KRIBHCO

REPORT
ON
INDUSTRIAL TRAINING
AT
KRISHAK BHARATI CO-OPERATIVE LTD.

KRIBHCO NAGAR, HAZIRA, SURAT.
(Training Duration: 19-06-2017 TO 03-07-2017)
SUBMITTED BY:
1. RAHUL PANSHALA (B.E. CHEM, SCET)
CHEMICAL ENGINEERING DEPARTMENT
SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY, SURAT.
SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 1

CERTIFICATE
This is to certify that Rahul Panshala (B.E. CHEM)

student of Sarvajanik College of Engineering &
Technology; surat has satisfactorily completed his
industrial training as a vocational training for the
duration of 19th June 2017 to 03th July 2017.
Date :
Sign :

INDEX
SR NO. SUBJECT PAGE NO

1 ACKNOWLEDGEMENT 4
2 INTRODUCTION TO KRIBHCO 5
3 AMMONIA PLANT 6
4 UREA PLANT 19
5 POWER PLANT 28
6 OFFSITE PLANT 47

ACKNOWLEDGEMENT
We are highly obliged to Krishak Bharti Co-operative Ltd. Hazira-Surat for
providing us with the vocational training. The training was an enriching
experience, which will be beneficial to me in our future endeavours.
We would extent my heartily regards to Mr. P. V. Kachhadiya (Marketing

Manager ) for helping us in the successful registration process in the plant for
training.
We would also like to thank Mr. Sanjay Dasgupta (Sr. Manager, Process) for
guiding us throughout the training. We would also like to thank Mr. Mandal
(AGM, Process).
We would also like to thank Mr. V. K. Singh (Sr. Manager, Ammonia-II) for
explaining us about the various processes in Ammonia-II plant. We would also
like to thank Mr. B. Sai Prem (GET, Urea-I) for explaining us about the various
processes in Urea-I plant.
We would extend our gratitude towards Mr. R.G. Nair for helping us to get in
touch with the Hazira plant. We would also like to thank Mr. Sunil Jain for
being our sponsor.
We will try our level best to retain the experience and knowledge gained
during this period.

INTRODUCTION TO KRIBHCO
Krishak Bharati Cooperative Ltd (KRIBHCO) is a Multi-State Cooperative Society deemed to
be registered under the Multi-State Cooperative Societies (MSCS) Act, 2002. The
Government of India through the Department of Fertilizers was a member of KRIBHCO but
its equity holding was reduced to NIL on 4th July 2013 under the provisions of the MSCS
Act 2002. KRIBHCO is not owned nor controlled nor financed by the Government of India /
Any State Governments.
KRIBHCO was incorporated on 17th April 1980 as a national level Multi State Cooperative
Society to implement first gas based “state-of-the-art” high capacity Fertilizer
Complex consisting of 2 x 1350 MTPD Ammonia plants and 4 x 1100 MTPD Urea plants
each with annual installed capacity of 8.91 Lakhs MT Ammonia and 14.52 lakhs MT of
Urea at Hazira District-Surat, Gujarat, India based on natural gas from Bombay High/ South
Bassein. Hazira fertilizer complex was commissioned in 1985 in record time with saving of
Rs. 90 crore in project cost.
In an endeavor to make constant improvements, KRIBHCO implemented various schemes to

enhance its capacity and improve the energy consumption. Capacities of ammonia & urea
plants were reassessed to 2x1520 MTPD Ammonia and 4x 1310 MTPD Urea with annual
installed capacity of 10.03 Lakh MT ammonia and 17.29 lakh MT of urea.
The Hazira Fertilizer Complex was subsequently revamped in 2013 to increase its
production capacity by 4.65 LMTPA of Urea. After the revamp, the rated capacity has been
enhanced to 2x3325 MTPD Urea (21.95 LMTPA) and 2 x 1890 MTPD Ammonia (12.47
LMTPA). With this, the Hazira fertilizer complex has became largest single location urea
plant in India.

AMMONIA PLANT
WHAT IS AMMONIA?
Ammonia is a compound of nitrogen and hydrogen with the formula NH3. It is a
colourless gas with a characteristic pungent smell.
Its major application include in the production of nitrogenous fertilizers. Ammonia (NH3) is
produced from atmospheric nitrogen and hydrogen from a hydrocarbon source. Natural
gas is the most commonly used hydrocarbon feedstock for new plants; other feed stock that
have been used include naphtha, oil, and gasified coal. Natural gas is favoured over the
other feed stocks from an environmental perspective.
Under normal conditions of temperature and pressure ammonia exists as a gas which is
lighter than air. Although in wide use, ammonia is both caustic and hazardous. NH3 boils at
−33.34 °C (−28.012 °F) at a pressure of one atmosphere, so the liquid must be stored under
high pressure or at low temperature.
PLANT OVERVIEW
The Hazira ammonia plant was earlier based on the KELLOG process with a capacity of
producing 1520 MTD . But now the plant has been revamped and is using KBR process
with a capacity of 1890 MTD. The product of this plant i.e ammonia and the by-product of
this plant i.e carbon dioxide are both used as a raw material for the UREA plant.
The Hazira ammonia plant is self sufficient for its steam and power consumption. However
it derives steam and power from the power plant during its startup.

Ammonia production from natural gas includes the following processes:
1) Desulphurization of the feedstock
2) Primary and secondary reforming;
3) Carbon monoxide shift conversion
4) Removal of carbon dioxide
5) Methanation
6) Ammonia synthesis.
7) Purge gas recovery
All these processes have been discussed below
Catalysts used in the process may include :

1) Cobalt
2) Molybdenum
3) Nickel
4) iron oxide/chromium oxide
5) copper oxide/zinc oxide
6) Iron.
PROCESS DESCRITION
1) DESULPHURIZATION
The natural gas coming from the basin contains some liquid fuel along with the
natural gas. Hence a feed gas knock drum is used for removing the liquid fuel. The
natural gas from the knock drum enters the feed gas preheater where the natural
gas is preheated to a certain optimum temperature.
Desulphurizer unit is designed for NG feed containing 50 ppmv of sulphur and is

desulphurised using zinc oxide catalyst. Bulk of the sulphur in feed gas is of reactive
type and hence, the same can be absorbed by zinc oxide. The feed gas is reported to
contain 0.1% O2 which if not removed shall be harmful to front-end catalyst. The
feed gas may also contain small amount of organic sulphur. Feed gas flows through
two identical reactors 102-DA and 102-DB, in parallel. Each reactor contain 3

catalyst beds, with 12 m3 of CoMoX catalyst being placed on top bed, followed by
12 m3 ZnO catalyst in the middle bed and another 12 m3 ZnO catalyst in the 3rd
and last bed.
12 m3 of CoMoX catalyst has been provided to convert organic sulphur to inorganic

sulphur (H2S) in presence of hydrogen and also to function as a deoxo unit for
removing the oxygen in feed gas. Natural gas at the exit of desulphuriser is expected
to contain less than 0.25 ppm sulphur. The reactions involved in catalyst beds are as
follows:
a) Reactions involving in CoMoX catalyst bed:

In presence of hydrogen (mixed with feed gas) the catalyst makes the following
Reactions possible:
i. RSH+H2  RH+H2S
ii. R1SR2+2H2  R1H+R2H+H2S
iii. COS+H2  CO+H2S
iv. O2+2H2  2H2O
b) The reactions involved in the ZnO bed:
ZnO+H2S  ZnS+H2O
All forms of sulphur compounds in feed NG after getting converted to reactive

sulphur in CoMoX catalyst bed, travels downwards where, the reactive sulphur is
desulphurised in two beds of ZnO catalyst. The desulphurised feed gas is mixed
with the process steam before entering the 101-B primary reformer mixed feed pre
heat coils. The combined steam natural gas mixture is then preheated to 510ºC in
the mixed feed preheat coil located in the convection zone of the primary Reformer
furnace utilizing the heat from the hot flue gases leaving the reformer, radiant
section.

2) PRIMARY REFORMING
After the sulphur compounds have been removed, it is desired to reform the feed gas
NG under conditions suited for producing hydrogen (H2) in an economical manner.
This is achieved in presence of adequate amount of steam and by allowing the
Mixture of feed NG and steam to pass through vertical tubes filled with nickel
Catalyst, at elevated temperature and pressure, to promote the desirable reactions.
The overall reaction is endothermic and requires constant heat Input from the
burners placed on the roof of radiant section of primary reformer furnace to the
vertically placed catalyst filled tubes in radiant section.
The nickel based primary reforming (nickel content around 18-20%) and secondary
reforming (nickel content 9-12%) catalyst promote two simultaneous equilibrium
reactions in the primary and secondary reformers. NG feedstock containing very
small % of higher hydrocarbons undergo following reactions inside catalyst filled
reformer tubes:
CnHm + nH2O  nCO + ( n + m/2)H2 [ endothermic ]

CO + H2O  CO2 + H2 [ exothermic ]
CH4 + H2O  CO + 3H2
Temperature: As the reforming temperature increases the conversion of natural gas

increases. As a result the content of CO decreases and that of CO2 and H2 increases.
Pressure: The pressure of the system is so nearly fixed that reforming pressure
should be considered invariable. However, increasing pressure has an effect similar
to reducing temperatures.
Steam rate: The most economical steam to carbon mole ratio is3.5:1.0. As we
increase this ratio the methane and CO2decrease and vice versa.
The Primary Reformer consists of 504 tubes suspended in 12 rows of 42 parallel

tubes each, in the radiant section. Each row of tubes terminates in a manifold placed

within the radiant section of furnace. There are 12 centrally located risers on each
of these manifolds. These risers lead the gas flow to a water jacketed transfer line
located over the top of primary Reformer furnace.
As the reforming reaction is endothermic heat is supplied externally to the tubes.

The furnace operates with down-firing of Natural gas between the tubes to develop
a process gas temperature of 818ºC at the catalyst tube outlet.
There are 234 Arch burners arranged in 13 rows of 18 burners each. Natural gas,
purge and flash gases from ammonia synthesis loop and Absorber K.O. drum are
used as fuel for the reformer furnace.
Inside the catalyst tubes the natural gas-steam reforming reaction takes place. The
gas mixture is passing through the risers, attains a temp of about 821ºC. Some heat
leakage from gas, passing through transfer line to the water jacket takes place. The
transfer line directs the partially reformed gas into the secondary reformer at the
following conditions:
Pressure: 33.1 Kg/cm2 Temperature: 824ºC
The reformer furnace is designed to attain maximum thermal efficiency by

recovering heat from the flue gases leaving the reformer radiant section.The desired
draft is induced by the induced draft fan, having a condensing steam turbine drive.
The reformer also comprises of an auxiliary boiler for generation of 105.5 kg/cm2
steam. The cooled flue gases leave the combustion air pre-heater at temp 135ºC and
discharged through a stack to atmosphere by induced draft fan maintaining a
negative reformer furnace pressure of 6mm water gauge.
The combustion air is sent to the arch and auxiliary boilers by a forced draft fan
after preheating the combustion air to 427ºC. in the air pre-heater by recovering
sensible heat of the flue gases.
3) SECONDARY REFORMER
Primary reformed gas containing 55.5% H2 and 29.4% CH4 (dry mol %), enters
secondary reformer, 103-D, via primary reformer effluent transfer line, 107-D.
The present ammonia production is based on Purifier process, where molar ratio of

H2/N2 (inlet to purifier Box) is kept as 2:1 compared to a ratio of 3:1 (in ammonia
synthesis gas) in conventional process. The above necessitates use of about 53%
extra Air (compared to conventional process). This extra air goes for additional
combustion
and provides additional reaction heat for more CH4-steam reaction to take place
over the catalyst bed.
The catalyst bed consists of 36.0 M3 of nickel catalyst. The catalyst is supported on
two beds of high alumina (low silica content) balls
The reactions taking place are,
i) CH4 + 2O2  CO2 + 2H2O , Heat = ―-― (exothermic)
ii) H2 + ½ O2  H2O , Heat = ―-― (exothermic)
iii) CH4+ H2O  CO + 3H2, Heat = ―+‖ (endothermic)
iv) CO+H2O  CO2+H2, Heat = ―+‖ (endothermic)
Gas from secondary reformer at around 8850C passes directly to primary and
Secondary waste heat boilers and then to the shift converters.
4) H. T. SHIFT CONVERTER
The process gas containing adequate quantity of steam enters the high temperature
shift converter at about 360oC. The CO conversion reaction takes place over the
catalyst bed where a large percentage of the CO content will be oxidized in
accordance with the following reactions:
CO + H2O  CO2. + H2 , Heat = “+” (exothermic)
The HT shift conversion catalyst is basically an iron oxide catalyst. For the present
Purifier based process adopted for this plant, low steam to gas ratio is envisaged, for
which copper promoted iron oxide catalyst is excellent. Copper promoted iron
oxide catalyst prevents unwanted side reactions, also.

