1.

THE INDIAN FARMERS FERTILISER

COOPERATIVE LIMITED
During mid- sixties the Co-operative sector in India was responsible for
distribution of 70 per cent of fertilisers consumed in the country. This Sector had
adequate infrastructure to distribute fertilisers but had no production facilities of
its own and hence dependent on public/private Sectors for supplies. To overcome
this lacuna and to bridge the demand supply gap in the country, a new
cooperative society was conceived to specifically cater to the requirements of
farmers. It was an unique venture in which the farmers of the country through
their own Co-operative Societies created this new institution to safeguard their
interests. The numbers of co-operative societies associated with IFFCO have risen
from 57 in 1967 to 39,824 at present.

Indian Farmers Fertiliser Co-operative Limited (IFFCO) was registered on

November 3, 1967 as a Multi-unit Co-operative Society. On the enactment of the
Multistate Cooperative Societies act 1984 & 2002, the Society is deemed to be
registered as a Multistate Cooperative Society. The Society is primarily engaged in
production and distribution of fertilisers. The byelaws of the Society provide a
broad frame work for the activities of IFFCO as a Cooperative Society.

IFFCO commissioned an ammonia - urea complex at Kalol and the NPK/DAP

plant at Kandla both in the state of Gujarat in 1975. Another ammonia - urea
complex was set up at Phulpur in the state of Uttar Pradesh in 1981. The
ammonia - urea unit at Aonla was commissioned in 1988.

In 1993, IFFCO had drawn up a major expansion programme of all the four
plants under overall aegis of IFFCO VISION 2000. The expansion projects at Aonla,
Kalol, Phulpur and Kandla were completed on schedule. All the projects conceived
as part of Vision 2000 had been realised without time or cost overruns. All the
production units of IFFCO have established a reputation for excellence and
quality. Another growth path was chalked out to realise newer dreams and
greater heights through Vision 2010. As part of this vision, IFFCO has acquired
fertiliser unit at Paradeep in Orissa in September 2005. As a result of these
expansion projects and acuisition, IFFCO's annual capacity has been increased to
3.69 million tonnes of Urea and NPK/DAP equivalent to 1.71 million tonnes. In
pursuit of its growth and development, IFFCO had embarked upon and
successfully implemented its Corporate Plans, ‘Mission 2005’ and ‘Vision 2010’.
These plans have resulted in IFFCO becoming one of the largest producer and
marketer of Chemical Fertilisers by expansion of its existing Units, setting up Joint
Venture Companies Overseas and Diversification into new Sectors.

IFFCO has now visualized a comprehensive plan titled ‘Vision-2015’ which is

presently under implementation. IFFCO has made strategic investments in several
joint ventures. Godavari Fertilisers and Chemicals Ltd (GFCL) & Indian Potash Ltd
(IPL) in India, Industries Chimiques du Senegal (ICS) in Senegal and Oman India
Fertiliser Company (OMIFCO) in Oman are important fertiliser joint ventures. As
part of strategic diversification, IFFCO has entered into several key sectors. IFFCO-
Tokio General Insurance Ltd (ITGI) is a foray into general insurance sector.
Through ITGI, IFFCO has formulated new services of benefit to farmers. 'Sankat
Haran Bima Yojana' provides free insurance cover to farmers along with each bag
of IFFCO fertiliser purchased. To take the benefits of emerging concepts like
agricultural commodity trading, IFFCO has taken equity in National Commodity
and Derivative Exchange (NCDEX) and National Collateral Management Services
Ltd (NCMSL). IFFCO Chattisgarh Power Ltd (ICPL) which is under implementation is
yet another foray to move into core area of power. IFFCO is also behind several
other companies with the sole intention of benefitting farmers.

The distribution of IFFCO's fertilizer is undertaken through over 39824 co-

operative societies. The entire activities of Distribution, Sales and Promotion are
co-ordinate by Marketing Central Office (MKCO) at New Delhi assisted by the
Marketing offices in the field. In addition, essential agro-inputs for crop
production are made available to the farmers through a chain of 158 Farmers
Service Centre (FSC). 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 belongs 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 activities for their benefit every year.

At IFFCO, the thirst for ever improving the services to farmers and member co-
operatives is insatiable, commitment to quality is insurmountable and harnessing
of mother earths' bounty to drive hunger away from India in an ecologically
sustainable manner is the prime mission. All that IFFCO cherishes in exchange is
an everlasting smile on the face of Indian Farmer who forms the moving spirit
behind this mision.

IFFCO, to day, is a leading player in India's fertiliser industry and is making

substantial contribution to the efforts of Indian Government to increase food
grain production in the country.

Some of the well known fertilisers used in India are :

Nitrogenous Fertilisers
Urea 46%N
Ammoniam Sulphate (As) 21%N
Ammoniam Chloride (ACl) 26%N
Calcium Ammoniam Nitrate (CAN) 25%N

Phosphatic & Potassic Fertilisers

Single Super Phosphate (SSP) 16% P2O5
Muriate of Potash (MOP) 60%K2O
Sulphate of Potash (SOP) 48%K2O
Di-ammonium Phosphate (DAP) 18 - 46
Rock Phosphate (RP) 16 - 20% P2O5

NPK Grades
10:26:26
 12:32:16
14:35:14
15:15:15
16:20:00
17:17:17
19:19:19
20:20:00
23:23:00
28:28:00

Prices of IFFCO's Fertilisers

(Applicable only within India)
(Indian Rupees Per Tonne (w.e.f. 1st April, 2010)

UREA NPK NP DAP

N-46% 10-26-26 12-32-16 20:20:0:13 18-46-0
M.R.P. 5310 7897 8337 6895 9950
Local Taxes Extra, where ever applicable.

IFFCO PHULPUR UNIT

IFFCO Phulpur unit is being operated in two units namely UNIT-1 and UNIT-
2. The unit-1 started to produce urea in 1981 and in 1997 unit-2 starts
production commercially.

A brief description of both the units is as bellow…..

UNIT-1
Production Capacity;

Plant Capacity Supplier

Ammonia 1215 MT/day M/s. Pullman Kellog, USA
Urea 2115 MT/day M/s. Snam Progetti, Itly
Power Boiler 3x125 MT M/s. BHEL
Turbo-generator 1x12.5MW M/s. BHEL

Main Features;

Zero Date 26th May 1976

Commercial Production 28th March 981
Project Cost Rs. 205.00 Crores
Total Area 1070 Acres
Plant 320 Acres
Township 480 Acres
Cardet 150 Acres
Ash Pond 120 Acres

Total Production (Till 31.03.2010);

Product Total Production (Lakh MT)

Ammonia 89.96
Urea 155.44

UNIT-2
Production Capacity;

Plant Capacity Supplier

Ammonia 1740 MT/day M/s. H T A S, Denmark
Urea 3030 MT/day M/s. Snam Progetti, Itly
Power Boiler 1x200 MT/hr M/s. BHEL
Turbo-generator 1x18 MW M/s. BHEL

Main Features;
 Zero Date 20th April 1995
Commercial Production 22nd December 1997
Project Cost Rs. 1186.8 Crores
Indian Currency Rs. 859.8 Crores
Foreign Currency Rs. 327.0 Crores

Total Production (Till 31/03/2010);

Product Productin (Lakh Mt)

Ammonia 62.09
Urea 106.92
 2.HISTORY OF DEVELOPMENT OF UREA

Urea was first identified in 1773, when it was isolated by crystallization of urine. It
was first prepared synthetically from Ammonia and Cynic acid in 1828 by Wohler.

NH3 + HCNO = NH2CONH2

It was the first organic compound prepared by synthesis from inorganic materials.
The present method of synthesis from CO 2 and NH3 is known in principal in 1868
but commercially it was prepared in 1922 in Germany. However there was some
commercial production in Canada in 1920 using CaCN 2.

CaCN2 + 3H2O = NH2CONH2 + Ca(OH)2

Urea has been considered slow released Nitrogen fertilizer in colder region
because it has to undergo two transformations before it is available to crack.

First transformation according to hydrolysis takes place as:

NH2CONH2 + H2O = 2NH3+CO2

Second transformation according to nitrification takes place in which Ammonia is

oxidized in the soil by microbial means, first to nitrate and then to nitrile. These
reactions proceed at a faster rate in warm, moist soil and at slower rate in cold,
under some circumstances as when urea is placed to seed in local high
concentration of ammonia during hydrolysis accumulation of nitride during
nitrification, presence of biuret can cause excessive damage to crops.
 3.PROPERTIES OF UREA
Urea [CO(NH2)2], also known as carbamide or carbonyl diamide, is marketed as a
solution or in solid form. Most urea solution produced is used in fertilizer mixtures,
with a small amount going to animal feed supplements. Most solids are produced
as prills or granules, for use as fertilizer or protein supplement in animal feed, and
in plastics manufacturing. Five U. S. plants produce solid urea in crystalline form.
About 7.3 million Megagrams (Mg) (8 million tons) of urea were produced in the
U. S. in 1991. About 85 percent was used in fertilizers (both solid and solution
forms), 3 percent in animal feed supplements, and the remaining 12 percent in
plastics and other uses.

