Ammonia Process:

Desulfurization

Secondary Reformer Shift Converter (HT) Shift Converter (LT)

Primary Reformer

Urea Stripper Rich Solution+CO2 Benfield Area- Absorber

Ammonia Reactor SynGas Compressor Methanator Process Gas

NH3 Seperator NH3 Compressor Storage

Primary Reformer:

CH4+H20------- CO+3H2

Wall and Terrace furnace is used for cracking methane for Hydrogen production.

Wall and Terrace

There are 28 burners in each row for 8 rows. There are 224 burners. There are 432 catalyst tubes. In wall
and Terrace, induced draft is used. There are 4 windows below each burner which can be manually
operated for temperature control.

There are 2 sections of burners. Radiant part is located in lower section. The convection/exchanger is
present in upper section. The tubes are installed in convection exchange. There are 5 types of coils in
convection part.
1) BFW Coils—Boiler Feed Water
2) Air Preheat Coil—Air Temperature is increased then sent to Secondary Reformer
3) Process Steam Coil— Heating steam for Process
4) Power Steam Coil – Heating steam for Generation
5) Feed Gas Coil – Temperature Increase for Process

Secondary Reformer:

The gas is entered via transfer line to secondary reformer. The air is entered through the air intake. The
output has CO and CO2 which is then transferred to shift converter.
Shift Converter:

There are two shift converters first at high temperature then at low temperature. Shift converters are
used to convert CO to CO2 using catalyst. CO is poisonous gas and it is harmful for reaction. Shift
converters are used to remove CO.

Benfield Area:

The gas from Shift converter is transferred to Absorber part in Benfield Area. Benfield Solution (KCO3) is
poured from above and gas is mixed with solution which is collected in lower region. The Benfield
solution is rich in CO2 which is then transferred to Stripper area. There are two strippers in which steam
is added to remove CO2. Extracted Benfield solution becomes weak and CO2 is transferred to Urea area.
Weak Benfield Solution is then recycled and delivered into Absorber area.

Methanator:

CO+H2---CH4+H2O

The CO is removed using catalyst and converted in Methane. The CH4 is present in little amount. The N2
and H2 are then transferred to Syn Gas Compressor.

Syn Gas Compressor:

The N2 and H2 are then compressed in Syn Gas compressor which is then transferred to Ammonia
Reactor.

Ammonia Reactor:

The Haber process is used in ammonia reactor.

3H2 +N2 <=========> 2NH3 + heat

Ammonia Separator:

Ammonia is separated from N2 and H2. The reacted gas is then recycled into NH3 reactor.

Ammonia Refrigeration:

Ammonia refrigeration provides ammonia condensation and Syn gas compressor inter-stage cooling. It
provides efficient compression. Ammonia compressor is used to liquefy NH3 which is then used in
storage.

Equipment Ammonia:

Flanges:

Flange is a method of connecting pipes, valves and pumps. It also provides easy access for cleaning,
inspection or modification. Flanges are usually welded or screwed into such systems and then joined
with bolts.
Weld Neck: This flange is circumferentially welded with bore of the pipe and flange matching each
other.
Slip-on: The flange is slipped on the pipe and fillet welded.
Blind: It is used to cover the end of the pipeline.
Socket Weld: Flange is counter-bored before accepting the pipe and fillet welded.
Threaded: Flange is threaded or screwed. It is used in low pressure application.

Valves:

The valve has three basic functions. 1) To regulate the flow and pressure 2) To maintain the constant
direction of flow 3) To stop flow

There are various kinds of valves based on their design. There are control valves such as butterfly and
globe valve. The control valves have various positions and they are not based on fully open or fully
closed position. Other valves without throttle are check, gate and ball valve. Non-throttling valves have
only two positions (on and off).

Check valves have single-flow direction. Other valves allow both directions.

Steam Traps:

Steam traps are designed to remove the condensate by trapping the steam from steam line, hence
preventing steam loss. Furthermore, some steam traps require air removal. In order to work properly,
steam traps should be able to sense the difference between steam, air and condensate.

There are three basic operating principles on which steam traps work.