Since the reaction is endothermic in nature hence a lower temperature will shift
the reaction towards products side. Therefore, the temperature in the converter is
kept around 417oC
The process gas from HTS flows to two parallel L T shift converters i.e. LTS and LTG.
5) L T SHIFT CONVERTER
In this converter 3.3 % CO content is decrease to 0.3%. The catalyst provided in LTS
is copper zinc which is highly sensitive for sulfur and chloride poisoning and high
temp. With a fresh catalyst it is desirable to operate it lower inlet temperature of
204ºC and as catalyst ages the temperature gradually rises to 224ºC.
The gas comes out from the LT shift converter at 236ºC and 29.6 Kg/cm2
The heat is recovered and sent to the CO2 absorber. The steam from the LTSC is
passed through the various heat exchanger units to cool at 93ºC and the stream
enters the raw gas separator to separate condensate and the gas flows to CO2
absorber.
6) CO2 ABSORBER
Due to the increase in the capacity of the ammonia plant the existing Benfield
system is replaced
with BASF‖s two stage aMDEA system to reduce energy. Carbon dioxide contained
in the raw synthesis gas acts as a poison to the ammonia synthesis catalyst for
which CO2, must be removed from the gas stream to ppm level before make-up
ammonia synthesis enters ammonia synthesis loop. Removal of the bulk of the CO2
from the process gas is accomplished by absorption in a counter
Current flow of activated MDEA solution in the CO2 absorber towers.
There are 3 types of aMDEA solution is used:
 Lean aMDEA- contains no impurity (i.e. CO2)
 Semi lean aMDEA- contains some amount of absorbed CO2
 Rich aMDEA – contains large amount of absorbed CO2

The process gas from the top of the raw gas separator 102-F enters the CO2 bulk
absorber, 101-EA at 700C and flows upward through two beds of tower packing.
As the gases flow upwards through the packed beds they are contacted by the down
flowing semi-lean activated MDEA solution, which absorbs most of the CO2.
The gas from the top then passes into the bottom section of CO2 lean absorber,
101-E, which serves as the lean section of CO2 absorber. Decarbonated gas, passes
from the top most packed bed of 101-E to “wash” section, located in the narrow
tower section at the top part of CO2 lean absorber, 101-E.
Rich aMDEA solution from the bottom of the new bulk absorber is then sent to a
new HP Flash Drum 123-E. In this drum most of the impurities are degassed from
the rich solution to ensure high purity carbon dioxide product.
Rich solution from the bottom of 123-E flows to the new LP Flash Drum, 122-E,
where it is flashed at 1.65 kg/cm2. Flashing at this pressure removes most of the
carbon dioxide from the rich solution. The solution flows down through the packed
section where it is contacted with the rising vapor. Semi-lean solution is withdrawn
from the bottom of the LP Flash Drum, 122-E. Most of the semi-lean solution is
pumped to the top of the bulk absorber. About 20 percent of the semi-lean solution
is heated to 108°C in a lean/semi-lean exchanger flows to the top section of the
existing Stripper, 102-E. Vapor from the Stripper enters the bottom of the new LP
Flash.
Heat is supplied by the reboiler, 105-C, for stripping. The stripped carbon dioxide
flows up the stripper. The semi-lean aMDEA solution is converted into lean solution
as it flows down the packed bed by being contacted with stripping steam produced
by the reboiler.
The lean solution from stripper is cooled by heat exchange with stripper feed, with
LP BFW water, and with air. This lean solution is then pumped to the lean absorber.
The carbon dioxide vapours along with steam are sent to a condenser (from the L P
flash). The steam is condensed and the pure carbon dioxide is sent to the urea plant.

7) METHANATOR
The objective of the methanation reaction is to remove completely the oxides of

carbon from the synthesis gas. Carbon oxides are deleterious to the ammonia
synthesis catalyst. Removal of the carbon oxides is accompanied by their conversion
to methane, which acts as an inert constituent in the gas mixture flowing through
ammonia reactor. The methanation reactions take place in the presence of nickel
based catalyst. The methanation catalyst contains approximately 18-20% nickel
oxide (by wt) and is extremely active.
The reactions are given below.
The (i) reaction is more exothermic compared to reaction (ii).
(i) CO + 3H2  CH4 + H2O + HEAT (exothermic)
(ii) CO2 + 4H2  CH4 + 2H2O + HEAT (exothermic)
8) DRYING OF SYNTHESIS GAS
In the Purifier based ammonia process, drying of synthesis gas, forms a very
important process step.
This is due to the fact that, operations in purifier are carried out at extreme sub
zero temperatures for which synthesis gas has to be devoid of water vapor, in order
to prevent ice formation.

According it is necessary to remove water vapor content in the gas, by passing
through an effective “drying system”. The gas drying system adopted here is, water
vapor removal through dual bed
(Regenerative type) of zeolite molecular sieve. During passage of synthesis gas
through a bed of alumino silicate (zeolite) beads, the water vapor is adsorbed in the
beads, thereby leaving only traces (1ppmv) of H2O vapor in synthesis gas entering
purifier.
The hot syn gas from the methanators is cooled upto 4oC and is sent to knock out
drum. At this temperature majority of the water is condensed and separated. The
chilled gas from the knock-out drum, at around 4oC and 27 kg/Cm2g pressure,
then goes to synthesis gas driers, 109-DA/DB, with one operating normally & the
other one under regeneration.
9) PURIFIER
Dried raw synthesis gas is cooled to about minus 130°C in the cryogenic purifier by
heat exchange with make-up syngas and with purifier vent gas in the upper plate
fin exchanger, 135-C. The gas then flows through a turbo expander, where energy
is removed to develop the net refrigeration required for the purifier. Expander
energy is recovered by generating electricity in 131-JG. The pressure drop across
the expander is about 2.1 kg/cm2.
The expander effluent is further cooled to minus 175.5°C and partially condensed
in 133-MC and then enters the purifier rectifier column 137-D. Liquid from the
bottom of the rectifier is partially evaporated at reduced pressure in the shell side of
the rectifier overhead condenser, 134-C. This cools the rectifier overhead and
generates reflux for the rectifier.
The rectifier bottoms contain the excess nitrogen, all of the methane and about 53
percent of the argon. The partially evaporated liquid leaving the shell side of the
rectifier overhead condenser is reheated and vaporized by exchange with the
purifier feed and then leaves the purifier as waste gas. The waste gas is used to
regenerate the syn gas drier and then sent as fuel to the auxiliary boiler in the
primary reformer.

The make-up syngas from the top of the rectifier overhead condenser is reheated
by exchange with purifier feed to about plus 2°C and sent to the syngas compressor
at 24.4 Kg/cm2. The operation of the purifier is controlled by a hydrogen analyzer
on the syngas, to maintain the exact ratio of 2.998 to 1 (hydrogen to nitrogen) at
synthesis gas compressor second stage suction. The only remaining contaminant in
the make-up syngas is about 0.23 percent argon.
10) SYNTHESIS GAS CONVERSION
The pure syn. gas is compressed in a turbine driven two stage centrifugal
compressor. Inter case cooling and chilling is provided for optimum volumetric
efficiency. Ammonia is separated in Ammonia separator 1.7 % of ammonia is
admitted in recycle stage of synthesis compressor. The Compressor outlet gases at
19ºC are cooled with cooling water in syn. gas compressor after 156 to 40ºC.
11) AMMONIA SYNTHESIS
Ammonia is produced in a fixed 3 catalyst bed, vertical converter 105-D. The

converter configuration is a three stage quench/intercooled design. The quench is
between first bed and the second bed. Intercooler is provided between the second
bed and the third bed. Each bed is filled with 1.5-3mm iron promoted conventional
catalyst. The first bed is filled with pre-reduced catalyst. Make-up and recycle
gases from the syngas compressor are preheated by exchange with the converter
effluent in the feed/effluent exchanger, 121-C. It then flows to the converter.
The effluent from the first bed at about 515 °C, containing about 11.9 percent
ammonia, is quenched with portion of the feed to the converter, resulting in feed to
the second bed at about 400 °C. Ammonia concentration in the effluent from the
second bed at 490 °C is about 14.8 mole percent. Second bed effluent is after being
cooled in interchanger 122-C1 to around 400°C, enters 3rd catalyst bed. Ammonia
content in the gas leaving the final catalyst bed (i.e. 3rd bed) is around 18.75%.
Ammonia synthesis reaction is equilibrium controlled, exothermic reaction
inducing
significant temperature rise across catalyst bed.

The reaction step is as follows :-
3H2 + N2  2NH3 + heat (exothermic)
The converter outlet gas at a temperature of 325ºC flows through tube side of
ammonia converter exchanger. Outlet temperature is 164ºC. Converted gas then
flows through shell side of ammonia converter feed effluent exchanger.
Temperature is reduced to 52ºC Gas is further cooled to 40ºC in recycle gas cooler
by means of cooling water. Chilling of recycle gas is done in tube side of recycle
gas/converter fed exchanger and chilled to 6ºC. In second stage chiller where it is
chilled to –5.6ºC by refrigerant ammonia from third stage refrigerant flash drum. It
is further chilled to –12.5ºC in tube side of feed and recycled gas/converter feed
exchanger by using gas from outlet of ammonia separator. Final chilling to –23.3º
C is done by using refrigerant ammonia from fourth stage refrigerant flash drum in
shell side. Liquid ammonia is separated in ammonia separator.
12) REFRIGERATION SYSTEM
The primary purpose of the refrigeration is to condense ammonia for separating it

from the converter feed. Further it is applied to cool the make up gas for separation
of water, to condense and recover liquid ammonia from purge and flash gases, and
to cool the product to –33.0ºC.
It consists of first, second, third and fourth stage refrigerant flash drums. These four
drums are combined in one single vessel with partitions with operation pressure of
7.2 kg/cm2 and 1.014 kg/cm2 respectively. This pressure is controlled by refrigerant
compressor at different stages.

