DCM SHRIRAM LTD.(SHRIRAM FERTILISERS & CHEMICALS, KOTA)

A PRESENTATION ON

PRACTICAL TRAINING(20 MAY 2015 to 20 JUNE 2015)

SUBMITTED TO: SUBMITTED BY:

DR. RAJEEV GUPTA AISHWARYA VIJAY

MR. RAJESH BHATT 12/172

IV YEAR, EIC Engg.

COMPANY’S PROFILE

DCM SHRIRAM has manufacturing facilities of Fertiliser, Chloro Vinyl & Cement in Kota (Rajasthan)). The company operates on coal-based captive power facilities rated at 133 MW.

The Urea plant in Kota has a Production capacity of 379,000 TPA, making Kota one of the vanguards in the country’s production of urea, & Chlor- Alkali capacity of 700 TPD in both Kota & Bharuch.

DCM SHRIRAM opened doors in the year 1969 and from then on there was no looking back for the company.

The company has marked tremendous profit that has established its firm position in the field of fertilizers and chemicals. Already an ISO 9001 company, the excellent quality control procedures have resulted in the company being nominated for the elite ISO 14001 status, exclusively for fertilizers and power plants.

With an eye to quality, DCM SHRIRAM has adopted SAP-R3 practices for its commercial work and also adheres to the regulations of Total Quality Management (TQM).

There is a strong and proactive focus on safety, health and environment.  Some of the facilities have received international recognition such as British Safety Council Sword of Honour etc.

VALUES AND BELIEFS

CUSTOMER

FOCUS

INNOVATION AND

EXCELLENCE

PEOPLE DEVELOP

MENTTEAM WORK

RELATIONSHIPS AND

HUMAN DIGNITY

SOCIAL RESPONSIBILITY AND

ETHICS

FERTILIZER PLANT

AMMONIA PLANT: PROCESS DESCRIPTION

Ammonia plant with a rated capacity of 450 TPD was installed and commissioned in February 1969.

In September 1974, plant capacity was enhanced to 600 TDP.

Natural gas is being used as feed and fuel in the plant since September 2007 in varying proportion.

The Ammonia plant has been divided into following three sections:

• REFORMING SECTION• PURIFICATION SECTION• SYNTHESIS SECTION All the compressors have been located in a compressor

house. Cooling towers for ammonia and urea plants are located within the plant battery limit.

• REFORMING SECTION Natural Gas is supplied from Battery Limit by

GAIL at 42kg/cm2 pressure and with sulphur of less than 5ppm concentration.

C2Hm + nH2O nCO + (n+m/2)H2 + 49.3Kcal Reforming reaction in the primary reformer

takes place in the catalyst bed at elevated temperature around 960 oC reducing methane content to 0.29% at the secondary reformer exit.

The heat content of exit gases is used to raise 72T/hr of 36K steam in No.1 and No. 2 HP boilers, which is subsequently utilized in primary reformer.

• CO CONVERSION & PURIFICATION The process gas coming from no. 2 HP boiler at 360

oC and 27.5 kg/cm2 pressure and contains mainly steam, hydrogen, carbon monoxide (CO), carbon dioxide (CO2).

CO is converted into CO2 by the catalytic shift reaction b/w CO and steam, where Iron chromium and Copper zinc are the catalysts.

CO2 is sent to the urea plant. Residual CO and CO2 in the raw synthesis gas is then converted unto CH4 in the methanator in presence of nickel catalyst at 300 oC. Methane acts as inert gas and has no adverse effect on Ammonia Synthesis Catalyst.

• SYNTHESIS SECTION The synthesis gas, which is known as make up

gas of synthesis loop is compressed from 23kg/cm2 to 315-325 kg/cm2 by motor driven 3 stage reciprocating synthesis gas compressors.

In the making of ammonia, the impurities such as oil, CO2 and H2O contained in the make up gas are absorbed in liquid ammonia and removed together in ammonia separator.

After the ammonia is made, it is sent to Horton Sphere for storage from where it is pumped out to the urea plant.

UREA PLANT: PROCESS DESCRIPTION

Urea plant was commissioned in February 1969 with an installed capacity of 700 TPD.

The plant is based on Stamicarbon total recycle process technology.

The plant was expanded to 1000 TDP in August 1974 but can now operate at a peak level of 1250 – 1300 TDP.

