ws Va.wH, NATIONAL FERTILIZERS LIMITED ee Industrial Training Report Undertaken at “ NFL Nangal Unit” In Production Department An ISO 9001-14001-18001 Unit Training Period- June 21,2017 to August 01,2017 SUBMITTED TO:- SUBMITTED BY:- HRD DEPARTMENT PRASHANT KUMAR NFL NANGAL CHEMICAL ENGG DEPT NIT JALANDHARACKNOWLEDGEMENT am very grateful to Dr MANISH GAUR (Head-Training & Placement ment) and all other professors and lecturers of Department of Chemical Engineering jent who guided me time to time by providing me desired guidance. The industrial training in an industry/project site is an essential part of curriculum for tion of B-Tech. degree. | am grateful to authorities at National Fertilizers Limited, L for permitting me to undergo four weeks Industrial training in their esteemed tion. During this training | have learnt a lot, for which | pay my heartiest gratitude to Assistant Manager Mr. Shubhankar Mitra and other staff members of National rs Limited, Nangal who helped me in all respects in fulfilling my cherished desire of a successful Industrial training. 1am very thankful to all the supervisors and other officials for providing me complete details of their respective plants.ABSTRACT The traini raining report on the working of National Fertilizers Limited, Nangal has pared in accordance with the requirement of scheme off our year B-Tech. degree Chemical engineering being taught at ET LUCKNOW(UP). In this course industrial training is an integral part of the curriculum and can -aken in any reputed industry. | have done this training at National Fertilizers Limited, ich is situated in Naya Nangal (Punjab) and is very well connected with rail and it best in the uninterrupted power supply line is also provided by BHAKRA which make nd energy view aspect. It is very well known for its excellent performance over 1s. | have studied whole plant with New KBR Purified technology in ammonia plan tin itis pleasure to face the Industral life that helped me to convert my theoretical s into practical knowledge. During this training | came across many emergency \s in the plant that surely explained me, actual industrial life.CONTENTS > INTRODUCTION > COMPANY PROFILE > AMMONIA PLANT >UREA PLANTNFL, Bathinda (Punjab) NFL, Panipat (Haryana) National Fertilizers Limited (N.F.L.) is the largest manufacturer of nitrogenous fertilizers inthe Northern India. Itis presently operating five large fertilizers plants, two of which are located at Nangal and Bathinda in the Punjab State, one at Panipat in Haryana and two at Vijaypur in M.P. plants at Nangal, Bathinda and Panipat are now Natural Gas based. The overall installed capacity of NFL plants is 10.42 lakh MT per annum. The old plant at Nangal was commissioned in 1961 followed by expansion which was commissioned in 1978. Bathinda and Panipat plants were commissioned in 1979. Guna Plant which is the latest plant of NFL was commissioned in Dec, 1978 and is now in full production. The Vijaipur Plant was a landmark achievement in project management in India. The plant was completed well within time and approved project cost. In recognition of this achievement, the project was awarded the First Prize in Excellence in Project Management by Govt. of India. Subsequently the Vijaipur plant doubled its capacity toAMMONIA PLANT Ammonia, either directly or indi fertilizers, pharmaceuticals and is us; wide use, ammonia is both caustic and hazardous, In 200 i i . 16, worldwid estimated at 146.5 million tonnes, eae Ammonia, as used commercially, is often called anhydrous ammonia. This term emphasizes the absence of water in the Material. Because NH3 boils at -33.34 °C. (-28.012 °F) at a pressure of 1 atmosphere, the liquid must be stored under high pressure or at low temperature. “Household ammonia” or "ammonium hydroxide” is a solution of NH3 in water. The concentration of such solutions is measured in units of the Baumé scale (density), with 26 degrees baumé (about 30% w/w ammonia at 15.5 °C) being the typical high-concentration commercial product. Household ammonia ranges in concentration from 5 to 10 weight percent ammonia. Approximately 83% (as of 2004) of ammonia is used as fertilizers either as its salts or as solutions. When applied to soil, it helps provide increased yields of crops such as coro snd wheat. Consuming more than 1% of all man-made power, the production of ammonia is a significant component of the world energy budget.physical properties