INDIAN FARMERS FERTILIZERCOOPERATIVE LIMITED (IFFCO) PHULPUR U.P, INDIA SUMMER TRAINING REPORT SUBMITTED BY: Varun Kaushal nd 2 Year Chemical Engineering Dept. Registration Number: 15BCM0086 VIT University, Vellore-Tamil Nadu SUBMITTED TO: Mr. Subrata Sur Sr Manager (Training ), IFFCO Phulpur Unit, Allahabad (UP) India ACKNOWLEDGEMENT Industrial training is a part of our academic activities and every student has to attach himself with any one of the leading industries for getting insight of this subject. I wish to express my gratitude to entire IFFCO Phulpur Unit, Allahabad, especially its management and training department who gave me this opportunity by permitting me to work under their kind supervision I would like to express my thanks to Mr. Subrata Sur (Sr. Manager-Training) who provided me with an opportunity to do training. I sincerely thank Mr. AK Singh (Director) and Mr. R Maiti (DGM) for providing me with this remarkable opportunity to do internship in the esteemed IFFCO-Phulpur Plant. At the submission of this project we take the opportunity to express our deep sense of gratitude to Mr. Diwakar Mishra, Mr. Bhagirath Prasad and Mr. Pramod for supporting and guiding us and imparting us useful knowledge about the plant. We would also like to appreciate all the plant operators and engineers of this organization who helped us enough in quenching our thirst to smallest queries. Sincerely, Varun Kaushal 15BCM0086 VIT University Vellore, Tamil Nadu This report is submitted to: Mr. Subrata Sur Sr Manager (Training ), IFFCO Phulpur Unit, Allahabad (UP) India 2 Contents: o Introduction-4 o Various Plants through India-6 o Facts about IFFCO – Phulpur Unit- 8 o Detailed Description of the AMMONIA Plant-10 o Detailed Description of the UREA Plant-18 o Byproducts -24 o Effects of Process Variables on the Plant-25 o Offsites at IFFCO Phulpur-28 o Environmental and Pollution Control Measures-32 o Safety Measures-33 o References -34 3 INTRODUCTION IFFCO is the largest producer and marketer of fertilizers in India with a membership of 37,276 Cooperative Societies and it turn 50 million farmers. Presence of Cooperative in India First legislation for cooperative in India i.e. Cooperative Societies Act, 1904, was enacted to cater to the requirement of credit societies. The National Cooperative Union of India (NCUI) was established in 1929 as an apex promotional organization for strengthening the cooperatives. National Cooperative Development and Warehousing board was set up in 1956. Growth of Cooperatives in India National Cooperative Development Cooperation (NCDC) was established in 1963 under NCDC Act 1962 to promote production, marketing and export of agricultural produce. Number of Cooperative Societies increased from 35 thousand in 1965-1966 to 545 thousand in 2002-2003. The distribution of IFFCO's fertilizer is undertaken through over 39824 Co-operative Societies. In addition, essential agro-inputs for IFFCO has promoted several institutions and organizations to work for the welfare of farmers, strengthening cooperative movement, improve Indian agriculture. Indian Farm Forestry Development Cooperative Ltd (IFFDC), Cooperative Rural Development Trust (CORDET), IFFCO Foundation, Kisan Sewa Trust belong to this category. An ambitious project 'ICT Initiatives for Farmers and Cooperatives' is launched to promote e-culture in rural India. IFFCO obsessively nurtures its relations with farmers and undertakes a large number of agricultural extension activitied for their benefit every year. At IFFCO, the thirst for ever improving the services to farmers and member co- operatives is greedy, commitment to quality is insurmountable and harnessing of mother earths' bounty to drive hunger away from India in an ecologically sustainable manner is the primemission. IFFCO, today, is a leading player in India's fertilizer industry and is making substantial contribution to the efforts of Indian Government to increase food grain production in the country. 4 VISION 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 MISSION Augment the incremental incomes of farmers by increasing their crop productivity Maintain environmental health Make cooperative societies economically and democratically strong Ensure an empowered rural India through professionalised service to the farming community On 3 November 1967 Indian Farmers Fertiliser Cooperative Limited (IFFCO) was registered as a Multi-Unit Cooperative Society. It got deemed recognition under the provision of Multistate Cooperative Societies Act 1984 & 2002 later. With our vast marketing network of over 36,000 cooperative societies we reach more than 5.5 Crores ( 55 million ) farmers in India. ORIGIN OF IFFCO Till the mid 1960's, cooperatives in India had no production facility despite marketing nearly 70% of fertilisers. There was a need of setting up production facility. IFFCO was established as the farmers' own initiative in Cooperative Sector on 3rd Nov, 1967 with proposed plants at Kalol and Kandla in Gujarat. With the enactment of Multi State Co-operative Societies Act 2002, IFFCO is registered as a Multi State Co-operative Society. Since inception, IFFCO has consistently followed transparent, democratic and professional practices in Corporate Governance. 5 IFFCO has carved out a strong “Cooperative Identity” and is making sincere efforts to uphold the “Cooperative Values” by cherishing the “Cooperative Principles”. IFFCO endeavours to achieve highest levels of transparency, accountability and full disclosure to its members to uphold the spirit of Cooperative Principles and Cooperative Values as laid down by the International Cooperative Alliance (ICA). Initiative has been taken for strengthening IFFCO’s Member Cooperative Societies through a web based Member Portal for enabling them to access information relevant to them. PLANTS: Initially, IFFCO commissioned an ammonia-urea complex at KALOL and the NPK/DAP plant at KANDLA both in state of Gujarat in 1975. Another ammoni9a-urea complex was set up at PHULPUR in the state of Uttar Pradesh in 1981. The ammonia-urea unit at AMLA was commissioned in 1988. Recently IFFCO has acquired an NPK/DAP and Phosphoric acid fertiliser unit at PARADEEP in Orissa in September 2005. The marketing of IFFCO’s produ cts is channelled through cooperative societies and institutional agencies in over 29 states and union territories of India. KANDLA Initiated on 24th June 1971 and commissioned for commercial production in January 1975 ,Kandla is one of the oldest IFFCO plant and also a center of innovation - R & D Laboratory, at IFFCO Kandla, has taken up the work for development of various new fertilizers. IFFCO Kandla is also an ISO 14001:2004/ OHSAS 18001:2007/ISO 9001:2015 Certified Organization with an established Environmental Management System / Health and Safety Management System /Quality Management System. PRODUCTION DATA Kandla Plant Capacity is 2.42 MMTPA of NPK/DAP Production PHULPUR Commissioned in 1981, this facility has two Urea and two Ammonia production facilities. The IFFCO