a view of national fertilizer limted

7/29/2019 A View of National Fertilizer Limted

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NAVEEN | B.Tech | July 2, 2013 To August 14, 2013

Roll No.1711591

EEE

PANIPAT PLANT


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TABLE OF CONTENTS

Preface Acknowledgment Introduction to NFL National Fertilizers Ltd Introduction To PANIPAT Unit Salient Feature Of The Plants Plants And There Capacities Section A:SGP & CHP Section B:Ammonia Plant Section C:O & U Plant Section D:CPP Production Performance &Achievements


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PREFACE

Training report is an integrated part of the course of the 6 to 8 weeks summer training.Vocational training is a valuable experience for an engineering student. This expresses

the functional areas of engineering and also provides them an opportunity to be a part of

the real technical world.The succeeding pages of the report contain the theoretical aspects of

the practical things that I have learnt in 6 weeks training in the 4 Plant of N.F.L.

PANIPAT which are:

1. Steam Generation & Coal Handling Plant2. Ammonia Plant3. O & U Plant4. Captive Power Plant


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ACKNOWLEDGMENT

With practical understanding of any process undertaking is just like to mug up of all

things is applied that without practical understanding of process he is incomplete. But our

institute given chance to know how things practically happen.

I am also delighted beyond measure to express my profound sense of

gratitude to HRD Dept. Of NFL, PANIPAT for his uncountable assistance and worthyguidance in accomplishing the report without which my report would not have assumed

present form. Than s also to all friends who directly or indirectly provided their esteemed

co-operation that made this s report see the light of day.

Understanding of any process undertaking is just li e t all things is applied

that without practical understanding he is incomplete. But our institute has given us

chance things practically happen.

Vocational Trainee: Naveen Kumar HCTM,Branch : EEE KAITHAL


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INTRODUCTION OF NFL

National Fertilizer Limited was established in 23th August 1974, to set up two fuel oilbased plants at BHATINDA (Punjab) and PANIPAT (Haryana). Both of them were

commissioned in 1979. The NANGAL fertilizer plant of Fertilizer Corporation of India

(FCI) has been merged with NFL in 1978 on the recognition of FCI and NFL group ofcompanies. Later NFL executed its gas based plant at VIJAIPUR (MP) on HBJ gas pipe

line.VIJAIPUR plant had gone in commercial production in July, 1988. NFL is now

operating three fuel oil based plants located at Panipat, Bhatinda, Nangal and gas based

plant at Vijaipur. NFL produces two popular brands of chemical fertilizer i.e. Kisan Khad(Calcium ammonium Nitrate-CAN) and Kisan Urea. Besides the fertilizers it

manufactures and markets the industrial products (Liquid Oxygen, Liquid Nitrogen,

Nitric Acid, Methanol, and Argon) and by-products (Sulphur). NFL had signed a

memorandum of Understanding with the government of India in 1991 -92 all the years,after signing the MOU, government has rated the performance of the company as

Excellent. Company has been performing at high level of Capacity utilization over the

years. FERTILIZER, INDUSTRIAL PRODUCTS AND SERVICES Kisan Urea andKisan Khad :-NFLs popular brands are sold over a large marketing territory spanning

the length and breadth of the company. The company also manufactures and markets

Biofertilizers and a wide range of industrial products li e Methanol, Nitric Acid, Sulphur,Liquid Oxygen etc. Kisan Urea Kisan Urea is a highly concentrated solid nitrogenous

fertilizer, containing 46 .0%. It is completely soluble in water hence nitrogen is easily

available to crops. It contains Nitrogen in amide form which changes to ammonical forms

and is retrieved by soil collides for longer duration. Urea is available in Granular form

and can be applied by drill and broadcasting. Kisan Urea is ideally suited for all types ofcrops and for foliar spray, which instantly removes nitrogen deficiency. Kisan Urea also

has a strong and long lasting effect on crop resulting in bumper crops.


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NATIONAL FERTILIZER LIMITED INTRODUCTION

OF PANIPAT UNIT

The PANIPAT unit if NFL is situated on National Highway no 1 and Delhi-Amritsar

railway turn route. PANIPAT city is about 90 Km from Delhi and is covered in NationalCapital Region. PANIPAT is a historical city, which was the scene of historical battles.

Government of India passed a project on 10/2/1975 and construction was started from

30/4/75. The project was completed on 2/9/78 i.e. in 40 months. TOYO EngineeringCorporation, Japan and Engineers India Limited was the main con tractors. Total expense

on the project was of 221.33 crores of which 56.45 crores was in the form of foreign

investment. Urea production was started from 1/9/79. Till now


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SALIENT FEATURES OF THE PLANT

ANNUAL CAPACITY 511500 MT IN TERMS OF UREA

ANNUAL CAPACITY 235290MT IN TERMS OF AMMONIA

ANNUAL REQUIREMENT 300000MTOF RAW MATERIAL FUEL

OIL/LSHS

COAL 5, 45,000 MT

POWER 2, 18,000 MWH

WATER 5,630 MILLION GALLONS

ESTIMATED COST Rs 182.88 CRORES

FOREIGN EXCHANGE Rs 56.45 CRORES

LAND 442 ACRES

PLANT 131 ACRES


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PLANTS AND THERE CAPACITIES

AMMONIA PLANT 900 MT per day

UREA PLANT 1550 MT per day

SULPHUR RECOVERY PLANT 26.5 MT per day

STEAM GENERATION PLANT 3 X 150 MT per hour

CAPTIVE POWER PLANT 2 X 15 MWH

COAL HANDLING PLANT 150 & 250 MT per hour

BAGGING PLANT 4000 MT per hour

EFFLUENT TREATMENT PLANT 200 cubic meter per hour

RAW WATER PLANT 2400 cubic meter per hour


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SECTION A

STEAM GENERATION PLANT


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2.1 Introduction to SGP

2.1.1 Objective of SGP:-

In NFL, PANIPAT Unit Plant, all the basic unit operations need steam for their work and

mustOf the industrial equipment are driven by steam such as Turbo Compressors, Steam jetEjectors, preheater etc.

