
the atmosphere.
Pressurization
After completion of the desorption process, the adsorption phase will start by pressure
equalization between the two adsorbers. Further pressure will be developed with process
air by the air compressor.
The two absorber having the following cycles.
Adsorption (N2 production)
Desorption (Depressurization)
Again pressures build up.
| 42
Deoxydation
N2 gas from PSA unit is fed to deoxy system where the rest of oxygen is removed by
recombination with hydrogen. The gas is cooled by air and water; the condensed water will
be drained.
Drying
The remaining water is removed by means of an adsorption drier. The drier consist of two
beds. One bed is in the adsorption mode and the other in the regeneration mode.
Regeneration will be done by heating-up and then purging.
Safety
1.
Smoking and all naked flames are prohibited.
2.
Take special measures to avoid electrostatic charges. Do not wear shoes studded
with iron nails.
3.
Parts exposed to O2 must be free from inflammable materials.
4.
The clothing of personnel must be free from any oil and grease.
5.
The greased parts must be cleaned only with hydrocarbon chlorides or hydro
carbon fluorine chlorides.
6.
The storage of combustible material in plant area is prohibited.
7.
Prior to personnel entering to Nitrogen processing vessels and piping the

equipment must be purged with dry air. The laboratory analysis must be done
before vessel entry.
8.
It is prohibited to work in the area where concentration of N2 is more than the

recommended.
DESIGN DATA
Air Consumption
Air Consumption C-1161
Air consumption
1800 m3 /hr (process Air)
Design air inlet of adsorber
1340 Nm3 / hr.
Barometric Pressure (Inlet)
0.982 bar (a)
Ambient air temperature (Inlet)
+ 48 oC
| 43
Relative Humidity
85 %
Outlet temperature of air
63 oC
Pressure of Air
0.982 bar (a)
Plant Capacity
1. Gaseous N2 product.
400 NM3 /hr.
2. O2 content
<10VPPM
3. Product pressure at battery limit
7.0 bar (a)
4. Dew point at 1.013 bar
- 40 oC
Air Compressor C-1161

Manufacturer
ATLAS COPCO
Type
Rz 4 - 56 EPN - HS
The compressor consist of following equipment

1.
Two stage oil free screw compressor as package unit with suction filter.
2.
Intermediate and after cooler
3.
Water drain system
4.
Noise protection cover
5.
HV-Motor
Design data
Capacity
1340 NM3 /hr. ( Design )
Pressure
10 bar ( a )
Motor rating
250 Kw
Adsorber :
Manufacturer
LOHENNER
| 44
Design data
Volume
2.1 m3
Max. working pressure
12.0 bar ( a )
Maximum working temperature
80 oC
Diameter
1000 mm
Overall height
3930 mm.
Silencer
Manufacturer
LOHENNER
Design Data
Volume flow Max.
9200 NM3 /hr.
Pressure drop
<0.1 bar
Diameter
800 mm.
Overall height
3250 mm
Nitrogen buffer vessel

Manufacturer
LOHENNER
Design Data
Geometric volume
2.0 m3
Max. permissible working press.
12.0 bar ( a )
Max. permissible working temp.
80 oC
Diameter
1150 mm
Overall height
2340 mm.
Deoxo system
Manufacturer
HAMMER
This system is designed for reaction of remaining O2 with H2 to reduce O2 level in N2 gas
by <10 VPPM.
This unit consists of Deoxo reactor, Air cooled heat exchanger, Water cooled heat
exchanger and condensate trap with drain.
| 45
Design Data
Volume flow max.
450 Nm3 /hr.
11.50 bar ( a )
300 oC
Length
2250 mm
Width
1200 mm
Overall height
2600 mm
H2 ( Hydrogen):
Consumption
28 Nm3 /hr.
Pressure
9 - 12.5 bar ( a )
Temperature
45 oC
Analysis
N2
24.7 % by V
Ar
0.30
by V
CH4
0.80
by V
H2
74.2 % by V
Adsorption drier :
Manufacturer
ULTRAFILITER
Warm regenerated two-bed adsorber system as package unit.