Phulpur plant is known for taking up and successfully completing many R&D projects. It is a leader when it comes to technology and innovation. The Phulpur facility has many awards and laurels to its name due to its quality and efficient performance. Some of these include the Rajiv Ratna National Award, national productivity council award and many more. PRODUCTION DATA 6 In 2014-15 IFFCO's Phulpur plant produced a total of 0.824 MTPA Ammonia and 1.416 MTPA of urea, reaching a new height. It achieved lowest yearly energy consumption for both Ammonia and Urea Plants ANOLA Commissioned in 1988, this 260 hectares’ facility produces ammonia and urea. The facility has been winning a number of awards since 1989 and continues to do so. IFFCO Aonla Unit has received FAI Award for Best Production Performance (Winner) of an operating fertiliser unit for nitrogen (Ammonia and Urea) for Aonla-II for the year 2012-13 from The Fertiliser Association of India. PRODUCTION DATA The facility has a capacity of producing 1.148 Million MTPA of Ammonia and 2.000 Million MTPA of Urea. PARADEEP Acquired from Oswal Chemicals and Fertilisers plant, the plant was commissioned in April 2000.It can produce 2 million tonnes of the fertiliser a year. PRODUCTION DATA The plant can produce 2 Million TPA DAP/NPK, 7000 TPD of Sulphuric Acid and 2650 TPD of Phosphoric Acid Products of IFFCO Urea NPK DAP Bio-Fertilizer Sulfuric Acid etc. 7 FACTS ABOUT IFFCO PHULPUR Total Area 1068 acres Area Under plant 321 acres Area under Township Area under township, cordet, agricultural farms, green belt, ash ponds, roads, open space : 747 acres. Phulpur Unit - Milestones of Project Implementation Phulpur I Process Licensor Date of Commencement Ammonia Plant MW Kellog, U.S.A Oct. 10, 1980 Urea Plant Snamprogetti, Italy Oct. 15, 1980 Phulpur II Process Licensor Date of Commencement Ammonia Plant HTAS, Denmark Dec. 18, 1997 Urea Plant Snamprogetti, Italy Oct. 31, 1997 Commercial Production Phulpur I Urea Mar. 28, 1981 Phulpur II Urea Dec. 22, 1997 Plant Reassessed Capacity in TPA AMMONIA 823900 UREA 1415700 Phulpur fertilizer unit is LNG (liquefied natural gas) based in which it is used as a fuel as well as a feed .It is being supplied from gas pipeline commonly known as HBJ by GAIL(GAS AUTHORITY OF INDIA LIMITED) from Thuledi near Jagdishpur to Phulpur distancing almost 140 km. Coal supplies for the power plant are received from central coal field ltd. through railway wagons. Raw water is pumped from bore wells located around the 8 factory and township. Electricity meant for the plant is generated in the power plant for reliability. It also receive from UPSEB. Major inputs of this plant are as following. RLNG supplied at a pressure of 40.2 kg/cm2. COAL 1200 MTPD WATER 2400 MTPD GENERATED POWER 12.5 MWPer hr PRODUCTION AT IFFCO PHULPUR : Urea production capacity of P-1= 2015 TPD Urea production capacity of P-2=3030 TPD BRIEF TURNOVER FACTS: 9 DETAILED PLANT DESCRIPTION As mentioned above, IFFCO Phulpur Units comprises of 2 plants. Each plant has its own Urea and Ammonia Units. Both the Urea processes are Snamprogetti(Italy) and Ammonia plant use Kelloggs Process and Haldor Topsoe Process. AMMONIA PLANT •The Ammonia plant in Phulpur-I is based on MW Kellogs USA technology having capacity of 1215 MTPD and in Phulpur-II plant is based on Haldor Topsoe’s Denmark’s technology with a capacity of 1740 MTPD •The Ammonia Plant In Phulpur-I and Phulpur-II uses RLNG as raw material for feed and fuel. But there is a provision of using Naphtha also as raw material in Phulpur-II. •The main process steps for production of Ammonia in both the plants are similar and are briefly described below: This single stream plant is based on the Kellog Process with Reliquified Natural Gas as a raw material. The manufacture of Ammonia involves the following 6 basic steps: 1. Primary Reforming 2. Secondary Reforming 3. CO conversion 4. CO2 Absorption And Removal Of CO2 5. Methanation 6. Ammonia Synthesis 7.Refrigeration 1.PRIMARY REFORMING: Primary reformer furnace is a rectangular box structure lined internally with refractory from all the sides to serve the radiant section and a refractory lined rectangular duct as the convection section. The Primary Reformer consists of a 336 tubes suspended in 8 rows of 42 parallel tubes each,in the radiant section.Each row of tubes terminates in a manifold placed within the radiant section of furnace.There are 8 centrally located risers one on each of these 10 manifolds.These risers lead the gas flow to a water jacketed transfer line located over the top of the Primary Reformer furnace. As the reforming reaction is endothermic, heat is supplied externally to the tubes.There are 9 row of top gas fired with 18 burners in each row in the Primary Reformer radiant section.There are 9 tunnels at the floor level with holes on the sides for the hot flue gas to enter.These 9 tunnel burners are also provided so as to raise the flue gas temperature going to the convection section as per requirement. RLNG is mixed with superheated steam and is preheated with the flue gas of primary reformer furnace and is sent to the primary reformer catalyst tubes packed with nickel based catalyst and operating elevated temperature 800-812C and pressure of 31.6kg/cm2 at the outlet of the primary reformer.The hydrocarbon and steam react to form H2, CO, CO2 and residual CH4.The reaction being endothermic,heat is supplied to the catalyst tubes by burning RLNG externally outside the tubes. Since the reforming reaction is endothermic,an increase in reforming temperature will favour the reforming reaction there by reducing the CH4 content and CO2 content in the outlet gas.The expected design outlet temperature is 812C. The steam reforming of gas is a very complex reaction.Some of the gas compounds are broken down by the thermal catalytic cracking into simpler hydrocarbon such as CH4.These simpler hydrocarbons are further reformed through the steam CH4 reaction. Catalyst: - Nickel Temperature: - 800-812 C Pressure: - 31.6 kg/cm2 Reaction: - CH4 + H2O + heat = CO + 3H2 CO + H2O = CO2 + H2 + heat Effluent:- H2,CO,CO2,CH4&N2 2.SECONDARY REFORMING: Partially reformed gas from the water jacketed transfer line is directed to the refractory lined and water jacketed secondary reformer tangentially.The compressed process air supplied by the process air compressor at a pressure of 33kg/cm2 and 176C is preheated to 482C in the steam preheater coil located at the primary reformer convection zone to recover the heat in the flue gas.The air is added to furnish the N2 requirement for ammonia synthesis in the secondary reformer. The purpose of the secondary reformer is to reform the unconverted CH4 coming out of the primary reformer as well as to introduce the necessary quantity of N2 to the process stream.Reformed gas is partially burnt with oxygen in the air and the heat of combustion is utilized for the endothermic methane reforming reaction,at the sane time supplying required 11 quantity of nitrogen to make synthesis gas containing H2,CO,CO2,N2 