UREA PLANT
WHAT IS UREA?
Urea, also called carbamide, is an organic chemical compound which essentially is the
waste produced when the body metabolizes protein. Urea was discovered in 1773 by
the French chemist Hillaire Rouelle. In 1828, it became the first organic compound to be
synthetically formulated, by a German chemist named Friedrich Wöhler. Urea in fact is
the di-amide of carbonic acid with a chemical represented by
Urea is commercially produced in following forms
a.) Fertiliser Grade: The principal field of application of urea is for agriculture
purpose as a nitrogenous fertiliser. Fertiliser grade urea is generally marketed in
the forms of prills due to its free flowing characteristics. A certain quality of urea
is also used for making mixed fertilisers like NP or NPK of different grades.
b.) Feed Grade: Apart from its use as a nitrogenous fertiliser urea is also used for
the purpose of animal feed as a protein supplement in some of the advance
countries.
c.) Technical Grade: Another importance application of urea is for the
manufacture of thermosetting resin, the most important among which are urea
formaldehyde. urea melamine etc. Further urea is also used for manufacture of
several other chemicals and pharmaceuticals etc.
Because the nitrogen in urea makes it water soluble, it is highly desired for fertilizer
applications. The three nutrients required by the plants are Nitrogen, Potassium, and
Sodium. The basic objective of nitrogenous fertilizer is to convert the nitrogen gas into

the easily storable and transportable form which is easy to use by the end-user i.e. the
farmer.
Urea is colourless, odourless chemical substance. It is generally produced in the form of

white prills or crystals. Urea today occupies the key position amongst the various solid
nitrogenous fertilizers by virtue of its highest nitrogen content (Pure urea contains
46.64% Nitrogen), which allows a considerable saving in transportation and
distribution cost.
UREA SYNTHESIS
The urea production takes place through the following main operations:
a) Urea synthesis and high pressure recovery
b) Urea purification and low pressure recovery
c) Urea concentration
d) Urea prilling
e) Waste water treatment
1) UREA SYNTHESIS AND HIGH PRESSURE RECOVERY
Urea is produced by synthesis from liquid NH3 and gaseous CO2 . NH3 and CO2
react in the reactor R-1 to form ammonium carbamate, a portion of which gets
dehydrated to form Urea and water. The reactions are as follows:
2 NH3+ CO2  NH2COONH4
NH2COONH4  NH2CONH2 + H2O
Under synthesis conditions of 1900C temp and 160 kg/cm2 pr, the first reaction
occurs rapidly and goes to completion while the second reaction is slow and
determines the reactor volume.

The fraction of ammonium carbamate that dehydrates to form urea is
determined by NH3/CO2mole ratio, H2O/CO2mole ratio, operating temp and
pressure and the residence time in the reactor. In our case,
N/C = 3.6
H/C = 0.67
Residence time = 45 minutes (at 100% load)
CO2conversion = 65%
The liquid NH3coming directly from the ammonia plant at 250C is collected in
the ammonia receiver (V-1), from where it is drawn and pumped at 23 ata pr. by
means of an ammonia booster pump, Part of this NH3 is sent to M.P. absorber (C-
1), the remaining part is pumped by means of low speed heavy duty triplex
plunger pump at a pr. of 240 ata. Before entering R-1, it is used as driving fluid
in the carbamate recycle ejector (EJ-1) where the carbamate coming from
carbamate separator (MV-1) is pressurized up to the synthesis pr. for recycling it
to R-1. The liquid mixture of NH3and carbamate enters the reactor where it
reacts with gaseous CO
CO2 drawn at urea plant at 1.4 ata pr. and 40 0C temp is sucked by a centrifugal
compressor (K-1) and compressed upto a pr. of 160 Ata. A small quantity of air is
added to the CO2at K-1 suction in order to passivate the stainless steel surfaces in
H.P. and M.P. sections thus protecting them from corrosion due to
carbamate/Urea soln.
The reaction products leaving R-1 flow to the steam heated falling film
exchanger, stripper (E-1) operating at almost the same pressure as R-1. The
solution is heated as it flows down the falling film exchanger. The CO2content of
the solution is reduced by the stripping action of the excess NH3as is boils out of
the solution in E-1 tubes.
The heat for carbamate decomposition and excess NH3 liberation is supplied by
24 ata steam

The overhead gases from the stripper are mixed in a mixer (ME-1) with the
recovered solution from the M.P. absorber (C-1) and flow via an additional baffle
mixer to H.P. carbamate condenser (E-5) where the total mixture, except for a
few inert, is condensed. After inert separation in MV-1, it is recycled to R-1 by
means of EJ-1. The non-condensable gases along with a little quantity of NH3 and
CO2from the top of MV-1 are sent to the bottom of M.P. decomposer (E-2).
Condensing the gases at high pressure and temp permits the production of low
pressure steam at 4.5 ata pressure in the shell side of E-5.
2) UREA PURIFICATION AND LOW PRESSURE RECOVERY
Urea purification takes place in two stages of decreasing pressures as follows :
I) First stage at 18 ata pressure (M.P. section)

II) Second stage at 4.5 ata pressure (L. P. section).
 FIRST STAGE RECOVERY
The solution with a low residual CO2content leaving the bottom of E-1 is let
down to a pressure of 18 ata and enters a falling film type M. P. decomposer
(E-2).
M. P. decomposer (E-2) is divided into three parts :

 Top separator (MV-2) where the flashed gases are removed from the
solution before it enters the tube bundle.
 Decomposition section (E-2) where the residual carbamate is

decomposed and the required heat is supplied by 24 ata steam
condensate flowing out of E-1 shell and 24 ata steam.
 Bottom holder (ME-2) to collect the solution with still lower residual
CO2.

The NH3 and CO2 rich gas leaving the top separator are sent to the medium
pressure condenser where they are partly absorbed in aqueous carbamate
solution coming from recovery section at 4.5 atm. The absorption heat is
removed by cooling water.
The liquid- vapor mixture from M.P condenser flows to M.P. absorber which
is a bubble-cap type tray column performing CO2 absorption and NH3
rectification of the vapor phase. The trays are fed by pure NH3 reflux is
drawn from ammonia booster pump discharge which eliminates residual
CO2 and H2O from the exit gases.
NH3 with inert gases leaving the column top is partially condensed in the
ammonia condenser. From where two phases are sent to ammonia receiver.
The inert gases saturated with NH3 leaving the receiver, enter the ammonia
recovery tower where additional amount of NH3 is condensed by the cold
NH3 coming from the urea plant battery limit. The condensed NH3 is
recovered in NH3 receiver.
The inert gases with the residual NH3 content are sent to the inert wash
tower where they meet counter current water flow which absorbs gaseous
NH3. The absorption heat is removed by cooling water, from the bottom of
the tower; water ammonia solution is recycled back to medium pressure
absorber by means of centrifugal pump. Now there are three valves trays in
inert wash tower where the inert gases are submitted to final washing by
means of the cold condensate. The inert are sent to the blow down are free
from ammonia.
 SECOND STAGE RECOVERY
The solution leaving the bottom of medium pressure decomposer is expanded

at 4.5 ata pressure and enters the low pressure decomposer falling film type.
This is divided into three parts:
 Top separator where the flash gases are removed before the solution enter

the tube bundle.
 The decomposition section where the last residual carbamate is

decomposed and required heat is supplied by means of stream
saturated at 4.5 atm.
 Bottom holder to collect the Urea solution.
The gas is leaving the top separator are send to the low pressure condenser
where they are absorbed in aqueous carbamate solution from the waste
water treatment section. The absorption and condensation heat is removed by
the cooling water.
From the condenser bottom the liquid phase, with the remaining inert gases
is send to carbamate solution tank. From here carbamate solution is recycled
back to medium pressure condenser by means of centrifugal pump.
The inert gases with essentially contain NH3vapour flow directly in to the
low pressure falling film absorber where the ammonia is absorbed by a
counter current water flow. The absorption heat is removed by cooling
water. The inert gases are washed in the low pressure inert washing tower
and are collected to blow down practically free from ammonia.
3) UREA CONCENTRATION
In order to concentrate the urea solution to 99.7 %, a two stage vacuum

concentration section has been provided. The urea solution leaving medium
pressure holder with about 69% urea is sent to tube side of pre-concentrator is
operating at 0.33 ata pressure.
The pre-concentrator is divided into three parts:
 First part is top separator where flashed gases are removed before the
solution enters the tube bundle. The vapors from top separator are extracted by
pre-concentrator vacuum system.

 Second part is concentrator section here the solution is being concentrated
up to 85 %. The heat is supplied by condensing the M.P decomposer off gases
along with absorbent from M.P Carbonate pump discharge.
 Third part is bottom holder to collect the urea solution.
The urea solution leaving vacuum pre-concentrator separator is pumped to 1st

vacuum concentrator operating at 0.3 atm pressure by one of the pumps vacuum
concentrator feed pump.
The mixed phase coming out of enters I vacuum separator where from the vapors
are extracted by the 1st vacuum system, while the solution with 95% urea enters
the 2nd vacuum concentrator operating at 0.03 atm pressure.
The mixed phase coming out of 2nd vacuum concentrator enters the 2nd vacuum
separator where from the vapors are extracted by the II vacuum system. The two
concentrators are fed by L.P. saturated steam at 4.5 atm for supplying heat for
water evaporation.
4) UREA PRILLING
The melted Urea leaving the second vacuum separator is sent to the prill bucket by
means of centrifugal pump. The Urea coming out of the bucket rotating at 250-300
rpm is in the form of drops falling along the prilling tower and encounters a cold
air flow which causes its solidification and cooling.
The solid prills falling to the bottom of prilling towers are sent to the belt conveyor
by the rotary scraper. From here they are sent through screeners to retain lumps
only and then to belt conveyor which carries the product to the automatic weighing
machine and to the Urea storage section or bagging unit.
5) WATER TREATMENT
The water containing ammonia, urea and carbon dioxide, coming from the first

and second vacuum system is collected in the buffer waste water tank. From this
tank solution is pumped to the waste buffer tank and then it is pumped to the waste
water distillation tower operating at a pressure of 2.5 atm. Before entering to
distillation tower the solution is preheated in exchangers by means of the purified
water flowing out of the reboiler of distillation tower.
From these after a first stripping of ammonia in upper part of tower, it is pump to
the M.P hydrolyser where urea is decomposed by means of steam at 24 atm. Here
before entering the M.P hydrolyser, the solution is preheated in an exchanger with
the solution coming out of itself.
The vapors produced in M.P hydrolyser are sent to the overhead condenser, while
the solution after getting cooled in exchanger is pumped by H.P hydrolyser feed
pump to the deep hydrolyser where urea is almost totally hydrolysed by direct
mixing of H. P. steam in H.P hydrolyser.
Before entering to H.P hydrolyser, the solution is preheated in exchangers with the
solution coming out of itself. The vapors produced in hydrolyser are sent M.P
hydrolyser for heat recovery while the solution after getting cooled in exchanger
returns to the top of the lower part of tower in which the remaining NH 3is stripped
out by means of vapour produced in reboiler of tower.
The vapors leaving the top of tower, along with those obtained from M.P hydrolyser
are condensed in overhead condenser where from the carbonate solution flows to
the reflux accumulator. The heat of condensation in overhead condenser is
removed by cooling water. The carbonate solution from reflux accumulator is
recycled back to the L.P. condenser by means of reflux pump and the inert carrying
small quantity of NH3vapors are vented in air.

POWER PLANT
OVERVIEW
The captive power plant of KRIBHCO has been installed for the purpose of meeting:-
A) The high pressure steam required for:-
 Steam turbine driven CO2 compressor drives and for other process steam
heat exchanger for urea plant
 Steam turbine driven power generators & auxiliary equipment &

exchangers of power plant
 Ammonia plant and HAEP plant are self-sufficient for steam requirement.
However, they will draw steam from the power plant during start up, shut
down and plant upset conditions only and may draw upto100 T/H per
phase.
B) The electrical power required for driving various equipment of KRIBHCO fertilizer
complex.
The captive power plant is capable of producing 30MW power to meet the power
requirements of plant. There are three boilers and each capable of generating,
275MT/H of steam at 105Kg/cm2 at 510degree c. all the 3 boilers are connected to a
single common header to supply high pressure steam, to different use points. At a
time two boilers are under running condition and one boiler is under inspection or
maintenance. The power plant was designed by M/s Foster Wheeler, UK.
Two turbo generators (M/s by BHEL) are installed to generate power. Each set is
capable to generate 15MW power. These turbines are partially condensing type.
The captive power plant KRIBHCO has also tied up with GEB, to meet the emergency
requirements. The urea plant is completely dependent upon the power plant for
steam. Hence if power plants trips then urea plant also trip. Urea plant draws steam
to the extent of 275-280 T/H, for running it CO2 compressor turbine and process
heating.