1) Thermostatic Steam traps work on the principle of temperature difference. They are designed to open
when the cool fluid passes and remain closed when hot fluid is passed through. The temperature control
is set on thermostat below which the thermostatic element moves in such a way as to open the valve.
2) Mechanical Steam traps work on the principle of density. They are designed to open when denser
condensate passes through and remains closed when light density steam is passed through it.
Mechanical steam traps are operated using buoyancy force of a floating object. There are two basic
categories for mechanical traps: bucket and float. Float has two types i.e. Lever Float and Free Float.
Similarly, Bucket has two types i.e. Inverted bucket and Open bucket
3) Thermodynamic Steam traps work on the principle of fluid velocity. The condensate travels at much
slower speed than hot steam. When condensate is passed through, the valve remains open and fluid is
discharged. However, hot steam has much higher velocity at inlet of steam trap. The high velocity
creates pressure difference which results in closing the valve.

Strainers:

Pipeline strainer is used for mechanically removing solids from flowing fluid. This is accomplished by
using perforated metal or mesh wire straining element. The purpose is to prevent the debris or particles
from damaging the exchangers, compressors, pumps and steam traps from detrimental effect of
sediment.

There are two types of strainers. 1) Y-strainers 2) Basket Strainer

Y-strainer is used for is vertical piping and Basket strainer is used for horizontal or inclined piping.

Filters:

Filters are used to remove the particles and impurities from the liquid. Strainers are basic filters.

The actual process of filtration is based on adsorption. The large particles are stuck in between particles
whereas smaller particles are stuck onto the surface of individual filter.

Machinery Ammonia:

Pumps:

Pumps are used to add energy/pressure to the liquid. There are two types of pumps i.e. Kinetic/ Turbo
pumps and Positive Displacement pumps.

Turbo pumps increase the kinetic energy of the fluid which is then used to increase the pressure of the
fluid. The types of turbo pumps include centrifugal and axial pumps.

Centrifugal pumps have radial flow direction since the flow is entered axially and it is spread in
centrifugal direction to the casing. However, axial pumps have axial flow as the fluid is compressed and
discharged in axial direction. There is no direction change.

However, Positive Displacement pumps compress a fixed volume of liquid using movable boundary. The
types of positive displacement pumps include Reciprocating and Rotary pumps. Reciprocating pumps
include Piston and Diaphragm pumps. The piston pumps use movable piston to compress the liquid and
eject it. The diaphragm pumps use movable diaphragm which is connected to movable shaft. The liquid
is collected into diaphragm which is then compressed and ejected.

Rotary pumps include Peristaltic and Multiple Gear lobe pumps. Peristaltic pumps have stationary and
flexible piping with central gear. The gear rotates and compresses the liquid in flexible pipe. Multiple
gear lobe pumps move the liquid using multiple gears. The gears move without contacting each other.
At the end, the fluid is compressed between gear and casing and ejected.

Centrifugal Pump:

The centrifugal pump has various components.

Bearings are connected to the shaft. It provides support to the rotating shaft and it is connected to the
housing. The bearing is used to provide support for radial and axial loads. Radial load is perpendicular to
the direction of the shaft. Axial load is in the direction of the shaft. Both kinds of bearings are used to
support the shaft.

Impellers are used to transfer energy from the shaft to the liquid. There are three types of impellers
based on number of shrouds (covering) i.e. Closed impeller, Semi-open impeller and Open impeller.
Closed impeller has shrouds in the front and the back. Semi-open impeller has shroud at the back of the
impeller. Open impeller has no shrouds.

Volute casing is used to cover the impeller. It gathers the water from impeller and redirects it into single
direction.

Backing plate is placed behind the impeller to seal the volute casing. The backing plate is connected to
packing box. The packing box contains mechanical seal or packing to seal any leakage from the shaft.

Operation: The impeller rotation provides centrifugal force to the liquid which is sent outward in radial
direction. The outward flow produces low pressure zone at the eye of impeller. The liquid is pumped
into suction end which is then thrown in radial direction. The velocity is increased. The volute casing
redirects the flow in single direction and expands the fluid which results in velocity drop. The drop in
velocity increases pressure of the liquid which is then ejected.

Sealing:

The sealing is involved where pumps with rotating shafts are used. The sealing is used as a barrier
between what is inside the pump and the atmosphere. The sealing is used to minimize leakage from the
shaft connected to pump. Shaft seal basically consists of rotating part and stationary part. If shaft seal is
properly designed, it is riding on a lubricating film of thickness 0.00025 mm.

There are various kinds of sealing which includes stuffing box, lip seal and mechanical shaft seal. Stuffing
box contains packing ring which is axially compressed until it makes contact with the shaft. The packing
ring is compressed using packing gland. Lip seal contains rubber ring which is sliding against the shaft.
This type of seal is used in low differential pressure.