In unit operations

1) For evaporation supply the steam to evaporate2) For crystallizations supply the steam to crystallizer

3) To create the negative suction pressure mostly supply in the steam jet ejector

4) For combustions purpose such as gasification process

5) To exchange the heat of desire product by use of steam.

SGP starts from-1) Handling &Storage of Coal, Fuel Oil, LHSH, LDO & Methanol

2) Boilers)Coal Fired Boilerb) Fill Fired Boiler

3) Pollutions Control Sections

4) Steam Network Section

Unloading of coal

2.2 UNLOADING, HANDLING & STORAGE OF COAL

FUEL OIL, LSHS, LDO & METHANOL

2.2.1 PROCEDURE FOR HANDLING AND STORAGE OF FUEL OIL / LSHS:-

FO/LSHS is used as raw material (feed stock) in the Steam Generation & Ammonia &Methanol plant as a fuel .Daily consumption of oil in Ammonia & Methanol is 860t & in

SGP is 60t

The oil unloading system is designed to unload 90 wagons at a time .The oil from oilwagons

Is transfer to the storage tanks where it is heated to 75-80 by providing steam .Forheating?

Saturated steam is used at maximum temperature of 150 and pressure 5kg/cm2 at the rateof

15t/Hr

One stream of oil is given to NH3-II plant & other two streams are given to Day tank for

oilFired boiler-4 & day tank for coal fired boiler -1, 2, 3 each of capacity 104kl .Then oil is

Transferred to two separate preheaters from both the tanks where temperature is

increased to125 & finally is given to their respective boilers.

Procedure for handling and Storage of light diesel oil:-

Light diesel oil is unloaded from tankers transfer to L.D.O. storage tank of capacity 14kl&


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Then given to the boilers

Procedure of Handling and storage of methanol:-

Methanol from methanol plant transferred to Methanol storage tank of capacity

500m .One

Stream is given to NH3-II plant and other stream is given for loading of railway wagons.Methanol is produced in NH3-II plant at the rate of 67MT/day. It is widely used in plastic

asWell as in pharmaceuticals.

Procedure for Coal Unloading, Handling and Storage:-

Coal is used in SGP for burning purposes. Daily consumption of coal in SGP is about1000T/Day &daily production of steam is about 182t/day. Coals from coal wagons are

Unloaded in the tippler where vibrators is used which draw the coal on belt conveyer

&through belt conveyer it is drawn in coal yasd

From coal yard it is drawn to the underground Hooper with the help of bulldozer & fromthe

Hopper it is drawn to the belt conveyer. Here we use magnets for removing iron particlesof

Coal & Hammer Crusher for reducing the size of coal.4

Then by using Belt Conveyer coal after crushing is transferred to coal pulverizing yard

30000t. Angle of repose of unloading belts

COAL FIRED BOILER

2.3.1 INTRODUCTION:-

The integrated service boilers for the PANIPAT Expansion Fertilizer Project are differentfrom

Conventional boilers. These boilers are radiant, outdoor, bid rum, high head, non-

reheated type

& pulverized coal is used as principal fuelThese boilers are designed to heat up external high pressure saturated steam from heat

Boilers, along with generated steam coal is used as principal fuel

These boilers are designed to heat up external high pressure saturated steam from wasteheat

Boilers, along with generated steam in the boiler to the same final superheated steam

These boilers generated 117t/hr. of steam and 65t/hr. external import steam. The finalSuperheated steam generated 182t/hr. will have a pressure of 91kg/cm2 & temperature of

510

2.3.2 MAIN BOILER STRUCTURE:-

The boiler designed of the top supported type & allowed to expand downwards. The mainBoiler is supported four rows of column on either side of the boiler (S1, S2, S3 &S4)

Boiler feed water which is coming from NH3-II plant which is preheated to 145 & then

Passing through the economizer where its temperature is rises to 182-188 then it istransferred

To the steam drum. In the steam drum it is converted to the saturated steam & remaining

water

Is not converted to steam is transferred to mud drum through bank tubes


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In the mud drum temperature of the condensed water is raises by the flow of the flue

gases from the mud drum through bank tubes. In the mud drum temperature of the

condensed water is rises by the flow of the flue gases. From the mud drum preheated

water is then transfer through the tubes along the sides of Furnace and recirculated to the

steam drum and the above processes continuously running. The purpose of recirculationis that, we cant leave the steam drum empty. The temperature of the saturated steam

leaving the steam drum is around 310 to 315C. The Saturated steam is then given toplating super heater where its temperature is rises to about 40

oC to 410C. The

temperature of the platen super heater is 905C

2.3.3 COAL PULVERSIZING SECTION;-In this section ball mill is used to pulverize the coal. Firstly coal which is crushed in the

hammer crusher to the size about size 25 mm is then transferred to the coal bunkers &

from coal bunkers & from coal bunkers through feeder to the centre of revolving ball ofthe ball mill. Hot air is given to the Ball which is coming by passing through the air

