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Fatima Fertilizer Company Limited Internship Report
Fatima Fertilizer Company Limited Internship Report
USMAN ASGHAR
By
And
And we
we send
send down
down from
from the
the sky
sky rain
rain charted
charted with
with blessing,and
blessing,and we
we produce
produce therewith
therewith gardens
gardens and
and grain
grain from
from harvests.
harvests.
(THE
(THE GLORIOUS
GLORIOUS QURAN,
QURAN, SURAH
SURAH QAF,
QAF, 50:9)
50:9)
((
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Objective
The main objective of this internship was to learn about the working of a Chemical Process
Plant and get something about the processes involved, technology, materials, design &
construction, operation & maintenance of the plant. As we know that fertilizer industry is the
back-bone of our agriculture of the country & it is well developed segment of our manufacturing
sector.
Secondly, AMMONIA/UREA manufacturing is a delicate process involves high
pressure/temperatures & it is also corrosive in nature. This is something that I wanted to learn
about; it couldnt be better than the plant-site of Fatima Fertilizer Company Limited. It was also
ideal choice, as this group has the only NP,CAN plant in Pakistan.
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Mission
Pursue as a team, the progressive strategy based on the principle of maintaining the spirit
of excellence to remain among the best companies of delivering competitively priced
quality products, achieving sustainable growth rate in all activities and generating optimum
profits to the satisfaction of all stakeholders.
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Process Units:
One Nitric Acid unit designed to produce 2500MTPD on 60% basis & 1500MTPD on 100%
basis.
Power generation unit with 2 gas turbines of 26.0 MW each & 2 Emergency Diesel
Generators.
Buildings Include :
Electrical Sub-Stations
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Material Warehouse
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Laboratory
Office Cum Emergency Accomodation. (OCEA)
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Process Technologies
Ammonia Plant
Sojitz Corporation, Japan has provided performance guarantee for the Plant. Based on Kellogg
process, steam reforming of the natural gas, the Plant has a designed production capacity of
1,500 MTPD.
The machines and equipment of the Ammonia Plant have been revamped by General Electric
(GE). Natural gas is reformed to produce Ammonia for the entire Complex and carbon dioxide for
the Urea Plant.
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Urea plant
Urea Plant is based on Stamicarbon's latest Technology System 2000 plus with
patented Safurex material using total recycle, carbon dioxide stripping with pool reactor process
(Approximately 66% of new Urea plants in the world are based on Stamicarbon technology).
Urea Plant at Fatima Fertilizer Company Limited has a designed capacity of 1,500 MTPD.
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CAN is hygroscopic by nature and absorbs moisture from the atmosphere therefore it can be used
in the soil without sufficient water. It contains 13% Nitrate Nitrogen which supplies nutrients
immediately to the plants and 13% Ammonium Nitrogen gives food slowly till ripe up of the crop.
Raw Material: NH3, CaCO3 , Ammonium Nitrate, HNO3.
phosphorus
(20%)
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Nitro-Phosphate Plant:
Nitro Phosphate (NP) plant is based on modern European technology.
The Plant has been designed to use low grade rock phosphate without compromising on product
quality in order to maximize profitability.
Once commissioned, the Plant will be capable of producing 1,200 MTPD of NP.
NP is a PRILLED fertilizer in which each prill has evenly distributed amounts of nitrogen (22%).
Raw Material : Rock Phosphate, HNO3 .
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It is Designed to produce 500,000MTPA with the raw material of Ammonia & Air.
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Diagrams :
Following are the types of Diagrams normally used.
PFD:
Process Flow Diagrams(PFD), it only keeps into accounts the flow of process as it proceed
without keeping into consideration the each and individual component that comes across the
flow.
P&ID
It is read as piping and instrumentation diagram. It is most effective and detailed diagram for the
understanding purpose of the process and instrumentation of the process. It gives the detail of
piping. This diagram will show which instruments are used during the flow but it does not
determines the exact and ACTUAL position of the instrument in terms of coordinates.
Isometrics
It gives the Exact dimentioning of the whole piping & instrumentation system in 3D coordinates
that helps in erection of the plant.
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Outputs :
1. Ammonia
2. Carbon dioxide
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Heat Exchanger
Heat exchangers are used to create the temperature drop or rise in fluids. There are
various types of heat exchangers such as:
1. Shell & tube
2. Plate type
3. U-type
4. Kettle type
5. Straight
After a period of use the fouling factors arise in the exchangers that is the rusting and a
layer of foreign items get settled at the bottom decreasing the flow rate. The fouling can
arise due to the following factors.