Molecular Formula NH 2CONH2

Melting Point 132.17 .C

Heat of Fusion 57.08Cal/gm

Heat of Combustion 2531Cal/gm

Crystalline Structure Tetragonal

Nitrogen Content 46.6%

Colour White

Bulk Density 672.756 to 789

kg/m3

Angle of Response 23 to 30

Triple Point 102.3

Dielectric Constant 3.52 to -0.2

Dissolution Constant 1.5

Specific Heat 0.42 Kcal/hr/K

Crushing Strength 27.8kg/cm2

Fertilizer Control Order (FCO) has defined following quality of
urea:
 Prill size : +2.8mm not greater than 10%
 Moisture Content : 1% max;
 Biuret : 1.5%max
 4. PLANT DESCRIPTION (IFFCO PHULPUR UREA-I)
PROCESS DESCRIPTION
The urea production process takes place through the following main
operation----

- Urea synthesis and high pressure recovery

- Urea purification and low pressure recovery
- Urea concentration
- Urea prilling
- Waste water treatment
a. Urea Synthesis and High Pressure Recovery
Urea is produced by synthesis of liquid Ammonia and Gaseous Carbon
Dioxide. In the reactor R-1 the ammonia and CO2 react to form ammonium
carbamate, a portion of which dehydrates to form urea and water. The reactions
are as follows……

2NH3 + CO2 = NH2COONH4 + HEAT

NH2COONH4 = NH2CONH2 + H2O - HEATs

At synthesis conditions (T=190C, P=150 Kg/cm2) the first reaction occurs

rapidly and goes to completion, the second reaction occurs slowly and determine
the reaction rate.

The formation of ammonium cabamate that dehydrates is determined by

the ratio of the various reactants, the operating temperature and the residence
time in the reactor.

The mole ratio of ammonia to CO2 is around 3.6:1. The mole ratio of water
to CO2 is around 0.67:1. The liquid ammonia, coming from ammonia storage, at a
temperature of around -10C is preheated in the ammonia preheater E-10 and
then received in ammonia receiver V-1 and hot liquid ammonia at 35C from
ammonia plant is received directly in ammonia receiver V-1.
 From V-1 ammonia is drawn and pumped by mean of centrifugal pump P-5
(operating at 23 ATA discharged pressure), partially to medium pressure absorber
C-1 and the remaining volume is directed to the high pressure synthesis loop.

The ammonia to the synthesis loop is first taken to low speed, heavy duty
reciprocating pumps P-1 A/B/C. These pumps discharge ammonia to a pressure of
about 240 atm. Before entering the reactor, the ammonia at this high pressure is
used as a driving fluid in the carbamate ejector EJ-1, where the carbamate coming
from the carbamate separator MV-1 is taken to the synthesis pressure. The liquid
mixture of NH3 and carbamate enters the reactor where it reacts with
compressed CO2.

The CO2 drawn at urea plant battery limit at about 1.1 atm pressure and
about 45C temperature enters the centrifugal compressors K-1 and leaves it at a
final discharge pressure of about 155 atm.

A small quantity air is added to the CO2 at the compressor suction in order
to passivate the stainless steel surfaces, thus protecting them from corrosion due
to both the reactant and reaction product.

The reaction product leaving the reactor flow to the steam heated falling
film stripper E-1, which operates at essentially the same pressure as the reactor.
The mixture is heated (by medium pressure steam on shell side) as it flows down
the falling film exchanger. The CO2 content of the solution is reduced by the
stripping action of the ammonia as boiled out of the solution.

The decomposition of ammonium carbamate is an endothermic reaction.

Heat for this reaction is supplied by 26 atm saturated steam on the shell side of
the stripper. The overhead gases from the stripper, and the recovered solution
from the medium pressure absorber C-1, the pumped through plunger pumps P-
2A/B, flow to the high pressure carbamate condenser E-5/6, where the total
mixture except some inert, is condensed as carbamate and recycled to the reactor
by mean of ejector EJ-1.

Condensation of the gases at high pressure and temperature permits

production of steam at 4.5 atm in the high pressure carbamate condenser. Non
condensable gases consisting of N2, O2, H2 and also containing a small quantity of
NH3 and CO2 unreacted the condenser, are released from the top of the
carbamate separator MV-1. This gaseous mixture is send to the bottom of the
medium pressure decomposer E-2.

b. Urea Purification and Low Pressure Recoveries

Urea purification takes place in two stages at decreasing pressures as
follows……..

1. Medium pressure at 18 ata pressure.

2. Low pressure at 4.5 ata pressure.

i. Medium Pressure Purification and Recovery at

18 ata
The solution with a low residual CO2 content, leaving the bottom of the
stripper at synthesis pressure is let down to 18 ata pressures and enters medium
pressure decomposer.

The medium pressure decomposer has been divided into two parts …….

1. Top Separator (MV-2): where the released flash gases are removed before
the solution enters the tube bundle.
2. Decomposition section (E-2, falling film type): where the residual
carbamate is decomposed and the heat required for decomposition is
supplied by mean of 26 ata steam condensate flowing out from the shell
side of the stripper.

The NH3 and CO2 reach gases leaving the top separator (MV-2) are sent to
medium pressure condenser E-7, where they are partially absorbed in aqueous
carbamate solution coming from the low pressure recovery section. The
absorption heat is removed by tempered cooling water circulation is the tube
side of medium pressure condenser E-7.

Tempered water circulation is provided to prevent carbamate solidification

maintaining proper cooling water temperature inlet to the tube side of the
medium pressure condenser. The cooling water temperature inlet to
condenser is maintained by mean of in-line pump P-19.

In the MP condenser the CO2 is almost totally absorbed. The effluent from
E-7 flows to the MP absorber C-1. The gaseous phases (entering C-1 along with
liquid effluents from E-7) enter the rectification section of MP absorber C-1.
The rectification section has bubble cap trays and effect CO2 absorption and
NH3 rectification.

The bubble cap trays are fed by pure reflux ammonia at the top trays which
eliminates residual CO2 and H2O from gases leaving MP absorber from the
top. Reflux NH3 is drawn from the NH3 receiver and pumped to the
rectification column by mean of centrifugal pump P-5.

Inert gases (H2, N2, O2) saturated with ammonia and having max. of 100
ppm CO2, leave the top of the rectification section of MP absorber. The
bottom solution is recycled by the pump P-2A/B to synthesis recovery section.

NH3 with inert gases leaving the MP absorber top is partially condensed the
ammonia condenser E-9. Both uncondensed gases phase and condensed liquid
ammonia are sending to ammonia receiver V-1.

The inert gases, saturated with ammonia living the receiver V-1 enter
ammonia preheater E-10 where an additional amount of vapor ammonia is
condensed by heating cold ammonia (at around -10C) coming from ammonia
storage area and used as makeup feed to urea plant in addition to hot
ammonia taken directly from ammonia plant. The condensed ammonia from
E-10 is received in the receiver V-1 and so is the ammonia make um feed.

The inert gases with residual ammonia content are sent to medium
pressure ammonia absorber E-11, which is a falling film type and where they
 meet counter-current condensate flows which absorb gaseous ammonia. The
absorbing heat is removed by cooling water flow on the shell side of E-11.
From the bottom of E-11 the water ammonia solution is pumped to the MP
absorber C-1 (at second bubble cap tray from the top) by mean of centrifugal
pump P-7A/B.

The upper part of MP ammonia absorber designated as C-3 consist of three

valve trays where the inert gases are submitted to final washing by pure
condensate.

The inert leaving the top of E-11/C-3 are practically free from Ammonia.

ii. Low Pressure Purification and recovery stage 4.5

Ata
The pressure of the solution leaving bottom of the MP decomposer is
letdown to 4.5 ata and then enters the low pressure decomposer which consist of

- Top separator (MV-3), where the released flash gases are removed before
the solution enters the lower tube bundle.
- Decomposition section E-3 (falling film type), where the residual carbamate
is decomposed. The required heat for decomposition is supplied by mean
of saturated seam at 4.5 ata.

The gases leaving the top separator (MV-3) are sent to the low pressure
condenser E-8 where they are absorbed in an aqueous carbonate solution
coming from the waste water recovery section. The absorption and
condensation heat from LP condenser E-8 is removed by cooling water. From
the LP condenser E-8 the liquid phase , with remaining inert gases, is sent to
the carbonate solution tank V-3. From there the carbonate solution is recycled
back to the medium pressure condenser E-7 by mean of centrifugal pump P-
3A/B. the inert gases from V-3 which essentially contain ammonia vapor and
 some inert flow directly into the low pressure falling film absorber E-12, where
the ammonia is absorbed by a counter current water flow. The absorption
heat is removed by cooling water flow on shell side of E-12. The top portion of
E-12 has three valve trays and is designated as C-4. Pure condensate is
introduced into the top tray which flow down through other trays of C-4 and
then E-12 to recover ammonia. Vent gases leaving C-4 are only inert and are
free from ammonia.

c. Urea Concentration Section

As it is necessary, in order to prill urea, to concentrate the urea solution up
to 99.8% by wt. a vacuum concentration section in two stages is provided.