heater for the following two purpose:-1. For the drying of the pulverized coal

2. For the movement of the pulverized coal to the furnaceHot air enters the mill housing below the ball and is directed upward passes through

theclassifier vanes. The rising hot air around the ball picks up the pulverized coal, the

lighter particles carried by the air passes through the classifier & heavier particles arereturned from the classifier to the ball for additional grinding. Finally the pulverized coal

having particle size 200 meshes & air leaves the Ball Mill through classifier

2.3.4 COAL COMPOSITION

MOISTURE 6-10%VOLATILE MATTER 16-20 %FIXED CARBON 39-45%

ASH 30-35%

Table 2.1 coal composition

2.3.5 COMBUSTION CHAMBER OR BIOLER FURNANCE

At the four corner of the combustion chamber or boiler furnace one wind box is installed.At each corner one burner is located. Each burner will comprise of four streams which

are given to the furnace, these are coal +Air ,Tail Gas, LDO+ steam & hot air nozzles

arranged vertically in an insulated wind box Air is sucked from the atmosphere by the

forced draft fans & supplied to the air heater. After passing through the heatertemperature of the air is increased and then it is passed through the heater temperature of

the air is increased and then it is transferred to the wind box. For the burning of the coal

oil gun is used & all the other streams are given for the complete combustion of the coal& unburned coal particles are dropped to the bottom where screen is used to transfer

them to bottom ash hopper


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The flue gases which is produced after the combustion of the fuel is moving upward to

the furnace is centrifugal force. Centrifugal force is developed when all the streams from

the four corners will meet at a single where the burning is taking place

The temperature of the combustion chamber, where burning of the coal is done is

1070C .During the upward movement of the flue gas temperature difference betweenlower and upper part of the of boiler which is going to be in between 100C to 150C

2.3.7 PROCEDURE FOR DISPOSAL OF ASH:-We used coal as a fuel for the running of the boiler, approximate 1000MT/day of coal is

used and huge amount of ash is generated. For efficient running of the boiler continuous

removal of ash contents is essential .Heavier particles of burned coal are retained in the

bottom ash hopper of the boiler and the light particles are collected in the ElectrostaticPrecipitator. Finally the mixture of ash & water is discharged through feed gate &

clinker, grinder, which reduces the size of the clinker to about 50 mm to the ash slurrypit. Then ash slurry is disposed to ash pond area.Import steam which is coming from the

NH3-II plant at a temperature 313C and Pressure105ata is given to the import steamsuper heater where we get superheated steam whose temperature is around 510-520C.

The temperature of the final super heater is 872C for controlling the temperature of the

superheated steam, one super heater is used whose temperature is ling in between 370-400C. So after desuper heater finally we get superheated steam whose temperature is

500C and pressure is 91 atm which is then given to different sections in the plant. It

produces 182 Tonne/hr of superheated steam.

The flue gas which leaves from the furnace is leaving at the temperature of 530-540C,So arrangement is made for the waste heat recovery. Firstly the flue gases pass through

import steam super heater where some amount of heat is recovered and temperature ofthe flue gas reduces to 430C.Then it passes to economizer where the temperature is reduced to 338C and then it is

passed through air heaters which are used for preheating the air sucked by forced draft

fan the temperature of the flue gases are sucked by force draft fans and are given to theESP for the removal of fly ash or dust.


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SECTION BAMMONIA-II PLANT


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3.0 INTRODUCTION TO AMMONIA-II PLANTThis plant is the nerve centre of the NATIONAL FERTILIZER PANIPAT. This plants

main objective is to produce NH3, AMMONIUM NITRAT, and SULPHUR

The ammonia gas required for the production of urea is being produced over here

There are several unit in AMMONIA-II plant these are as follows1) AIR SEPERATION UNIT

2) GASIFICATION UNIT & GAS PURIFICATION3) CARBON RECOVERY

4) RECTISOL-I

5) CO-SHOFT CONVERSION6) METHANOL

7) RECTISOL-II

8) NITROGEN WAS

9) REFRIGERATION10) SULPHUR RECOVERY PLANT

11) AMMONIA STORAGEThese are arteries of the AMMONIAII plant

3.1 HABER PROCESSThe Haber process combines nitrogen from the air with hydrogen derived mainly from

Natural gas (methane) into ammonia. The reaction is reversible and the production ofAmmonia is exothermic.

THE CATALYST

The catalyst is actually slightly more complicated than pure iron. It has potassiumhydroxide added to it as a promoter - a substance that increases its efficiency.

THE PRESSURE

The pressure varies from one manufacturing plant to another, but is always high. Youcan't go far wrong in an exam quoting 200 atmospheres.

RECYCLINGAt each pass of the gases through the reactor, only about 15% of the nitrogen and

hydrogen converts to ammonia. (This figure also varies from plant to plant.) By continual

recycling of the unreacted nitrogen and hydrogen, the overall conversion is about 98%.

EXPLAINING THE CONDITIONSThe proportions of nitrogen and hydrogen

The mixture of nitrogen and hydrogen going into the reactor is in the ratio of 1 volume ofNitrogen to 3 volumes of hydrogen.Avogadro's Law says that equal volumes of gases at

the same temperature and pressure contain equal numbers of molecules. That means that

the gases are going into the reactor in the ratio of 1 molecule of nitrogen to 3 ofhydrogen.

That is the proportion demanded by the equation.

In some reactions you might choose to use an excess of one of the reactants. You would

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this if it is particularly important to use up as much as possible of the other reactant - if,

for example, it was much more expensive. That doesn't apply in this case.