and a small quantity of CH4 is obtained. Reformed gas from the primary reformer enters the secondary reformer top portion through transfer line.The gas enters at 812C and 31.3kg/cm2 and flows down through the annular space of process air inlet pipe and the top heat liner.Preheated air at 468C is introduced to the process through a mixer burner below passing straightening vanes through the air inlet pipe.After the ignition,the hot gases at a temperature of 1238C pass through the catalyst beds. Catalyst: - Chromia at top and nickel at bottom Temperature: - 1238 C Reaction: - 2H2 + AIR (O2 + 3.8N2) =2H2O + 3.8N2 + heat CH4+5AIR (O2+3.8N2) =CO2+2CO+6H2O + 19N2 + heat 2CH4 +3H2O + heat = CO + CO2 +7H2 Effluent: - H2, N2, A, CO, CO2, CH4 3.CO CONVERSION: HIGH TEMPERATURE SHIFT CONVERSION: Hot reformed gases from the secondary reformer are cooled by heat recovery in three waste boilers producing HP stream.Then it enters High Temperature Shift Converter at about 30.5kg/cm2 and temperature 371C through the catalyst bed.In the presence of iron-chromium catalyst,CO reacts with steam to form CO2 and H2.The temperature rises as the reaction is exothermic. Catalyst: - Iron-Chromium Temperature: - 371C Pressure: - 30.5 kg/cm2 Reaction:- CO + H2O = CO2 + H2 + heat LOW TEMPERATURE SHIFT CONVERSION: After heat recovery gas at a comparatively lower temperature 200C is introduced in Low Temperature Shift Converter where in the presence of copper-zinc catalyst the water gas shift reaction proceeds and CO content in gas mixture brought down fron 3.3% to around 0.3% by volume. Catalyst: - Copper – Zinc Temperature: -236 C Pressure: - 28.2 kg/cm2 Effluent:- H2,N2,A,CO,CO2,CH4 12 The gas comes out of LTS at following approximate conditions: Pressure=28.2kg/cm2, Temperature=236C 4.CO2 ABSORPTION: The gas leaving the CO conversion section,consist mainly H2,N2,CO2 and steam.This is cooled in exchangers and condensate from gas is separated out.The raw synthesis gas at pressure of 27.5kg/cm2 and 82C containing 22.7%dry volume CO2 is introduced at the bottom of CO2 absorber tower where a counter current stream of benefield solution absorbs CO2 from the gas.The raw synthesis gas free from CO leaves the absorber.The absorber of CO2 by benefield solution involves the following reaction: K2CO3+H2O+CO2=2KHCO3 A 27% Potassium Carbonate solution enriched with 3% of diethanolamine as an activator and 0.3 to 0.5% of vanadium pentaoxide as corrosion inhibitor is called the Benefield solution and is a good reagent for CO2 absorption and the process is known as Benefield Process. REGENERATION OF BENEFIELD SOLUTION: The purpose of CO2 stripppers is to regenerate Benefield solution for reuse in the CO2 absorber.The Benefield solution which has absorbed the CO2 is regenerated in a pair of CO2 stripper tower.The strippers operate at 0.9kg/cm2 pressure and at 125C at bottom.Reboiling heat is supplied by two sets of reboilers namely the gas boilers and the steam boilers.The solution from the strippers is heated to 125C and by thermo siphoning the vapour solution mixture returns to the strippers from the top of reboilers. In the first three beds from the top the down coming rich solution comes in intimate contact with hot liberated CO2 and water flowing upwards and bicarbonate gets converted to carbonate under the action of heat and low CO2 partial pressure: 2KHCO3=K2CO3+CO2+H2O The remainder of the partially regenerated Benefield solution flows downward to the stripper bottoms through the 4th bed and gets regenerated to lean solution and collects at the strippers bottom and is cooled to 117C in the tubeside of lean solution BFW exchanger 107C. A major portion of partially regenerated solution is withdrawn from the level hold up maintained below the third bed of CO2 stripper and is pumped to the middle of CO2 absorber as semi lean solution at a temperature of 116C with the help of two semi lean solution pumps. Semi lean partially regenerated solution is taken from an intermediate point of the CO2 strippper by the semi lean carbonate circulating pumps and fed to distributor provided on the top of the third bed of the absorber. The partially cooled lean carbonate solution is withdrawn from the CO2 strippers bottom by lean carbonate solution circulating pumps and is directed through a distributor over the top bed of absorber at a temperature of 70C.The flow rate is 261M3/hr gas leaving absorber top contains 0.05% CO2. 13 A portion of semi lean carbonate solution is withdrawn from a trap-out pan below the third bed of packing by circulating pump and returned to the absorber mid section.The balance of the carbonate solution continues down through a bed of 25mm packing in each stripper tower. Solution moves to the bottom of this solution where it accumulates on a trap out pan from which it flows into the CO2 stripper reboilers for regeneration. The stripped CO2 saturated with water vapours at 107C leaves the top of the stripper and flows to the CO2 stripper condenser and is cooled with cooling water to 40C.The condensed water vapours in the gas is separated in the CO2 stripper reflux drum.The CO2 saturated with waters vapours is sent to Urea Plant. 5.METHANATION: In the methanation step final traces of carbon oxides present in the process gas leaving the absorber is converted into CH4 by reacting with H2 present in process gas in presence of a nickel catalyst at a temperature of around 300C.The oxides of carbon are poisons for the ammonia synthesis catalyst and are therefore required to be eliminated.At the exit of methanator a pure synthesis of H2:N2 mole ratio of 3:1 is obtained with less than 1%CH4, which is eventually purged from the synthesis loop. Catalyst: - Nickel Temperature: - 300 C Reaction: - CO + 3H2 = CH4 + H2O + heat CO2 + 4H2 = CH4 + 2H2O + heat Effluent: - H2, N2, CH4, A, CO+CO2 (in traces) The hot methanator outlet gas is cooled in two steps in Methanator BFW Heater,where it is cooled to 134C and then by cooling water in Methanator Effulent Cooler to 38C.The gas then flows to synthesis gas compressor suction drum.The condensate collected in compressor suction drum and the purified synthesis gas leaving the drum is sent to synthesis gas compressor. 