The solution leaving the LP decomposer E-3 bottom having about 72% by
wt. of urea is sent to the first vacuum concentrator E-14, operating at a pressure
0.3 ata. The liquid/vapor phase coming out from E-14 enters the gas liquid
separator MV-6, where from the vapors, are extracted by the first vacuum system
ME-4 while the solution enters the second vacuum concentrator E-15, operating
at a pressure of 0.03 ata.

The two concentrator E-14 and E-15 use saturated steam at 4.5 ata. The
liquid vapor phase coming out from E-15 enters gas-liquid separator MV-7 where
the vapors are extracted by the second vacuum system ME-5.

i. First Vacuum System ME-4

First evaporator is operated at 130C and 0.3 Kg/cm2 a pressure, overhead
vapors from the top of first vacuum separator is directed to the shell side of
precondenser E-25 and heat of condensation is removed by cooling water in the
tube side. Ammonia vapor and residual CO2 is absorbed in condensate, forming
dilute ammonia carbonate solution and flow down through barometric leg to
waste water tank V-5.
 Uncondensed gases are sucked by the ejector EJ-2 (motive fluid being 4.5
ata steams) and discharge in the shell side of after condenser is E-27 which also
receives uncondensed gases from second vacuum system ME-5. Heat of
condensation is removed by cooling water flowing in the tube side of E-27. Dilute
ammonia water solution flow down to waste water tank and non condensable are
vented out from the shell side.

ii. Second Vacuum System ME-5

Second evaporator is operated at 140C and 0.03 Kg/cm2 pressure.

Overhead gases from second vacuum separator MV-7 are sucked by a booster
ejector EJ-4 (motive fluid being 4.5 ata steam) and discharged at slightly higher
pressure to the shell side of first inter condenser E-28 where heat of
condensation is removed by cooling water flowing in the tube side. The liquid
solution flows down through barometric leg to V-5.

Non condensed gases are drawn by the ejector EJ-5 (motive fluid being 4.5
ata steam) and discharged to the shell side of second inter condenser E-29 where
the latent heat of condensation is again removed by cooling water. Liquid flow to
V-5 and non condensed gases are sucked by ejector EJ-6 and discharged to the
after condenser E-27 where non condensable from first vacuum system also join.

d. Urea Prilling
The melted urea leaving the second vacuum separator is pumped to the
prilling bucket ME-8A/B by mean of centrifugal pump P-8A/B.

The molten urea coming out from the prilling bucket in the form of drops
falls along the prilling tower ME-6 and encounters a cold air flow which causes its
solidification and subsequent cooling.

The solid prills falling to the bottom of the prilling tower are sent to the belt
conveyer MT-1 by the rotator scraper ME_12. From here urea prills are passed
through screen ME-10 which retains lumps only. Product prills are conveyed by
belt conveyer MT-3 to the bulk urea storage or bagging plant.

Urea lumps retained on screen ME-10 are conveyed by mean of belt

conveyer MT-2 an underground tank V-7 where the lumps are dissolved in
condensate at 100C. The urea solution from this tank is pumped to the main urea
solution tank vessel V-4 by mean of pumps P-9A/B via filter FL-1A/B to remove
any foreign matter.

e. Waste Water Treatment

The water containing Ammonia and CO2 coming from first and second vacuum
section is collected in waste water tank (V-5). The waste water contains 5-6%
NH3, CO2 <1% and Urea 1-1.5%. This is also known as Ammonical water. This
waste water is pumped at the top of a distillation tower (C-2) to remove NH3, CO2
and urea. The NH3 and CO2 gases leaves the column from the top and the urea
get separated at the middle of the column and it is send to the urea Hydrolyser
(R-51) which hydrolyze the urea and convert into carbamate then further
hydrolization break this carbamate into Ammonia and CO2. The purified water is
discharges from the shell side of a reboiler mounted at the bottom of the
distillation column.

The distillation column is operates at the pressure of 2.5 kg/cm3. The distillation
column (C-2) is consists of 45 sieve trays. The feed means waste water is
introduced at the tray numbers 37, 39 and 41 counting first from the bottom.
Before introducing in the column the feed waste water is get preheated in the
tube side of a shell and tube heat exchanger by the effluent of the reboiler. In the
distillation column ammonia and CO2 in the feed are stripped by mean of vapor
product produced in the reboiler, which is supplied by 4.5kg/cm 2 saturated steam.
The liquid steam from the holder above 20 th tray is taken out to hydrolyser urea in
hydrolyser by means of steam. The vapor from the hydrolyser enters at the 37 th
trays and liquid is recycled back to the distillation column at 20th trays.
 The vapor leaving the top of the distillation column are condensed in an
overhead condenser. The condensate (the carbamate solution) is received in the
reflux accumulator. By means of centrifugal pump a part of solution is recycled
back to the top of the distillation column as reflux, while the remaining part is
supplied to LP carbamate condenser.

The distillation column bottom effluent containing only traces of ammonia is

taken to reboiler and then hot liquid effluent is fed to the shell side of the solution
preheater, where it is cooled and pumped by the means of the centrifugal pump
to the water cooler, where it is cooled by cooling water to a temperature about
40 C and then discharged of the of the factory effluent system. A provision for
injection of small quantity of air in the bottom of the distillation column is
provided to passivate the entire section.

This purified water is used as the same as DM water.

 5.EQUIPMENT USED IN UREA MANUFACTURING
5.1. Reactor(R-1)
Supplier- Mitsubishi Heavy Industries Ltd. Japan

The liquid mixture of NH3 and gaseous CO2 are fed in reactor where these react to
form ammonium carbamate, a portion of which dehydrate to form urea and
water.

Reactor is vertically mounted and made of carbon steel. It is internally lined with
5mm thick stainless steel liner 316L.Ammonia/carbamate and CO2 feed nozzle
extend inside the reactor up to 1.8m and each are capped on top end. For
distribution of NH3/carbamate feed 345 holes (I.D.10 mm equi-spaced) are
provided. These are drilled along 855mm length. Similarly CO 2 distributor has 270
nos. 0f equi-spaced holes (I.D.6mm.) provided over a length of 880 mm inside
reactor bottom.

Operating Details

Operating Pressure 151Kg/cm2a

Operating Temperature 185.C

Design Pressure 166Kg/cm2a

Design Temperature 195.C

Density of reactor 950Kg/m3

Reactor Volume 157m 3

Maximum Temperature and Pressure

Gradient during startup and shutdown:

Temperature 50.C/hr

Pressure 60Kg/cm2/hr
Minimum Acceptable Temperature and Maximum Pressure Gradient during
Hydro Test:

Temperature 20.C/hr

Pressure 60Kg/cm2/hr

Mechanical Details

1. Length 3600mm
2. I.D. 2305mm
3. O.D. 2494mm
4. Internal Lining 5mm 316L
5. Total no. of sieve trays 10
6. Height between each tray 2500mm
7. Holes on sieve trays 421 holes of 8mm I.D.
8. Overflow Pipe(I.D.) 219.1mm with 8.2 mm
thick
9. NH3/carbamate inlet distributor equally spaced 345
holes of
10.holes dia. 10mm
11.CO2 inlet distributor holes equally spaced 270 holes of :dia.6mm

Material Of Construction

1. Shell . . . . . . ………..Carbon steel

2. Sieve trays . . . . ……….. SS 316-L(modified)
3. All internal walls and liner in contact with fluid……. SS316-L (modified)
4. Man hole Gasket . . .. ……..Teflon, Aluminium
 5.2. Medium Pressure Absorber :C-1
Supplier: B.H.P.V. Vishakhapatnam

M.P. Absorber (C-1) contains four bubble cap trays at the top. Vapor liquid
mixture enters through an entry pipe which runs down inside column and is
equally divided into four perforated arms. Each perforated arm has 270 holes of
12mm dia. Each and are equally spaced on three rows facing downwards. There
are four bubble cap trays at the top of rectification section numbered from
bottom. A liquid seal of 50mm is maintained on each bubble cap plate.4 th and 3rd
trays are fed pure reflux NH3 and aqueous NH3 solution respectively which
eliminate residual CO2 and water from the ammonia leaving C-1.Carbamate
solution from bottom plate down-comer falls in a closed ended channel and then
overflows to a distributor.

Mechanical Details

Length 9000mm.

Internal diameter 1830mm.

Thickness 23.5mm.

No. of bubble cap trays 4

Cap size and nos. 75mm.,165 caps per tray

No. of slot in each cap 19no. rectangular slots(25mm height,width 6.5mm)

Liquid seal on each tray 50mm.

No. of holes in vapor liquid entry pipe 270no. holes 12mm dia equally
(spaced 3rows facing down wards)

Vapor Liquid Inlet nozzle diameter 203.2mm

Pure ammonia inlet nozzle dia. 76.2mm

NH3 solution inlet 38.1mm

Vapour outlet dia. 254mm.

H2O inlet nozzle dia. 25.4mm.

Recycle solution inlet nozzle 76.2mm.

Solution transfer nozzle dia 101.6mm.

Solution outlet nozzle 203.2mm.

Manhole dia. 508mm.

