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TRAINING PRESENTATION ON IFFCO (INDIAN FARMERS FERTILIZERS COOPERATIVE LIMITED)

PRESENTED BY: JAINENDRA MANI TIWARI EC(08)

INTRODUCTION
Indian former fertilizer co-operative limited (IFFCO) was established on 3 November 1967. In Bareilly district IFFCO unit is located in Aonla. Aonla unit an ammonia-urea complex i.e comprised of two phases ,AONLA I AONLA-II. Aonla I was commissioned in May 1988 Aonla-II in December 1996.

OBJECTIVES OF IFFCO
Provide latest and reliable information and extend other services to all those actively involved in the

development of Indian agriculture and rural development.


To evolve appropriate dissemination strategies for effective use of IT Enabled Services in Rural India.

MISSION AND VISION


IFFCO's mission is "to enable Indian farmers to prosper through timely supply of reliable, high quality agricultural inputs and services in an environmentally sustainable manner and to undertake other activities to improve their welfare To augment the incremental incomes of farmers by helping them to increase their crop productivity through balanced use of energy efficient fertilizers, maintain the environmental health and to make cooperative societies economically &

democratically strong for professionalized services to the farming community to ensure an empowered rural India.

AMMONIA PLANT
Capacity-1740MTPD Consultant- M/s Haldor Topsoe, Denmark Tech.

UREA PLANT
Capacity-1515MTPD Consultant- M/s Snam Progetti, Italy Based on-snamprogetti, ammonia stripping process

POWER PLANT
Two gas turbines Capacity-24MW Supplied by Hitachi, Japan Main boiler- 150MT/ hr steam

IFFCO In Brief KALOL UNIT


Year of Commissioning - 1975 Annual Ammonia Capacity - 3.63 Lakh MT Annual Urea Capacity - 5.45 Lakh MT

PHULPUR UNIT

CORPORATE OFFICE NEW DELHI

Year of Commissioning 1981/1997 Annual Ammonia Capacity - 8.24 Lakh MT Annual Urea Capacity - 14.16 Lakh MT

AONLA UNIT
KANDLA UNIT
Year of Commissioning - 1975 Annual NPK/DAP Capacity24.15Lakh MT

PARADEEP UNIT
Year of Acquiring - SEP2005 Annual Capacity -20.00 Lakh MT (DAP + COMPLEX)

Year of Commissioning 1988/1996 Annual Ammonia Capacity 10.03 Lakh MT Annual Urea Capacity 17.29 Lakh MT

AMMONIA PLANT

INTRODUCTION
This plant is based on HALDOR TOPSOE technology with natural gas and naphtha as a

raw materials. The total capacity of Aonla complex is enhanced to 2700 te/day of Ammonia.

HOW AMMONIA IS MADE


Ammonia is produced by the reaction between H2

and N2 ,where the ratio is 3:1,besides these two components the synthesis gas also contains inert gases such as- Ar and CH4 to a limited degree.
N2 + 3H2 ---> 2NH3
Source of H2 natural gas , naphtha , heavy oil. Source of N2- is atmospheric air.

DESCRIPTION OF AMMONIA PROCESS


Desulphurization of natural gas.

Primary reforming.
Secondary reforming. High temperature shift conversion.

Methanation.
Refrigeration system. Ammonia wash section.

USES OF AMMONIA
I t is used for direct application to the soil and in aqua condition with solutions of other nitrogenous fertilizers like ammonium nitrate and urea. It uses in the production of nitric acid, soda ash, cleaning agents, leather tanning, petroleum refining, pulp and paper industry, textiles, refrigeration , rubber, and synthetic resin industries, explosives and food and beverage industries.

PLANT HAZARDS
The major hazards in ammonia production plant are as follows:- Fire/explosion due to leaks from hydrocarbon feed system. Fire /explosion hazard due to leaks of synthesis gas in the CO removal/synthesis gas compression areas(75% hydrogen). In ammonia storage the release of liquid ammonia is a credible major hazard event.

UREA PLANT

INTRODUCTION
In IFFCO Aonla urea plant having the capacity 4x 1100 MT/Day. IFFCO's Urea is not merely a source of 46% of nutrient nitrogen for crops, but it is an integral

part of millions of farmers in India.

PHYSICAL AND CHEMICAL PROPERTIES


MOLECULAR WEIGHT-60.05 BOILING POINT-Decomposes at atmosphere before boiling DENSITY(crystal) -1.315 HEAT OF COMBUSTION-2531cal/gm

NAME OF EQUIPMENT USED


TURBINE Co2 COMPRESSURE TURBINE CONDENSOR UREA MELT PUMP PRILLING TOWER ROTARY SCRAPER

HOW UREA IS MADE??


N2 + 3H2 -> 2NH3 (AMMONIA) 2 NH3 + CO2 ->H2N-COONH4
(AMMONIUM CARBAMATE)

H2N-COONH4 (NH2)2CO + H2O (UREA)

DESCRIPTION OF UREA PLANT


Main operations performed: Urea synthesis and high pressure recovery Urea purification and low pressure recovery Urea concentration Urea prilling Waste water treatment

UREA SYNTHESIS & H.P. RECOVERY


Urea is produced by the synthesis from liquid ammonia and gases CO2 , both being supplied by ammonia plant.

UREA PURIFICATION & L.P.


Urea solution from the H.P. stripper enter the M.P. decomposer after pressure reduction through a level control valve.

The urea solution from MP decomposer bottom enters the LP decomposer after expansion through the level control valve.

UREA CONCENTRATION

The liquid from the bottom of LP decomposer is further concentrated in two vaccum concentrators in series.

LADDER LOGIC

PROGRAMMABLE LOGIC CONTROLLERS

INTRODUCTION
Before the advent of solid state logic circuits, logical control systems were designed & built

exclusively around electromechanical relays. In late 1960s an American company named Bedford Associates released a computing device they called the MODICON. Modular Digital Controller Other engineering firms developed their own version of this device and it eventually came to be known in non-proprietary term as PLC.

Purpose is to replace electromechanical relay as logic elements.


PLC has many input terminals ,through which it

interprets high & low logical states from sensors & switches. It also have many outputs. In efforts to make PLCs easy to program their programming language was designed to resemble ladder logic diagrams.

CONTROL SYSTEMS
A control systems is the electronic equipment needed to control particular process.

It many include everything from a process control computers, if one is used to the factory computer down through the PLCs There may be many of them networked together.

ROLE OF PLC
PLC is the part of control system that directly controls the manufacturing process.

Accepts the data from the input devices connected to it & uses data to monitor the control systems.
PLC sends data to the output device connected to

it cause that action to take place.

INPUT DEVICES
PLCs can receives input from either automatic or manual devices. PLC can receives the data from the user via push button, keyboard or similar devices.

OUTPUT DEVICES
A PLC can output to devices for use in automated control. Output devices may be motors, solenoids, servomotors, stepping motor, & valves.

WORKING OF PLC
PLC operate by monitoring input signals & providing output signals.

When changes are detected in the signals PLC react through the user programmed internal logic to produce output signals. PLC continuously scans the program.

FRONT VIEW OF PLC

ADVANTAGES & DISADVANTAGES


Flexibility Correcting error Space efficient Low cost Testing Visual observation