6.COMPRESSION AND AMMONIA SYNTHESIS: The pure synthesis is compressed in a two case centrifugal compressor driven by a back pressure condensing steam turbine to a final pressure 155kg/cm2.Recycle gas(12%vol % of ammonia) from synthesis convertor outlet is introduced at the last stage of compression. The compressor outlet gas at 68C is cooled with cooling water in synthesis gas compressor after cooler to 46C. The synthesis gas from compressor discharge has approximately the following composition: Component Mol% 14 H2 58.27 N2 19.30 CH4 8.68 NH3 9.92 The make up gas/recycle gas mixture under the conditions mentioned above now flows to the ammonia synthesis loop.The compressed gas mixture is cooled,chilled successively in three ammonia refrigerated chillers operating at successfully lowered temperature to condense and separate the ammonia contained in the gas. The gas is split into two streams to reduce loop pressure drop and recover refrigeration. The major flow passes through the tube sides of feed and recycles gas first stage and second stage chillers in succession and is cooled to 22 C in first chiller and then to 1 C in second chiller. The minor stream flows to shell side of converter feed/ feed and recycle gas exchanger where it exchanges heat with cold stream of ammonia separator outlet gases. The gas cools down to -9 C. A hand control valve controls the flow through this exchanger. The gas stream again combines together and enters the tube side of feed and recycle gas third stage chiller here the gas is cooled to – 23.3 C. Gas flow now enters ammonia separator. All the condensed NH3 in the gas is separated here. The NH3 separated here forms the main part of product NH3. Along with liquid NH3 the water vapours contained in syngas together with small traces of CO2 left after methanation are also removed in this separator. This serves as another purification step for the gas before entering the converter catalyst bed. Converter feed leaving NH3 separator enters the tube side of a converter feed/ feed recycle gas exchanger and gains heat from a part of the incoming feed. Gas temperature is around 24 C after this exchanger, the gas flows to converter effluent exchanger where temperature is raised to 140 C. Gas entering synthesis converter has following composition: Component Mol% H2 63.34 N2 20.98 NH3 2.08 CH4 9.43 SYNTHESIS CONVERTER: Synthesis converter consists of a high pressure shell containing a catalyst section and a heat exchanger. The catalyst section is a cylindrical shell which fits inside a pressure shell and is called the basket. The basket contains four catalyst beds, each supported on screen covered grids. Top bed is the smallest with each succeeding bed containing greater volume to limit the exothermic heat of reaction which is sharpest in the upper beds. The catalyst basket leaves an annular space between basket and the pressure shell. The main inlet to the converter is at the bottom of the pressure shell and converter feed flows upward through the annular space to the shell side of converter interchanger at the top. It is 15 recommended to have a flow through annular space always to reduce heat flux from the basket to shell so that converter shell is maintained within design temperature limit. In the converter – interchanger gas picks up heat from the hot converter effluent stream while circulating around the exchanger tubes. For temperature control of the top bed at 410 C a part of the feed can be directly introduced to the top bed which by passes the exchanger and acts as quench for first bed. The combined stream passes into first catalyst bed at the prevailing pressure of 141 kg/cm2 and 410 C, the ammonia synthesis reaction takes off and proceeds in the catalyst bed with a sharp temperature rise to 497 C. The gases pass through the grid supporting the next bed. In order to maintain catalyst temperature at desired levels and thereby achieve maximum yield, provision is made to inject to feed gas as quench in the space between each catalyst bed. These quench flows; by passing the converter interchanger can be conveniently controlled. Inter bed quenching has additional advantages is that it provides for exceptionally good temperature control and operating flexibility which promotes maximum formation of product, eliminate catalyst hot spots, and thus contributes to long catalyst life. There are temperature recorders and indicators for every bed. The gas flows downward through all the bed at optimum temperature. The outlet temperature of 2nd, 3rd, 4th bed is likely to vary between 460 – 470 C. Hot gases after reaction at about 470 C leave the bottom catalyst bed and passes up through a centre return pipe into the tubes of converter interchanger to give up heat to the incoming feed. The gas leaves the converter at a pressure of 141 atm. and temperature of 287 C with nearly the following composition. Component Mol% H2 54.93 N2 18.16 NH3 12.00 CH4 10.34 NH3 synthesis reaction is not a once through process. The conversion rate is hardly 21% so the H2: N2 mixture contained in the gas is again recycled back to converter after removing product ammonia and making up the pressure. Converter effluent from interchanger exchanges heat with boiler feed water (from deaerator) and gets cooled to 165 C in ammonia converter boiler feed water heater. It then flows to ammonia converter feed/ effluent exchanger and exchanges heat with the incoming feed and gets cooled to 43 C. The gas called ‘recycle gas’ goes to the last wheel of second case of synthesis gas compressor. The whole process as mentioned above, from synthesis gas compressor discharge to the suction of the recycle gas stage in closed circuit system is termed as “ammonia synthesis loop”. The ammonia synthesis reaction taking place at elevated temperature and pressure in presence of a promoted iron catalyst can be depicted as below: N2+3H2=2NH3+Heat 16 As the reaction is exothermic,a rise in temperature lowers the equilibrium % of ammonia and at the same time accelerate the reaction.If reaction is near equilibrium,rise in temperature will lead to decrease in conversion and viceversa. Catalyst: - Iron Temperature: - 420-480 C Pressure: - 145-150 kg/cm2 Reaction: - N2 + 3H2 = 2NH3 Effluents: - H2, N2, NH3 7.REFRIGERATION: The primary purpose of the refrigeration system is to condense product ammonia for separating it from the converter feed.Further it is applied to cool makeup gas for separation of water to condense and recover liquid ammonia from purge gas and flash gases and to cool the product run down to -33C and degassing inerts. Liquid ammonia separated in ammonia separator operating at 147kg/cm2 and purge separator operating at 140 kg/cm2 are letdown to Letdown Drum operating at 17kg/cm2.This letdown in pressure helps to flash most of the dissolved gases in the ammonia product.Flashed gases from letdown drum combines with the gases from gas chiller.These two flash gas streams then go to the fuel gas knock outdrum. Approximate composition of flashed gases from Letdown Drum is: Component Mol% H2 47.45 N2 18.25 CH4 18.98 NH3 10.21 Liquid ammonia from letdown drum is letdown further through level control valve to third stage Refrigerant Flash Drum operating at a pressure of 0.014kg/cm2.pressure being controlled by Refrigerant Compressor.Here temperature is around -330C. Liquid ammonia is letdown to second stage Refrigerant Flash Drum also when necessary,to maintain level due to varying refrigerant load in ammonia plant.It is combined with flashed gases from second stage refrigerant flash drum before being sent to the second case of compressor.After three stages of compression in the second case the gases are sent to refrigerant compressor intercooler where it is cooled 106C to 43C with cooling water to remove the heat of compression.The pressure of the gas leaving the cooler is 6.2kg/cm2.The flashed gases from first stage