Operating Details

Ooerating Pressure 18Kg/cm2

Operating Temperature TOP 47.5C

BOTTOM 88C

Designed Pressure 22Kg/cm2

Designed Temperature 110C

Density of carbamate soln. 922Kg/m3

Hydraulic test pressure 40.3Kg/cm2

Material Of Construction

Shell, Heads and All internals SS316-L

Supports SS316-L&285 Gr.C

Gskets Spiral wound AISI316+Teflon

 5.3. Distillation Column(C-2)
Supplier: Larsen And Toubro, Bombay

Preheated Ammonium carbamate solution leaving preheater enters the top of

distillation column.NH3 and CO2 in feed stripped by means of vapor produced in
the reboiler (E-16) and enter C-2 at the bottom. Vapor leaving top of the tower is
condensed in an overhead condenser (E-20) from where solution collected in the
reflux accumulator V-8.Feed to reboiler is taken from C-2 bottom. Vapor from E-
16 are back to the distillation column below 1 st plate. Rising vapor while travelling
through tray comes in intimate contact with solution strip out NH 3 and CO2. There
are two distributors, one is below 21st tray. The distributor is well supported to
shell and divided into three parts. From the middle portion having vapor hood at
the top which prevents solution from entering through middle opening, only gas
will pass. Overhead vapors leave through 14 th outlet nozzle and are taken to
overhead condenser (E-20).

Four thermocouples are provided to measure temperature above 41 st, 30th, 20th
and 10th plate. Two gauges for level have been provided at bottom.

Mechanical Details

Length 35670mm.

I.D. 1248mm.

No. of sieve trays 45

No. of bell caps 135

Insulation 70mm. thick

Vapor outlet nozzle dia. 14inches

Reflux inlet nozzle dia. 1.5inches

Solution feed nozzle dia. 4inches

Vapor inlet nozzle dia. 16inches

Utility air inlet nozzle dia. 1inch

Water outlet nozzle dia. 6inches

Operating Details

Design Pressure 4Kg/cm2

Design Temperature 165C

Operating Pressure 2Kg/cm2

Operating temperature 135C

Volume 44m3

Material Of Construction

Shell, Heads and Internals SS304

Supports A240 type 304 & A 515 Gr.55

Gaskets Compressed asbestos

5.4. Stripper(E-1)
Supplier: FBM Milano

Stripper is a high pressure falling film type heat exchanger. Reactor effluents are
heated in stripper to decompose and strip off unconverted carbamate at
synthesis pressure. Reactor effluents are admitted at the top portion of stripper
and are fed to the circumferential annular section of the distributor plate.
Solution then overflows a weir of diameter 1570mm. and is distributed through
holes of distributor over a bed of pall rings. Here counter current contact takes
place between the liquid and gases leaving the stripper tubes. Grid below the
packed bed is placed just above the ferrules to keep them in position. Each ferrule
has holes at two different planes. At the bottom plane there are 4 tangential holes
of 2.4mm diameter, through which liquid enters each tube in the form of a film
along the wall. The solution outlet at the bottom is provided with a vortex
breaker. There are two types of level sensing elements at the bottom (a) dp
transmitter, (b) radioactive source.

Mechanical Details

Tube

Material
Titanium

Heat transfer area 787

on I.D.m2

No. of tubes 2780

I.D.
20.0mm.

O.D.
27.0mm.

Ferrule

Material
2RE69

Height of bottom set of holes from tube 50mm.

sheet

Height of top set of holes from tube 409mm.

sheet
Bottom Grid

Material 2 RE 69

No. of holes 5376

Hole dia. 12mm.

Packings

Material 2RE69

Type Pall ring

Ring size

Distributor Plate

Material 2RE69

No. of hole 1200

Hole 9mm.dia

No. of weep holes 45

Material of shell Carbon steel

5.5. Hp Ammonia Feed Pumps(P-1a/B/C)

Supplier: Worthington, Hamburg

Taking suction from discharge header of Ammonia booster pumps p-5A/B, HP NH 3

feed pump pumps anhydrous liquid ammonia at a high pressure of
240Kg/cm2.This liquid ammonia stream serves as a driving force for ejector EJ-1 to
recycle carbamate to reactor. This is a 5 plunger reciprocating vertical pump. An
electric motor drives it through a Torque converter and speed reducing gear.
Speed of the pump can be controlled from torque converter by adjusting the
opening of control valve on the torque converter. The lubrication of all the parts
housed in the crankcase is done by a Rotary oil pump which takes suction from
the oil sump of crank case. There is a pressure switch provided in the discharge
line of lube oil sump. High pressure of lube oil is relieved by a pressure relief
valve. Each stuffing box is provided with oil injection. Oil from a small
reciprocating pump is injected into the space in LP packing of each plunger. Oil
outlet from each plunger is taken to MV-5 .The speed of each pump can be
controlled by a HIC. In discharge there are one PG, one high pressure alarm and a
high pressure trip. Each pump has got an individual safety valve in suction and
discharge head. Following are the main parts :

 Crank Case: The frame is a very rigid casting and is made of 2 pieces. The
lower part of the frame serves as oil sump for lubricating oil.
 Crank Shaft: It is a one piece forging of carbon steel. Holes have been
drilled in the crank shaft to carry lube oil for pressure lubrication.
 Main Bearings: 5 are line bearing and one is thrust bearing. These bearings
are sleeve bearing and made of three compartments.
 Connecting Rod and Crank Pin Bearings: Each connecting rod is one piece
steel forging. Crank pin bearing split shell made of three component alloy.
 Cross Head Pin Bushing: These bushings are forced fit in the connecting rod.
These have annular groove on outside surface for lubrication purpose. It is
made of aluminium bronze multi-component alloy steel.
 Cross Head: Cross heads are made of Nodular cast iron turned and ground.
Cross heads have annular grooves for lubricating cross head area.
 Cross Head Pin: Cross head pin is forced fit into cross head and is held in
position by retaining rings and dowel pins to avoid turning. The cross head
is drilled to lubricate the face of the cross head.
 Tie Rods: Two tie rods for each head transmit the vertical cross head
motion to the plunger. The plunger is fixed on the tie rods with the help of
nuts. Tie rods are made of Cr. Mo. Steel.
Mechanical Details

No. of plungers 5

Plunger dia. 86mm.

Stroke length 152mm.

Plunger speed at 195 r.p.m. 0.99m/s

Suction Nozzle diameter 4inches

Discharge Nozzle dia. 4inches

Valves wing

Flushing Oil Flow 0.47L/hr.

Direction of rotation Clockwise from

coupling end.

Operating Details

Fluid Hndled Anhydrous liquid

NH3

Minimum Capacity 15m3/hr

Normal Capacity 41.5m3/hr

Maximum Capacity 47m3/hr

Sp.Gr. at operating temperature 0.58

Viscosity 0.13cps at 40C

Minimum Suction Temperature 30C

Operating Suction Temperature 40C

Design Suction Temperature 60-62C

N.P.S.H. required 5.2m

N.P.SH. available 10m

Normal Suction Pressure 21.6Kg/cm2

Maximum Suction Pressure 28Kg/cm2

Vapour pressure at operating temp. 14.85Kg/cm2

Normal discharge pressure 240Kg/cm2

Maximum discharge pressure 264Kg/cm2

Minimum Speed 63r.p.m.

Maximum Speed 195r.p.m.

Normal Speed 101.9r.p.m.

94.2r.p.m.

106.2r.p.m.

129.8r.p.m.

Mechanical Details

Length 3600mm

I.D. 2305mm

O.D. 2494mm

Internal Lining 5mm 316L

Total no. of sieve trays 10

Height between each tray 2500mm

Holes on sieve trays 421 holes of 8mm I.D.

Overflow Pipe(I.D.) 219.1mm with 8.2 mm

thick

NH3/carbamate inlet equally spaced 345

5.6. Prilling Tower(Me-6)

Erector -M/S. E.C.C., Bombay

This is a concrete structure of 96 meter height. Urea melt enters rotating prill
bucket situated just below the prilling tower ceiling. Melt enters at a temperature
about 140.C and is distributed in fine droplets over the cross section of the tower
of 22 meter diameter and having free falling height of 72.5meters.It is a natural
draft tower where ambient air enters through bottom lower openings having total
area 57m2.During the fall through bucket, the droplets of urea first solidify and
then cooled to a temperature of about 60-65 .C.Hot air outlet windows are
provided at the top having total area 153m2.The prills are scraped by rotating
straight double arm scraper and fed to the prill tower conveyor through openings
in the rake floor. The inside wall of the tower is painted with epoxy painting and
bottom floor where prills fall are coated with FRP coating to resist
corrosion.1000mm*1000mm inspection windows with light are provided every
four flights of external stairway. One elevator runs parallel to prill tower.
 5.7. Prill Bucket And Spare (Me-8 A/B)
Supplier: CAZZOLA, ITALY

Liquid urea melt enters the prill bucket ME-8A/B which is rotated by variable
speed motor. Out of the two buckets, one will be in use and the will be kept as
spare. Facility has been provided for change over of the bucket and the clogged
bucket can be washed with condensate in condensate washing tank provided on
the other side of the support structure. Direction of rotation of bucket is
clockwise when viewed from top.

Mechanical Details

Length of bucket 280mm.

Weight of bucket 16Kg.

Speed of bucket 200-500r.p.m.