Earlier each boiler was both coal and natural gas fired, but due to ample amount of
natural gas and naphtha available coal firing equipment was permanently removed.
Due to uncontrolled price of naphtha, currently KRIBHCO is receiving natural gas
from GAIL and GSPC.
Recently a new Gas Turbine Power Plant is being developed at KRIBHCO, capable of
producing 72MW power. However currently the GT plant delivers only 16MW.
The power plant has been virtually divided into 4 parts:-
Water circuit
1. Steam circuit
2. Air circulation circuit
3. Fuel(Natural gas) circuit
All these parts have been discussed below in detail.
(Above is the block flow diagram of the plant for each boiler)
WATER CIRCUIT

The water circuit consists of following vital parts/equipments:-
1. Make-up water storage

2. Make-up water pumps
3. De-aerator
4. Boiler feed pump
5. High pressure feed water heater
6. Economiser
7. Boiler drum
8. Water walls
The water needed for producing steam is obtained from DM water plant, urea plant
(condensate water), and power plant (obtained from CEPS).
1. MAKE UP WATER TANKS
The make up water stored into 140MT capacity make up water tank which receive
water from DM water plant, Urea plant, and Power plant. The tank discharges into a
common suction manifold serving 3 mega pumps. A man hole is provided on the roof
of tank, directly above a caged internal ladder. A flange-bolted access door is
provided on the tank wall.
Three number of make up water pumps are provided to supply feed water to the de-
aerators, one serving each de-aerator and one stand-by. Make up pump also supplies
water to the chemical preparation tanks of HP and LP dosing system and also to
sample coolers.
2. DEAERATOR
The water obtained from DM plant consists of high amount of dissolved oxygen
which has to be removed so as to prevent corrosion of boiler. This is done in de-
aerators.
Heating steam is fed into the top of the de-aerator water storage tank via a steam
dome, passing through the scrubber, upward and horizontally through the trays so
that heated water is brought into intimate contact with an oxygen free atmosphere.

Heating steam to the de-aerator is derived from four sources: the main turbine pass-
out, the pressure reducing and de-superheating stations (PRDS), the boiler blow-
down flash vessel and the feed water pump turbine exhaust.
The upward flow of steam carries liberated oxygen to the top of the tank; where
sufficient steam in vented to remove liberated oxygen.
3. HIGH PRESSURE FEED WATER HEATER
The two horizontal single-pass, U tubes, shell and tube high pressure feed water
heaters receive the feed water from the feed pumps; heating steam being derived
from the associated pass out condensing power turbine or from the PRDS. Normally,
a single feed pump set serves one feed water heater. The feed water heater comprises
a two-piece shell, accommodating a multi-tube element. Mounted horizontally, the
unit is supported on the two feet-one for each section. The overall length is 13.26 M.
4. ECONOMISERS:
Economiser is a kind of feed water heater. Waste heat recovery arrangement is made
in it. The flue gas at the outlet of superheaters has sufficient heat and if not recovered
may cause atmospheric pollution in addition to low efficiency of boilers.
The economisers are located in the boiler rear enclosure heat recovery are (H.R.A)
and are arranged counter flow to the gas flow. The lowest-bank, nearest the gas
exists in the low temperature (LT) section, and the high temperature (HT) section is
mounted on top.
5. BOILER DRUM:
The boiler drum is situated at the top of boiler assembly. The boiler drum is
considered as a transition between the water circuit and the steam circuit.
Boiler water circulating and rising through water walls flow to the drum as a steam
and water mixture. The steam and water are separated inside the drum by the steam
separators, the steam passing to the superheaters and the water recycled for further
heating.

Water after circulating through the water wall returns to the drum as a steam and
water mixture through the front and rear girth baffles to the horizontal separator.
Each girth baffle forms a compartment isolated from the drum feed water to conduct
the steam and water mixture from the water wall.
6. WATER WALLS
The water wall is the prime steam generating part of the boiler. The walls of furnace
are formed by series of tubes through which water is circulating by the phenomenon
of natural circulation.
The upper and lower ends of these tubes are connected with top and bottom headers,
which are in turn connected with the boiler drum through risers and bottom
headers, respectively. Water while ascending through the wall tubes receive heat and
gets converted into steam.
OVERVIEW OF WATER CIRCUIT

STEAM CIRCUIT
The steam coming out from the boiler drum still contains minute amount of moisture in it,
which has to be removed before feeding the steam into the turbo generators (as the
remaining moisture can cause corrosion). That is, the steam has to be super saturated. This
task is achieved by using a set of 3 super heaters. The secondary and the platen super heaters
are located in the main furnace area, while the primary super heater along with both the
economizers is located on the rear side of the boiler (also known as HRA-Heat Recovery
Area).
The flue gases first come in contact with the secondary super heater, followed by platen
super heater, and finally moving to the rear section of the boiler via a notch provided in
between.
Hence, the steam circuit consists of the following components:
1.) Primary super heater

2.) Platen super heater
3.) Secondary super heater
4.) Turbo Generator
5.) PRDS-Pressure Reducing and De-superheating Station
1.) PRIMARY SUPER HEATER
The primary super heater is located in the rear enclosure and is arranged in the
counter flow to the flue gases. The steam temperature increases from 330oC to 378oC,
while the flue gas temperature reduces from 751oC to 605oC. From primary super
heater steam enters to the first stage attemperator. Steam temperature can be
maintained via the attemperator by spraying water. Hence, the temperature of steam
reduces to 351oC.
2.) PLATEN SUPER HEATER
From first stage attemperator, the steam enters into the platen super heater, which
consists of 15 multi-tube pendants uniformly arranged across the boiler and
suspended into the furnace.

The steam temperature increases from 351oC to 440oC, while the pressure decreases
from 112.2 kg/cm2 to 108.9 kg/cm2. Final control of steam temperature is achieved by
the use of second stage attemperator. The spray water used by the attemperator is
taken from boiler feed water system.
3.) SECONDARY SUPER HEATER
Secondary super heater is the final super heater providing the output steam. The
super heater elements are arranged in the parallel flow with the flue gas. The
temperature rise across the final super heater is from 423oC to 515oC, while the
pressure reduces from 106 kg/cm2 to 104.2 kg/cm2. Flue gas temperature drops from
968oC to 828oC.

(Above shows the arrangement of various super heaters, economisers and burners in
the various section of boiler. The right part is the main boiler part while the left part is
the rear section of the boiler where the heat of flue gases is recovered.)
4.) TURBO GENERATOR
Two turbo generators (M/s by BHEL) are installed to generate power. Each set is
capable to generate 15MW power, running at 7 to 7.5 MW (considering GT). These
turbines are partially condensing type.
The high pressure superheated steam is first expanded in steam nozzles where
pressure energy is converted to kinetic energy first.
The high velocity steam passes through the turbine blades in stages and this kinetic
energy is converted to mechanical energy.
The fixed blades provided in between the rotor blades again coverts the pressure
energy to kinetic energy and properly guides to next stage moving blades for further
energy conversion.
Generator converts the mechanical energy to electrical energy.
5.) PRESSURE REDUCING DESUPERHEATING
There are four pressure reducing and de-superheating stations to supplement the
pass out steam from the TG turbines. Two of the stations supply steam at a pressure of
13.15 Kg/cm2 and a temperature of 270oC to the high pressure feed water heaters,
while the other two stations supply steam at 1.89 Kg/cm2 and 150oC to the two de-
aerators. Normal operation is with one station in each pair on duty and the other two
on hot stand-by. A small flow of steam maintains stations on hot stand by condition at
working temperature, ready to be brought on steam in the event failure of an
operating station.
The pressure reducing and de-superheating stations maintain a constant downstream

pressure and therefore, constant pressure steam to the de-aerators and feed water
heaters.

• THE NORMAL STEAM DISTRIBUTION PATTERN IS AS BELOW:-
POWER PLANT
TGS:- 130 T/HR
BFP TURBINE: 10 T/HR
PRDS: 00 T/HR
TOTAL: 140 T/HR
PROCESS PLANTS
UREA PLANTS:- 250 T/HR
AMMONIA PLANTS: 00 T/HR
HAEP : 00 T/HR
TOTAL: 250 T/HR
• GRAND TOTAL :390 T/HR

AIR CIRCUIT
For the combustion of any fuel sufficient amount of oxygen is required. Since ample
amount of oxygen is available in air hence air is used along with the fuel for the
combustion. The task of supplying air to the furnace of each boiler, draught plant has
been installed.
The draught plant for each boiler comprises two forced draught fans supplying combustion
air and two induced draft fans for extracting flue gases.
All fans run at constant speeds with interlocks. A F.D fan cannot be started unless its paired
I.D. fansis running.
The draught system installed at KRIBHCO is a balance draught system.

1. FORCED DRAFT FANS
The main aim of the F.D. Fans is to suck the air from atmosphere and supply it to the furnace.
The fan runner, of backward-curved aerofoil bladed type, comprises backsheet, conesheet,
blades and driving hub. The back sheet, which supports the blades, is bolted to the cast steel
driving hub which, in turn, is keyed to the fan shaft.
Radial vane control gear comprises of twelve streamlined vanes. Imparting a swirling motion
to the air in the direction of its rotation as it enters the inlet of the impeller. The effect of the
swirl is to reduce the work done on the air by the impeller and, in consequence, the power
absorbed.
The motor windings are cooled by air, in a closed circuit through an external air tube cooler,
impelled by two centrifugal fans; one fitted to each end of the motor shaft(rotor). Six anti-
condensation heaters are fitted to each motor to maintain the windings in a dry condition
and should be energised during periods of standing-by.
2. Induced draft fans
The main aim of the I.D. Fans is to suck the flue gas from furnace and supply it to the
chimney.
The single inlet suction box connects the fan casing via an inlet eye. The fan casing, inlet eye
and suction box are flange jointed about the horizontal centre line.
The fan runner, of backward-curved laminar bladed type, comprises backsheet, conesheet,
blades and a driving hub which, in turn, is keyed to the fan shaft.
Differential vane control gear, comprising six streamlined vanes is located in a frame
attaching the fan inlet flange, these vanes, form the I.D. Fan control damper.
Differential vane imparts a spinning motion to the gas in the direction of its rotation as it
enters the inlet to the impeller. The effect of the spin is to reduce the work done on the gas by
the impeller and, in consequence the power absorbed. Differential movement between vanes
improves control at low speeds and is effective and an economical throughput control down
to 25% of the design volume.

3. AIR HEATERS
The main aim of the air heater is to increase the temperature of the feed air while using the
heat of the hot flue gases, but at the same time it keeps some optimum temperature of the flue
gases so as to prevent deposition of the soot in the chimney.
Hot flue gases form the boiler enters the air heater at the top and passes through the rotating
elements whose surface extract heat. Cold air from forced draught fan enters the air heater at
the bottom and passes through the heated rotating elements whose surfaces impart heat to
the combustion air. The rotating elements are continuously regenerated and cooled as they
pass through the gas and air paths.
During boiler start-up conditions, hot air is returned to the forced draught suction thereby
raising the elements cold end temperature above acid dew point.
Thermocouples are located in each gas inlet and air outlet ducts. If higher air to gas
temperature difference is obtained, the fire alarm is initiated.
4. CHIMNEY
Combustion process inside a furnace is possible only when a steady flow of air is given and
simultaneously products of combustion are taken out. When only chimney is used, the system
is natural draft system; and when this is aided with forced draft fan or induced draft fan or
both, the system is a mechanical draft system
Chimney contributes only a small draft to the total need like large unit of ours. The main idea
to use chimney of such a large height is to discharge the products of combustion high
enough above ground level to dilute these and minimise air pollution nuisance.
The chimney is 50m high having bottom and top OD 18.00m and 5.43m respectively. Top of
the chimney is covered with cast iron cap. In between chimney‖s inner shell and brick lining
air gap has been maintained which aids in thermal insulation effect.