Refrigerant Flash Drum join the gas from intercooler and again compressed to a final pressure 17kg/cm2 in the last four wheels of compressor.The 17 compressed flash gases are condensed by cooling water in Refrigerant Receiver.The overhead from the receiver is chilled with ammonia in flash gas chiller to a temperature of 1C. The approximate composition of flash gases from flash gas chiller is: Component Mol% H2 25.92 N2 14.82 CH4 29.64 NH3 25.92 The three drums are combined in one single vessel with partitions with operating pressure of 6kg/cm2,2.3kg/cm2 and 0.01kg/cm2 respectively.These pressures are controlled by Refrigerant Compressor at different stages.These drum receive flashed ammonia from refrigerant receiver by successive letdown.These drums serve as ‘Head Drums’ for the various refrigerant ammonia chillers used un synthesis loop.The refrigerant ammonia while taking up the heat gets vaporized and is compressed by refrigerant compressor condensed and received in refrigerant receiver and then again sent back to these drums for refrigeration.The whole refrigeration cycle is a closed circuit. Product ammonia from flash drum at -33C is pumped to atmospheric ammonia storage tank.The atmospheric storage tank is having capacity of 10,000tonnes.The urea plant uses ammonia at 4C. UREA PLANT The Urea Plant is based on Snamprogetti’s Ammonia stripping process. The Phulpur-I plant is having capacity of 2115 MTPD while in Phulpur-II there are two units with a capacity each of 1515 MTPD. The process of manufacturing of urea in both the units is same except for Phulpur-II where all the sections are separate for two streams except for Prilling and waste water treatment section which are common for both the units. WHY UREA? Plants take nitrogen in form of nitrates. This is the reason why we manufacture urea in IFFCO plant to feed agriculture field. Urea nitrogen content (46.6%) is quickly converted into nitrate in the presence of catalyst presents in agricultural field. Urea is produced by synthesis from liquid NH3 and gaseous CO2 . NH3 & CO2 react to form ammonium carbamate, a portion of which is dehydrated to form Urea and water. The fraction of ammonium carbamate that dehydrates is determined by the ratio of the various reactants, the operating temperature and the residence lime in the reactor. The reaction to produce Urea from NH3 and CO2 takes place in two stages at elevated pressure & temperature. 18 2NH3 + CO2 = NH2COO NH4 + 38.1 K.cal/g.mole (1) NH2 COONH4 = NH2CONH2 + H2O -7.1 K.cal/g.mole (2) The first reaction is strongly exothermic, therefore heat is liberated as this reaction occours. With excess NH3, the CO2 conversion to carbamate is almost 100%, provided solution pressure is greater than decomposition pressure of carbamate. The decomposition pressure is the pressure at which carbamate will decompose back into CO2 and NH3. Decomposition pressure is a function of NH3 concentration in the feed and solution temperature and increases if either temps. Of NH3 recycle is increased. It is desirable to operate at high temperature and high ratio of NH3 to CO2 provided reactor pressure is high enough to prevent carbamate from decomposing into CO2 and NH3. This will maximize CO2 conversion to Urea as shown in the reaction (2) The 2nd reaction is endothermic; therefore heat is required for this reaction to occour. The heat for this reaction comes from the formation of carbamate. This reaction is a function of temp. And NH3 concern in feed. The solution effluent from the reactor being a mixture of 19 Urea solution, ammonium carbamate, unreacted NH3, water and CO2 is extreamly corrosive in nature. 1: UREA SYNTHESIS Liquid ammonia (through reciprocating and centrifugal pump; here we only use reciprocating pump due to low cost) along with recycle Carbamate and gaseous carbon dioxide at high pressure (through compressor) enter the Reactor (R-1) and react to form ammonium Carbamate. This Carbamate then dehydrates to form Urea and Water. Liquid Ammonia from HP Ammonia Feed Pumps P-1 A /B / C at ~ 240 Ata and 350 C serves as the motive fluid in Ejector EJ -1 and drives the Carbamate from HP Carbamate separator MV-1 to the Reactor R-1 . On mixing with Ammonia from Pump P-1 A/B/C the mixture enters Reactor R-1 at the bottom at ~160 Ata and 1200C . Carbamate recycle ejector EJ-1 is steam jacketed to avoid crystallization of Carbamate. MAIN REACTION 2 NH3 + CO2 = NH2COONH4 +38.1Kcal/gm mol. AMMONIA CARBONDIOXIDE AMM. CARBAMATE NH2COO NH4 = NH2CONH2 +H2O +7.1Kcal/gm mol. AMM. CARBAMATE UREA WATER Here carbon dioxide is limiting agent. The total conversion is decided by this only. Carbon dioxide converted only 60% in process feed remaining feed are recycled again to get better conversion. Here any inconvenient will manage by NH3 flow rate 2:UREA FORMATION IN HIGH PRESSURE SECTION: Flow sheet 20 Process description: (High pressure means 135kg/cm2) Liquid Ammonia and gaseous CO2 along with recycled liquid Carbamate from HP Carbamate Separator MV-1, rise in the Reactor from bottom to top. Liquid ammonia and gaseous carbon dioxide react to form liquid Carbamate. The reaction products coming out of the Reactor (R-1) through the overflow pipe flow to the HP stripper Carbon dioxide from CO2 compressor ( K-1 ) enters the bottom of Reactor (R-1) through a separate nozzle at ~160 Ata and ~1300 C. Unconverted Carbamate, present in Reactor (R-1) outlet urea solution, is decomposed and stripped off in the HP Stripper ( E-1). Stripped Urea solution from the bottom of the Stripper (E-1) goes out to MP Pre decomposer (E-53) / Separator/Decomposer (MV-2/E-2). 3. Medium Pressure Section Urea solution from the HP stripper enters the MP pre-decomposer /MP decomposer. Unconverted Carbamate decomposes to ammonia and CO2 vapors, there by concentrating urea in solution 21 The vapors from the MP decomposer are condensed in Pre Conc. / MP condenser using Ammonium Carbamate solution from the LP section. The Carbamate solution overflows from the Pre Conc./ MP condenser into MP Absorber where the excess ammonia and inert are separated in form of the vapors These vapors are further purified in the top section of the Absorber with reflux ammonia. Ammonia with inert gases leaving the top of MP absorber is mostly condensed in Ammonia Condenser, with cooling water in tube side. From Ammonia condenser both liquid and gas phases are sent to Ammonia Receiver along with incoming liquid Ammonia. The inert gases, saturated with Ammonia, leaving the receiver enter the Ammonia Recovery Tower. Here Ammonia is further condensed by direct contact with cold Ammonia from the Battery limit and flows down the Ammonia Receiver. Inert with residual ammonia vapors from the Tower are sent to MP Ammonia Absorber where later gets absorbed with cold condensate in inert washing tower and recycled to MP Absorber as ammonia water. The inert are released to vent stack. 