1. Sedimentation
2. Corrosion
3. Algae growing
4. Salt deposit
5. Coking
6. Chemical reaction
The techniques which are used during operation fouling encountered in heat
exchangers are as under:
1. Mechanical cleaning
2. Chemical cleaning
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Inspection
In case of leakage of the tubes inside the heat exchangers, we take following actions:
1. Soap film test
2. Hydro-Blasting
3. Visual inspection
Valves
Valves are used to control the flow & direction of fluid & the amount of flow. There are various
types of valves such as
Check valves
Check valves are used to control the direction of flow. They allow the flow to occur in one
direction only. Following are few steps of check valves
Stop valves
These are used to stop and open the flow of fluid through a pipe. Following are few types of
stop valves:
1. Gate valve
2. Plug valve
3. Throttling valve (commonly used in BUTTERFLY VALVE)
Maintenance of Valves
Valves maintenance must be carried out time to time. The problems may be of the following
types.
1. Fouling should be removed
2. Valves seats are to be changed from time to time
16 FATIMA FERTILIZER COMPANY LIMITED
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Gaskets
All flanged joints have a sealing called gasket between the flanges. The servise determines the
gaskets material specification. Gasket provides tight sealing and prevents any leakage. It
damages with the passage of time and are replaced with new one. Gaskets are generally made
of asbestos and other material . there are various types of gaskets which are used in the plant
and some of them are as under:
Teflon Tape
T o prevent further leakages in smaller pipes, Teflon tape is used for sealing.
Steam Traps
They are used to remove the condensate from the steam pipes. Types of steam traps being
used are:
1. Float type
2. Bucket type
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Plant Machinery
This section includes all the moving parts & machines
1. Turbines
2. Compressors
3. Pumps
4. Fans
5. Blowers
6. Moving Electronics
Turbines
Turbines are used to convert the velocity of air into mechanical work. Following are the types
Impulsive turbine
This type of turbine has direct impact of steam & has satisfactory nozzles
Reaction turbine
It has larger expansion occurring in the buckets in other words have larger pressure drop.
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Governors:
Governors are used in turbines to regulate the amount of flow. Commonly used governors are
as listed below:
1. Fly ball governors
2. Board governors
3. Hydraulic governors
4. Oil relay governor
Rotors :
Rotors are the moving buckets that increases the pressure in turbines. Commonly used types of
rotors are :
1. Solid rotors
2. Buildup rotors
Pumps :
Pumps are used to increase the pressure of liquids.
Types
Various types of pumps commonly used are:
1. Positive displacement pumps
2. Centrifugal pumps
Impeller types:
Impellers of the pumpa are of three types:
1. Open impellers
2. Partially closed impellers
3. Closed impellers
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Components :
1. Shaft
2. Sleeve
3. Impeller
4. Inner ring
5. Volute casing
6. Gland packing
7. Impeller Blade
Packing
Packing is provided to avoid leakage
1. Carbon ring packing
2. Labyrinth seal packing
Sealing :
Packing can be mechanical, mentioned below:
1. Hard face
2. Soft face
3. Spring
4. O-ring
Lubrication :
Lubrication may be of following types
1. Self lubrication
2. Oil lubrication
3. Forced lubrication
Bearing :
They are commonly used to avoid thrust of 2 types
1. Radial thrust
2. Axial thrust
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Compressors :
Compressors are used to increase the pressure of gases.
There are six main compressors installed on Ammonia plant, mentioned below:
1. Feed Gas compressors (C-101) with Steam Turbine driver CT-101
2. Air compressor (C-102) with Steam turbine Driver CT-102
3. Ammonia Expander compressor (C-103) with dynamo driver
4. Synthesis gas compressor (C-104) with Steam turbine driver CT-104
5. Ammonia Refrigeration compressor (C-105) with S.T. driver CT-105
6. Ammonia refrigeration Booster Compressor (C-106) with S.T. driver CT-106
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Welding
Welding is used as a permanent fastening of materials. Following types of welding are
commonly used in industries.
1. Oxyacetylene welding
2. Gas Tungsten arc welding
3. Shielded metal arc welding
Piping
Piping standards used are:
Industrial practices for gaseous oxygen transmission & distribution piping system : CGA
G4.4
Fittings
Pipe fittings are used to connect pipes with each other or to the equipment with required space.
