INTRODUCTION

• Indian Farmers Fertilizer Cooperative Limited (IFFCO)

is one of India's biggest cooperative society which is
wholly owned by Indian Cooperatives.

• Founded in 1967 with just 57 cooperatives.

• we are today an amalgamation of over 36,000 Indian

Cooperatives.
• Phulpur Unit came into existence on 16th January, 1974
with the laying of foundation stone by the then Prime
Minister of India Mrs. Indira Gandhi. Spread across 1068
acres.
• Phulpur Unit comprise of two state-of-art Ammonia & Urea
manufacturing complexes which got commissioned in the
years 1981 and 1997 respectively.
• Currently, Phulpur Unit supplies over 17 lakh MT of Neem
Coated Urea to the farmers in the eastern region of the
Country. Over the last 37 years,
• PLANT CAPACITY

UREA-I :
UREA-II2115
: 3030MTPD
MTPD == 88.13
126.25MT/Hr
MT/Hr

UREA-I : 2115 MTPD = 88.13 MT/Hr

UREA-II :
UREA-II :3030
3030 MTPD
MTPD ==126.25
126.25MT/Hr
MT/Hr
 Ammonia plant
• Ammonia plant is based on HALDOR TOPSOE
TECHNOLOGY.

• We get Nitrogen from Inert Gas (From

Atmosphere) plant and hydrogen from Natural
Gas.
• We get Nitrogen from Inert Gas (From
Atmosphere) plant and hydrogen from Natural
Gas.
 RAW MATERIAL FOR AMMONIA
• NATURAL GAS IS SUPPLIED AT THE BATTERY
LIMIT BY GAS AUTHORITY OF INDIA LIMITED
(GAIL).

• FROM GAS WELLS LOCATED IN BOMBAY

THROUGH HAZIRA-BIJAPUR-JAGDISHPUR
(HBJ) PIPELINE.
Component of RLNG
 STEPS FOR AMMONIA
MANUFACTURING
• DESULPHURIZATION
• HIGH PRESSURE CATALYTIC
REFORMING
• WATER GAS SHIFT REACTION
• CARBON DIOXIDE ABSORPTION AND
STRIPPING
• AMMONIA SYNTHESIS
• REFRIGERATION
 USES OF UREA
1. AGRICULTURE:
 Action of Urea in Soil
Urea + urease ⟶ ammonia + carbon dioxide

2.EXPLOSIVE :
 Urea nitrate

3.CHEMICAL INDUSTRY
 Reaction
• 2NH3 (Liq.) + CO2 (g) ⥨ NH2COONH4 +38.1kcal/mol

• NH2COONH4 ⥨ NH2CONH2 + H2O -7.1kcal/mol

 Effect of NH3/CO2 Ratio
EXCESS CO2 Excess NH3
 TECHNOLOGIES FOR UREA
MANUFACTURING
1.Once-Through Urea Process

2 .Partial Recycle Process

3 .Stripping Process Based Plants (Internal

carbamate recycle)
 Stripping Process
A . Snamprogetti Process (Italy)
[Currently using in IFFCO PHULPUR]

B . Stamicarbon CO2 Stripping Process

C . ACES ( Advanced Process for Cost and

Energy Saving ) process
 WHY SNAMPROGETTI
• High NH3:CO2 ratio in the reactor
• Conversion of carbamate to urea
• Highly efficient ammonia stripping
• Reduces the recycling of carbamate and the size
of equipment
• The use of excess ammonia to avoid corrosion
• As promote the Decomposition of unconverted
carbamate into urea
 SNAMPROGETTI STAMICARBON ACES PROCESS
PROCESS PROCESS

REACTOR
PRESSURE 151 140 175
(ATM)
REACTOR
TEMP.(°C) 188 183 190
MOLAR NH3/CO2
RATIO 3.2 2.95 4
MOLAR H20/CO2
RATIO 0.5-0.6 0.39 0.6
CO2 CONVERSION
IN REACTOR (%) 60 58 68
NH3 CONVERSION
IN REACTOR(%) 41 36 34
NO. OF HIGH
PRESSURE 4 4 5
VESSELS
RECIRCULATION
STAGES 2 1 2
Synthesis MP Vaccum Condensate
LP Prilling
and HP purification treatment
recovery concentration
recovery and recovery
 PROCESS DESCRIPTION
The Snamprogetti urea process is known worldwide.
The process is divided into six sections:
1. SYNTHESIS AND HIGH PRESSURE (HP) RECOVERY
2. MEDIUM PRESSURE (MP) PURIFICATION AND
RECOVERY
3. LOW PRESSURE (LP) PURIFICATION AND
RECOVERY
4. VACUUM CONCENTRATION
5. PROCESS CONDENSATE TREATMENT
6. FINISHING: PRILLING
 CO2 AT UREA PLAT BATTERY
LIMIT

• Carbon dioxide is received at urea plant

b/l at ~1.57ata and ~ 40’ c.