4. Low Pressure Section: The urea solution from MP Decomposer bottom enters the LP Decomposer after let down through a level control valve. As a result of expansion. Most of the remaining Carbamate undergoes decomposition. Thus urea solution is further concentrated and is then sent to the vacuum concentrators through a level control valve. The vapors enter the LP Condenser shell and get absorbed in an weak Carbamate solution. LP Condenser has cooling water in tube side. The liquid thus formed goes to the carbonate solution Tank from where it is recycled back to MP Condenser. The inert gases from the Tank containing ammonia vapors are absorbed with cold condensate in LP Ammonia Absorber and sent to vent stack. The liquid flows down to the Tank. 5. Vacuum concentrator: The liquid from the bottom of LP Decomposer is further concentrated in a vacuum pre-conc. & two vacuum concentrators in series. With the help of MP gases/low pressure steam, Urea solution is concentrated from 70% to 99.7% by wt. The vacuum is created and maintained by three vacuum systems consisting of a set of steam ejectors and condensers. o 1: at 1kg/cm2. o 2: at 0.1kg/cm2. o 3: at 0.04kg/cm2 respectively. 22 Urea melt thus obtained is then pumped to the prilling tower top. The vapors from the vacuum separators are condensed in the condensers and sent to the waste water tank. 5. Urea Prilling: By using property of liquid urea we converted liquid urea into crystallized form with desired shape and size. This important property of the fluid is when liquid urea is at temperature below 133Oc at atm pressure its crystallization occurred. (if by any reason we can’t achieve this situation we recycled the whole fed before enters into the prilling tower)This property is used in prilling tower for crystallization of urea. And desired shape and size is given out through the bucket holes specification and by controlling speed of rotation of the bucket. Generally we placed 214 rpm for desire size of 1.74mm of urea particle through bucket. Rpm will depend upon the load and size of the product obtained. 23 Process description: The molten urea thus obtained from the 2nd vacuum separator holder is pumped to the top of prill tower and fed into a prill bucket . The Urea comes out through the holes of the rotating prill bucket and falls down the prill tower. Air by natural draught flow upwards counters current. Urea prills are then transported to the bagging plant through belt conveyor. Urea before packing BYPRODUCTS: The one and only one byproduct of urea plant is BIURATE. WHY BIURATE FORMS? Biurate were formed due to following four factors: 1: high temperature. 2: high pressure. 3: high concentration of ammonia feed. 4: high residence time in vacuum section. What is Biurate? When two molecules of urea is joined together at high temperature and with high residence time in vacuum section biurate formation were occurred. 24 Harmful effects: According to F.C.O. the minimum biurate concentration in urea is 1.5%. If it will exceed from this level it would be harmful for the plants in agriculture field. (Biurate burns the newly growing plant seeds.) WASTE WATER TREATMENT: Vapour containing water and little NH3 and CO2 from process and steam of ejectors from vacuum system are condensed and collected in waste water tank. It is thus pumped to a better waster water tank and thus to a distillation tower where after stripping of NH3 in the upper part, the solution is contaminated with urea is sent to hydrolyser. Here urea is hydrolyzed at high pressure by 38 atm. superheated steam. Vapors being sent to the distillation tower overhead condenser. Solution from hydrolyser goes back to the distillation tower for further NH3 removal. Vapors from the top of distillation tower goes to overhead condenser with vapors from the hydrolyser. One part of this solution is recycled to the distillation tower top as reflux and the remaining portion to the L.P. condenser. Liquid from bottom of distillation towers called the effluent or purified waste water which can be used as B.F.W. or as cooling tower make up. EFFECT OF PROCESS VARIABLE IN UREA PRODUCTION The equilibrium conversion to Urea will be favored under the following process variables : I) Higher ammonia concentration. II) Less H2O concentration. III) Higher temperature. IV) Higher pressure. V) Increased residence time. I) EFFECT OF NH3 / CO2 RATIO: Theoretical ratio of NH3 / CO2 is two. But in this condition Urea yield is only around 43.44% at 170 atm. and 1550 C. This low yield can be improved by changing NH3 / CO2 ratio when the excess ratio of NH3 is increased to 279%, Urea yield will change from 43.44% to 85.2%. On the other hand when the excess ratio of CO2 is changed from 0-300%, Urea yield will increase only from 43.44% to 46%. The effect of excess CO2 is very small. More over, in the CO2 rich condition the soln becomes very corrosive. In general, most all the Urea plants are operated under NH3/CO2 ratio around 2.5 to 5.0. II) EFFECT OF H2O/CO2 RATIO: Water is a product of Urea formation, presence of excess H2O shifts the equilibrium reaction in reverse direction and yield of urea is poor. However water has to be added for recycling unconverted NH3 and CO2 back to the reactor. Lower the amount of water in reactor higher is the yield of Urea. Excess H2O in reactor also reduces effective volume for urea formation and additional energy is 25 required to get rid of this H2O. Study shows that presence of one mole of excess H2O per mole of carbamate reduces equilibrium yield of urea to half. III) EFFECT OF PRESSURE AND TEMPERATURE: As per Le-chaterlier’s principal higher pressure favored carbamate formation. At the operating condition carbamate formation is almost instantaneous and reaction tends to completion provided reaction heat is removed simultaneously. Lower temperature favoured carbamate formation, being an exothermic reaction. In case of Urea formation, higher temperature is favorable, because the reaction is endothermic. The relation is such that when temperature increases, the conversion increases proportion only, maximum equilibrium conversion is achieved at around 196-2000 C. Reactants are highly corrosive at higher temperature. Operating pressure is totally dependent on the temperature at which conversion takes place. Urea conversion takes place in liquid phase, so equilibrium pressure becomes increasingly higher when the temperature rises. IV) RESIDENCE TIME: Urea conversion reaction is slow and takes 20 mins. To attain equilibrium. Higher residence time favoured equilibrium. Conversion and normally reactors are designed for residence time of 30 mins to one hour depending upon there operating parameters. Residence time in Urea reactor plays an important part on equilibrium conversion. Where operating parameters including mole ratio are not favourable for a good yield, higher residence – time compensates to some extent to achieve a better yield. But this is done by providing higher reactor volume which increases capital investment. BIURET IN UREA: The formation of biuret during Urea production is not desirable as it is toxic to the plants and it should not exceeds more than 1.5% in Urea as per Fertiliser control order. It is produced when Urea is heated in the absence of free NH3. 