of ammo, nia ammonia has flammable limits of - 16%-25: monia —air mixtures is % By volum ana soluble in water, AES Celsius. The mixture can es oe eta Tok oxyenn y solute Be amount ot heat io Cetede ignited. Ammonia is the dissol kg of ammonia gas occurs ut 2180kj (520kcal), is produced when ‘ammonia is produced in a process know, in mas the Hi rain theres anon cage ee . is (orn the air, Other eeseeaes wi high temperatures andthe ear aaipted ‘Carbon dioxide) are removed from the gas stream and the nitrogen and hydro, lover & eressreg 'ydrogen passed over an iron catalyst at high temperature and form the ammonia. ‘The major constituent in the production of urea is AMMONIA In order to compensate need of this major constituent ammonia plant is located in front end of NFLNANGAL UNIT. The ammonia plant further categorized into three main sections in NFL NANGAL UNIT.‘CO; Removal “Methactae ‘esos Spite OREFORMER OaMDEA section aves OSTEAM NETWORKSed on BR p, ‘urifier TM te, he ts main specification on cetsed by KBR, The, chnology which is low energy steam rocess). This combines one ‘t's 8 Low Energy pa os finest plant from other units of NFL immonia. The performance and gq nB SYNCS lop in NFL aes oo Pressure reforming jest feature of this plant is thet ono! ths Plants based on wnt? Produce 950 MTPD of it prod on Lean Natural G: team Generatl luce S0TPD al Gas Composition, The te ion Plant (SGP), of saturated steam led to reduction in load on ‘The description of these subs units of ammonia Plant is given as fol lowing. REFORMER Reformer or reforming is basically conversio In of _ m furnace is basicaly divided into three matn eects oe coe OO He The reforming lain sections, convection section Oransition zone Radiation zone. The basic difference in this furnace by KBR from others is that it is Top fire furnace which make it best than others. The convection zone has 6 coils. The radiation zone contains 132 tubes and having 3 rows in which these tubes are aligned (i.e. 44 tubes per row are aligned). It also contains 56 burners aligned in 4 rows at the top section +4 burners at the bottom) Two fans FD & ID are also lined with this reformer. The FD( Forced Draft) fan is used to supply air for combustion & on other hand ID extract the flue gas at temperature>50 degrees but less than 140 degrees to the air.ler emPreSSed t0 57.3 ke/em Pass through feed n. ‘through Feed Phe hot 82s i passed through of organic sulphur compounds eater wi Desulphurizor contain bed. ae Present in feed nO. lo The Hess ™hich ensure hydrogenation HS in feed gas is removed in 5 H2S+Zn0-W.. Desulphurized gas is mi o ~>2nS+H20, ‘ ixed with mixed feed is Sent to the tubes pac ® Preheated to 4g rca Pi degrees in convection section. Then this acked with teformi NB catalyst in radiant zone. For ‘methane above aMDEA SECTION (ACTIVATED MONO DIMETHYL ETHANOAL AMINE) After LTS there is 16% COzand 0.2% CO. Now in aMDEA section there is basically concentration of COz from 16-40%. Now the process gas enter data about 70 degrees at bottom of CO2absorber is concentrated by counter current with SEMI LEAN aMDEA solution then flowed upward further concentrated with LEAN aMDEA solution. The gas leaving at the top of the absorber having <50 ppm of COzis further send to Methanation Tower.As the £25 before last step aMDEA In the scrubber tg Fecovey AMMONIA SYNTHEs}, > up & recycle stream mixture ammonia is i 7m Synthesi, synthesized in two adiabatic yor” SYMhesis gas jg dn fixed bed ve contain 17.70 mole 963 je se Provided with inter ed bY heat err ‘converter. Make send to chiller. jut at 453 degrees is coon tercooler i ee m a erted effiuent to 58 degrees further to 38 degrees and Liquefied ammonia from production plants is either used directly in downstream plants or transferred to storage tanks. From these the ammonia can be transferred to road tankers, rail tank cars or ships. Ammonia is usually stored by using one or other of three methods:- Fully refrigerated storage in large tanks with a typical capacity of 10,000 to 30,000 tonnes (up to 50,000) ~Pressurised storage spheres or cylinders up to about 1,700 tonnes_ semi-refrigerated tanks emissions during normal opera tanks are almost unknown with ar eT® Medlgibe ransfer. eo a ‘ leaks wh KS of ammonia from Rats storage —_— being during transport or probability of an ammonia leak or pees ane mal residual risk is small, the effects be very serious. It is therefore f hazardoy