Material of Construction

Bucket Material Aluminium

Operating Details

Design Capacity 80,000Kg/hr

Normal Capacity 65000Kg/hr

Minimum Capacity 31000Kg/hr

Urea Temperature 128.1C

 5.8. Mp Ammonia Absorber(E-11,C-3)
Fabricated: Nicola Albia

MP Ammonia Absorber E-11: This is falling film type heat exchanger. Ammonia
vapors and inert coming from shell side of Ammonia preheater enter at the
bottom of MP Ammonia Absorber. Water coming from C-3 at the top of E-11 heat
exchanger, comes down through ferrules in the form of a thin film along the
tubes. Upcoming ammonia is absorbed by water. Heat of solution is dissipated to
cooling water flowing through the shell. The ferrules have the two sets of holes
on it. Both have 3 holes in them which are tangent to tube surface and are at
120.to each other. Water containing ammonia goes down through a distributor to
tube sheet of E-11.E-11 operates at 3.5 Kg/cm 2 pressure at shell and 17 Kg/cm 2 at
tube side. Cooling water flows through shell side.

MP AMMONIA ABSORBER C3: Gases rising from heat exchanger E-11 are
scrubbed with water on the sieve trays in columnC-3 which operates at 16 Kg/cm 2
pressure and 78C temperature. Cold condensate from absorption cooler is used
as absorption water and is fed to 3rd tray. Gases are particularly free of ammonia
while leaving absorber at the top. Medium pressure stream is injected above 3 rd
tray to keep the gases leaving absorber out of explosive range. The liquid coming
down from trays is distributed over tube sheet of exchanger E-11.

5.9. MP Decomposer(E-2)
Supplier: Larsen And Toubro Ltd. Bombay

Solution from stripper is flashed in MP separator (MV-2) at 18 Ata pressure. Due

to flashing some ammonia and carbon dioxide is released from solution. Rest of
the solution is heated in MP decomposer E-2 to decompose carbamate into
ammonia, CO2 and water at 18 Ata pressure. Solution containing water, urea,
unconverted carbamate and ammonia is fed over the tube sheet. Solution enters
the decomposer tubes through a set of four holes provided in ferrule. Holes being
tangential to ferrule ensures distribution of liquid in the form of film along the
surface of decomposer tube. Level of liquid around ferrules and above the holes
provides static head for solution to flow through ferrule and decomposer tube.

5.10. MP Separator (Mv-2)

Supplier: Larsen and Toubro Ltd. Bombay

Solution from stripper is let down to 18 Ata and then enters MP separator.
Reduction in pressure reduces some ammonia and CO 2.Remaining liquid comes
down through a downcomer and is distributed over a packed bed of Rasching
Rings. Gases coming from decomposer bottom are at higher temperature.MV-2
operates at 22Kg/cm2 pressure and 185C temperature. There is a heat exchanger
between liquid streams flowing downwards and gaseous phases moving up into
the packed bed. Gaseous stream from packed bed along with gases liberated due
to flashing leave MP separator through 12th vapor outlet.

5.11. MP Decomposer Holder (Me-2)

Supplier: Larsen and Toubro Ltd. Bombay

Solution from MP decomposer comes down to M.P. holder which is a small vessel.
It has 6inch solution outlet line. Inert gases from carbamate seperatorMV-1 also
enter here. There is one tapping for level indication and controller. There are two
sight glasses which are at 180degree to each other and gasket used for this is of
Teflon. In front of shock glasses, a transparent shock resistant shield is provided
for safety in case of sight glass rupture.
 5.12. Carbamate Condenser (E-5)
Fabricator: Nuovo Pignone

Gases rich in ammonia and CO2 escaping from the stripper enter the carbamate
condenser mixer where the carbamate solution from M.P. system is also fed. This
mixed feed enters the tubes of the carbamate condenser. As NH 3 and CO2 react to
form carbamate, a lot of heat is liberated. This heat is utilized in the production of
4.5ata steam in the carbamate condenser.E-5 operates at 147C on shell and 170C
on tube side while corresponding operating pressure are 3.5 and 150 Kg/cm 2
respectively. Shell side also has condensate coming from E-6 which is laid in series
with this condenser. Condensate level of this heat exchanger is an important
feature. For this there are 8 tappings. Partition plate keeps bundle submerged in
the condensate.

5.13. Carbamate Condenser(E-6)

Fabricator: Nuovo Pignone

Carbamate solution with CO2 , NH 3 from carbamate condenser E-5 enters

carbamate condenser E-6 on the tube side. Unconverted CO 2 reacts with ammonia
and forms carbamate. Reaction being exothermic releases a lot of heat which is
recovered by generating 4.5Ata steam.E-6 operates at 147C at shell and 158C at
tube side while corresponding pressure being 3.5 and 150 Kg/cm2.Steam
condensate from MP decomposer shell side comes to the shell side of carbamate
condenser E-6.This is a U-tube heat exchanger.For any makeup of condensate,it
can be drawn from condensate pump.Condensate from here goes to E-5.A drain
point has also been provided for shell side.

Heat transfer area,diameter,length of tubes,material of

construction, gasket material etc. are same.On shell side only difference is that no
LRC is used in E-6 and condensate outlet nozzle dia is 6inch in E-6 and that in E-5
is 3 inch.
 5.14. Mp Condenser(E-7)
Supplier: Larsen and Toubro, Bombay

Gases from MP separator MV-2 and carbamate solution from MP carbamate

pump P-3A/B enter the shell side of MP condenser. CO 2 and ammonia from MP
separator condense in the carbonate solution forming ammonium carbamate. In
the condenser heat produced by the reaction of carbamate formation is removed
by cooling water whose inlet temperature is controlled around 40C.Shell side inlet
and outlet temperature are 140 and 82C respectively while corresponding temp.
At tube side are 38 and 70C.Operating pressure at shell and tube side are 17 and
3.5Kg/cm2.MP condenser is a shell and tube heat exchanger having carbamate
solution on shell side and cooling water at tube side. Gases and carbonate
solution enter a mixer where carbonate solution is sprayed through a 30degree
cone sprayer. It then flows to shell side of condenser. Tempted cooling water
flows in two passes through tube bundle. Carbamate solution leaves the
condenser with a very little free CO2.

5.15. Hp Steam De-super heater (Me-11)

Supplier: M/S. Kinetics B.V. Amsterdam

Superheated M.S. steam at 328C is available from the CO 2 compression turbine

extraction stage and also from K.P. steam de-super heater if any, are
desuperheated in M.P. steam desuperheater (ME-11).Superheated steam enters
in ME-11 where desuperheating is done by spraying water. The water spray
nozzle extends inside the steam chamber. Outlet temperature if HP steam
desuperheater is controlled at 225C.Inlet MS steam temp. Is 328C while
condensate inlet pressure is 32Kg/cm 2.16 tap holes are provided in inlet and
outlet flanges and are oriented at 11degree.Desuperheated MS steam at 225C is
used for supplying necessary heat at stripper shells. Body is manufactured from
carbon steel while nozzle from stainless steel.
 5.16. Prill Tower Rotary Scraper(Me-12)
Supplier: M/S. Arenco-BMD Sweden

Scraper is used to unload the product from prilling tower bottom floor to the belt
conveying system. Machine consists mainly of:

Forearm Chasis: This is a steel element with fixing feet, embedded in the concrete
floor of prilling tower.

Central Chasis: As a base for the rotating part, a welded construction with a
rotation- race mounted on the upper and underneath the drive units.

Drive Units: Machine is driven by motors each coupled with a hydraulic coupling
and a gear box.

Hydraulic coupling serves a dual purpose, on the one hand it

safeguards against possible over loading and on the other hand it ensures a
gradual startup. Startup torque of motor is reduced by this arrangement. A speed
controller (belt driven by hydraulic coupling shaft) is incorporated to monitor
when normal speed of scraper slows down. Each drive unit consist of electric
motor of 11KW rating and 1000rpm speed, hydraulic coupling of constant oil
filling type with safety fuse plug, gear reducer and gear wheel with pinion. Bulk
density of product urea is 700Mg/m3 and prill temp. is 60-75C. Frame, chasis and
scraper arm is made of carbon steel painted with two coats of synthetic epoxy
resin. Scraper blades are made of stainless steel lined with hard chromium
material.

5.17. Blow Down (Me-14)

Supplier: M/S. Kaveri Structurals, Madras

All safety valves blowing ammonia/CO2 vapor, steam etc. are received by stack.
Five different lines carrying relieved vapors of PSV join this stack. Stack is provided
with steam heating and condensate flushing arrangement. Steam enters through
2inch Nozzle at the neck and 1inch nozzle at the bottom stack. 1inch steam line at
bottom is extended up to 1900mm inside .Steam comes out through 10 nos.
drilled holes facing downwards. Blow down is designed at atmospheric pressure
and 200C temp. Capacity of this is 8.6m3.Stack diameter at bottom and top is 2000
and 1047mm.Shell and heads are made of A285Gr.C while internals of A106Gr. A
and gasket material is compressed asbestos.