Mechanical seal consist of two parts i.e. Stationary and Rotating parts. Rotating part is axially pressed
against stationary part. The basic principal is that when two axial surfaces are pressing against each
other, the leakage between shaft and sealing is minimal. The stepped shaft can be used. In more
practical situation, the rotating seal ring can be connected to shaft and stationary seal ring to the pump
housing. The seal faces pressing each other will provide minimum seal gap. The spring can be used in
rotating part to increase the axial pressure.

Air Booster:

Air booster is connected to Air intake in order to supply high pressure air. The booster operating
principle is using large surface area piston from air inlet side to compress the hydraulic liquid in small
area. Principle of decreasing cross-section increases the pressure at hydraulic side.
In air booster, the blower like fan is used to increase the flow rate and pressure of the air.
Urea Process:

Urea Production Process is divided into two parts.

Wet Part:

 CO2 and NH3 compression

 Synthesis
 LP recirculation
 Evaporation and Condensation
 Desorption and Hydrolization (waste water purification)

Dry Part:

 Urea Granulation
 Classification
 Waste gases purification

There are two raw materials required for Urea production. CO2 is supplied via multi stage compression
cycle and inter stage cooling. CO2 is dehydrogenated after second stage of compression by catalytic
combustion in hydrogen converter. Ammonia is supplied at high pressure through pump. Compressed
liquid NH3, CO2 compressed gas are introduced in carbamate condenser. Carbamate and Unreacted
NH3+CO2 are introduced into Urea reactor where Carbamate is converted into Urea and Water. The
liquid effluent is then transferred into HP Stripper.

HP stripper is shell and tube type heat exchanger where effluent is contacted with CO2 to decompose
un-converted carbamate. The urea carbamate solution is discharged into Rectifying Column while off gas
is sent to HP carbamate condenser. After further purification, the Urea is sent to evaporator to remove
moisture. The granulation converts liquid urea to solid. The screening is used to classify Urea grain
according to size.
Urea Process Flow:

NH3 plant + CO2 LPC- CO2 Inter cooling HPC- CO2

Inter cooling
HP Scrubber
High Pressure
Carbamate
HP Stripper Urea Reactor NH3 + CO2 compressed
Condenser

75% Urea Evaporator

Rectifying Column Flash Separator
Solution
Heater
Tank

LP Carbamate
Condenser Screening Granulation

Equipment Urea:

Pipe Fittings and Steel Nipples:

Fittings are used in pipe and plumbing systems to connect different kinds and sizes of pipes to branch or
re-direct the piping systems. There are various types of fittings such as 45 elbow, 90 straight elbow, Tee,
Bushing, Hex plug, Nipple, Cap, Cross and Coupling.

Joining:

Joining consists of large number of processes to assemble individual parts into larger, more complex
component and assembly. Joints transmit and distribute forces. Joining processes include welding,
brazing, soldering, mechanical fastening and adhesive bonding.

There are temporary and permanent joints. Mechanical fastening is temporary whereas welding,
brazing, soldering and adhesive bonding are permanent joints. There are basically five types of joints i.e.
butt, tee, corner, lap and edge joints.

In Butt joint, the two ends are connected edge to edge.

In Tee joint, the edges are joined in the T-form.

In corner joint, the edges are joined at the corner.

In Lap joint, the edge faces are over-lapped to create lapping.

In Edge joint, the edge faces are joined parallel to each other.

Gaskets:

Gaskets are placed in between two objects in order to prevent leakage. It is used with flanges and bolts
to create a connection. The gasket should adapt to flange irregularities and dimensional change of
flange system caused by temperature changes during operation.

Gaskets are normally used with flanges. Benchmark for good gaskets is good compressibility, good
recovery, and strength, chemical and thermal resistance. Gaskets can be divided in two basic types:
metallic and non-metallic. Metallic gaskets are used for medium and high pressure applications. They
require good sealing surface than non-metallic gaskets. Metallic gaskets include cam profile, corrugated,
metal jacketed and ring joints gaskets.

Non-metallic gaskets are used for low and medium pressure applications. Non-metallic gaskets include
Teflon, rubber, graphite and fiber reinforced gaskets.