There is always a down-side to using anything other than the equation proportions. If you

have an excess of one reactant there will be molecules passing through the reactor which

can't possibly react because there isn't anything for them to react with. This wastesreactor space - particularly space on the surface of the catalyst.

THE TEMPERATUREEQUILIBRIUM CONSIDERATIONS

You need to shift the position of the equilibrium as far as possible to the right in order toproduce the maximum possible amount of ammonia in the equilibrium mixture.

The forward reaction (the production of ammonia) is exothermic.

According to Le Chatelier's Principle, this will be favoured if you lower the temperature.

The system will respond by moving the position of equilibrium to counteract this - inother words by producing more heat.

In order to get as much ammonia as possible in the equilibrium mixture, you need as low

a temperature as possible. However, 400 - 450C isn't a low temperature!

RATE CONSIDERATIONS

The lower the temperature you use, the slower the reaction becomes. A manufacturer istrying to produce as much ammonia as possible per day. It makes no sense to try to

achieve an equilibrium mixture which contains a very high proportion of ammonia if it

takes several years for the reaction to reach that equilibrium.

You need the gases to reach equilibrium within the very short time that they will be incontact with the catalyst in the reactor.

THE COMPROMISE

400 - 450C is a compromise temperature producing a reasonably high proportion ofammonia in the equilibrium mixture (even if it is only 15%), but in a very short time.

THE PRESSUREEquilibrium considerations

Notice that there are 4 molecules on the left-hand side of the equation, but only 2 on the

right.According to Le Chatelier's Principle, if you increase the pressure the system willrespond by favouring the reaction which produces fewer molecules. That will cause the

pressure to fall again.

In order to get as much ammonia as possible in the equilibrium mixture, you need as high

apressure as possible. 200 atmospheres is a high pressure, but not amazingly high.

RATE CONSIDERATIONSIncreasing the pressure brings the molecules closer together. In this particular instance, it

will increase their chances of hitting and sticking to the surface of the catalyst where theycan react. The higher the pressure the better in terms of the rate of a gas reaction.

ECONOMIC CONSIDERATIONS


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Very high pressures are very expensive to produce on two counts.

You have to build extremely strong pipes and containment vessels to withstand the very

high pressure. That increases your capital costs when the plant is built.

High pressures cost a lot to produce and maintain. That means that the running costs of

your plant are very high.

THE CATALYSTEQUILIBRIUM CONSIDERATIONS

The catalyst has no effect whatsoever on the position of the equilibrium. Adding a

catalyst doesn't produce any greater percentage of ammonia in the equilibrium mixture.Its only function is to speed up the reaction.

RATE CONSIDERATIONS

In the absence of a catalyst the reaction is so slow that virtually no reaction happens inany sensible time. The catalyst ensures that the reaction is fast enough for a dynamic

equilibrium to be set up within the very short time that the gases are actually in thereactor.

SEPARATING THE AMMONIAWhen the gases leave the reactor they are hot and at a very high pressure. Ammonia is

easily liquefied under pressure as long as it isn't too hot, and so the temperature of themixture is lowered enough for the ammonia to turn to a liquid. The nitrogen and

hydrogen remain as gases even under these high pressures, and can be recycled.


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SECTION C

OFFSITES AND UTILITIES PLANTS


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The 0&U group of plants consist of the following sections: -

i) Raw Water Plant.

ii) D.M. Water Plant.

iii) Instrument .Air Compressor House.iv) Cooling Tower.

v) Sulphur Recovery Plant.vi) Effluent Treatment Plant & Steam Generation Plant.

(i) RAW WATER FILTERATION PLANTThis water treatment plant has a design capacity to treat 2400 NM3/hr of raw

Water into portable occasional over lead of 20%. The plant consists essentially of

Flash Mixers Clarifloculators, rapid gravity filters and a chemical House

Comprising of Alum tanks, lime tanks and a chlorine room etc.The raw water from the pumping main is received by the inlet of the RCC Ventury

Flume. In the ventury flume the calculated amount of alum solution is closed formixing with the raw water. The chemically treated water then flows to

clarifloculators. The pludge thus formed after chemical treatment settles down inthe clarifloculator where from it is expelled out while the clear water overflows to

the launder leading to filter beds. The filter water is disinfected with the addition

of chlorine and then collected in filter eater sump.

(ii). D.M. WATER PLANT

D.M. water plant was supplied by M/s Ion Exchange (India) Ltd. It consists of

cation units, Degasser Towers, An-ion units. Mixed bed units No.l&2. Filteredwater coming from raw water filtration plant is received in filter water reservoir.

From reservoir filter water passes through a strongly acidic cat-ion exchangeResin where cat-ions like Ca, Ng & Na are removed, the water passes throughDegasser tower where dissolved, Ce2 is removed. Then water passes through

Anion exchange resin and Anion like CI, S, Se4 and silica, are removed in this

unit. Free from cations and anions water passes through mixed bed unit No.l,where further removal of cations and anions takes place. Then treated water

coming out from MB, unit goes to DM water tank.

Return condensate from Ammonia and Urea Plants is collected in D.M. water

tank after treatment in cat-ion unit No.2. Then D.M. water is pumped from DMwater tank to mixed bed No.2(MB) for further polishing and collected in polish

water tank, which is supplied to boilers through Ammonia Plant.

(iii) INSTRUMENT AIR COMPRESSORS HOUSE

The purpose of this section is to supply instrument air and service air to all theplants. The instrument air compressor house consists of three instrument air

compressors and one service air compressor. One is kept in line generally.