FUEL CIRCUIT (NATURAL GAS)
The fuel required for the firing of the boiler used in KRIBHCO is natural gas. Natural gas is
taken from ONGC. Gas coming has to be made fit for the combustion in boiler (reduce
pressure). Hence the fuel circuit basically consists of:
1. Gas Pressure Reducing System(GPRS)

2. BURNER
1. GAS PRESSURE REDUCING SYSTEM(GPRS)
Natural gas from ONGC is supplied at a pressure of around 40 Kg/cm2 g to the FWPPL
battery limit and is filtered there and pressure reduced to 4.5 Kg/cm2 g. before being
supplied to constant pressure header across all the three boilers.
A 300 mm diameter manual isolating valve is provided at the inlet of the GPRS for local
isolation. In addition to that, a quick closing valve of the same size is also provided for
emergency remote isolation of the whole gas system.
A filtering section is provided by two – 300 NB Swinney 20 micron filters each of which
is capable of carrying full gas flow.

The pressure reducing section consists of two full duty streams in parallel. Each stream
consists of a slam shut valve followed by the two pressure reducing valves and a relief
valve.
The slam shut valve is an actuated ball valve which is normally open but closes rapidly
upon high gas pressure. The pressure is sensed on the down stream side of the system.
The pressure reducing valves are of two types, one is pilot operated axial flow valves and
the other is phenmatic valve.
The boiler were designed for two distinct modes of operation high load where gas would
generate substantially all the stream output and low load where gas would provide a pilot
function. Hence each 100% reducing stream consists of two in parallel, a 200 mm main
reducing stream and a 50 mm pilot reducing stream. The pressure settings are such that
the pilot stream comes into operation first followed by the main stream as the demand
rises.
2. BURNERS
There are eight horizontal intervene pulverized fuel burners manufactured by

Hamworthy and arranged through the wind box in pairs at 3,365 m centres located at
19,230 mm, 16,730 mm, 14,230 mm and, 11,730mm. Each burner is fitted with a
central gas burner.
Each burner comprises the following:
 Centre gas gun for pilot gas flame.

 Gas manifold and spuds for main MCR gas flame.
 Air register, incorporating primary swirler and burner front plate.
 Primary air wind box, non-return damper and tertiary air dampers.
 Burner air fan.
 Gas/Electric igniter.
 Flame scanners for monitoring the ignition and gas flames.
Each burner has been designed to carry 26982 kg/hr. of hot air (182°C), 7634 kg/Hr. of
atmospheric air and 2045 kg/hr. of natural gas to give 100% MCR load.

CHEMICAL DOZING
The D.M water / condensate has to be treated with certain chemicals to remove all the
impurities. Usually the pH of the feed water is kept greater than 7 so has to prevent corrosion.
The remaining oxygen in the water after the deaerator is removed by adding hydrazine to the
water. The oxygen gets removed by the following reaction;
N2H4 + O2  2H2O + N2
The advantage of adding hydrazine is that even in excess it reacts with water to make it
alkaline in nature thus preventing corrosion.
Hydrazine is fed into the feed water and boiler filling line via low pressure chemical
injection.
As the pH increases corrosion is prevented however it leads to scale formation tendency. To

prevent this condition the water is treated with tri-sodium phosphate. The phosphate ion has
the unique tendency to form loose sludge like material with the ions present in the water,
which can be removed by frequent blow down. Thus preventing scale formation.
Tri-sodium phosphate is injected into the steam drums via high pressure chemical injections.
The boiler should be blowdown at regular intervals to limit the total dissolved solids in the
boiler water and to remove any sludge resulting from water treatment.
Silica in boiler water is maintained in such a manner that the steam should not have more
than 0.02 PPM silica. Silica volatilises at high temperature & pressure & carried along with
steam. They get deposited at turbine blades.
After a boiler has been shutdown, the water wall header should also be blown down using
drain valves provided at the bottom header.
The desired analysis of boiler water and feed water is:
i. Boiler Make-Up Water pH : 8.5 to 9.5

Cond. : Less than 1 micro siemens per Cm.

Silica : Less than 0.02 ppm
ii) boiler Feed Water pH : 8.5 to 9.5

Cond. : Less than 1 micro Siemens per Cm.
N2H4 : 20 to 30 ppb
iii) Boiler water pH : 9.0 to 10.5

Conditioning: Less than 50 Micro Siemens per Cm.
Silica : Less than 1 ppm.
Phosphate: 5 to 10 ppm.
COOLING WATER SYSTEM
Power plant gets the supply of cooling water at two different pressures and two
different sources from the cooling tower of power plant operating under offsite
control. The cooling water is circulated in a closed cycle with a four cell induced draft
cooling tower. The four cell cooling tower dissipates the heat of return cooling tower
and the cold water collects in the basin. From basins, the water flows to the pump
sumes. There are two sets of pumps.The first set of four pumps known as the
circulating water pumps are meant for supplying cooling water to the TG condensers,
while the second set of three pumps known as auxiliary cooling water pumps are
meant to supply cooling water to all the rotating equipments of steam generation
plant and to different sections of offsite facilities.
The cooling water is filtered water mixed with certain conditioning chemicals to
prevent both scale formation and corrosion.

GAS TURBINE PLANT
KRIBHCO is currently installing a new 72 MW natural gas turbine based co-
generation system. Generated electricity will be supplied to the fertilizer plant for
meeting the power requirements. The excess power generated will be exported to the
grid, resulting in replacement of grid electricity. The power generation will be about
72 MW and the captive power requirement of the plant is about 37 MW. Thus 35
MW of excess power will be supplied to the state electricity grid.
Waste heat from the gas turbine will be recovered in heat recovery boiler that will
send the generated steam to the fertilizer plant for process application. The heat
recovery steam generator is a horizontal natural circulation type boiler with
supplementary firing which can produce upto190 metric ton per hour at 513oC and
108 kg/cm2.
(The above block flow diagram depicts the upcoming KRIBHCO gas turbine power
plant.)

Gas turbines are a type of internal combustion engine in which burning of an air fuel
mixture produces hot gases the spin a turbine to produce electricity. Combustion
occurs continuously in gas turbines as opposed to reciprocating IC engines.
Gas turbines are comprised of three sections mounted on the same shaft:
1.) Compressor
2.) Combustion chamber
3.) Turbine
1.) COMPRESSOR
The compressor can be either axial flow or centrifugal flow. The gas turbine at
KRIBHCO is of axial flow type. Axial flow compressors comprise of multiple
stages of rotating and stationary blades (stators) through which air is drawn in
parallel to the axis of rotation and incrementally compressed as it passes through
each stage. The acceleration of the air through the rotating blades and diffusion
by the stators increases the pressure and reduces the volume of the air. The
compression of air also causes the temperature to increase.
2.) COMBUSTION CHAMBER
The compressed air is mixed with the fuel injected through nozzles. The fuel air
mixture ignites under constant pressure conditions and the hot combustion
products are directed through the turbines where it expands rapidly and imparts
rotation to the shaft.

3.) TURBINE
The turbine comprises of stages, each with a row of stationary blades to direct
the expanding gases followed by a row of moving blades. The rotation of the
shaft drives the compressor to draw in and compress more air to sustain
continuous combustion. The remaining shaft power is used to drive a generator
which is used to produce electricity.
About 60% of power produced by the turbine is used to drive the compressor.

OFFSITE PLANTS
INTRODUCTION
“OFFSITES” is the “OFF the Site” plant. All those plants, which are not within battery limit of
main process plants, are called offsite facilities. KRIBHCO‖s Offsite plants provide following
facilities:
1. Water Pretreatment plant
2. D.M. Plant
3. Cooling Towers
4. Ammonia Storage and Handling
5. Air Compressor House
6. Inert Gas Plant
7. Product Handling Plant
Out of these, WPT, D.M. Plant and Cooling Tower are grouped as Water Circuit.
KRIBHCO‖s source of water supply is from river Tapi. The rainwater from the catchment
areas collects in the reservoir of the Ukai dam. The Kakrapar well feeds two canals,
KRBC (Kakrapar Right Bank Canal) and KLBC (Kakrapar Left Bank Canal). The KRBC
feeds the Hazira branch and the last length of canal is know n as Suwali Minor. The
original Suwali Minor irrigation was renovated and strengthened to carry about
350cusec water for industrial use in addition to the agricultural use in this area.
KRIBHCO has installed three submersible pumps of 1750 m3/hr capacity each in the
Kakrapar canal. Delivery line is 85km long and 42” in diameter. Discharge pressure of
two modified pumps is 0.6kg/cm2.
1) WATER PRE-TREATMENT PLANT

The water treatment system consists of:
a) Raw water inlet arrangement

b) Stilling chambers.
c) Flow Measuring Device (Parshall Flume)

d) Flash Mixers.
e) Clariflocculators
f) Rapid gravity sand filters
g) Chemical House
h) Clarified water storage tank.
i) Filtered water storage tank.
j) Overhead wash water tank.
k) Chlorination facility
l) Clarifier Bypass Arrangement
The raw water from the reservoir is pumped to the inlet of the treatment facility, where two
nos. butterfly type control valves, one on the main line and other on the branch line, are
provided. Each of the control valves are provided with isolation valves also. Raw water
through these valves enters a stilling chamber with a detention time of 2 minutes. Raw
water is pre-chlorinated at the stilling chamber through the PVC diffusers provided. Pre-
Chlorination is the application of chlorine to raw water prior to any unit treatment process.
The point of application as well as the dosage is determined by the objectives viz. control of
biological growth in raw water, promotion of improved coagulation, prevention of mud ball
formation and slime promotion in filters, reduction of taste and colour and minimising the
post chlorination dosage when dealing with heavily polluted water.
The pre-chlorinated water enters either of the two parshall flumes in parallel provided for
flow measurement. At the down-stream end of the parshall flume, the required quantities of
chemicals are a~ed from the solution. Preparation tanks in the chemical house. The raw
water alongwith chemicals flows through a RCC.Dhannel and enters the flash mixer where
it is subjected to thorough and intense mixingwith thechemicals bythe agitators provided.
Water from the flash mixer enters either of the clariflocculators through the bottom and
discharges at the flocculation chamber.
The water entering the flocculating zone is subjected to slow agitation by the paddles
provided which enhances the formation of easily settleable flocs. The flocculated water
enters the clarification zone through the bottom of the flocculating zone. In the clarification
zone, the water rises slowly to the top. Due to the quiescent velocities maintained in the
clarification zone, the chemical sludge settled on the floor of the clariflocculator and the
clarified water slowly emerges at the top and overflows into the peripheral circular

launder. The chemical sludge settled on the floor of the clariflocculator is scraped of by the
scraper arms in the rotating bridge by a carriage drive.
The clarified water collected in the peripheral launder of the clariflocculator is led to the
filter bed or the clarified water storage tank. A parshall flume is provided for measuring the
flow into the storage tank. Clarified water enters the filter beds through the filter inlet
channel and is subjected to rapid gravity filtration. During the filtration process, the
residual suspended matter in the clarified water is retained on the sand bed and the filtered
water enters the filtered water storage tanks through the pure water channel. The stored
filtered water is post chlorinated for disinfection and is distributed for further utility. The
residual suspended solids retained on the sand bed are removed by backwashing after
completion of one cycle. Air blowers for supplying air for scouring prior to back washing
are provided and a wash water tank for storing filtered water for backwashing is also
provided.
2) D.M. PLANT
The suspended and biological impurities are already removed in pre-treatment plant. The
dissolved impurities must be removed completely before its use as boiler feed. The process
used for removal of dissolved impurities is known as demineralization. The process is ion
exchange process.