Machinery Urea:

Bearings:

Bearings are used to provide support to rotating part such as shaft. There are basically two types of
bearings i.e. Sliding and Rolling bearings. Sliding bearing includes journal bearing which is also known as
plain bearing. It provides radial location.

Rolling bearings are of two types i.e. Roller and Ball bearings. Ball bearings have further two types of
angular and deep-grove ball bearings. Roller bearings are of four types i.e. Cylindrical, Tapered, Thrust
and Needle Roller bearings.

Compressors:
Compressors like pumps are used to increase pressure. Compressors are used for increasing pressure for
gas instead of liquid.

Compressors have similar types as pumps. They are also classified into two types i.e. Turbo compressors
and Positive Displacement compressors. The air compressors are based on positive displacement. They
are divided in two main types i.e. Reciprocating type and Rotary type. There are four types of
compressors in reciprocating type such as single-stage, two-stage, rocking piston type and diaphragm
type.

The rotary type of compressors consists of three types i.e. Rotary sliding vane type, Rotary helical screw
type and Scroll type.

Instrument Air Compressor:

Instrument air compressor used in FFBL is based on rotary helical screw type compression. The cavity
between rotors is created at the inlet and air is entered. The air passes from the primary rotor lobes into
secondary rotor lobes. The air is compressed as the rotor moves and compressed air is discharged after
subsequent stages of compression.

D.A.P Process:

Main Process:

Phosphoric Acid and Liquid NH3 is pumped into pre-neutralizer where reaction occurs which converts
reactants into neutralized slurry. The slurry is pumped used Variable Frequency Drive (VFD) pump into
Rotary drum which mixes the slurry completely. The slurry is then pumped into Granulator where
granular DAP is formed. The drier uses hot air to remove moisture from DAP which is then forwarded to
conveyor belt. Bucket elevator is used to rise DAP to higher floors where it is fed into feeder. The
screens are attached to feeder which separate DAP according to size. There are three sizes: Under-size,
On-Size, Over-Size

Under-size (<3 mm) is sent to recycle belt then bucket elevator then Granulator. Over-size (>5mm) is
sent to Crusher where it is crushed into smaller size and sent to recycle belt then bucket elevator then
granulator.
On-size (3-4 mm) is sent to bucket elevator then polishing screens for dust removal. Polished DAP is sent
to fluidized bed cooler which is used to reduce the temperature. DAP is then sent to coater which is
rotary drum used for coating the DAP.

D.A.P Support System:

There are two auxiliary systems which are supporting the main process of D.A.P

Scrubbing:
De-dusting:

De-dusting system consist of fans which are used to transfer powdered D.A.P back into granulator for
grain formation. The suction ducts are installed at each stage after Feeder and around the area for dust
recovery.

D.A.P Process Flow:

Pre Neutralizer VFD Pump Rotary Drum Granulator Drier

Screening Feeder Bucket Elevator Conveyor Belt

Under Size On Size (2- Over Size

(<3 mm) 4 mm) (>4 mm)

Recycle Belt On Size Belt Over Size Crusher

Bucket Elevator Bucket Elevator Recycle Belt

Granulator Polishing Screen Bucket Elevator

 Fluidized Bed Cooler Granulator

Coater (Rotary Drum)

Equipment D.A.P:

Piping:

Piping in industry is not limited to pipes but includes components like fittings, flanges, valves, bolts,
gaskets and bellows etc.

Piping material selection is very important in pipe design. Most commonly used materials in industry are
Carbon steels, Alloy steels, Stainless Steels.

PMS is used as a guide for piping engineer to select the pipe according to material details, dimension
details, type of ends, schedules/thickness, branch off, NDT requirements, various codes and standards
being followed for all piping items.

Insulation:

Insulation is used to prevent heat exchange from the tube to outside atmosphere. There are two types
of insulation i.e. Hot insulation and cold insulation. Hot insulation is used for high temperature pipelines,
furnace linings etc. The ceramics are used in furnace linings and asbestos ropes are used for piping
insulation. Cold insulation is used for Nitrogen supply lines at very low temperatures. The foam is used
for cold insulation on piping.

Machinery D.A.P:

Turbines:

Turbines are used to generate rotation from the mechanical energy of the flowing fluid. There are two
types of turbines i.e. Reaction and Impulse turbines.

Reaction turbines rotate due to pressure difference across the runner blades as the fluid moves through
it. Blade profile plays important role in turbine design.