intained instal ar lation hi ofa map ef ee Nowe re Pract Dud bah population ana could rom domestic sei storage and handling ammonia storage tanks to be sited i ® sited close to instal explosion, since these could increase the rae eae Res Rata rik ot fre or @ release of ammonia. Storage Tanks Anhydrous ammonia is stored in three types of tank as outlined above: ~ Fully refrigerated at a temperature of about -33°C, these tanks are provided with refrigeration equipment A ~Non-refrigerated tanks in which the ammonia is stored at ambient emperature ~Semi-refrigerated spheres Refrigerated storage is preferred for storage of large quantities of liquid ammonia. The the case of a line or tank failure is much slower than with initial release of ammo! pressurized ammonia. There are several construction types for the storage of refrigerated liquid products. The most important types are:- 2 ~Single containment: a single-wall insulated tank, normally with 2 containment bund around itpouble containment: this ned to contain the stone ar desi! tne liquid: The FOof rests on the qe Mt Off atta Pre er wall | 8d Withstang as _ full containment: the two walle x 'stand the fav fe ee are this clo, ‘static pressure of the stored amount of liquid, i i be constructed in conformity ae this case ce craee ee n agreed, Fests on, the storage tanks and taking account at code So designed to contain Ms Pressure and at const Perati Se wall. The tank must Men Of Pressure vessels or iperatur tne design and materials of co re, it Mstructi appropriate national, or recognisag jon re blast resistance of storage en Interna onal, yaad be checked by consul in standard, then sulting an # could make demand: son against high Pressure and inthe some cases the minim i case of The stor te el Dron gece serened mii storage tanks should Beleen aaa monia into cold armor 1 2 Equipped with ®vaporation and the “ ammonia high level alarm. ‘wo independent level cy roller” phenomenon. indicators, each having a Furthermore, an installed alternative power si equipment. The flare must be located at a suitable distance from the tanks Relief vah should be provided, appropriate for the duty using an adequate margin between Beeratng and relief pressure. UTILITIES The ammonia and urea manufacturing facilities are separate, so each has its own utilites. These are listed below. Ammonia manufacture used to produce steam for the |. Heat from the process 62s from turbogenerator. Heat recovery The heat of the gas from the primary reformer Bed a a primary reformer using 2 boiler. The gasis then ees fo the secondary reformer (Step 2) suse 10 produ a eee ieee shift converter, the eee i a eae synthesis xcess water from the water for ami F loop is used for boiler feed water and asthe absorbingcatdo” dioxide stripper cre used UCARSOL 8 ve a mixture of cone R remo ei ondensation and the: by Pye synthesis: ammonia recovery Gases purged from the ar gecompression are Mi introduced at the Bo jw of the ammonia in tl fuel gas to heat the pI a8 ure, condensed an rmixtUR REA PLANT ueean aoe NTOBENOUS fertize preferred it 8 P ertilizer worldwide, i " utiization ij Idehyde resins a His gh ioral gs a a) adhesives. Rouelie ga ld Fertig: ne 224, itbeing the discover f v the synthes Itst dis liquid fertilizer, 1498. Ths is Considered to be the g, fr 'S of ur fone, Urea in urine in 1773. 4 4 ir Imo pe compound. I 1870, Bassa row produes yt eS Of an organic ag YENE acd by Woes in tube in what was the first synthesi pe Urea by heating me ‘SOmpound from an inorganic t : of mm H:CONH2, indicates that urea ean be Urea by dehydration, ee, Beets brs tealed considered ttn femicall formula of, the Di amide of carboni 2 ie acid CO(OH), the amide of Carbamic acid NH.COOH, Fertilizer is generally defined as" any material supplies one or more of the chemical elements requi ofthe fertilizer industry is to provide the primary endseccuan on ome me man ain in macro quantities. Primary nutrients are normally ed nutrients which are required are chemical compounds containing one or more of ehine peeae dr coueciizers. They produced by chemical reactions. Whatever may be the Fc Se i — important ingredient for plant growth is the nutrient content. The ae Rev we Nitrogen, Phosphorus and Potassium. However, their concentration in a chemical fertilizer is. expressed as a percentage of total nitrogen(N), available phosphate (P:0s) and soluble K:0. The grade of a fertilizer is expressed asa set