There are 5 nos. of activated carbon filters each with 14.9m3 of activated carbon to remove
chlorine and organic impurities. KRIBHCO is provided with 4 nos. of cation exchanger,
each having a capacity to treat 180 m3/hr and 2060 m3 of water per regeneration. Ion
exchange resin Indion 225 Na is used. Each bed is charged with 14.9609 m3 of resin. The
cation exchangers are regenerated with 4% HCl. There are four trains of anion exchangers
having four weekly basic exchangers and four strongly basic exchangers. The capacity is
same as cation exchangers. The WBA units are charged with 5.4 m3 of Indion 850 and SBA
with 4.520 m3 of Indion FFIP resin. The regeneration of anion exchanger is done by
thoroughfare method to conserve chemical consumption and get maximum chemico-
economic efficiency.
Between cation outlet and anion inlet KRIBHCO has four nos. of degasser towers. The
towers are packed with rasching fall rings. Towers are equipped with six nos. of blowers.
Air at pressure of 50 MMWC is blown to the packing and water is allowed to drip through
it. So, an extended surface area of water comes in contact with air. The weak acid H2CO3
breaks into H2O and CO2. CO2 is vented out. This takes away load of anion exchanger and
gives service with minimum cost. Degassed water contains less than 5 ppm of CO2. This
water is then passed through anion exchangers. The outlet of anion exchangers contain less
than 0.1 ppm silica and conductivity less than 10 microsiemens.
There are four nos. of mixed bed units each containing 2.28 m3 of Indion 225 Na and 4.25
m3 of Indion FFIP mixed thoroughly to polish the water and remove last traces of impurities.
The capacity of MB units is 180 m3/hr and 25000 m3 per regeneration.
CHEMISTRY OF DM PLANT
Exchange of Cations:
When water with some dissolved salts is passed through a resin bed which can exchange
cations Ca++, MG++, Na+ etc. come in contact with the resin, replace the H+ ions moved out of
resin matrix, neutralise the charged negative ion SO4, Cl, CO3 etc. and combine with them
to form corresponding acids like HCl,H2SO4, H2CO3 etc. This type of ion exchange process
can be represented as:
2RH  CaSO4  R2 Ca  H 2 SO4
RH  NaCl  RNa  HCl

Some cases complete removal of cations is not necessary but only the salts responsible for
hardness are to be removed or modified. In that case simply the cations of the salts are
replaced by sodium ion so that highly soluble salt is produced which is soluble at all
temperature. In those type of cation exchangers, also called softners, the solid matrix has
the affinity for cations, the mobile ion associated with matrix is Na+ and the results are
sodium sulphate, sodium chloride and sodium carbonate etc. The reaction may be
represented as
2RNa  CaSO4  R2 Ca  Na 2 SO4
2RNa  MgCl 2  R2 Mg  2 NaCl
These exchanges of one cation for another cation are called cation exchange process. After
certain extent of exchange of ions, the resin becomes poor in stock of Hydrogen ion and we
say it is exhausted. Exhausted resin does not mean that 100% H ions are used, but it is
hardly 60 to 70% exhausted and the exchange continues but the decrease in free mineral
Acid (FMA) concentration and increase of pH of cation exchanger effluent water shows the
drop in activity and efficiency of cation exchanger resin bad. With this 30 to 40% of
Hydrogen (H+) ions in matrix the exchange efficiency is too poor, so it must be regenerated.
The regeneration of “Cation Exchanger Resins”, strong or weak, is done with H+ ions.
The resins which has higher affinity for other divalent and monovalent cations in normal
service periods with abundance of H ions with it, is compelled to release all those cations in
exchange for Hydrogen ions when higher concentration of H ions are present around it.
Hydrogen ions are supplied by dilute acids. H2SO4 and HCL are mostly used for
regeneration of cation exchanger resins.
Reaction may be written as:
R2 Ca  2HCl  2RH  CaCl 2
R2 Ca  H 2 SO4  2RH  CaSO4
RNa  HCl  RH  NaCl
2RNa  H 2 SO4  2RH  Na 2 SO4
Thus the regeneration process with the help of dilute acids (HCl or H2SO4) can bring back
the active properties of resin to original stage. Difference of regeneration process for weak
and strong cation exchanger resins can be regenerated with Acids of lesser concentration (2

to 3%), while the strong cation exchanger resin must be regenerated with Acid of higher
concentration (4 to 6%), since the affinity for H+ ions of two resins differ. In this same way
for regeneration with H2SO4 lesser concentration is required than that for HCl because the
former has two atoms of Hydrogen for each molecule of acid while the later has only one.
Exchange of Anions:
Water after passing through the cation exchanger bed, contain lot of free mineral acid due
to conversion of various salts into corresponding Acids. When this water is passed through
the bed of Anion Exchanger Resins, the Hydroxyl Ions (OH) associated with the solid matrix
is replaced by the ionised Anions (Negative ions) of the Acids. The negative ions like SO 4--,
CL-, CO3—displace the OH- ions from the resin matrix and get themselves fixed into matrix
place. The OH ions released from resin combine with the H+ ions of ionised Acids of water
and form H OH i.e. H2O. This completes the removal of salt.
The reaction of exchange process is written as:
ROH  HCl  2CL  H 2O
2ROH  H 2 SO4  R2 SO4  2H 2 O
2 ROH  H 2 CO3  R2 SO3  2H 2O
These processes of exchange of Negative ions of Acids with the Hydroxyl ions of resin are
called Anion Exchange process. The resins used for this process are known as Anion
Exchange Resins. These are various forms of resins of anion exchanging type and are
classified into two groups, weak Anion exchanger resins and strong anion Exchanger Resins
according to the affinity only for strong Anions like SO4--, CL- etc. and are incapable to
exchange weak Anions like CO3—and SiO2 etc. so they are known as weak Anion Exchange
resins. Other which can exchange all Anions weak or strong are named as strong anion
exchanger resins. Thus if a plant is having both types of Anion exchangers, the weak Anion
exchanger precedes strong Anion exchanger. CO3 a weekly base anion forms an unstable
Acid with Hydrogen i.e. H2CO3 and can be easily removed by mechanical methods like
aeration with Air or de-aeration with steam. In water treatment plant aeration is only way
to be adopted. The appliance used for removal of H2CO3 with it.
H 2 CO3  H 2O  CO 2

Thus CO2 is vented with air and H2CO3 is removed without any chemical consumption. In
degasser (packed tower) the water with H2CO3 is sprayed from top. A blower introduces
atmospheric air from the bottom of the tower. This mechanical process of CO2 removal is
most economical. Degasser is always located before a strong Anion Exchanger and after a
strong cation exchanger. A weak Anion exchanger may be placed before or after a degasser.
All Anion exchanger weak or strong are regenerated with OH- ions when they are
exhausted. The exhaustion is estimated by the extent of lost OH- ions from the matrix or the
solid resin. When 70 to 80% ions are lost the exchange rate becomes retarded the
regeneration is a must. The regeneration of Anion resin can be done with Alkali like caustic
soda, soda ash or Ammonium Hydroxide. The strongly basic Anion exchanger resins require
only strong alkali NaOH for regeneration, where as the weakly basic Anion resin can be
regenerated by any alkali strong or weak according to availability and/or suitability of
process.
The regeneration process is reverse of service process. Those very resins which show higher
affinity for other Anions and release OH ions during service cycle are compelled to release
al these Anions in exchange for OH- Ions when a solution rich in OH- Ions comes in contact
with resin at the time of regeneration. The reaction of regeneration process of anion
exchanger may be written as:
RCl  NaOH  ROH  NaCl
R2 SO4  2 NaOH  2ROH  2 Na 2 SO4
RCl  NH 4 OH  2ROH  NH 4 Cl
2ROH  H 2 SO4  R2 SO4  2H 2 O
R2 SO4  2 NH 4 OH  ROH  NH 4 2SO4

When a solution of alkali passes through the exhausted Anion exchanger resin bed, the OH -
ions are retained by resin and salts of Sodium or Ammonia are released which are
discharged as effluents. After some time when 100% resin is saturated with OH- ions, no
more consumption of alkali is there and unreacted alkali comes out of resin bed. The
quantity of alkali to be used depends upon the efficiency or regeneration, extent of
exhaustion of bed and process used. A strong basic Anion exchanger resin bed require
higher concentration of NaOH than the weakly basic Anion exchanger resin be. In the same

way a weak alkali used for weakly basic Anion exchanger resin must be having 4 to 5%
concentration while the same resin can be regenerated with 1 to 2 % concentration of
strong alkali.
Thus the service cycle and the regeneration cycle follow each other. An unit is put into
service after regeneration and after testing for its product quality. If quality is within
specification, it is taken in service cycle. When designed quality of water has passed
through the bad or when output quality is below specification resin bed is exhausted and
cut out of service for regeneration.
Mixed Bed Unit:
Bulk of salts of raw water is removed by passing it through the cation exchanger and Anion
Exchanger units. However 100% efficiency of such a big exchanger cannot be guaranteed
and any left out salt cannot be tolerated in boiler of moderate pressure. Hence a polishing
unit is provided to trap any cations and or Anions still present in water.
In a mixed bed unit the strongly acidic cation exchanger resin and strong basic Anion
exchanger resin are mixed together to form some homogenous mixture. Thus a mixed bed
unit acts like countless number of cation and Anion exchanger beds in series. Cations are
picked up by strongly cation exchanger resin and the corresponding Acid formed is
neutralised by the strong Anion exchanger resin lying just beside the former. So instead of
having a number of separate units for exchange of cations and anions, a single unit or a
pair of units called mixed bed units are provided. Regeneration of a mixed bed resin is
difficult task. The two resins (cation and anion) must separate properly before regeneration
is attempted. The separation is done by the principle of gravity and density. The cation
exchanger resins are denser and heavier, so that at lower elevation than the lighter Anion
exchanger resin which float on top when agitated by a back flow of water. Thus washing of
bed is mainly to separate out the bed and grad the two separately.
The two beds of cation and anion resins are regenerated separately on the general principle
of regeneration of ordinary strong cation and strong Anion resins. When regenerated, the
separate beds are mixed together properly and rinsed to the mixed bed unit into service
again.
A mixed bed unit is only a polisher unit. Since the ionic load on this unit is very little,
regeneration is done after long time.

Page 1 of 8
D M PLANT
Treated
Water From
WPT 12-FI-21
ACTIVATE DEGASSER
D CARBON STRONGL TOWERS WEAKLY
12- Y BASIC
FILTERS B-1
LIC03
A TO E ACIDIC ANIONS
FILTERE CATIONS DEGASSED A TO D
D A TO D WATER
Group Alarm
WATER STORAGE Group
Page 2/8 Group
TANKS TANKS 12-LIC01/ Alarm
Alarm
Page 3/8 2 Page 4/8
P-1 P-2
ACID FOR
12-CIA-32
REGENERATION
Group Alarm Page
7/8 12-SIA-03
STRONGL
RCST DM WATER MIXED YBASIC
STORAG STORAGE BEDS ANION
12-TI- E TANK TANK A TO D A TO D
2Nos. 3 Nos. 12-AI-01
03 12-SIA-01
12-SIA-02 Group Group Group
RCST FROM Alarm Alarm
UREA
Alarm
Page 6/8 12-CIA- Page 5/8 Page 4/8
12-CIA-29 12-FI-22 34
DM WATER TO
AMMONIA
P-7 CAUSTIC FOR
P-8 DM WATER TO UREA
ANION
DM WATER REGENERATION
RCST TO POWER TOPOWER
Line colour code Group
Alarm
Page 8/8

3) COOLING TOWERS
Most industrial processes need cooling medium for efficient and proper operation water is
the most effective cooling medium used over the world. These systems using water as
coolant are called as Cooling Water Systems. They control temperatures and pressures by
transferring heat from hot process fluids into the cooling water, which carries the
unwanted heat away. As this happens, the cooling water heats up and must be either cooled
before it can be used again or replaced with fresh make up water
I TYPES OF COOLING WATER SYSTEMS:

There are three basic cooling water systems. The choice of the right cooling water system
depends on various factors such as type of process fluid being cooled, nature of the process,
availability and cost of water, characteristics of water and environmental considerations.
(a) Open recalculating system
This is the most widely used industrial cooling design. It consists of Cooling towers,
pumps and heat exchanger. The pump keep the water re-circulating through heat
exchanger where it picks up heat on to the cooling tower where heat is released by
the evaporation of water. Thus the heated water gets cooled in the tower with
natural or mechanical draft provided in tower. Because of evaporation, the water in
open re-circulating system undergoes change in its basic chemistry or in a simpler
term, it gets concentrated.
(b) Closed re-circulation system
These systems use the safe cooling water repeatedly in a continuous cycle. First the
water absorbs heat from process fluids, then releases it in another heat exchanger. In
these systems an evaporative cooling tower is not included.
(c) Once through systems -
In these systems, the cooling water passes through heat exchanger equipment only
once. The mineral content of the cooling water remains practically unchanged, as it
passes through the system. These types of designs are possible only when water is
available in abundance at much lower cost. Lakes, rivers, or seawater are the main
sources of water in this case.