5.18. Vent Stack (Me-15)

Supplier: M/S. Kaveri Structurals, Madras

Vented NH3/CO2 vapour along with inert gases from M.P. absorber (C1),MP NH 3
absorber(C3),LP NH3 absorber (C4),Reflux accumulator (V8) and oil NH 3 separator
(MV-12) are sent to this stack. Stack is provided with steam heating and
condensate flushing arrangement .Steam enters through 3inch nozzle at the neck
and 1inch nozzle at bottom.1inch steam line at bottom extends up to 650mm and
steam comes out through 10nos. drilled holes(5mm dia.) facing downwards. Stack
is provided with 16inch manhole and 1inch overflow siphon breaker. Any NH 3/CO2
condensate collected in the stack can be sent to drain collecting tank via 2inch
overflow line and 1inch drain line. Shell and heads are made of A 285 Gr. C and
gaskets of compressed asbestos.

5.19. Vent Stack (Me-16)

Supplier: M/S. Kaveri Structurals, Madras

Any NH3 and CO2 vapours released from urea solution tank(V4),waste water
tank(V5) and drain collecting tank (V6) are sent to ME-16. Stack is provided with
steam heating and condensate flushing arrangement .Steam enters through 2inch
nozzle at the neck and 1inch nozzle at bottom.1inch steam line at bottom is
extended inside up to 650mm closed at the end. Steam comes out from 1inch line
via 10 drilled holes of dia.5mm.1inch water inlet nozzle is provided at the neck
.Stack is provided with 16inch manhole and 1inch overflow siphon breaker. Stack
dia. at the bottom is 750mm and at top is 260mm. Material of construction is
same as 1st vent stack.

5.20. Stripper Steam Condensate Drum(Mv-4)

Supplier: B.H.P.V. ,Vishakhapatnam

From stripper shell outlet condensate is received in this tank where condensate is
separated and sent to MP decomposer shell. The vessel is vertically erected.
Steam condensate from stripper shell enters in MV-4 through 6inch nozzle. One
6inch outlet nozzle comes out from bottom from where condensate is sent to E2
shell. Equipment is provided with one 8inch dia. manhole .The condensate level is
controlled by LRC-5.Equipment is also provided with tapping for level gauge, for
level controller, high and low level alarms. Equipment operates at 225C and 25
Kg/cm2.Equipment is of height 2600mm, ID 1000mm,thickness 15mm provided
with 90mm thick insulation. Shell is manufactured from ASTM A516 Gr.70-carbon
steel and gaskets of spiral wound AISI-304 with impregnated asbestos.

5.21. Hydrolyser(R-51)
Supplier: Larsen and Toubro

The water from distributor (above 20 th tray) of C-2 containing around 1% weight
of urea is pumped to hydrolyser via preheater E51A/B. This solution enters
hydrolyser through 4inch nozzle of the bottom at one end. Urea present in the
solution hydrolyses to NH3 and CO2 at high temp. and high retention time.
Solution passes through 4 compartments one after other where it is heated to
240C with the help of 35Kg/cm 2 pressure, superheated steam. The steam enters
through 3inch nozzle. Solution leaves hydrolyser through 4inch nozzle at other
end. Three 2inch vapour outlet nozzles from different places are provided for gas
outlet from top of the hydrolyser. All three lines join to 2inch vapour outlet
common header. Four drain lines are also provided in the hydrolyser to drain the
four compartments to cy. Two more 2inch nozzles are also provided for PSV-401
and pressure transmitter PRC-403.Hydrolyser shell is made of carbon steel and
cladded with 3mm thick min. SS 316 L. All internals are made of SS 316 L and
baffle plates are 8mm thick. Hydrolyser operates at 240C and 35Kg/cm 2 pressure.
Length of hydrolyser is 8300mm, ID is 2600mm and corrosion allowance is not
provided.

5.22. Ammonia Receiver(V-1)

Supplier: BHPV, Vishakhapatnam

The receiver serves as a suction vessel for ammonia booster pump(P-

5A/B).Condensed ammonia from ammonia condenser(E-9) is received in
ammonia receiver(V-1).The inert gases saturated with NH 3 leaving the receiver
enter ammonia preheater(E-10) where an additional amount of ammonia is
condensed by cooling with cold makeup ammonia from ammonia storage.
Condensed ammonia is then taken to the ammonia receiver(V-1).Fresh ammonia
at around 1C from ammonia storage is received in V1 via preheater E-10.Hot
ammonia of around 30C from ammonia plant joins d/s line of LRC-11V near VI.
The vessel is erected horizontally. One 76.2mm ammonia recycle line is connected
at top from P-5A/B discharge. One 101.6mm line is connected to receiver to
collect ammonia in case safety valves of P-1A/B/C blows. Both liquid ammonia
inlet lines from E-9 and E-10 run down inside V-1 up to 2900mm.Vessel is
provided with tapping for high level alarm, low level alarm.V-1 operates at 37C
and 16.2Kg/cm2 operating pressure. It is of length 9650mm, ID 3000mm,thickness
30.5mm and corrosion allowance of 3mm.Shell and header are made of carbon
steel and gaskets of spiral wound AISI304 with impregnated asbestos.
 5.23. Steam Condensate Vessel(V-2)
Supplier: B.H.P.V., Vishakhapatnam

This is horizontal atmospheric tank. Condensate required in urea plant are

supplied from steam condensate vessel(V-2).D.M. water from off-sites enter
steam condensate vessel(V-2).3inch LP steam tapping is also taken to steam
condensate vessel(V-2) for heating of condensate during start-up. Condensate
from V-2 is pumped by condensate pump P-10A/B TP HP washing pump P-11
suction, stripper D/P cell flushing pump P-18A/B suction, HW and LW flushing
networks, desuperheater ME-11 and ME-25 and MP and LP ammonia absorbers.
As operating pressure of steam condensate vessel is atmospheric, some of the
condensate flashes to form steam. This steam is condensed in E-13 abd
condensate returns back to V-2. Tapings are taken from V-2 for high and low level
alarms. One local level gauge is also provided.V-2 is equipped with one side
manhole, drain and overflow lines.V-2 operates at 100/130C and 0.1/2.0Kg/cm 2
pressure. Shell is made of C-steel(ASTM A-516 Gr.60) and gaskets of compressed
asbestos.

5.24. Carbonate Solution Tank (V-3)

Supplier: Rolle, Italy

Carbonate solution from LP condenser (E-8) along with some inert gases flow to
carbonate solution tank(V-3).Carbonate solution is recycled to MP condenser(E-7)
by medium pressure carbonate solution pumpP-3A/B. Inert gases essentially
contain NH3 vapour which flow directly to low pressure absorber(E-12/C-4).There
is one safety valve PSV-29 which protects tank from over pressurization. The tank
is equipped with tapings for level gauge and level controller. From MP
absorber(C-1) solution can be transferred to this tank via 101.6mm nozzle. There
is provision for 4.5Ata steam coil inside the tank.V-3 operates at 40C and
2.2Kg/cm2 pressure. It is of length 11000mm,ID 4500mm,thickness 12mm and
equipped with 70mm thermal insulation. Shell is manufactured from SS304,
supports of SS304 and A285 Gr. C and gaskets of compressed asbestos.

5.25. Urea Solution Tank(V-4)

Supplier: M/S. Vijay Tanks and Vessel Pvt. Ltd.

Urea solution tank(V-4) is used to collect 71% urea solution in case of shutdown
or start-up and urea melt in case of prilling failure. It is also used to recover urea
solution coming from urea solution recovery tank (V-7) after being pumped by P-
9A/B and filtered through filters FL-1A/B. The tank is equipped with steam coil for
maintaining solution temperature at around 100C.One thermocouple is provided
at the bottom to indicate solution temperature.V-4 top vent line is connected to
2nd vent stack ME-16 and as such it is operated under atmospheric pressure. The
tank is provided with condensate connection. Urea solution is pumped by urea
solution pump (P-20A/B) to 1st stage. One 3inch recycle line with isolation valve is
provided from urea solution pump(P-20A/B) common discharge line to V-4.One
vacuum breaker is provided at the top.V-4 operates at 110-140C and atmospheric
pressure. Its height is 7320mm,ID is 5900mm,thickness 5mm and insulation
38mm.It is manufactured from AISI304.

5.26. Waste Water Tank(V-5)

Supplier: M/S Vijay Tanks And Vessels

Water vapour along with small quantities if ammonia and carbon dioxide is
condensed in vacuum condensers of 1st and 2nd vacuum system and is returned to
waste water tank (V-5) via barometric leg. The tank is divided into two
compartments. The baffle which divides at bottom having 5mm thickness and rise
up to 1000mm.The baffle is placed at a distance of 1300mm from the wall on the
diameter of the tank. The bigger compartment receives solution from drain
collecting tank and waste water scrubber. The smaller compartment receives
water from condensers of vacuum system with the pipes dipping into the liquid so
as to provide the water seal required. The tank is equipped with vacuum breaker
to avoid pulling vacuum in the tank especially during shutdown. One 3 inch
tapping is taken from V-5 top for venting of vapours to vent stack. Further 1inch
LW condensate connection is provided for filling up during initial start. Tapings
are taken for level indicator and temperature indicator. Tank V-5 is equipped with
local level gauge and also with high and low level alarms. The tank is provided
with one 20inch roof manhole and also one 24inch shell manhole. Waste water
outlet nozzle is taken out from bigger compartment which is pumped bu P-4A/B
to the distillation column (C-2) via solution preheater(E-18).V-5 operates at 45C
and atmospheric pressure. Its height is 5490mm,ID is 5000mm and thickness is
5mm.It is manufactured from AISI 304.