• AVERAGE WATER CONTENT IN CO2, ON WET BASIS, VARIES

FROM 3.6% TO 4%
AT 35 TO 40’C TEMPERATURE AND 1.57 ATA PRESSURE.
 NECESSITY OF CO2 COMPRESSOR IN
UREA PLANT
• CO2 is one of the reactants for urea formation and fed to
the
reactor where urea reaction takes place at ~156 Ata
pressure and
190’C temperature.

• CO2 is available at urea B/L at ~ 1.57ata pressure. So it is

necessary to compress CO2 just more than synthesis
pressure and
this is done with the help of centrifugal compressor.
 Make : BHEL, INDIA
Purpose : To drive CO2 compressor
Type : Extraction cum condensing.
Number of row of HP blades : 1 Impulse and 14
reaction
Number of row of LP blades :1 Impulse and 11
reaction
 UREA SYNTHESIS
Pressure: 160 Kg/cm2a

Temperature:175-185 oC

NH3/ CO2 Mole ratio: 3.6:1

33% Urea soln.
Conversion: 60%

Recycle
carbamate
CO2
NH3
C T
M P Urea Reactor
 UREA PURIFICATION NH3+ CO2
R-1

33% Urea soln. High pressure

146 Kg/cm2a
NH3+ CO2
44% Urea soln.
Medium pressure 18
Kg/cm2a NH3+ CO2

Low pressure 4.5

62% Urea soln.
Kg/cm2a

70% Urea soln.

 UREA PURIFICATION
70% Urea soln.
NH3+ CO2 + H2O

Vacuum Pre-concentrator
0.4 Kg/cm2a

Hydrolysis/
85 % Urea soln. Distillation
 UREA PURIFICATION
85% Urea soln.
NH3+ CO2 + H2O

First Vacuum Stage

0.3 Kg/cm2a

95 % Urea soln.
NH3+ CO2 + H2O

Second Vacuum Stage

0.03 Kg/cm2a Hydrolysis/
99.7 % liquid Urea Distillation
 Urea Concentration
urea solution coming from Reactor
~33% urea

HP Stripper
~44% urea

MP decomposer
~60% urea

LP Decomposer
~70% urea
 Urea Concentration
• urea solution coming from LP
decomposer
~70% urea

• Vacuum Pre concentrator

~85% urea

• First Vacuum Evaporation

~95% urea

• Second Vacuum Evaporation

~99.7% urea

• Prilling / Granulation
 PRILLING TOWER

Height : 104 M
Dia: 26 M Prill bucket

Urea melt

Air Air
Bagging
Scraper
 Prilling

Prilling
Bucket

Prilling Tower
The melt urea solution temperature is Bagging Plant
maintained above 1320C to avoid the
solidification of urea. Also the urea
melt temperature is maintained
below 1400C to keep the BIURET
under allowable limit of 1.5% in the
product urea.
 UREA PRILLS

Urea fertiliser supplied to the farmers in

the form of urea prills contains about
46% Nitrogen. This nitrogen helps to
improve the crop yield by increasing
fertility of the soil.
The BIURET in the product urea is
maintained less than 1.5%.

H H

N C N
H H
 Advantages
1. Saving of 10% of the losses of urea would amount to 2
million tons of urea or a reduction in subsidy component
to the tune of ` 1,700 crores per annum (considering
total subsidy on urea to be `18,000 crores per annum).
2 .Proportional saving in the consumption of naphtha or
natural gas.

3 .Increased crop yields due to better nitrogen utilization.

4 .Reduction in environmental pollution of ground water
due to leaching of nitrates and gaseous emissions.
5 .Opportunity for entrepreneurs to commercialize local
Neem Resources and Development of Small Scale
Industries in rural areas.
 AGENCY FOR QUALITY CONTROL

GOVERNMENT OF INDIA
 MINISTRY OF AGRICULTURE
 MINISTRY OF FERTILISER

THE FERTILISER CONTROL ORDER, 1985

&
ESSENTIAL COMMODITIES ACT, 1955
 PHULPUR UREA vs. FCO LIMIT

FCO PHULPUR
LIMIT UREA
Total N% (Minimum on 46 46.6
dry basis)
Moisture% (Maximum) 1.0 0.45
Biuret% (Maximum) 1.5 1.0
Size :+2.8 mm% (Max) 10 3.0
-1.0 mm% (Max) 20 1.0