KRIBHCO has adopted open recirculation type of cooling system in Hazira plant. The
cooling water requirement of the is around 80000 M3/hr. The plant has 5 cooling towers, 2
for urea, 2 for ammonia and 1 for power plant.
The ammonia cooling tower is having 7 cells, designed, erected & commissioned by M/S
Paharpur Marley. Each cell is provided with an induced draft fan of 8 blades, 8.535 m in
sweep and made up of FRP. The tower is capable to cool water from 450C to 350C, when the
wet bulb temperature is 300C i.e. range of 100C and approach of 50C.
The urea plant has it‖s own cooling tower with 5 cell each. The construction of the cooling
tower is same as that of the ammonia plant.
The power plant cooling tower is having is having 4 cell. Each cell is capable to cool around
2000M3/hr of water from 450C to 350C.
MATHEMATICS OF COOLING TOWER
The hot water coming from the units is conveyed to the cooling towers and is cooled by
evaporation to the atmosphere of part of the same water. The cold water collected in a
basin under the towers is then pumped to the cooling system.
Part of the circulating water is lost for: Evaporation Entertainment by air flow (mist)
Action of wind (blow off through tower side walls above basin). Owing to these losses,
the salt contents in the circulating water increase and then it is necessary to purge
continuously the system, sending to blow-down part of the circulating water. Then it is
necessary to supply continuous make up water to the system to compensate the circuit
losses. The system has been designed so that content of salts in the circulating water
RxT
E
555
doesn‖t exceed three times the contents of salts in the make up water.
Where
R= Circulation rate of cooling water (M3/hr)
E= Evaporation loss of water (M3/hr)

T = (Temperature of the return water to the cooling tower) - (Temperature of the
water in sump of the cooling tower) ( º C)
Concentration number” or cycle number “C “ Among cycle number, blow-down,

loses, etc. these are the following relations:
E
BD M  E W  B
C 1
TDS in circulating water Hardness in circulating water
C C
TDS in make up water Hardness in make up waterr
Where
D= Rate of loss of water due to windbag, leakage, etc. (M3/hr)
M= Rate of make up water (M3/hr)
B= Rate of blow down (M3/hr)
C= Cycles of concentration.
W= Wind losses (m3/h)

MCm  ECe  WCw  BCb
Where:
Cm = salt concentration in make-up water (g/m3)
Ce = Salt concentration in evaporated water (g/m3)
Cw = Salt concentration in water list for wind action (g/m3)
Cb = Salt concentration in blow-down water (g/m3)
But
Ce = 0 and ECe = 0 because the content of salts in evaporated water is practically

zero.
Cw = Cb because the water lost for wind in the tower and the water sent to blow-
down are coming from the same cooling water circuit.
MCm  Cb W  B
CW M

Cm W  B
Then the relations can be written as follows:
E M
C 1 C
W B BD
It follows:
This relation can be utilized for calculation of the correct blow-down flow rate, required to
maintain the necessary “cycle number”.

Corrosion inhibitor, Dispersant, Bio dispersant and sulphuric acid are dosed to maintain Zn,
PO4 (Ortho), PO4 (Organo) and pH respectively to control corrosion, Scaling and Fouling.
The micro-organism is controlled by dosing oxidizing biocide “Chlorine” every day.
However, occasional spot dose of non oxidizing Biocides destroy a few species, which may
get immune to chlorine. Na Chlorine and Na Bromide base Chlorine Activators are dosed to
activate biocidal efficiency (penetrating power) of Chlorine.
4) AMMONIA STORAGE TANK
The ammonia storage tank comprises of following :
1) 2 storage tanks
2) 1 common refrigeration unit
3) 2 ammonia vapour blowers
4) 3 ammonia transfer pumps
5) 2 ammonia heaters
6) 2 ammonia vapourisers
7) 1 common flare systems
The atmospheric storage tank system comprises of 2 storage tanks, each of capacity of
10000 MT of liq. Ammonia. The heat penetrating the system inspite of the insulation,
provided on the tank and pipe line carrying liq ammonia would lead to rising pressure
in the storage tanks due to evaporation of ammonia. To avoid any risk from over
pressure in the tanks the vapour ammonia is withdrawn from the tank and fed to the
refrigeration system. The vapour ammonia is converted into liquid form and returned to
the tanks.
1 vaporizer has been provided in each tank to keep the pressure in the tank within the
limit particularly in the colder days. Liq. Ammonia will be taken from the base of the

storage tank which flows by gravity to the vaporizer and the liquid is vaporized by
electric heating arrangement thus maintaining the pressure in the tanks.
Ammonia storage tank is a vertical cylindrical type with a domed roof and designed as a
double integrity or cup- in-tank. The liq. Ammonia is held up into the inner cup. The
inner cup is covered at the top by a suspending deck extending upto the outer shell. The
deck hangs upto about 250 mm above the inner cup. One central hole is provided on
the deck which allows ammonia vapors to escape and fill up the annular tank portion
and top portion of tank. These vapor serve as an inner insulation from heat penetrating
to the liq ammonia . the cylindrical portion of the tank is insulated on the outside with
expanded polystyrene slabs and cladded on the outside with 22 G aluminium sheets by
means of SS hoop bands. The suspended deck are insulated on the top with the mineral
wool of 250 mm thickness.
Tank is erected over a raised foundation such that there is a gap of about 600 mm
between the bottom of the tank and the ground. This provides free air passage which
prevents formation of frost or ice on the bottom side.

5) AIR DRYING PLANT
Instrument Air is used in plants to operate pneumatic instruments. Moisture, present in the
form of droplets as well as water vapour in compressed air, is the greatest enemy of
pneumatic systems. When atmospheric air is compressed, it gets adiabatically heated to
around 1500C to 160°C. For most industrial applications, compressed air is required at
nearly ambient temperature and hence has to be cooled in an after cooler. During cooling,
moisture condenses in the after cooler and most of the water droplets are separated in the
moisture separator. Even if all droplets are removed in the moisture separator and filter, Air
at the exit of the moisture separator and filter, moisture Is still moisture separator is
saturated at the existing conditions of temperature and pressure. This water vapour will
condense when the air is further cooled in the piping. Condensation also results when the
compressed air is expanded in instruments, tools and machines and other points of utility.
Two Air Drying plants are supplied each with a capacity of 3000 NM3/ hr. of compressed
air at a pressure of 8.0 kg/ cm2g. One plant will be generally in operation and other plant as
stand by.
These air drying plants are Blower Closed Circuit type LLOYD STEEL Model BCC A -30000,
which can be operated in Blower open circuit also if necessary, designed to dry air,
saturated at 8.0 kg/cm2 g and 40°C to the dew point of -40°C measured at atmospheric
pressure
The mode of operation is fully automatic and can be operated manually also.
All compressed air dryers are also provided with a pre-filter and after filter. The pre-filter is
located at the inlet of the dryer and removes water and oil droplets and dust down to 5
microns particle size with an efficiency of 99.7 to 99.9 %. For pressures up to 17.6 Kg/cm2 g
it is provided with an automatic drain trap to discharge water and oil droplets. For higher
pressures, a manual drain arrangement is provided.
The After filter is located downstream of the dryer and removes any desiccant dust carried
over by the dry air.

Drying of gases or liquids involves removal of moisture using desiccants. The most widely
used desiccants are Silica Gel, molecular sieves and Activated Alumina. These drying agents
are most suitable for industrial absorption processes and they are highly active regenerable
absorbents, which can be reused for a very large number of cycles before replacement. Each
granule of desiccant may be considered as a vast honeycomb of pores too small to be seen
even with an optical microscope. These pores give the desiccant a very high internal surface
area that attracts and adsorbs moisture. The capacity for adsorbing moisture varies from
desiccant to desiccant and depends on various parameters like inlet temperature, pressure,
humidity etc.
After the desiccant is completely saturated, the moisture is driven away from its pores by
reactivation. This process is called adsorption. In most cases, an external source of heat is
employed to reactivate the saturated desiccant after which the desiccant bed is allowed to
cool down to keep it ready for adsorption once again.
The condensed moisture in droplet form is separated from air by triple effect of
impingement, flow direction, change, & flow area change. The separated moisture
periodically removed by auto drain trap provided at
Bottom
6) INERT GAS PLANT
The process used for producing nitrogen is the liquefaction and distillation of air.
Depending upon its constituents, a mixture of gases can be separated by one or a
combination of the following methods.
(a) Adsorption by a liquid
(b) Adsorption by a solid
(c) Chemical reaction
(d) Liquefaction and distillation
(e) Precipitation by freezing
Carbon-di-oxide is removed from the air stream in this plant by adsorption by a

solid material (molecular sieve). Moisture is removed by the condensation and
adsorption by the molecular sieve material.