5.27. Hp Carbamate Solution Pump(P-2a/B)

Supplier: Worthington, Hamburg

Ammonium carbamate solution from MP absorber C-1 is boosted up to synthesis

pressure and is sent to Mixer ME-1 by these HP carbamate pumps. Normally one
pump is required for continuous service and the other installed standby. This is a
5 plunger vertical reciprocating pump. It is motor driven through a torque
converter and speed reducing gear. Torque converter varies the speed over a
wide range of 30% to 100% whenever required. The power end of the pump is
lubricated with the help of a gear pump which is run by a motor. The crank case
serves as the oil sump. A pressure switch and a low pressure alarm are provided
in this oil circuit to save the machine from damage in case of any oil failure. The
oil pressure is adjusted by a pressure setting relief valve. The stuffing boxes are
supplied with LW condensate 10.0Kg/cm2 pressure or waste water from P-4A/B
discharge for sealing and lubricating. Normally waste water remains in line. This
water goes out to the closed drain system. There is a pulsation dampener in the
suction and discharge sides of each pump. Safety valves are provided on suction
dampeners. Each safety valve has by-pass valve. In suction as well as discharge
side of the pump adequate flushing water connections have been provided. The
pump is provided with speed indicator and controller in field as well as in the
control room. A high pressure trip with an alarm is provided in discharge line. A
pressure gauge and high pressure alarm are also provided. Before two discharge
valves a recycle valve is provided. During the start up of the machines it recycles
the solution back to MP absorber C-1.

Mechanical Details

No. of plungers 5

Plunger dia. 105mm

Stroke length 152mm

Plunger speed at 126rpm 0.64m/s

Suction nozzle dia. 4inches

Discharge nozzle dia. 3inches

Valves Wing type

Fluid flow rate 1.5m3/hr

Direction of rotation Clockwise when seen

From coupling end

OPERATING DETAILS

Fluid handled Carbamate solution

Minimum Capacity 15M3/hr

Normal Capacity 41.8M3/hr

Design Capacity 47.0M3/hr

Minimum Suction Temp. 60C

Normal Suction Temp. 75C

Design Suction Temp. 110C

NPSH Required 6.1m

NPSH Available >6.5m

Minimum Suction Pressure 15Kg/cm2

Normal Suction Pressure 17Kg/cm2

Maximum Suction Pressure 22Kg/cm2

Minimum Speed 41rpm

Normal Speed 112rpm

Maximum Speed 126rpm

 6. Ammonia Production
Ammonia is synthesized from hydrogen (from natural gas) and nitrogen
(from the air). Natural gas contains some sulfurous compounds which damage the
catalysts used in this process. These are removed by reacting them with zinc
oxide, e.g.
ZnO + H2S → ZnS + H2O
The methane from the natural gas is then converted to hydrogen:
CH4 + H2O = 3H2 + CO
CH4 + 2H2O = 4H2 + CO2
CO + H2O = H2 + CO2
Air is mixed in with the gas stream to give hydrogen to nitrogen ratio of 3:1.
Water, carbon monoxide and carbon dioxide (all of which poison the iron catalyst
used in the ammonia synthesis) are removed. The carbon monoxide is converted
to carbon dioxide for use in urea production, and the carbon dioxide removed:
CO + H2O = CO2 + H2
The remaining traces of CO and CO2 are converted to methane and then
the gases cooled until the water becomes liquid and can be easily removed.
The nitrogen and hydrogen are then reacted at high temperature and pressure
using an iron catalyst to form ammonia:
N2 + 3H2 = 2NH3

IFFCO Phulpur plant has been operating in two separate units with common
off-site plants. Older one is known as UNIT-1 and the newer one is known as
UNIT-2. Both the units have separate urea and ammonia plants. The capacity of
UNIT-1 is 1215 MT ammonia per day; supplier of this plant is M/s. Pullman Kellog,
USA. In UNIT-2, 1740 MT ammonia is being produced per day; supplier of the
process is M/s. H.T.A.S., Denmark.
 7. Off-sites

7.1. D. M. Plant
In the DM plant the deep bore raw water containing various impurities is
demineralised, i.e., feed from the various minerals present in it to make it 100%
free from particulate matter for its uses as boiler feed water and process water.

Specification of the processed water is as bellow………

1. pH : 7-7.5
2. Turbidity : < 5NTU
3. Silica content : 33 ppm max.
4. Total Hardness : 348 ppm as CaCO3
5. Calcium Hardness : 160 ppm as CaCO3
6. Magnesium Hardness : 188 ppm as CaCO3
7. M. Alkalinity : 424 ppm as CaCO3
8. P. Alkalinity :0
9. Sulphates : 65 ppm as CaCO3
10. Chlorides : 57 ppm as CaCO3
11. Iron : o.06 ppm as Fe
12.TDS : 650 ppm

Recommended quality of DM water being used in high pressure boiler is as

bellow…….

1. Conductivity mho/cm : < 0.3 micro

2. Silica : < 0.o15 ppm as SiO2
3. Hardness : Nil

Plant Description
Demineralization Plant
The treatment scheme adopted in IFFCO DM plant Phase -2 nd consist of unit like
Pressure Sand filer (PSF), Strong Base Cation (SBC ), Degasser (DEG), Weak Base
Anion (WBA), Strong Base Anion (SBA), and finally mixed bed (MB). The set of
these units constitute a stream and then are divided into two numbers of such
streams(except PSF), each having the normal capecity to produce 140 m3 of high
purity DM water fit for boiler feed. The operation, control and monitoring of plant
is PLC based semi-automatic system. Depending on the requirement of DM water
and availability of units both the streams can be taken in service.

Removal of Impurities

Demineralization process is the most efficient and reliable process of raw water
purification to produce high quality boiler feed and process water. De-ionization
uses the exchange of these ions as a principal of purification. It is therefore called
an ion exchange process. The solid taking action in the exchange processes have
micro porous structure like fish net on which the mobile ions are attached
temporarily, are called Ion Exchange Resin.

The exchange of ions takes place between like charged ions and
equivalents. Thus demineralization process ocurs in two steps. In first step
dissolved cations in water are echanged with equivalent hydrogen ions (for
Hydrogen fromm cation resin) present on exchange sites of cations exchange
resin whereas in second step dissolved anios in water at on exchange sites of an
anion exv]change resin.

Process Description
Exchange of Cat-ions
When water containing dissolved salts is passed through a resin be which can
exchange cat-ion and which is properly charged with hydrogen ions, like sulphate,
chlorides, carbamate etc. Which form corresponding minerals acids like H2SO4,
HCl, H2CO3 etc respectively.
 After certain reactions extent of exchange of ions during service period, the
cation resin becomes poor in stock of hydrogen ions and is said to be exasted. In
order to make the resin bed active so as to give designed treated water quality it
is regenerated using dilute acid solution.

Re2Ca + 2HCl = 2ReH + CaCl2

Re2Mg + 2HCl = 2ReH + MgCl2

Exchange of Anions

When this water is passed through the bed of anions Cl, CO3, SiO2 etc combined
with resin matrix replacing their hydrogen ion.

In the DM plant the exchange of anion is performed in two stage. First in

WBA where almost strong anions are removed and second in SBA where almost
weak anion exchange may be represented as follows………

ReOH + HCl = ReCl + H2O

2ReOH + H2SO4 = Re2SO4 + H2O

2ReOH + H2CO3 = Re2CO3 + H2O

2ReOH + H2SiO3 = Re2SiO3 + H2O

Regeneration………….

ReCl + NaOH =ReOH + NaCl

Re2SO4 + 2NaOH=2ReOH + Na2SO4

Re2CO3 + 2NaOH=2ReOH + Na2CO3

 Since in this plant have two anion exchanger beds in series, WBA, SBA, the
thorough fares regeneration procedure is adopted in which four to five percents
caustic solution is first passed through SBA and the effluent released from SBA is
then passed through WBA for further dilution.

Reverse Osmosis
The RO plant is generaly used for the final purification of the effluent or
waste water for its reutilisation for the sake of environment control. The water
from the cooling water, DM plant and water softening plants are sent to the RO
plant for the purification. The treated water from the RO plant is used for
irrigation, for caol spraying to settle the coal dust, for horticulture and the left
over is finaly throuwn away.

RO is done through a membrane filter of the range of angestrom(10 -10)

scale. The size of the impurities and the dissolved salts is of the range of max. 10 -9,
and hence are stoped but the membran and only water molicules can pass
through it. The membran material is spiral wounded polyamide but the exact
specification are not even told to IFFCO by the manufacture.

Before sending to the RO plant effluent water is first send to the

pretreatment plant. In this-dolomite (45% CaO and 32%MgO) is used. Magnecium
silicon can not be removed by any chemical treatment. The concntration of
magnecium silicate reduced from 17 ppm to 10 ppm in the pretreatent plant.
Finaly this water is sent to the RO plant for the fianl treatment.