Impulse turbines rotate due to force of impulse as high speed jet of fluid strikes the bucket. One type of
impulse turbine is Gravity fed turbine. Gravity turbines are rotated when the fluid flows due to force of
gravity. The fluid flow rotates the bucket and produces mechanical output. The blade profile and fluid
velocity plays important role in impulse turbine design. Axial flow gas and steam turbines are good
examples of impulse turbine.
Steam Turbine:

Steam turbine is kind of impulse turbine. It has two main components. These are stator and rotor vanes.
The stator vanes are attached to the housing and rotor is attached to the shaft. The rotor wheels are
attached to chain of buckets at the end. Operating principle of steam turbine is similar to gas turbine.
The inlet steam strikes the buckets which are rotated. The rotation of bucket results in shaft rotation.
The pressure is decreased as the steam is accelerated from high pressure to low pressure. The turbine is
divided into several stages. Each stage consists of a single set of rotors and stators.

Governors:

Governors are used to regulate the supply of steam into the turbine based on the shaft rotation.

Oil governors of three types

1) Flying ball governor 2) Hydraulic pressure governor 3) Oil Relay governor

Flying ball governor consists of spring which is attached to rotating shaft. The spring is attached to ball
system. The increase in shaft rotation increases centrifugal force which increases the gaping of the ball.
The ball is connected to valve which is closed as the gaping increases with increase in rotation. Flying
ball governor is used for narrow selection which can lead to hunting (fluctuating rpm).

Hydraulic pressure governor has hydraulic actuation system instead of flying ball system. The increase in
shaft rotation increases oil pressure in the oil tank. The pressure increase closes the steam valve in
steam inlet cylinder. The hydraulic governor has broad selection so it can tolerate hunting.

Oil Relay governor combines the accuracy of flying ball governor and tolerance of hydraulic pressure
governor. The oil relay governor has rotation shaft connected

Coupling:

It is used to transfer power and torque. There are two main types of couplings. 1) Rigid coupling 2)
Flexible coupling

The coupling is required by connecting shafts of standard lengths say 6-8 m. Rigid couplings are used for
the shafts which have no misalignment. Types of rigid couplings include sleeve, clamp, ring compression
type and flange couplings. Flexible couplings are used for the shafts which have misalignment and
impact. Types of flexible couplings include Oldham, universal type and pin type couplings.

Utilities Process:

Utilities act as subsidiary unit for production. Utilities unit consists of following areas:

 The Natural Gas distribution

 Electric Power Generation & Distribution
  Raw water storage & distribution
 Raw water clarification & filtration
 Waste and Storm water handling
 Cooling tower & Cooling water pumps
 Demin water production
 Boiler Feed water system
 Steam Generation
 Instrument & service air system
 Potable Water system
 Chilled & hot water system (HVAC)
 Fire water distribution

Natural Gas is being supplied by SUI Southern Gas. Power Generation system consists of two gas turbine
generators and one diesel driven emergency generator.

Instrument and Service Air System will comprise of three non-lubricated screw type air compressors,
one air dryer system having two vessels, one air receiver to store and supply instrument to the air.

Water treatment system consists of the following: raw water and potable water storage, raw water
processing. Raw water storage consists of 1 storage basin and 3 industrial water pumps. Potable water
storage consists of 1 storage tank, 2 water pumps, dosing system and different filters (activated carbon,
quartz and iron filter).
Raw water processing consists of one re-activator clarifier and dosing systems (Alum, Hypochlorite,
Polymer, Caustic Soda).

Cooling tower system and Fire water system is also set up in utilities. De min water is produced for
reaction. Furthermore, Reverse osmosis plant is installed for purification of water.

Equipment Utilities:

Boiler/Furnace:

Boiler is type of heat exchanger which is used to transfer heat into the system. Both gas and oil fired
boilers use controlled combustion of the fuel to heat water. The key boiler components include burner,
combustion chamber, heat exchanger and controls. There are two main types of boilers i.e. Firetube and
watertube boilers.

Machinery Utilities:

DDEG:
Diesel driven emergency generators are used in case of power failure. The capacity of DDEG is 2.5 MW.
DDEG is V-type 16- cylinder engine. It is used to power the critical load such as Gas turbine rotation
using motors, Ammonia plant critical areas and control station.

HRSG:

Heat recovery steam generator is used to generate steam using the heat from the gas turbine. HRSG
consists of vessel and tube exchanger which is used to heat (boiler feed water) BFW which is supplied
from BFW pump.