The Urea Plant has been divided into six sections:• SYNTHESIS SECTION• FIRST STAGE RECIRCULATION SECTION• SECOND STAGE RECIRCULATION SECTION• CRYSTALLIZATION SECTION• PRILLING SECTION• HYDROLYSER STRIPPER SECTION

• SYNTHESIS SECTION The synthesis reaction takes place at 200 kg/cm2

(19.6 MPa) pressure and 190 oC temp. The N/C ratio is maintained at about 4.

• FIRST STAGE RECIRCULATION SECTION This section operates at 20 kg/cm2 (1.96 MPa)

pressure. The depressurized solution after rectification at 160 oC is sent to second stage.

• SECOND STAGE RECIRCULATION SECTION

The solution from first stage is further purified here up to 68% urea at 3kg/cm2 (294 KPa) pressure and 150 oC temperature.

• CRYSTALLISATION SECTION The solution is concentrated here in an evaporator to a

concentration of 80% (Urea- 73% & Biuret- 7%). Solution containing crystals is filtered and centrifuged.

• PRILLING SECTION This section constitutes of an induced draft prilling

tower of 16m dia, a remelter system and a prilling bucket. Crystals from the dryer tube are melted in the remelter system and sent to a prilling bucket at the temp. of 138 – 140 oC. The prilling bucket revolves at 250 – 270 rpm. The free fall height of the tower is 54m.

• HYDROLYSER STRIPPER SECTION The hydrolyser is a vertical vessel and operates at 18

kg/cm2 pressure.

DISTRIBUTED CONTROL SYSTEM (DCS)

COMPONENTS OF DCS

Introduction Basic Configuration CPU Analog Input Module Digital Input Module Analog Output Module Digital Output Module Communication System Human Interface system (HIS)

INTRODUCTION A distributed control system (DCS) refers to a control

system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring.

A DCS typically uses custom designed processors as controllers and uses both proprietary interconnections and communications protocol for communication.

Input and output modules form component parts of the DCS. The input modules receive information from input instruments in the process (or field) and transmit instructions to the output instruments in the field.

BASIC CONFIGURATION Field Control station (FCS) It consists of input/output

modules, CPU and communication bus.

Operator station It is basically human interface

machine with monitor, the operator man can view the process in the plant and check if any alarm is presents and he can change any setting, print reports, etc.

Engineering station It is used to configure all input &

output and drawing and anything required to be monitored on the operator station monitor.

THE CPU Model is chosen based on

software to be used. The main memory is ensured

of high reliability by error correction code (ECC).

Addition of the new error detection and protection functions.

Other newly added functions include the memory management unit (MMU) and write protection which ensure data integrity, the parity check of addresses and data, the ECC memory, and a two wire signal self checker.

ANALOG I/O To input an analog voltage the

continuous voltage value must be sampled and then converted to a numerical value by an A/D converter.

The data value sampled will be somewhere between the voltage at the start and end of the sample.

The maximum (Vmax) and minimum (Vmin) voltages are a function of the control hardware. These are often specified when purchasing hardware.

DIGITAL I/O

The digital I/O module is configured by the card unit and either the terminal unit or connector unit.

It inputs and outputs 16 or 32 signal points and converts signals.

Since the types or I/O signal are software-set, no control switch or knob is found on this module.

COMMUNICATION SYSTEMS

The communication cards are used to realize the general-purpose communication of field control station and subsystems via serial links, so that the subsystem may be controlled or monitored.

HUMAN INTERFACE SYSYEM (HIS)

The human interface system programmed for a project/plan is designed in such a way that it would be easy for the operator to understand all the operations occurred in the plant.

COMMONLY USED TRANSDUCERS TEMPERATURE TRANSDUCERS• Thermocouple• RTD

SPEED TRANSDUCERS• Tachometers

FLOW TRANSDUCERS• Orifice type• Venturi tubes• Rotameters

LEVEL TRANSDUCERS• Ultrasonic• Radar - type

STRAIN GAUGES

CONCLUSION Training is preliminary to job and so this

training was a great experience in terms of learning. It came out to be a great platform for practical implementation of the theory we have read so far.

The architecture of the plants, the way various units are linked and the way working of the whole plant is controlled makes the student realize that engineering is not just about learning the structured description and working of various machines, but a greater part of planning and proper management.

THANK YOU!