7.2. Cooling Tower

In sny process industry, the waste heat generated during the various
processes is to be removed or utilizes through exchanger or some other
equipment by circulating cooling water which later becomes hot on absorbing
heat. So the hot water has to be cooled to a certain required temperature in the
cooling tower.
 The prcess of cooling hot circulating water in cooling tower is a quite simple
process. The hot water, when comes in contact with air, releases its heat in two
ways……..

1. Transfer of sensible heat due to the difference in the temperature of air

and hot water.
2. Transefer of latent heat due to evaporation of a part of water.

Various types of cooling tower used now a days are….

a. Atmospheric cooling tower

b. Spray pond type cooling tower
c. Natural Draft Cooling Tower
d. Mechanical Draft Cooling Tower
(these are being used at IFFCO-Phulpur)

Chemical treatment of the water is also done so as to overcum problem like

corrosion, scale formation, fouling ang biological fouling ( due to presence of
bacteria, algae and fungi). To avoid corrosion – corrosion inhibitor are added and
dispersants are used to avoid scale formation and fouling.

7.3. Water Softening Plant

Desired quality of the treated water in the softening plant are as follows..

1. pH : 10.4- 10.7
2. Total Hardness :< 50 ppm as CaCO3
3. Calcium Hardness : < 40 ppm as CaCO3
4. Turbidity : < 12 NTU

Cold lime softener is used for water purification and is further used in the
cooling tower as a makeup. Hardness- in this process is reduced from 350-400
ppm to 50 ppm by the cold limee process.
 8. Problem at IFFCO Due To Corrosion

Corrosion of Urea Plant Equipment

In manufacture of urea, the corrosiveness of the synthesis mixture has
posed the urea manufacture to lay very strict demond in the quality of
material of construction. Most severe corrossion in urea plant is at location
where urea and the corbamate solutions are handled at the high temperature
and pressure.

In view of high pressure, temperature, concentration and two phase

mixture in the urea reactor, a liner of the stainless steel 316L is used in the
construction. In ealier years of urea manufacture, lead and silver were used to
line the urea reactor. These were good only in the total absence of oxygen. For
day reactor titanium, zirconium and stainless steel used as liner material.

Corrosion in The H.P. Section

In the Phulpur plant- the HP equipments are reactor, stripper, HP
condenser, carbamate mixer, carbamate separator where solution are handled
at high temperature and high pressure, material in contact at higher rate
unless proper material are selected and adequate protection is provided.

Urea reactor at IFFCO Phulpur unit is lined with the modified 316L stainless
steel, HP condenser and separators are also made up of stainless steel. 316L
stainless steel surfaces of all these HP equipment have passive film of oxide.

Corrosion in MP Section

Severe corrosion condition exists in MP decomposer and mixer at inlet of

MP condenser, where aggressive condition prevails due to higher operating
temperature which is more than 150 0C. A material used in this section is 316L.
From HP section carbamate are sent to the MP decomposer bottom. The
oxygen helps to help to passivate the entire MP section.
Corrosion in LP Section

In this section corrosion is not as severe as handled at lower temperature

and pressure. Stainless steel 316L and 304L grade have been used as material
of construction.

Corrosion in Waste Water Treatment Section

Materials used in this section are stainless steel 305L and 304L. in
distillation column chances of corrosion are due to the high turbulence of
ammonia and CO2 vapors which is stripped by means of vapor produced in the
reboiler.

Corrosion Due To Urea Dust

Urea prills and dust being hygroscopic absorb moisture and corrode
concrete and steel structure badly. All structure and open electric installation
that may come in contact with the urea dust must be protected either by anti-
corrosive painting or by providing suitable cover.

Corrosion in Prill Tower

Inside walls and prill tower base, which are in the contact with the urea,
are subjected to corrosion due to reasons mentioned in the above problems.

Prilling tower walls in contact with urea are painted with the anticorrosive
paints such as epoxy paint. But in Phulpur unit prill tower base are coated with
FRP which has a better corrosive resistance properly than epoxy paints.
9. The 316-L (Modified) Stainless Steel
Background

Grade 316 is the standard molybdenum-bearing grade, second in importance to

304 amongst the austenitic stainless steels. The molybdenum gives 316 better
overall corrosion resistant properties than Grade 304, particularly higher
resistance to pitting and crevice corrosion in chloride environments.

Grade 316L, the low carbon version of 316 and is immune from sensitisation
(grain boundary carbide precipitation). Thus it is extensively used in heavy gauge
welded components (over about 6mm). There is commonly no appreciable price
difference between 316 and 316L stainless steel.

The austenitic structure also gives these grades excellent toughness, even down
to cryogenic temperatures.

Compared to chromium-nickel austenitic stainless steels, 316L stainless steel

offers higher creep, stress to rupture and tensile strength at elevated
temperatures.

Key Properties

These properties are specified for flat rolled product (plate, sheet and coil) in
ASTM A240/A240M. Similar but not necessarily identical properties are specified
for other products such as pipe and bar in their respective specifications.

Composition

Table 1. Composition ranges for 316L stainless steels.

Grade C Mn Si P S Cr Mo Ni N
Min - - - - - 16.0 2.00 10.0 -
316L 0.04
Max 0.03 2.0 0.75 0.03 18.0 3.00 14.0 0.10
5

Mechanical Properties

Table 2. Mechanical properties of 316L stainless steels.

 Yield Str Elong Hardness
Tensile Str
Grade 0.2% Proof (% in Rockwell B Brinell (HB)
(MPa) min
(MPa) min 50mm) min (HR B) max max
316L 485 170 40 95 217

Physical Properties

Table 3. Typical physical properties for 316 grade stainless steels.

Specifi
Thermal c Heat Elec
Mean Co-eff of
Conductivit 0- Resistivi
Densit Elastic Thermal Expansion
y 100°C ty
y Modul (µm/m/°C)
Grade (W/m.K) (J/kg. (nΩ.m)
(kg/m us
3 K)
) (GPa)
0- 0- 0- At At
100° 315° 538° 100° 500°
C C C C C
316/L/
8000 193 15.9 16.2 17.5 16.3 21.5 500 740
H

Grade Specification Comparison

Table 4. Grade specifications for 316L stainless steels.

Old British Euronorm Swedis

Japanes
UNS
Grade h e
No BS En No Name
SSJIS
S3160 316S1 X2CrNiMo17 SUS
316L - 1.4404 2348
3 1 -12-2 316L
Note: These comparisons are approximate only. The list is intended as a
comparison of functionally similar materials not as a schedule of contractual
equivalents. If exact equivalents are needed original specifications must be
consulted.

Possible Alternative Grades

Table 5. Possible alternative grades to 316 stainless steel.

Grade Why it might be chosen instead of 316?
Higher resistance to chlorides than 316L, but with similar
317L
resistance to stress corrosion cracking.

Corrosion Resistance

Excellent in a range of atmospheric environments and many corrosive media -

generally more resistant than 304. Subject to pitting and crevice corrosion in
warm chloride environments, and to stress corrosion cracking above about 60°C.
Considered resistant to potable water with up to about 1000mg/L chlorides at
ambient temperatures, reducing to about 500mg/L at 60°C.

316 is usually regarded as the standard “marine grade stainless steel”, but it is not
resistant to warm sea water. In many marine environments 316 does exhibit
surface corrosion, usually visible as brown staining. This is particularly associated
with crevices and rough surface finish.

Heat Resistance

Good oxidation resistance in intermittent service to 870°C and in continuous

service to 925°C. Continuous use of 316 in the 425-860°C range is not
recommended if subsequent aqueous corrosion resistance is important. Grade
316L is more resistant to carbide precipitation and can be used in the above
temperature range. Grade 316H has higher strength at elevated temperatures
and is sometimes used for structural and pressure-containing applications at
temperatures above about 500°C.

Heat Treatment

Solution Treatment (Annealing) - Heat to 1010-1120°C and cool rapidly. These

grades cannot be hardened by thermal treatment.

Welding

Excellent weldability by all standard fusion and resistance methods, both with and
without filler metals. Heavy welded sections in Grade 316 require post-weld
annealing for maximum corrosion resistance. This is not required for 316L.
316L stainless steel is not generally weldable using oxyacetylene welding
methods.

Machining

316L stainless steel tends to work harden if machined too quickly. For this reason
low speeds and constant feed rates are recommended.

316L stainless steel is also easier to machine compared to 316 stainless steel due
its lower carbon content.

Hot and Cold Working

316L stainless steel can be hot worked using most common hot working
techniques. Optimal hot working temperatures should be in the range 1150-
1260°C, and certainly should not be less than 930°C. Post work annealing should
be carried out to induce maximum corrosion resistance.

Most common cold working operations such as shearing, drawing and stamping
can be performed on 316L stainless steel. Post work annealing should be carried
out to remove internal stresses.

Hardening and Work Hardening

316L stainless steel does not harden in response to heat treatments. It can be
hardened by cold working, which can also result in increased strength.

Other Applications

Typical applications include:

·         Food preparation equipment particularly in chloride environments.

·         Pharmaceuticals

·         Marine applications

·         Architectural applications

·         Medical implants, including pins, screws and orthopaedic implants like total
hip and knee replacements

·         Fasteners