of three numbers in the order of percent N, P2Os and K20. If a nutrient is missing in a fertilizer, it is represented by a zero. Thus Ammonium lor "ganic or inorganic, natural or synthetic, which Sulphate is represented by 20.6- 00. PROPERTIES OF UREA PHYSICAL PROPERTIES OF UREA Non-Corrosive. Urea is a White, Odourless, HygroscoPic pols:molecular weight relative humidity Maximum Nitrogen ¢9 specific gravity Heat of fusion Heat of solution, in Bulk density : Table-1.1 SPECIFICFigure: Manufacturing of Ureasaturated UCARSOL ~—{CO, removal }«——UCARSOL 2 + ‘CO; stripper ‘Methanation |» water COz Synthesis Loop (Decompression _impuritss| Nii, recovery | ‘Ammonia os Industry Urea plant1.3 PROCESS TECHNOLOGY Although there are several processes currently used for the manufacture of urea, the underlying principle for all the processes is same. The two main reactions involved are: CO2+2NH3 €> NH2COONHs AH=-37.4Kcal/gm molNHzCOONH«s €> NH2CONH2+H:0 mol AH=+6.3Kcal/gm Undesirable side reaction taking place is: 2NH2CONHz €> NH2CONHCONH2+NH3 (Biuret) Both 1* & 2” reactions are equilibrium reactions. The 1* reaction almost goes to completion at 185-190°C & 180-200 atms. The 2" reaction (decomposition reaction) is slow \d determines the rate of there action. Unconverted CO2& NH3, along with undecomposed bamate, must be recovered and re-used. This is a troublesome step. The synthesis is r complicated by the formation of a dimer called biuret, NH2CONHCONH2, which must. it low because it adversely affects the growth of some plants. bles that affects the AUTO CLAVE REACTION are: ture (185°C) favours equilibrium yield at a given pressure (180atm). The conversion of bamate to Urea gradually increases as the temperature increases. However, after a ture, depending upon the pressure, the conversion suddenly drops with further re. The pressure corresponding to this temperature which is usually in the range own as the decomposition pressure which is about 180 atm. sufficiently slow at atmospheric pressure. However, it starts almost pressure of the order of 100 atm and temperature of 1500C. There is reduction in reaction and so high pressure favours the forward reaction. This pressure is to the temperature to be maintained & NH3:CO2 ratio.3)CONCENTRATION Higher the concentration of the reactants, higher will be the forward reaction according to the law of ‘mass action. CO2 being the limiting reagent higher NH3:CO2 ratio favours conversion. Since, dehydration of Carbamate results in urea production, lesser H20:CO2 ratio favours conversion. Water intake to the reactor should therefore be minimum, |ESIDENCE TIME is slow and takes about 20 minutes to attain equilibrium, sufficient time is to be ided to get higher conversion. Reactor is designed to accommodate this with respect to the other rameters of temperature, pressure and concentration. 5)BIURET FORMATION not a desirable substance because it adversely affects the growth of some plants. Its content in a should not be more than 1.5% by weight. 2NH2CONH2 <> NH2CONHCONH2+NH3 (Biuret)1.4 MAJOR ENGINEERING PROBLEMS te decomposition and recycle: that can be used for the manufacture of urea. Main difference in competing ‘design. Since, conversion is only 40-50% per pass, the unreacted off gases sed economically elsewhere. Recompression of off gases is virtually jion and formation of solid Carbamate in compressors. 8 uret formation is another problem. Vacuum evaporation of urea from 80% to about 99%, spraying to air cool and solidification must be done just above the melting point of urea and with a minimum Tesidence time in the range of several seconds. 3) Heat dissipation in the autoclave: The exothermic heat of reaction can be removed by coils or wall cooling. 4)Corrosion: This has been the major reason why the NH3-CO2 process was slow to develop. High cost silver or tantalum liners are used in the autoclaves with Alloy C, Titanium, Stainless Steel(321 SS), and Aluminium alloys used in other parts of the plant. Minimum pressure and temperature conditions with ‘excess NH3 are desirable to reduce the severe corrosion rates, Under these conditions, stainless steel can be used in the autoclave.UREA PROCESS IS CLASSIFIED IN FOUR SECTION 1)Synthesis Section. 2)Decomposition Section. 3)Crystallization & Prilling Section. 4)Recovery section. NFL Nangal has One of the finest prilling tower in Asia. This plant Produces around 1400 tonnes per day of the urea.