Design Data
Volume flow max.
446 Nm3 /hr.
11.5 bar ( a )
120 oC.
Length
1020 mm
Width
1150 mm
Overall height
2765 mm
| 46
PLANT OPERATION
Start up:
The plant operation is very simple as the unit is fully automatic as soon as we push the
button the product of N2 will be delivered with-in a few minutes.
Before starting the plant following points must be checked in detail.
1.
Check that power is available.
2.
Check that cooling water is available.
3.
Check that hydrogen (H2 ) is available.
4.
Check that instrument air is available.
5.
Start air compressor unloaded by pressing button HS-1101. Then switch the
compressor to load.
6.
Start PSA (pressure swing Adsorbed) by pressing button HS-2701.After some

time (few seconds) the PSA-valves will work according to the start-up cycle. As
long as purity of the gases are bad, N2 will be vent through the silencer of the N2
drier via S-2780, PCV-2794 is closed.
7.
Start N2 drier by pressing button HS-2727.
8.
If N2 purity at QIC-2757 is higher than 98 %, start deoxo by pressing HS2741. Also start H2 - supply via H2 control valve -2762 simultaneously.
9.
It O2 content at QIC-2792 is lower than 10VPPM, then open the product valve
PCV-2794 and close S-2780.
SHUT-DOWN
MANUAL SHUT-DOWN
1.
Stop the deoxo by pressing HS-2741. The product valve PCV-2794 will be closed
and by-pass valve S-2780 will be opened.
1.
Butter fly valve 2760 will close.
2.
The pressure in the deoxo and drier will be released to the atmosphere.
| 47
3.
Stop the air compressor by pressing HS-1101.
4.
Stop the PSA by pressing HS-2701.
5.
Stop the drier by pressing HS-2727.
EMERGENCY SHUT-DOWN
If there is any danger for plant equipment or operating staff, shut-down the plant by
emergency push buttons They will become stand still within a few seconds due to its
PLC ( programmable logic controller )
TROUBLE SHOOTING
If the plant is shut OFF as per Common alarm take the following actions for resetting.
-
First reset horn by push button HS-9302.
After problem has been solved reset alarm by push button HS-9301.
TROUBLE SHOOTING OF ADSORBER SYSTEM

If the product purity is lower than designed then.
1.
Check pressure rising and final pressure of each adsorber. If there is a

difference in the pressure of two adsorber, check the sealing of all piping
connections and flanges for any leakage.
2.
Check the correct functions of all butterfly valves.
3.
If the rise in pressure and final pressure of each adsorber is identical then.
Check quantity of delivered compressed air.
Check the adjustment of product flow valve FCV-2794. Increase in product flow
means less product purity and vice versa.
Check the drain of the air compressor.
An increase of water content in process air means a decreasing of product purity

/ quantity.
Check the inlet temperature of compressed air into the adsorber unit High inlet
temperature means low product purity.
| 48
Trouble shooting of Deoxo system.

If product purity is lower than designed then.
1.
Check correct hydrogen supply.
2.
Check temperature rise of the gas in the deoxo-reactor (TISA-2765). If temperature
rise is two low, insufficient reaction takes place which means decreasing product purity. If
the temperature is too high, the adsorber station is delivering gas with too much O2.
IMPORTANT REASONS FOR PERFORMANCE LOSSES
-
Leakage of valves, flanges or other connections.
Wrong switching lines of valves.
Moisture, dust and solid particle in blow off silencer
Fouling of adsorber molecular sieves by oil/moisture etc.
Changing of ambient conditions (day and night drifting)
Adsorber not completely filled up with ZMS (ZEOLITHIC MOLECULAR SIEVE)
Boiler # 1 HR&SG:
Boiler No. 1 is manufactured by bibcock and Wilcox Company of U.S.A and was installed
in 1954. Initially it was designed for coal firing, but in 1972 its firing method was modified
and changed from coal burning to Natural gas burning. Its steam generation capacity is
155000 Ibs/hr and is used for supplying steam for power generation and to Phase-II for
plant operation.
Manufacturer
= Babcock & Wilcox Boilers
Type
= Water tube
Capacity
= 155000 Ib/hr
Steam pressure
= 775 Psi (g)
Heating surface
= 13948 sq. ft.
Fuel
= Natural gas (modified) coal (design)
No. of Burner
= 04
| 49
Boiler water holding capacity
(at normal level)
Furnace draft
Heat recovery system
= Tubular type air pre-heater
Temperature control system
= Attemprator, surface contact type.
= 96,400 Ibs
= Balance draft
Boiler # 3 or Mitsui Boiler
Manufacturer
Evaporation Capacity
Mitsui Engineering Corporation, Japan

