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FIGURE..1
The total Urea Production from IFFCO Phulpur Complex was 16.84 Lakh MT
out of which 6.32 Lakh MT is from Phulpur-I and 9.92 Lakh MT from Phulpur-
II in the FY 2016-17.
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PRODUCTION CAPACITY
PHULPUR-1
PHULPUR-II
➢ Properties of Urea:
• Structure:
Color White
Heat of solution in water -57.8 Cal./gm
Critical relative Humidity
20oC 81%
30oC 73 %
Viscosity at 150°C 2.16 CPS
Crystallization Heat 47.0 Kcal/Kg
Fusion Heat 59.95 Kcal/Kg
Specific Heat (Cal/gm/°C) 20oC 0.32
➢ Uses of Urea:
• Agriculture:
More than 90% of world industrial production of urea is destined for use as a
nitrogen-release fertilizer. Urea has the highest nitrogen content of all solid
nitrogenous fertilizers in common use. Therefore, it has the lowest
transportation costs per unit of nitrogen nutrient.
Thus urea fertilizers are very rapidly transformed to the Ammonium form in
soils. Ammonium and nitrate are readily absorbed by plants, and are the
dominant sources of nitrogen for plant growth. Urea is highly soluble in water
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and is, therefore, also very suitable for use in fertilizer solutions (in combination
with ammonium nitrate: UAN), e.g., in 'foliar feed' fertilizers .For fertilizer use,
granules are preferred over prills because of their narrower particle size
distribution, which is an advantage for mechanical application.
• Explosive:
Urea can be used to make UREA NITRATE, a high explosive that is used
industrially and as part of some improvised explosive devices.
• Chemical Industry:
Urea is a raw material for the manufacture of many important chemical
compounds, such as:
➢ Various plastics, especially the UREA-FORMALDEHYDE RESINS.
➢ Various adhesives, such as urea-formaldehyde or the ureamelamine-
formaldehyde used in marine plywood.
• Potassium cyanate, another industrial feedstock.
Iffco’s phulpur unit is the country’s first unit to convert naptha feed to RLNG
feed .phulpur unit 2 contain steam and power plant ,water treatment plant,
cooling tower ,inert gas generation ,ammonia storage and handling ,effluent
treatment plant.
• POWER GENERATION
Power Generation in IFFCO is done by GASTURBINE GENERATOR
(GTG)The power plant is designed to produce 18 MW of power at 11 KV, 50
HZ. The power is produced by a turbo generator, driven by steam turbine. The
whole package has been supplied by BHEL, Hyderabad. The steam turbine uses
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steam at 115 kg/cm2 and 515 deg. C as the motive fluid and is an extraction
cum condensing turbine. The TG set is DCS controlled.. GasTurbine Generators
basically involve three main sections:
• The compressor, which draws air into the engine, pressurizes it, and
feeds it to the combustion chamber at speeds of hundreds of miles per
hour.
• The combustion system, typically made up of a ring of fuel injectors that
inject a steady stream of fuel into combustion chambers where it mixes
with the air. The mixture is burned at temperatures of more than 2000
degrees F. The combustion produces a high temperature, high pressure
gas stream that enters and expands through the turbine section.
• The turbine is an intricate array of alternate stationary and rotating
aerofoil-section blades. As hot combustion gas expands through the
turbine, it spins the rotating blades. The rotating blades perform a dual
function: they drive the compressor to draw more pressurized air into the
combustion section, and they spin a generator to produce electricity .
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ECONOMIZER:
An Economizer for a heat recovery steam generator utilized to improve the
efficiency of the Rankine cycle by preheating the water that flows to the
evaporator section.
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BOILER:
This section simply contains two drums and two tubes connecting them. Two
drums are WATER AND MUD DRUMS. Water (Steam) through these tubes
due to Density Difference that is due to Temperature Difference.
2. OFFSITE PLANTS
Offsite Plants are to support production plants. Without offsite plants,
production plants have no existence. So, offsite plants are of great importance.
Following are the plants come under offsite section:
o Raw water system
o Water Treatment Plant (Demineralized Water Plant )
o Cooling Towers
o Effluent Treatment Plant
o Instrument Air Plant
o Inert Gas Generation Plant
o Ammonia Storage Plant
turbidity from 2 to 5 ppm on silica scale but dissolved salts are more and
sometimes render the water useless for industries without proper treatment.
Thus surface water, if available in plenty is preferred because of its purity and
less laborious treatment.
In IFFCO underground sub soil water is the only source of raw water.