Types are mention below.
1. Flanges
3. Coupling
4. Union
5. Bushing
6. Cap
7. Plug
8. Elbows
9. Reducing Elbows
15. Lateral
I was told that in piping one must be more concerned about the IDs of the pipe than the ODs.
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End connectors :
They are used to connect pipe ends to connections. Various types are:
1. Welding Butt
2. Socket Weld
3.
Threading
4. Coupling
5. Bolt
Reducers
There are two types of reducers:
Pipe Racks:
They are steel made structures on which the piping system rests.
Refractory : ( Reforming )
They are insulation coatings depending upon application. Like fire brick and castable/ castings.
They are three types of fire bricks used there, heavy duty (3200F), used in furnace. The other
two are used in ducts and other equipments which are of 2400F & 2200F.
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Capacity:
The capacity of ammonia unit is 1500MTPD. Production of CO2 shall be 1415MTPD as 100%
CO2 (1150MTPD for Urea Plant and 300 MTPD for NP plant).
AMMONIA Product :
The product would be warm liquid to an adjacent urea plant, or cold liquid to storage, in any
combination. The guarantee case is 845 MTPD (100% NH3) warm product (to support the
1500MTPD urea plant) and balance of 655MTPD (100% NH3) cold product to Atmospheric
storage.
Ammonia content
min. 99.7wt%
Water content
Oil content
< 10mg/l
40 0C
-34 0C
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Desulphurization
Pre-reforming
Secondary Reforming
Shift Conversion
Steam system
Condensate treatment
This process I have conclude with PFDs & PnIDs. This process description is limited to
equipment within the Ammonia battery limit.
D-139B
MPC-5
K.O. Drum
LLPC-7
Feed gas
comp.
CT101
C101
condenser
Cold feed
pre heat
coil
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Desulphurization:
Sulphur is a poison to the reforming catalysts & the shift reactor catalysts. Any sulphur that
comes in contact with the reforming catalysts will reduce the catalyst activity. The low
temperature shift catalyst is permanently poisoned by small traces of sulphur. In the
desulphurizer Nickel/Molybdenum (Ni-Mo) catalyst bed is used through which after compression
mixed feed gas, sulphur & recycle rich hydrogen passed and then pass the same vessel where
bed of ZnO catalyst is used. The reaction takes place here:
H2S + ZnO
ZnS + H2O
PREREFORMING:
Desulfhurized feed gas is mixed with medium pressure (MP) stream preheated by exchanger
with the high temperature shift effluent and then further heated to 500 0C in the convection
section of the primary reformer. Mixture enters the pre-reformer where gas & stream react
adiabatically over a nickel based reforming catalyst to produce H2 & CO2. The stream to carbon
ratio is important to prevent carbon deposition on the catalyst, shift conversion of the CO &
prevent metal dusting.
Primary Reformer:
The outlet gas from the pre-reformer is re-heated in the convection section of the furnace and
sent to Primary reformer (INDUCED DRAFT). The feed/steam mixture is distributed to the
reformer catalyst tubes in the radiant section of the furnace and react reacts over the Nickelbased catalyst to form H2 and CO2.
During the early stages of reforming, heavier Hydro-Carbon are converted to CH4. The main
reforming reaction converts CH4 to H2 and CO.
CH4 + H2O
3H2 + CO
Heat for the endothermic reforming reaction is supplied by fuel gas burners. The firing pattern
can be shifted between lower & upper burners to obtain the most economic operation.
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Secondary reforming:
The partially reformed effluent from the reformers to the Secondary reformer via the transfer
line. The main reaction take places here are:
2O2 + H/C
O2 + 2H2
2H2O
(18% CH4)
SHIFT CONVERTION:
In the Shift Conversion step, CO reacts with steam to form equilent amount of H2 and CO2.
CO + H2O
CO2 + H2
The shift reaction is reversible and exothermic. The reaction rate is favored by high
temperatures whilst the equilibrium the equilibrium conversion is favored by low temperature.
Two stages of shift conversion, HTS & LTS, are provided; with intermediate cooling to moderate
the gas temperature and efficiency recover waste heat.
In the HTS reactor, the bulk of the shift conversion is carried out by copper or nickel promoted
iron oxide catalyst. About 70% of the shift conversion heat place in the HTS.