2 NH2CONH2 - NH2 CO NH CO NH2 + NH3 (Urea) (Biuret) The formation of biuret is favoured by higher temperature, higher concentration of urea solution, low NH3 content and higher residence time. 26 USES OF UREA: 1. As Fertiliser in agriculture; Due to high N-content of Urea demand of Fertiliser grade Urea is rising rapidly. Urea today accounts for a large percentage of Nitrogenous Fertiliser. 2. As cattle feed: Urea is used as cattle feed in western countries – sheep and cattle are capable of digesting Urea upto about 40% of their protein requirement. 3. As raw material for various industrial products: Urea also is used extensively in preparation of adhesives, textile, anti-shrink compound, and ion-exchange and as an intermediate in the preparation of pigments. CORROSION IN UREA PLANT EQUIPMENTS : Studies of corrosion in urea plant have led to the identification of the following type of corrosion: 1) Stress corrosion. 2) Inter granular corrosion. 3) Galvanic corrosion. 4) Crevice corrosion. 5) Pitting corrosion. 6) Condensation corrosion. Most severe corrosion in urea plant occurs at location where urea and carbamate solution are handled at high temperature and pressure. Studies have shown that major attack occurs at the bottom. 3 to 10 of the reactor directly; above where NH3, CO2 and ammonium carbamate are introduced. In view of higher pressure, temperature, cone and two phase mixture in urea reactor a liner of stainless steel 31 GL is used in the construction. Ti, Zr, and stainless steel are used as liner material. As to selection of material, corrosion resistance is not the only factor that determines the choice of material, other factor such as mechanical properties, workability weld ability and economic consideration are taken into consideration. 27 OFFSITES AT IFFCO PHULPUR SECTIONS: 1. Borewells and Raw Water Distribution System. 2. Cooling Tower. 3. DM and CPU Units. 4. Effluent Treatment Plant 5. Water Softening plant 6. Air – compressor – ELLIOTT 7. Instrument Air Drier – Split Flow 8. P.S.A. Unit 9. Naphtha Storage & Handling System 10. Diesel Generator set 11. Instrument Air Drier – HOC 12. Air compressor – IR. EFFLUENT TREATMENT PLANT INTRODUCTION: Removal & control of nitrogenous compounds such as NH3 that is present in waste being discharged from ammonia plant and urea plant is very essential in view of pollution control and water reuse philosophy. As water is one of the precious natural resources for running any industry its reuse and conservation is essential for environmental pollution control and to reduce operating cost of the industry. To overcome problems associated with disposal of ammonia effluent and making it fit for reuse the effluent treatment plant is installed in which NH3 present in effluent water is reduced by stripping process. BRIEF PROCESS DESCRIPTION To carry out the stripping process a packed column called steam stripper is provided in which the raw effluent is fed from the top and the LP steam is introduced from the bottom. The stripping occours and the treated water obtained is transferred to softening plant . The ammonia effluent treatment plant consists of following components : a) Two numbers of effluent collection pits and transfer pumps for storage and feeding the ammoniacal effluent to stripper. b) A preheater for heating the raw effluent going to steam stripper by outgoing hot treated water. c) Stream stripper for removal of ammonia by stripping process. d) A stripper sump where treated effluent collects. DESIGNED EFFLUENT QUALITY OF INLET : Ammonia - 2000 ppm Urea - 2000 ppm Suspended solute - Nil 28 T.D.S. - 50 ppm Flow rate - 30 M3/hr. (continuous) TREATED WATER QUALITY : Ammoniacal N - 50 ppm Power consumption - 225 KW / day Steam consumption - 10.6 T/hr. at pressure 4 Kg/cm2 and temperature 1500 C WATER SOFTENING PLANT Water source of raw water required for the plant is underground sub-soil water containing salts of sodium, magnesium and calcium, together with bicarbonate, carbonate, sulphates, chlorides and silica (Major constituents) and Nitrate, Phosphate, Iron, Organic matter and dissolved gases (Minor constituents). On using the raw water having high hardness as cooling water make up, these salts break during heat transfer process inside the heat exchangers and thereby forms scales. To bring down the concentration of calcium and magnesium hardness and also silica in cooling tower make up water, “cold lime softening process” is adopted. The raw containing high HCO3 alkalinity is reduced during treatment with lime solution and the treated water becomes suitable for cooling water make up. The capacity of the water softening plant under Phase-II is to treat 800 m3/hr. of raw water and the other design basis are : pH - 7.2 to 7.8 Total hardness - 348 ppm as CaCO3 Ca hardness - 160 ppm as CaCO3 Mg hardness - 180 ppm as CaCO3 M alkalinity - 424 ppm as CaCO3 P alkalinity - 0 Sulphate - 65 ppm as CaCO3 Chloride - 57 ppm as CaCO3 Sodium - 198 ppm as CaCO3 Total anion - 546 ppm as CaCO3 Permanent Hardness - 0 Silica - 33 ppm (max.) as SiO2 TDS - 650 ppm Design treated water quality and softening plant Phase-II outlet is following : pH - 10.4 to 10.7 Total hardness < 50 ppm as CaCO3 Ca hardness < 40 ppm as CaCO3 Turbidity < 12 NTU 29 The water softening plant is designed to treat 800 m3/hr. water of given raw water characteristics to produce soft water of the following components. 1. Parshal Flume. 2. Reactor Clarifier 3. Sludge Basin & Disposal. 4. Chemical Dogging System. REVERSE OSMOSIS PLANT Normally when 2 solutions are separated by means of semi – permeable membrane, the solvent flows from dilute solution to concentrated solution. If pressure is applied to concentrated side and if the pressure is greater than osmotic pressure, then solvent flow is reversed, i.e., it flow from concentrated solution side. This process is called reverse osmosis. It is advantageously used to extract water from concentrated solution. During R.O. process, pressure is continuously applied to the feed stream by a high pressure pump. Consequently feed stream gets divided into two parts. 