The compressed air from instrument air compressors at 9.3 kg/cm2 absolutepressure passes through two sets of dryer, which is filled with silica-gel for

removal of moisture. Air coming out from dryer is sent to instrument air feeder

for supplying to different plants through instrument air receiver in order to


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drive various valves and instruments.

(iv) COOLING TOWERS

The cooling water system provided in NFL, PANIPAT is closed re-circulating

system supplying cooling water to various consumers in the plant. The systemmainly consists of cooling towers, cooling water re-circulation pumps, supply &

return headers and cooling water treatment facility.There are three cooling water systems : -

1) C.W. system supplies cooling water to Ammonia Plant.

2) Urea Plant and Boilers, Instrument -Air Compressor, Caustic dissolvingfacilities & Sulphur Recover Plant.

3) C.W. system supplies cooling water to Crystallization section of Urea Plant.

(v) SULPHUR RECOVERY PLANTThe separation of sulphur by catalytic reactions is as follows:-

H2S + 3/2 O2 SO2 + H2OH2S + 1/2 O2 S+ H2O

2H2S+ SO2 2H2O + 3SThe capacity of the plant:

Generation steam : 26.5 T/day

Export steam : 6.4 T/Hr.Plant performance : 85%

PROCESS OF SULPHUR RECOVERY:

The Acid gas from Rectisol Section of Ammonia Plant is composed of 47.5%H2S, 50.3% C02 and a little COS & CO and flows to this unit, 70% of feed gas is

introduced into Acid gas exchanger where 1/3 of total H2

S is burnt to S02

with airsupplied through furnace air blower. The S02 reacts with H2S and formselemental sulphur. I he sulphur is thus condensed at 191

oC and separated in

sulphur storage tank. The gas stripped off the above sulphur is mixed with the

remaining 30% of feed acid gas and bypass from acid gas exchanger in such away that the temp. of mixed gas is controlled at 215

oC and proportion of H2S,

S02 in this gas is over 2:1 ratio. This gas reacts over the first catalyst bed of

reactor to form elemental sulphur. This gas is cooled to 177oC in acid gas

exchanger and stripped off and so condenses sulphur in the sulphur storagetank. The remaining H2S & S02 react again to form elemental sulphur.

D.M. WATER PLANT

Water in its natural form contains no. of dissolved salts such as sulphates,chlorides and nitrates of calcium magnesium and sodium. If water is used as

such in the boilers for raising steam, these salts will form scale on the tubes,

which in addition to heat losses lead to many other many problems. Hence,removal of these salts from the water becomes quite essential. Ion exchange

resign are used for this purpose of salt removal.

The de mineralizing water plant of NFL PANIPAT was supplied by M/s ION


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exchange (India) ltd Delhi.

It consisted of three units each of cation, anion, mixed bed, four secondary mixed

bed and three units of condensate cation. At the time of setting up of a captive

power plant, another stream to augment the existing capacity of polish water

generation was by M\s BPMEL. It consisted of one unit each of cation, anion,primary mixed bed, two secondary mixed bed and two condensate cations.

Filtered water is received from raw water filtration plant into two filtered waterreservoir feed water pumps discharge water from these reservoir tom cation units.

These are total five feed pumps each having a capacity 0f 130m3/hr and four cation

units. Three of these are charged with 13125L of cation resin and fourth unit ishaving 11900 0f resins. Cation like Na+, Ca++, and Mg++present in the water are

removed in the cation unit once exhausted, these units are regenerated with the

counter current flow of dilute sulphuric acid.

The present day resins are made of cross linked polystyrene and cross linking isdone by di vinyl benzene.Cation resins are made of sulphonated polystyrene

SO3H can be represented by as RH.anionic resin is similarly made but ischloromethylated and then is animated. The final product is quaternary

ammonium compound a strong base and is represented by ROH.

CATION UNIT:

In the cation units free H+ ion of the resin is replaced by Ca and Mg or Na ionsas per the following reactions.

Page No. 66 of 74

RH + NaCl---------------RNa+ HCl

2RH + MgSO4--------------------- R2Mg + H2SO4

2RH + Ca (HCO3)2---------------------------R2Ca +2CO2 + 2H20

Natural salts are converted into respective mineral acid and alkaline saltsplit into carbon dioxide. The outlet water has low pH.

DEGASSER:From the cation units water move to the degasser. Here the free CO2 content of

the water is splitted off with the help of air by passing the water over by therasching ring packed bed. Water from the degasser is received into three Nos.

degasser water sump each of having a capacity 40m3 from these sump

degassed water pumps discharge water into the anion units. There are total five

Nos of pumps each having a capacity of 150M3/ hr.

ANION UNITS:Anionic impurities of water beside CO2 and silica are removed in the anionic unit.

There are total four No of anionic units. Two anionic units having a capacity

7920L of resin while the two are 5965 and 8400L of resin. Anion present in thewater gets removed as per the following reactions.

2ROH + H2SO4---------------- R2SO4 + 2 H2O

ROH + HCl------------------------ RCl + H2O

MIXED BED UNITS (PRIMARY):Certain amount of sodium and silica ions gets slipped from cation and anion

units. Very large volume of resin is required to check these leakages. Hence


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these ions are removed in mixed bed units. It consists of bed of mixed cation and

anion resins. This water is stored in DM water tank there are two DM water tanks

each having a capacity 1400L. Each of cation and anion resin is charged in three

mixed bed units while in fourth unit the quantity is 1880L.