The effluent from the HTS is cooled to 2060C by heat exchanger with the pre-reformer feed in
the HTS effluent Reformer Feed Exchanger and then with the boiler feed water in the HTS
Effluent Boiler Feed Water Exchanger. The cooled effluent from the HTS first pass over the LTS
Guard Bed filled with Cu-Zi-Alumina, the same catalyst as the main LTS reactor. The guard bed
removes any traces of Sulphur. The process gas from the LTS convertor at 2280C preheats
boiler feed water in the low Temperature Shift Effluent Boiler Feed water Exchanger, the
process gas is cooled to 1230C in that & water condensed in the engaged separator. The
process gas enters the bottom of the Carbon dioxide Absorber for CO2 removal.
CO2 Removal:
The Carbon dioxide absorber is a two-stage split flow Catacarb system using a promoted
potassium carbonate solution that removes CO2 from the process gas in a two-stage absorption
process. The cat-a-carb solution also employs a minor rust inhibitor to decrease equipment
corrosion and fouling. Inlet conditions at the CO2 absorber are 1230C and about 29.5 kg/cm2.
Cat-a-carb process employs hot potassium carbonate solution to remove CO2 via the following
reversible reaction
K2CO3 + CO2 + H2O
2KHCO3
With a two-stage unit, the system has two absorption zones, the lower semi-lean or bulk section
and the top lean section. Process gas flows upwards in the bulk section through the bed
counter-current to the Cat-a-carb solution. Most of the CO2 is removed in this lower semi-lean
solution by means of a large circulation of partially regenerated semi-lean solution.
27 FATIMA FERTILIZER COMPANY LIMITED
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METHANATION:
Gas from the CO2absorber is first sent to Methanator Feed Knock Out Drum where any
entrained liquid are removed. The gas is then preheated to 3040C in the Methanator
Feed/Effluent exchanger ant the Methanator start-up exchanger, also provides extra duty when
the shift catalyst is new and the CO and the resulting methanator temp. Differential are lower
than designed.
The Methanator contains a bed of Nickel catalyst that promotes the reaction of CO2 & CO with
H2 to form CH4 & H2O.
CO2 + H2
CO + 3H2
CO + H2O
CH4 +H2O
The total amount of CO (a poison to the ammonia synthesis catalyst) leaving the methanator is
less than 5ppm by volume and the methane content about 3.0 mol% (dry Basis).due to the
highly increases from 3040C to 3340C at the outlet.
CONDENSATE TREATMENT:
Condensate is separated from process gas in the CO2absorber Feed Gas Separator and the
Methanator Condensate separator and also from CO2 gas in the regenerator overhead
Accumulator. The condensate consists mainly of water but also contains trace amounts of
dissolved ammonia, hydrogen, nitrogen, methane, argon, and CO and is treated in the
Condensate Treatment Unit.
Drying:
The chilled process gas is removed in the Methanator Condensate Seperator. The chilled
process gas goes to the Synthesis Gas dryers for removal of residual water, CO2 and NH3. The
water, CO2 are removed to avoid freezing in the passages of the Purifier Feed Effluent
Exchanger and to protect the ammonia synthesis catalyst from oxides. The drying agent has the
ability to almost completely remove any remaining carbon dioxides plus very small amount of
ammonia formed by side reaction in the reformer, HTS & brought in via the Syn-loop purge.
Each dryer is designed on-stream drying and a 12 hour regeneration period.
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Super heated
178-182
H.P. from
kg/cm2 syn:
gas out
F-101,LLPC
51.5-51
52kg/cm2
kg/cm2
1 stage after
st
cooler
L.P.
1st stage
CT104
M.P.
C.
20-21kg/cm2
3rd stage
2nd stage
120kg/cm2
From Cold box
H.P.C
119kg/cm2
2nd stage
Syn; gas
after cooler
Compres:
condenser.
Ext: 42kg
Induc: 3.8kg
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Ammonia synthesis:
Synthesis discharge from synthesis compressor with hydrogen to nitrogen molar ratio of 3:1 is
suitable for direct feed to the ammonia synthesis Convertor. The ammonia converter feed is preheated to 2280C by heat exchanger with convertor feed effluent convertor.
3H2 + N2
2NH3
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Conclusion
To say the least, I at FFCL got good idea about a process plant. I realized that working on a
field is not that simple as I used to think. It requires the dedication & hard work of people
involved in this business. It requires highly technical and management skill to sustain the level
of performance.
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