The separation of nitrogen and oxygen is carried out by liquefaction and distillation.
The atmospheric air is compressed to a pressure of approximately 9 kg/cm2g in a two stage

screw compressor each having a discharge capacity of 2306 kg/hr of dry air (1750 NM3/hr.
approximately) at a temperature of about 40C.
The compressed air supplied to the plant passes through the pre-cooler (E-114) where it is
cooled to a temperature of 5C approximately by heat exchange with chilled ethylene
glycol. The freon refrigeration system is used to cool the Ethylene Glycol to a temperature of
about 1C in refrigerator package. Then the air passes through a condensate separator to
separate the condensed moisture. The air is then passed through a molecular sieve
Adsorber, and as its passed downwards, through a bed of molecular sieve passage through
the sieve the remaining water vapour, carbon dioxide and hydrocarbons are adsorbed on to
the sieve and thus removed from the air stream. The outlet air from the adsorbers enters the
cold box for separation of nitrogen and waste gas stream.
The two numbers of molecular sieve adsorbers are provided to enable continuous operation
for one adsorber in service and other adsorber under regeneration cycle.
After an adsorption period of 8 hours cycle the inlet air is changed over to other adsorber
vessel for on-line service. The adsorber is reactivated by passing a hot waste gas (from the
plant) stream upwards through the vessel and venting to atmosphere. During this heating
cycle, the molecular sieve bed is progressively heated, releasing the adsorbed material
which is thus swept away into the atmosphere. The bed is then slowly cooled to a operating
temperature of about 10C by the waste gas stream. Thus the adsorber vessel is ready for
the next operating cycle.
The outlet air from the adsorber with a Dew point of -40C and with a 10 ppm (maximum)
of CO2 enters the main exchanger (E101/2) for cooling to a temperature of about -160C
against outgoing cold gaseous Nitrogen and waste gases, which is at a temperature of about
-170C.
Thus the product gaseous nitrogen and waste gases are warmed upto a temperature of
about 5C at outlet of main exchanger.
Air Separation:

The high pressure cold air with a small amount of liquid air enters into the distillation
column (C 101) where by means of fractional distillation the air is separated into three
fractions, a gaseous product Nitrogen, a liquid product nitrogen and a liquid
oxygen/nitrogen mixture (waste liquid containing approximately 35% oxygen).
Product Nitrogen System:
The refined gas at the top of column is divided into two parts. The first forms the gaseous
product while a second is condensed in the Re-boiler condenser (E105) to form the liquid
Nitrogen (Product) and a liquid N2 reflux for the column.
Gaseous Nitrogen:
The product Nitrogen is taken from the top of the Nitrogen column and passes into the
main exchanger where it is warmed to around 10C by incoming air which is
correspondingly cooled. It then passes into the product main line through the control valve.
PV-577 and emergency block valve NV-871.
Liquid Nitrogen:
Liquid Nitrogen is withdrawn from the Nitrogen column through valve LV-024/1 and
delivered into the liquid N2 storage tanks (T101 A/T 101 B).
7) PRODUCT HANDLING PLANT
Urea product handling plant is put up to receive the prilled urea from both the prilling
towers of Urea plants I & II and dispatch the same in 50 kgs. Bags. The product Urea silos 2
Nos. each of 45,000 MT can store the urea during off season. A bagging unit is provided to
bag the 6400 MT of urea in two shifts as well as to load and dispatch it in Rail/Road
transport. Prilled urea from the bottom of the prilling towers is taken either any one of the
storage silos for storing or direct to the bagging plant, for bagging purpose. The stored urea
in the silos is reclaimed with the help of urea scrapers. Screened and the lumps are broken
with the help of lump breakers. Later-on it is taken to the Bagging plant, filled in 50 kgs
bags with the help of automatic weighing cum tipping machine, stitched and taken to the
respective platforms with the help of series of conveyors and clutches. It will be loaded in
the trucks and wagons for dispatch.

Bagging & PHP General Description
Hazira Fertilizer Project of Krishak Bharati Cooperative Limited (KRIBHCO) promoted by

IFFCO is another new cooperative Fertilizer complex located on the way to Hazira from
Surat in the State of Gujarat.
This complex is put up to produce 2.00 million tonnes of Urea per annum. Natural Gas
from Basein Gas field will be used as feed stock for the plant. This complex is comprising 2
x 1700 MTPD Ammonia and 1600 x 4 MTPD Urea plants supported by required utilities
and off-site facilities.
Urea Product handling plant is put up to receive the prilled urea (6400 MTPD) from both
the prilling towers of urea plants I & II and dispatch the same in 50 kgs. Bags. The product
urea silos, 2 nos. each of 45,000 MT (total 15 days production) can store the urea during
off season. A bagging unit is provided to bag 6400 MT in two shifts as well as to load and
dispatch it by Rail/Road transport, prilled urea from the bottom of the prilling towers is
taken either to any one of the storage silos for storing or direct to the bagging plant. The
stored urea in the silos is reclaimed with the help of scraper reclaimers, screened & the
lumps are broken with the help of lump breakers. Later-on, it is taken to the bagging plant,
filled in 50 kg. Bags with the help of automatic weighing cum tipping machine, stitched
and taken to the respective platforms with the help of series of conveyors and clutches. It
will be loaded in the trucks and wagons for dispatch.
Photo cells are installed to count the number of bags loaded in the carriers. Day to day
production, silo stock, dispatches are registered in the recently developed Data Logger
System, installed in the Control Room.
Urea wet dedusting system is provided to collect the dusts coming out of the clutches and
bunkers, which will be dissolved and concentrated in the Dissolving & Concentrating plant
& then sent to urea plant for recovery. Process and instrument air requirement for bagging
is met from the compressor house of offsite plant.
Basic Of Design
8) Product handled : Fertiliser grade, Urea.
9) Urea Plant production capacity : 4 x 1600 = 6400 MTPD.

10) Temperature of Urea falling : 70°C.
In the Conveyor
11) Capacity of urea storing : 220 MTPH.

Conveyor (2A, 2B)
12) Storage capacity of Silo : 2 silos, 45000 MT each

(15 days production)Total 90000 MT.
13) Capacity of Urea reclaiming : 2 Scrapers – One in each silo, 400 MTPH
System(Normal).
14) Capacity of Urea bagging : 1200 Bags/hr/machine (max.)

Machines 4800 MT/shift/machine (max.) with
12 streams working.
15) Capacity of main Bunker : 150 MT (No. of Bunker – 1).
16) Capacity of individual Bunkers : 70 MT (No. of Bunkers – 8 on each phase).
17) No. of bagging streams : 16 Nos. (12 working + 4 stand by).
18) Capacity of empty bag storage : 32 lacs Jute Bags (One month -
Requirement).
19) Capacity of empty bag day : 2 storages – one in each phase 4 lacs Jute
Storage Bags each (One week stock).
20) Filled bag storage capacity : 25000 MT.

Process Design of H.E.
SECONDARY REFORMER BOILER FEED WATER
EFFLUENT
WORKING DESIGN DESIGN WORKING
UNIT IN OUT IN OUT IN OUT IN OUT

FLUID kg/hr 132000 132 323433 3234 348 348 404 404
QUANTITY, 000 33 920 920 000 000
TOTAL
kg/hr 132000 132 323433 3234 0 436 0 306
a)Vapour 000 33 15 74
b) liquid 0 0 0 0 348 305 404 373
kg/hr 920 305 000 325
TEMPERATURE C 401 331 435 350 313. 313.
8 8
DENSITY kg/m 10.2183 11.2 9.38 10.47 317 317
157
VISCOSITY cP 0.0373 0.03 0.0294 0.026
15 5
MOLECULAR g/mol 16.8432 16.8272
WEIGHT
SPECIFIC HEAT kJ/kg-K 4.3458 4.17 2.04276 2.017
39 6 686
LATENT HEAT kJ/kg 123 123 128
8.5 8.5 3.5
PRESSURE Atm 33.61 33.0 33.61 33.06
6
VELOCITY m/sec 2.6367 2.40
22
HEAT W 109334 154658
EXCHANGED 86.67 83.89

CALCULATIONS:
1. DENSITY:
1)We have the composition for the process gas composition
2) Also, we calculate the densities of each component at the given pressure and temperature
conditions using ideal gas law. (ρ= P*M/R*T)
3) Average density of the mixture can be found out as follows:

ρ = ρ *x + ρ *x + ρ *x . . . . . . . .
Component Composition T1 density T2 density
H2 33.97 1.214503616 1.3330453

N2 20.31 17.00305062 18.6626342
CH4 1.18 9.716028927 10.6643624
AR 0.24 24.29007232 26.660906
CO 7.67 17.00305062 18.6626342
CO2 5.52 26.71907955 29.3269966
H2O 31.11 10.93053254 11.9974077
Mixture 100 10.21834762 11.21570993
2. MOLECULAR WEIGHT
We have the Composition and molecular weight of each component.
Hence, average molecular weight is calculated as:
M = M *x + M *x +M *x ..........
Component Composition Molecular Weight
H2 33.97 2.016
N2 20.31 28.013
CH4 1.18 16.043
AR 0.24 39.948
CO 7.67 28.01
CO2 5.52 44.01
H2O 31.11 18.02
Mixture 100 16.8431991

3. SPECIFIC HEAT CAPACITY
1) We find the Specific Heat of every component at given temperature by using the
following formula:
Cp(A) = a1 + a2T + a3T + a4T
2) Average specific heat becomes:
Cp = Cp(A)*x + Cp(B)*x + Cp(C)*x . . . . . . . . .
Compone a1 a2 a3 a3 Cp at Cp at Compositio
nt 674.1 604.1 n
5K 5K
H2 3.29812 0.0008249 – 0.09475434 3.513 3.520 33.97

4 44 0.00000081430 E–09 2 5
15
N2 3.30 0.0014082 – 0.05641515 4.176 3.948 20.31
4 0.00000396322 E–07 6 3
2
CH4 1.70 0.009081 -0.00002164 6.840 6.398 1.18
5 4
CO 3.26 0.0015119 – 0.05581944 4.225 3.987 7.67
41 0.00000388175 E–07 3 5
5
CO2 2.28 0.0099220 – 0.06866686 6.342 5.989 5.52
72 0.00001040911 E–07 1 3
3
H2O 3.39 0.0034749 – 0.06968581 4.979 4.706 31.11
82 0.00000635469 E–07 7 6
6
Mixture 4.345 4.173 99.76

8 9
4. HEAT EXCHANGED
1) We are given the mass flow rate and the inlet and outlet temperatures.
2) Calculated the specific heat of the mixture.
3) Heat exchanged =
Q = m*Cp*(Tin – Tout )
Q = 132000*(4.3458)*(401-331)
heat exchanged = 10933486.67 W


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REPORT

KRISHAK BHARATI CO-OPERATIVE LTD.

(Training Duration: 19-06-2017 TO 03-07-2017)

1. RAHUL PANSHALA (B.E. CHEM, SCET)

CHEMICAL ENGINEERING DEPARTMENT

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY, SURAT.

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 1

This is to certify that Rahul Panshala (B.E. CHEM)

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 2

SR NO. SUBJECT PAGE NO

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 3

We would extent my heartily regards to Mr. P. V. Kachhadiya (Marketing

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 4

In an endeavor to make constant improvements, KRIBHCO implemented various schemes to

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 5

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 6

Catalysts used in the process may include :

Desulphurizer unit is designed for NG feed containing 50 ppmv of sulphur and is

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 7

12 m3 of CoMoX catalyst has been provided to convert organic sulphur to inorganic

a) Reactions involving in CoMoX catalyst bed:

All forms of sulphur compounds in feed NG after getting converted to reactive

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 8

CnHm + nH2O  nCO + ( n + m/2)H2 [ endothermic ]

Temperature: As the reforming temperature increases the conversion of natural gas

The Primary Reformer consists of 504 tubes suspended in 12 rows of 42 parallel

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 9

As the reforming reaction is endothermic heat is supplied externally to the tubes.

Pressure: 33.1 Kg/cm2 Temperature: 824ºC

The reformer furnace is designed to attain maximum thermal efficiency by

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 10

CO + H2O  CO2. + H2 , Heat = “+” (exothermic)

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 11

There are 3 types of aMDEA solution is used:

 Lean aMDEA- contains no impurity (i.e. CO2)

 Semi lean aMDEA- contains some amount of absorbed CO2

 Rich aMDEA – contains large amount of absorbed CO2

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 12

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 13

The objective of the methanation reaction is to remove completely the oxides of

8) DRYING OF SYNTHESIS GAS

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 14

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 15

10) SYNTHESIS GAS CONVERSION

11) AMMONIA SYNTHESIS

Ammonia is produced in a fixed 3 catalyst bed, vertical converter 105-D. The

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 16

3H2 + N2  2NH3 + heat (exothermic)

12) REFRIGERATION SYSTEM

The primary purpose of the refrigeration is to condense ammonia for separating it

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 17

Urea is commercially produced in following forms

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 19

Urea is colourless, odourless chemical substance. It is generally produced in the form of

a) Urea synthesis and high pressure recovery

b) Urea purification and low pressure recovery

e) Waste water treatment

1) UREA SYNTHESIS AND HIGH PRESSURE RECOVERY

2 NH3+ CO2  NH2COONH4

NH2COONH4  NH2CONH2 + H2O

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 20

SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY Page 21

2) UREA PURIFICATION AND LOW PRESSURE RECOVERY

Urea purification takes place in two stages of decreasing pressures as follows :