CONDENSATE CATION UNITS:

Steam condensate is received from ammonia plant. It contains ionic and colloidaliron. Colloidal iron is removed in colloidal filters while ionic iron is removed in

condensate cation units. Condensate coming from ammonia plant is first cooled

to 45 C in a condensate cooler. There are total five condensate units. Three unitsare charged with 1810L of resin while two are charged with 4200L of resin. After

polishing the condensate it is stored in DM water tanks.

SECONDARY MIXED BED UNITS:

DM water from DM water tank is pumped to secondary mixed bed units with thehelp of DM water pumps. Final traces of impurities are removed again with the

help of mixed bed cation and anion resins. After passing through the bed polishwater of the following specifications is obtained.

pH 7+0.2Conductivity 0.2 micro mhos/cm

Total iron as Fe 0.015 mg/l

Silica 0.015 mg/lHardness NIL

Polish water thus obtained is stored in polish water tanks. There are two polish

water tanks each having a capacity of 1500M3. it is pumped to ammonia pant and

captive power plant with the help of five nos. of polish water pumps each havinga capacity of 220M3/hr.

FINAL DISPOSAL AREAThis area is used for receiving, storing and finally disposing off the treated

water from ETP and storm water. This area is having five ponds. Their capacities

and services for which these are used are given below.Sl no. Name Capacity Service

1. Pond no 1 25,000 Ash pond

overflow & off grade effluent2. Pond no 2 25,000 -do-

3. Pond no 3 26,000 Treated water

4. Pond no 4 48,000 Storm water

5. Pond no 5 60,000

Treated water meeting the MINAS standard is received in pond no 3 and 5 from

final effluent pump discharge located in EFFLUENT TREATMENT PLANT.If this water is not conforming to MINAS standard, then provision is to

receive it in pond no no. 1& 2. Storm water from the factory is received in pond

no.4 and stagnant water area. It is then pumped from this place to pond no. 1&2


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with the help of four vertical pumps. Effluent from ponds no 1&2 is pumped to

factory for deashing in SGP and CPP. Three pumps each with a capacity of

500m3/hr, have been provided for this purpose.

Treated water received in pond no. 3 and 5 is supplied for irrigation in fields and

township. Provision is also being made to use this water as fire water and forkitchen garden in township. Two pumps each with a capacity of 275M3/hr has

been provided for this purpose.

WATER BALANCE ACROSS FINAL DISPOSAL AREA

WATER IN WATER OUT Sl no Source Qty M3 Sl no Supplied to Qty M31 From ETP 230 1. For deashing in SGP

2. Ash ponds 388 2. For deashing in CPP

3. For irrigation in township

4. For fire Header changing and for use in township.

SAFETYSafety & fire Department manned by qualified personnel in various disciplines

has been provided in the Factory. High quality safety equipments are madeavailable to the employees free of cost. In order to make workers safety

conscious, regular publicity and frequent training programmes are arranged.

As this plant containing chemicals therefore it is dangerous while working infactory.

As protecting from these gasses these are prepares and kept in spheres, still

there is chance of leakage of gasses; gasses like Ammonia, CO are very

dangerous to the human life. As some gases smell less they can be detected.For this reason windsocks have been installed at several places on Plant/building

tops to see the direction of wind. In case of any toxic gas / vapours in toatmosphere, it is preferable to run in a direction at right angle of wind. They havea separate department known as 'Safety Department' that gave the knowledge

about these things. Fire station also comes under this section. They placed fire

detectors at different places. Some secret automatic systems are also there forsecurity purposes.

Safety Comes In Cans

I CAN, YOU CAN, WE CAN

HOW WINTER PROJECT IS USEFULIndustrial training is very useful for an engineer. It gives an overall idea

about the companys production problems one has to face in realizing companies

goals, when he is in the field. Winter Project done under IFFCO fetched me muchof the practical knowledge. I was at least aware of many factors that play crucial

role in an Managers life while working with in an industry. Training made me

understand the rudiments of an manager.At IFFCO I came in contact with workers and officers of various cadres. I

found both of them to be well versed in their fields.

Exposure to industry makes an MANAGER grasp the subject in a better


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way since confidence plays an important role in it and it is some thing which can

be gained only by practical training.

Having came in contact of IFFCO AONLA, its glories, its triumphs, its

success due to its toiled, zeal and zest employees. I am fully inspired to work

hard with dedication and my uttermost sincerity.


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SECTION D

CAPTIVE POWER PLANT


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CAPTIVE POWER PLANTSince inception, PANIPAT unit was drawing power from HVPN. Electricity is the

main driving force after steam, being used for moving auxiliary equipments. The

unit requires about 27MWs of power per hour when running at full load.

NEED FOR CPP

It was thought to install a captive power plant in which electric power forour requirement shall be generated in a COAL FIRED BOILER. The benefits

Envisaged were:

1. Any disturbance in the HVPN grid used to trip the whole plant. Lot ofmoney was lost due to this as each re-startup costs around 40 to 50 lakhs

rupees. Moreover, frequent trippings had an ill effect on machines and

equipments extending the re-startup period.

2. Three boilers of 150Te/hr steam capacity were initially installed in SGPto keep 25 boilers running and one stand by as designed steam requirement was

less than 300Te/hr. but in actual operation steam requirement was more and allthree boilers had to be run and there was no breathing time for their

maintenance. As new boiler was to be installed for CPP, its capacity was sodesigned that it could export around 60Te of steam for process requirement so

that only 2 boilers of SGP would be run keeping the 3rd as stand by.

With these points in mind CPP was installed. The functioning of CPP canbe sub-divided into parts:

1. BOILER AND ITS AUXILIARIES: for generation of high pressure

superheated steam.