at peak
90,000 Kg/hr
at MCR 85, 000 Kg/hr
Design pressures
60 Kg/cm2 G.
Steam pressure
at super heater outlet 50 Kg/cm2 G.
Steam temperature
Feed water temperature
drum inlet 165 oC
Draft system
forced draft
Firing system
oil & gas
Fuel
at super heater outlet 450 + 5 oC
natural gas
Furnace oil
gas air heater
The Mitsui Boiler is fitted with combination firing steam using oil and gas as fuel. Burners
firing are automatic and equipped with safety tripping devices.
The unit is equipped with wind box housing adjustable blade type air regulator for
producing the necessary turbulence, air movement, provided with manual control device,
inspection and ignition doors, stainless steel damper impeller, explosion door etc.
For fuel oil firing, complete line starting from Furnace oil receiving station to all burners.
Each burners is provided with manual shut off and electro-preumatic shut off valve
connected to flame protection devices. Steam consumption for Furnace oil atomization is
not more than 1.1% of Boiler minimum production.
| 50
Turn down ration of the Boiler is not less than 4 to 1

Package Boiler
Manufacturer
HMC, Pakistan
Evaporation Capacity
30000 Kg/hr
Design pressures
45 Kg/cm2 G.
Steam temperature
Air temperature
Draft system
Fuel
natural gas
Economizer
at super heater outlet 395 + 5 oC

at FDF inlet 25 oC
forced draft
The Package Boiler is fitted with combination firing steam using oil and gas as fuel.
Burners firing are automatic and equipped with safety tripping devices. The unit is
equipped with wind box housing adjustable blade type air regulator for producing the
necessary turbulence, air movement, provided with manual control device, inspection and
ignition doors, stainless steel damper impeller, explosion door etc.
For fuel oil firing, complete line starting from Furnace oil receiving station to all burners.
Each burners is provided with manual shut off and electro-pneumatic shut off valve
connected to flame protection devices. Steam consumption for Furnace oil atomization is
not more than 1.1% of Boiler minimum production.
Instrument air/ Plant air section

For the supply of plant air and Instrument air, a air compressor IGB 3601 A having
capacity of 3520 Nm3/hr is provided along with the provision of air supply from Ammonia
plant air compressor 101 J.
To meet power failure emergency air compressor IGB 3601 B and air reservoir IFA
3601 is also provided.
For Instrument air two set of air dryers are provided.
| 51
| 52

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Department of Chemical Engineering and Technology

UNIVERSITY OF THE PUNJAB

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INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

Digitally signed by ICET Students

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

FEED STOCK SPECIFICATIONS:

Pressure at battery limits:

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

The process is described in the following sections:

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

RAW SYNTHESIS GAS PREPARATION

Conversion of carbon mono oxide and steam in the reformed gas.

| University Of The Punjab

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Natural gas feed preheat for desulphurization.

Steam super heating.

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

Reformer fuel preheats.

Combustion air preheats for the reformer burners.

CH4 + H2O 3H2 + CO

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

SYNTHESIS GAS PURIFICATION

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

C by the methenator effluent in the methenator feed exchanger A-190-C a by pass is

INTERNSHIP REPORT (Pak American Fertilizer Limited)

| University Of The Punjab

Downloaded From : http://www.ICETStudentS.com

SYNTHESIS GAS COMPRESSION AND AMMONIA