Raw water from raw water storage is used for following purposes:
-In Water Treatment Plant
-Cooling Water Make Up
-For Fire Protection System
-For Cleaning Plant Area
-For Drinking Purpose
The water that could be used in Plant (D. M. Water) should have following
specifications:
• PH – 6.8 to 7.3
• Silica < 0.02 ppm
• Total Electrolytes – 0.1 ppm (Max)
• Hardness – Nil
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FIGURE..3 – DM PLANT
o COOLING TOWERS
Most of the units of any chemical plant are Heat Exchangers (may be
condenser, Boiler or Evaporator). So, every heat exchanger requires a cold fluid
to absorb heat and one hot fluid to release heat. In most of the heat exchangers
cold fluid is water and the plant to cool water is called cooling tower.
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Cooling Tower is also a type of heat exchanger and in IFFCO heat absorbing
fluid is air and heat releasing fluid is water. So,water cools down in this process.
Round shapes in the above photo at the top are Induced Draft (ID) Fans. ID
Fans suck air from atmosphere passes it through water, so air comes in contact
with water and heat transfer takes place as a result of which water cools
down.Chlorine (stored in yellow tanks) is also mixed in water to kill bacterias
and to increase its purity level. Hydro Chloric acid and Hydrogen Sulphate are
also mixed to maintain PH of water.
Effluent treatment plant is for the treatment of waste water of Ammonia and
Urea Plant. Waste water contains a little bit ammonia, salts and several other
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In the air stripper air comes in at bottom and comes out with impurities at top.
In the steam stripper steam comes in at bottom and comes out with impurities at
top.
The plant is designed to produce 3000 M3/hr of dry air. This is split flow no
loss type air drier. Supplier for this drier is M/s Gaso Energy Systems (India)
Pvt. Ltd. Pune.
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Atmospheric air can’t be used directly to open and close valves because it
contains moisture and many other impurities that could cause corrosion and
could kill the life of valves. So, Air used in plants is moisture and impurities
free and is known as instrument air. Instrument air is in use in each of the plants
and is kept in green color tanks in every plant.
Flow chart of Instrument Air Plant is given below:
• Heat Exchanger
• Expansion Turbine
• Condenser
FRACTIONAL DISTILLATION:
Fractional Distillation is the method of separating two fluids on the basis of
their boiling points. Because Nitrogen is most light here so, we get Nitrogen at
the top in the gaseous form.
➢ AMMONIA STORAGE
3. AMMONIA PLANT
RLNG
UREA MANUFACTURING
• REACTIONS:
Urea is produced from ammonia and carbon dioxide in two
equilibrium reactions:
produce 4.5 bar steam some of which can be used for heating purpose in the
downstream sections of the plant. The NH3 and CO2 in the stripper effluent are
vaporized in 4 bar decomposition stage and subsequently condensed to form
acarbamate solution. Further concentration of urea solution takes place in the
Evaporation section, where 99.7% of urea melt is produced. Figure
stamicarbon CO2 stripping process
C. (ACES Process )
ACES ( Advanced Process for Cost and Energy Saving ) process has been
developed by Toyo Engineering Corporation. Its synthesis section consists
of the reactor, stripper, two parallel carbamate condensers and a scrubber all
operated at 175 bar. The reactor is operated at 1900 C° and an NH3:CO2 molar
feed ratio of 4:1.
Its consist of five main sections
• Synthesis section
• Purification section
• Concentration and prilling section
• Recovery section
• Process condensate treatment section
• Selection Of The Process
Process Description
FIGURE..13-UREA REACTOR
Oxygen in the air (supplied with carbon dioxide) forms a passive oxide layer on
the insides of vessel surfaces to prevent corrosion by carbamate and urea. The
Reactor product contains 38 % by weight Urea.
• HIGH PRESSURE STRIPPER
Urea enters the tube of HP Stripper operating at 147 atm/190 °C which is falling
type heat exchanger. The stripper tubes are provided with liquid dividers also
called ferrules. Urea reactor supplies a mixture of urea, ammonia, carbon
dioxide, water and carbamate. In the HP Stripper unconverted is converted into
ammonia and carbon dioxide by using Henry’s Law.
HENRY’S LAW in HP stripper:
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vapors of ammonia carbon dioxide and water. The purpose of this section is to
partially strip out the
reactants, ammonia and carbon dioxide from the urea solution and, after their
condensation in water, to recycle the obtained solution to the reactor, together
with the ammonia and carbon dioxide aqueous solution resulting from the
downstream sections of the plant. The ammonia excess is separated in this
section and recycled to the reactor separately. A distillation column is provided
for this purpose. The operating pressure is 17 bar g. A particular feature is
included in this section. Ammonia and carbon dioxide are partially condensed in
the shell of a preheater within the vacuum section, thus recovering some energy
in the form of 200kg of steam per ton of urea. Another particular characteristic
of the MP section is the washing of the so-called inerts (CO, H2 and CH4
contained mainly in the carbon dioxide and the passivation air). As already
emphasized, the quantity of passivation air in the Snamprogetti technology is
very small (one third compared with other technologies). It is therefore easy to
recover ammonia from the inerts without the risk of explosion mainly due to
H2/O2 mixtures. No hydrogen removal from carbon dioxide is required.