2. TURBO-GENERATOR AND ITS AUXILIARIES: to generate power, usingsteam from the boiler.

Operation of CPP is based upon microprocessor based computerizedInstrumentation which allows automatic operation, start up, shut down of thewhole or the part of the plant.

BOILERBoiler has been supplied by M/S MITSUI ENGINEERING AND SHIP

BUILDING CO. OF JAPAN. It has a capacity to produce maximum 230Te/he of

steam at 105KG/cm2pressure and 4950C temp. 150Te/hr steam is used for

power generation if both generators are running at 15MWH each. Around 60Testeam per hr is drawn for process use and joins with the SGP steam header.

The basic principle of this boiler is the same as discussed earlier for SGP

boiler that is formation of steam by heating boiler feed water inside furnace fired

by coal and heavy oil, utilization of heat of the gases and venting these gases ata safe height. Main differences between the two boilers are:

1. SGP boiler is tangentially fired where as CPP boiler is front fired with 6

coal burners and 6 oil gun fixed inside the coal housing.2. SGP boiler can be loaded upto 30% load with oil firing only whereas CPP

boiler can be fully loaded with oil alone.

3. Height of combustible zone in CPP boiler is more and it has residence


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time of 1.5 sec where SGP boiler has 1.0 sec.

4. Mills used for pulverizations of coal in SGP are negative pressure bowl

mills whereas in CPP ball tube mill are used which are positive pressure

mills.

5. Due to more residence time and better pulverization the efficiency of CPPboiler is about 4% higher.

6. Boiler feed water required for steam generation can be fully generated inCPP itself.

A part of the steam generated is exported for process use in ammonia plant and

rest is utilized for power generation in turbo generators as described below:

Description

MITSUI RILEY TYPE BOILER

Maximum evaporation 2,30,000kg/hrDesign process for boiler 124kg/cm2G

Steam temp at outlet 4950CHeating surface 1250M2

FUEL COAL SYSTEMThe purpose of fuel coal system is to pulverize coal to dry coal and to

convey the pulverized coal from ball tube mill to burners by primary air for coal

firing.

Fuel coal system consists of three systems:1. coal supply system.

2. primary air system.

3. seal air system.

Coal supply systemPrimary air system

The primary air system performs two functions. It provides the properamount of air required to convey the pulverized coal to the burners and the heat

necessary to dry coal so it can be pulverized and burned efficiently. The details

of primary air fan are:-

Make MEIDEN

Degree of protection IP 55

No of poles 4Frequency 50Hz

RPM 1475Power factor 0.89Insulation class F

Rated power 195kW

Type of construction IEC-34

Normal temp rise limit 700C

Seal air system


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The seal air is distributed to the components by the sealing of the mill

system by the sealing air fan. The sealing air fan takes suction from silencer and

discharges it to a common header. The controller for each mill system provides a

constant differential pressure to protect against coal leaking into the bearings and

seals. This system should be in service before being placed in operation.

Crusher dryer systemCrusher-dryer performs the CRUSHING function. Metered coal from the

feeders blends with a properly heated amount of air from the primary air fan and

enter the crusher dryer. The non clogging pre crushing flash dryer operatesCoal bunkers Coal feeders Crushers dryers Ball tube mill

continuously at constant speed. Rotating hammers drive the incoming coal

against a breaker plate and adjustable crusher block, increasing the surface area

of the coal and mixing it with the incoming preheated air.

BALL TUBE MILLGrinding the coal to the proper fineness is done by ball tube mill. The

crushed coal and air mixture from the crusher dryers enter the mill through themill inlet boxes on both ends of the mill. The mill barrel rotating at constant

Speed, contains thousands of kilograms of various sizes of hardened steel balls

Which cascade down upon the entering coal and pulverize it to talcum powderConsistency. The heated primary air, entering with coal, not only completes the

drying process, but now conveys the coal dust from the mill through the mill

output boxes to the classifiers on both ends of the mill. The specifications of the

balll tube mill are as:-

Make MEIDENDegree of protection IP 55Insulation class F

No of poles 4

Voltage 3300VFrequency 50Hz

Current 98A

Power factor 0.89

Type of construction IEC-34Power rating 445kW

Connection Y

Temp. risk limit normal 700C

RPM 1430

The pulverized coal from the BTM is fed to the boilers with the help of

primary air fans. The coal is burnt in the boiler to generate steam to move theturbines. The forced and induced draft fans are used to assist in the combustion

of fuel and steam production. These two major types of fans supporting the units

operation.


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FORCED DRAFT FANThe forced draft fans supply the proper amount of secondary air required

to support the combustion of the fuel delivered to the boiler. The details of the FD

fan are:

Make MEIDEN

Rating continuousInsulation class F

Rated power 320kW

Voltage 3300VPower factor 0.85

Current 71A

RPM 980

Poles 6Connection Y

INDUCED DRAFT FAN

The induced draft fans control the furnace draft by drawing the gases ofcombustion through the boiler, regenerative air heaters, delivering them to the

stack. Thus the FD fan provides combustion air for the furnace while the ID fan

removes flue gases from furnace through chimney. The details of the ID fan are:

Make MEIDEN

Rating continuous

Insulation class FRated power 295kW

Voltage 3300VPower factor 0.83Current 67.5A

RPM 735

Poles 8Connection Y

POWER GENERATION

There are two 15MW turbine generator sets to generate power at 11kVwhich is fed into 132kV bus of PSEB and again distribution network.