1. Permeate stream (low in dissolved solid content) 2. Reject stream (very high in dissolved solid content) PROCESS DESCRIPTION: The water is fed to the R.O. plant from R.O. feed pit. In the feed some chlorine is introduced in concentration of 1 ppm. This chlorine kills bacteria and algae, which is harmful to membrane. From feed pit the water is entered into solid catalyst classifier. In this classifier dolomite and lime is introduced in solid form (not in fully powdered form). Here 0.1% of a polymer solution is also added. This polymer coagulates the silica, which is deposited on dolomite and lime, into large size. Hence the effluent from classifier is reduced in silica and turbidity from that of water in feed. To the classifier effluent 10% sodium – hexa-meta phosphate (SHMP) is added. The solution acts as an anti scalar. The effluent then enters into 4 continuous filters. These filters are actually sand filters having sands of uniform size. The effluent from these fitters is maintained at pH 6.5 by addition of 30% HCl and stored in clarified water storage tank. The rejects from solid contact classifier and 4 continuous filters are sent to sludge – pit where it is poured and dried. The dried solid material was then sent into ash pond . This classified water is used as power water and in chemical tanks (dolomite, lime etc) . Introducing it in multigrade filters, in which different sizes of sand layers are used as filter, further purifies this water. The effluent from multigrade filters then passes through a basket type catridge filter. The cartridge filter removes suspended particles from water. When the differential pressure across the catridge filter reaches 1 kg/cm2 when the flow rate through cartridge filter reduces, the cartridge filter must be replaced. The effluent from this filter then enters into 2 micron cartridge filters, removes suspended particles upto 5 micron. The effluent from micron cartridge filter then enters into R.O. skid. The R.O. unit consists of single stream 3 stages. There are total 37 pressure tubes each containing 6 No. of membrane modules :- The 1st stage contains 20 pressure tubes. The 2nd stage contains 11 pressure tubes. The 3rd stage contains 6 pressure tubes. 30 The membrane elements mainly made of polyamide films, imported from USA. The total input flow rate to this R.O. unit is 150 m3/hr. the flow rate through each pressure tube is 7 m2 / hr. (approx.) Flow Rate : (m3/hr.) Stage Input Product Reject 1 150 75 75 2 75 35 40 3 40 15 25 Hence total product water is (75+35+15) = 125 m3/hr. and reject is 150 m3/hr. The maximum load can be handled by this R.O. unit is 165 m3/hr. R.O. membrane modules are interconnected inside the pressure tubes with push fit type of interconnecters. This R.O. unit consists of 2 sacrificial pressure enters the pressure tubes and passes through the R.O. membrane elements. The purified water (permeate) travels through the product header and gets collected. A cleaning system provides means to remove foulness from the membrane elements and to fill up pressure tubes with these infactant solutions. The cleaning system comprises of a cleaning solution tank, a pump and a cartridge filter. Cleaning Solution : (for 1000 lit. of water) * Solution –I (for inorganic fouling) : 1. Citric acid - 20 Kg 2. Liquid non – ionic detergent (triton x 100 or tergitol – 8 ) – 1 lit. Adjust to pH – 4 with NH4OH. * Solution – II (for CaSO4 and Organic ) 1. Sodium tri polyphosphate - 20 Kg. 2. Sodium salt of EDTA – 2.4 Kg 3. Detergent – 1 lit. Adjust to pH – 7.5 with H2SO4 * Solution –III (for high Organic fouling ) 1 Detergent - 1 lit. 2 Sodium perborate - 5 Kg 3 Formaldehyde (37%) – 13.5 Kg Adjust to pH-8 with H2SO4 . The product water is stored in product water tank and from there supplied to different plants, such as DM plant and softening plant inlet. Once the recirculation is completed for the desired time, pump is switched off and all the flexible hoses are disconnected, the blanks are removed from feed and permeate headers and the blank is put on the stages, where the flexible hoses are fixed, the system is started and flushed for 15 to 20 mins till the permeate quality is within the desired limit and the system is taken into line. 31 Power Distribution: T.G.1 - 12.5 MW T.G.2 - 18 MW Total power required 25.17 M Urea1 - 3.7 MW Urea 2 - 6.5 MW For Ammonia pump - 01,P1/A/B/C Carbamate pump - P2/A/B/C C.T.P. - 02,P1/A/B/C/D C.T.F. –ME,A/B/C/D/E Needs total power – 3.24 M.W. ENVIRONMENT AND POLLUTION CONTROL At IFFCO Phulpur Unit there has been an emphasis on keeping the environment clean and safe. Due to a continuous and dedicated efforts in this direction goal of zero discharge of effluent has been achieved. Strategy : Regular monitoring of effluent. Reduction of effluent generation. Reuse of liquid effluent generated. Using the solid waste for useful purpose. Measures Taken : Natural draft prill tower of 96 M height for reduced dust emission. 100 M high chimney and ESP in boiler to reduce dust emission . Cooling tower blow down reduction. Reuse of steam condensate from ammonia and urea plant in steam generation plant. Reuse of inert gas plant effluent in softening plant. Reuse of waste water from urea plant in cooling tower after treating in Hydrolyser System. Reuse of Jacket cooling water of ammonia plant in cooling tower. Reuse of impure condensate from power plant in cooling tower. Reuse of raw water pump house ejector water softening plant. Utilisation of Effluent for : - Deashing operation in steam generation plant. - Irrigation in farm land, green belt etc. - Dust suppression in ash pond and coal yard. 32 - Use of fly ash for making bricks. Fly ash being supplied to cement manufacturing plant. ACTIONS IN HAND : In order to reduce the data water consumption further and also to take care of effluent to be generated in expansion plant, following two major schemes are being implemented. 1) Sewage Treatment Plant is being installed to treat township sewage. This water after treatment will be used in plant and raw water consumption is expected to reduce by about 3000 m3/day. It is expected to be completed by June 1997. 2) Reverse Osmosis Plant will be put up with its pretreatment alongwith DM plant effluent segregation scheme. The segregated DM plant effluent will be first treated in pretreatment plant to remove this impurities. Treated H2O from pretreatment section will be finally treated with the help of R.O. membranes to get the water quality fit for reuse in the plant. Total cost of the plant is expected to be Rs. 8.51 crores. Plant completion is expected by March 1998. SAFETY MEASURES: IFFCO Phulpur believes in the philosophy of “prevention is better than cure”. All necessary steps are being taken to avoid accidents. All employees are being given training to avoid accidents. However, to handle any eventualities a team of qualified and trained personnel with necessary modern facilities are available round the clock. An incident accoured on 04.05.96 when Naphtha caught fire in ammonia plant and it could have caused severe damage to the ammonia plant, being a major fire ancient, however the fire was brought under control within 25 mins. This speak volumes about the preparedness of fire fighting staff. Facilities Available : 10 Kms length of fire hydrant line ring with 13 single heated and 13 double heated ground hydrant and 23 single headed fire escape and internal hydrants. 3 fire tenders equipped with latest fire fighting facilities. 16000 m3 total water storage out of which 8000 m3 water exclusively reversed for fire fighting only. 3 Motor driven and 2 diesel driven water pumps. Each of 410 m3/h capacity. 1 Motor driven pump of 10m3/h capacity. Fixed foam system for Naphtha storage area. Fire jeep and rescue van. Breathing apparatus – 15 33 Explosive meter - 10 Gas detectors O2 meters Smoke detectors REFERENCES: IFFCO Material www.google.com www.wikipedia.com www.slideshare.net 34