• LOW PRESSURE SECTION
Further stripping of ammonia and carbon dioxide is made in the LP section,
operating at 3.5 bar g. The vapors, containing ammonia and carbon dioxide, are
condensed and recycled to the reactor via the MP section. An appropriately
sized tank is provided in this section to collect all the solutions from the plant
when it is shut down for long time. Therefore, in no circumstances are solutions
discharged from the plant.
• VACUUM CONCENTRATION
The urea solution leaving the LP section is about 70% b.w. and contains small
quantities of ammonia and carbon dioxide. The final concentration of the urea
solution (99.8% b.w.) is made under vacuum in two steps at 0.3 and 0.03 bar
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abs. for the prilled product, and in one or two steps for the granular product,
according to the granulation technology chosen. An important feature of this
section is the pre concentration of the urea solution to about 86% b.w. The
necessary heat is provided by partial condensation of the vapors (ammonia and
carbon dioxide essentially) from the MP section evaporator. Particular care is
taken in the design of this section to minimize temperatures and residence times
so as to keep the biuret at minimum values. A simple solution has been found to
the problem of lump formation in the second vacuum separator: lump formation
is prevented by wetting the internal walls of the separator by means of a small
recycle of molten urea.
• UREA PRILLING
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Unfortunately, dueto the large quantity of air, such a system has a rather high
investment cost as well asa considerable operating cost. Snamprogetti has
patented and applied a very simplesolution in one plant that consists ofthe
addition of an inorganic acid to the urea melt, just before the prilling tower, in
order to drastically reduce the quantity of ammonia in the air from the prilling
tower. The values obtained are20-70 mg/Nm3. An interesting side-result
of this method is that the quantity of free ammonia in the prills is greatly
reduced and there is a drastic reduction in the presence of ammonia in the work
environment(conveyor belt chutes, storage). Of course the prilled urea contains
about 2,000 ppm of relevant salt, with no detrimental effecton the use of urea
as fertiliser and other industrial uses.
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.
FIGURE..16-UREA AT BOTTOM OF PRILL TOWER
FIGURE..17-NEEM COATING
1. Saving of 10% of the losses of urea would amount to 2 million tons of urea or
a reduction in subsidy component to the tune of ` 1,700 crores per annum
(considering total subsidy on urea to be `18,000 crores per annum).
2. Proportional saving in the consumption of naphtha or natural gas.
3. Increased crop yields due to better nitrogen utilization.
4. Reduction in environmental pollution of ground water due to leaching of
nitrates and gaseous emissions.
5. Opportunity for entrepreneurs to commercialize local Neem Resources and
Development of Small Scale Industries in rural areas.
➢ Controlling agency
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➢ Safety Aspects
Safety is the state of being ''safe'', the condition of being protected Against
physical , social, financial , emotional ,physiological , educational Or other
consequences of failure, damage, error, accidents, harm or any Other events
which can be non-desirable. This can take the form of being Protected from the
event or from exposure to something that causes Health or economic losses. No
industry can afford to neglect the Fundamentals of safety in design and
operation of its plant and Machinery. It is important that all the people
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responsible for management and operation of any industry should have a good
knowledge of industrial safety.
➢ Accident factors
1 a personal accident injury occurs as a result of accident
2 an accident due to un safe act and/or unsafe condition
3 unsafe act/unsafe condition exists due to faults of persons
4 faults of persons due to negligence
GY
➢ Safety Precaution
1. when taking sample of anhydrous ammonia and when operating or working
on ammonia valves, equipment containing ammonia such as ammonia feed
pumps, operators laboratory and maintenance personal must wear safety
overalls.
2. goggles and rubber gloves. If any part of the skin has been exposed to
ammonia , wash immediately and thoroughly with water
3. work on the ammonia equipment should be done from the upwind side of the
equipment to avoid or minimize contact with escaping ammonia.
4. the location of fire hydrants, safety showers , eyewash fountains ammonia
canisters gas mask, emergency air breathing apparatus should be well known to
all person's
5. instruments containing mercury must not be used if ammonia is likely to
come in contact with mercury
C. warning Oinstrument
1. oxygen, carbon dioxide , chlorine, ammonia indicator with replaceable
sensors.
2. explosive meters for measuring explosive range
3. fire fly instrument for confined space entry
III. References
• Ammonia-2 Training Manual, IFFCO Phulpur .
• Offsite Plants Training Manual, IFFCO Phulpur .
• Power Plant Training Manual, IFFCO Phulpur .
• Urea-2 Training Manual, IFFCO Phulpur .
• Urea - Wikipedia, the free encyclopedia,
• http://en.wikipedia.org/wiki/Urea
• The Urea Technology, Snamprogetti Training Manual.