TURBINE

The turbine used is supplied by M/S SGP of AUSTRIA. It is condensing cumextraction turbine designed as single casing reaction turbine with single control

stage and high pressure (HP), mild pressure (MP) and low pressure (LP) reaction

parts.The turbine is fed with high pressure steam at 100kg from boiler and flows

through various control valves for normal and emergency operation. It gets high

velocity through the nozzle group and then passes over the impellers fixed on to


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the rotor and fixed diffusers thus rotating the turbine. The enthalpy of steam is

utilized in steps. Steam is also extracted from various stages. HP1 at 10.4kg/cm2,

HP2 at 8.1kg/cm2, feed water bleed at 4.3kg/cm2 and LP bleed at 0.9kg/cm2.

The exhaust steam from the turbine is condensed in a condenser

maintained under vacuum to extract maximum steam enthalpy. The output of theturbine depends on flow of steam and heat difference that is on condition of

steam at the main steam valve and the pressure at the turbine outlet orcondenser pressure. The turbine is connected to the generator through speed

reducing gears.

The exhaust steam is condensed in a condenser using cooling water. Theresulting condensate can be fed back to LP heater but is normally sent to the

polishing water plant.

As shall be clear from the attached block diagram various bleeds from the

turbine are utilized for heating purpose. HP1 and HP2 are used for heating boilerfeed water in HP1 and HP2 heaters. Feed water bleeds is used for heating the

feed water tank and LP bleed is used for heating the polish water make up to thefeed water tank.

A lubrication system is also there to lubricate the various bearings of theturbine, gears and generator. Normally the oil pump driven by the turbine shaft

supplies oil but auxiliary motor driven pumps are used for start up and during

shutdown. A turning gear has been provided for slow cooling of turbine rotor.Latest instrumentation has been used in this plant. Baileys network-90

microprocessor based instrumentation system is being used. The NETWORK 90

SYSTEM is a distributed process control system. Using a series of integrated

control nodes. The network 90 system allows controlling process variables likeflow, pressure and temperature according to a control configuration. There is

operator interface unit (OIU) like a TV screen on which various parameters canbe displayed and controlled. It allows fully automatic start-up/shut-down of boiler,turbine and other auxiliaries.

Description:-Make Simmering Graz Panker, Austria

Type Multifunction (28 stages)

Capacity 65 T/H at 15 MW

RPM 6789 at 50 HzCritical speed 3200-3600 RPM

GENERATORS

CPP is having two number turbo generators of capacity 15MW each. TheGenerators are type SAT three phase, 50Hz, 11kV, 984amps, at 0.8 power factor

rating supplied by M/S JEUMONT SCHNEIDER OF FRANCE. These are totally

enclosed self-ventilated type with two lateral airs to water coolers for cooling. Thealternators are able to bear 10% overload for one hr with an increase in temp. of

100C while maintaining the voltage as near as possible to the rated one. The

excitation is compound and brushless with exciter rotor and Rectifier Bridge


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mounted on the extended main shaft on non-driving end. The excitation is

controlled automatically with automatic voltage regulator and a PLC controller. All

protection relays installed for protection of generator are solid state having high

accuracy, quick response and low power consumption.

Under normal running conditions of the plant and healthiness of the PSEBgrid, we generally run in synchronism with the grid merely drawing the power

corresponding to minimum charges to be paid to state electricity board. In caseof any disturbance in the grid measured by higher low frequency, high rate of

change of frequency, low voltage etc. our system gets isolated from the grid

automatically. With both generators running, we are able to feed power to thewhole plant, thus production is not affected. In case only one TG is in line and

grid cuts off, urea plant is cut off automatically to balance the load with one

generator. As soon as the grid becomes stable, the generators are again

synchronized with it.

SYNCHRONOUS GENERATOR [3 Phase] [T.Gs]Description:-

Make- SAT, (JEUMONT SCHNEIDER)-FRANCE

Degree of protection IP (54)

Type of excitation Brush lessInsulation class Rotor- F

Stator- F

Temperature rise Rotor- 800C B CLASS

Stator- 700COutput Voltage 11,000V 5%

Frequency 50HzCurrent 984 ASpeed 3000 RPM, Permissible-3500 RPM

Excitation Voltage 163V

Excitation current 580 APower factor 0.8

Duty Continuous

Noise level at 186mt. 85dB 3dB

Total weight 45TonnesCapacity 15 MW, 12.75 MVA at 0.8p.f (Lag)

Connection Star-Delta

Max. Inlet temperature Air 500C

Water 360C

EXCITATION CHARACTERISTICS

At no load I = 276A V = 55V

At MRC I = 580A V =163V

At 125% of MRC I = 672A V = 189V


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REACTANCES

Synchronous Xd 133%

Transient Xd 18.2%

Subtransient Xd 12.1%

TIME CONSTANT 4.5 secs

EFFICIENCY AT 0.8 PF

At 100% load 97.53%

At 75% load 97.25%

At 50% load 96.49%

EFFICIENCY AT UNIT PF

At 100% load 98.03%At 75% load 97.06%

At 50% load 96.82%


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PRODUCTION PERFORMANCE & ACHIEVMENTS

RECORDS Peaks in Production Scale

Highest Production of Ammonia on single Day 1041 MT (on02.01.1998)

(Against 900MT/Day rated Capacity)

Highest Production of Urea on single day 1918 MT (on 17.12.2000)

(Against1550 MT/Day rated Capacity)

Highest Annual Production of Ammonia 316619 MT (97-98)

(Against 297000 MT rated Capacity)

Highest Annual production of Urea 562250 MT (97-98)(Against 511500 MT rated Capacity)

a view of national fertilizer limted

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