REPORT ON

INTERNSHIP TRAINING
AT
NATIONAL FERTILIZERS LIMITED
PANIPAT

SUMBITED BY – YUVRAJ HENSH

CHANDIGARH UNIVERSITY
UNIVERSITY Roll No. – 20BCH1006
Bachelor of Technology (B.tech)
CHEMICAL ENGINNERING
 CERTIFICATE

This is to certify that the Internship project entitled Internship

Report at NATIONAL FERTILIZERS LIMITED (NFL) being
submitted by YUVRAJ HENSH, In fulfilment of the requirement
for the award of degree of Bachelor of Technology in
CHEMICAL Engineering from CHANDIGARH UNIVERSITY,
has been carried out under my supervision and guidance.

DATE:-

Signature of Authority
 ACKNOWLEDGEMENT

I have undergone training at NATIONAL FERTILIZERS LIMITED,

PANIPAT During this training, I have learnt a lot for which I pay my
heartiest gratitude to all the staff members of NFL Panipat who
helped me in all respects in fulfilling my cherished desired of getting
a successful industrial training in an esteemed organization.
I am very grateful to Mr.Viswa Ratan, Mr. J.K. Mandal and who
deputed me with senior engineers Mr. Rahul Garg who also provided
me sound knowledge of various equipment and process details.
I would like to thank Mr. Abhishek Kumar Sharma for their necessary
and timely guidance Further I am grateful to and Mar. I P Singh who
have not only inspired but given practical exposure of plant.
Last but not the least, I pay my sincere thanks to all the supervisors
and the other official at the site of NFL. Panipat for providing me
complete details of their respective plants and for guiding me time to
time

PREFACE
Chemical Engineering is an engineering field which deals with
the study of operation and design of chemical plants as well as
methods of improving production. Chemical engineers develop
economical commercial processes to convert raw material into
useful products. Working in an industry provides us a practical
approach to our theoretical basis of knowledge acquired in our
class room. It has been a great pleasure; training at NATIONAL
FERTILIZERS LIMITED, PANIPAT. This industry helped me to
boost up my practical skills correlating the theories of book into
actual work environment. The following implants training report
presents all my observation, analysis made during my training
from 27 June 2022 to 25 July 2022 period of 4 weeks. I have
tried to grasp the basics of various processes involved in the
plant. This report is the reflection of what I have assimilated
during the training period at NFL, PANIPAT. I have
also discussed about all the processes, their basic principles,
their working and about the safety aspects in the plant. I hope
that my experience at NFL will not only help me in future as a
chemical engineer but also in my current studies.

YUVRAJ HENSH
Chandigarh University
Address- NH-95, Ludhiana

INTRODUCTION
(1.1) ABOUT NFL PLANT
NFL has five gas based Ammonia-Urea plants viz. Nangal &
Bathinda plants in Punjab, Panipat plant in Haryana and two plants at
Vijaipur at District Guna, in Madhya Pradesh. The Panipat, Bathinda
& Nangal plants were revamped for feed stock conversion from Fuel
Oil to Natural Gas, an eco-friendly fuel. Vijaipur plants of the
company were also revamped for energy savings & capacity
enhancement. National Fertilizers Limited (NFL) is Government
Corporation that manufactures chemical fertilizers, organic fertilizers
and industrial chemicals. It is under the ownership (of Ministry of
Chemicals and Fertilizers, Government of India.
Panipat unit of NFL was commissioned on 1st
Sept 1979 based on gasification technology of Feed Stock on
LSHS /Fuel Oil with the annual installed capacity of 511500 MT of
Urea. Subsequently as per guidelines of GOI, in order to reduce
subsidy burden & Carbon footprint, NFL revamped the Panipat Unit
on LSTK basis for changeover of Feedstock from LSHS/FO to
Natural Gas and commercial production on Gas was commenced
during March 2013.

(1.2) SALIENT FEATURES OF PANIPAT UNIT

Installed Capacity: 511500 MTPA
Capital Investment: 338.27 Crores
Initial Commencement of Production: September 1, 1979
Commencement of Production on Gas after Revamp: March 28th,
2013
Production capacity of Ammonia plant: 900 MTPD
Production capacity of Urea plant: 1550 MTPD

(1.3) PRODUCTS
NFL is engaged in manufacturing and marketing of Neem Coated
Urea, three strains of Bio-Fertilizers (solid liquid) and other allied
Industrial products like Ammonia, Ammonium Nitrate, and sulphur
bentonite. The brand name of the company is popularly known in the
market as ‘KISAN’. The company has also started production of
certified seeds under its Seeds Multiplication. Program for sale under
its own brand name as Kisan Beej.

(1.4) Sub-plants under Panipat

Unit
 Ammonia plant
 Urea plant
 Steam Generation Plant
 GTG plant
 Bentonite sulphur Plant
 AMMONIA
PLANT

 PRODUCTION CAPACITY :- 900 MTPD

(2.1) ABOUT AMMONIA:-
Ammonia is one of the highly produced inorganic chemical in the
world Synthetic ammonia is produced from the reaction between
nitrogen and hydrogen. In pure form, it is known as anhydrous
ammonia. Ammonia is also produced in the human body and is
commonly found in nature. It is essential in the body as a building
block for making proteins and other complex molecules. In nature,
ammonia occurs in soil from bacterial processes. It is also produced
when plants, animals and animal wastes decay.
(2.2) PROPERTIES OF AMMONIA:-
Ammonia is a colorless highly irritating gas with a sharp suffocating
odor. It dissolves easily in water to form ammonium hydroxide
solution which can cause irritation and burns. Ammonia gas is easily
compressed and forms a clear, colorless liquid under pressure. It is
usually shipped as a compressed liquid in steel cylinders. Ammonia is
not highly flammable, but containers of ammonia may explode when
exposed to high heat.
There are two methods for manufacturing of ammonia:
 Haber method
 Modern method
HABER PROCESS
Haber discovered the high pressure synthesis of ammonia in 1913.
Haber process for manufacture of ammonia from nitrogen and
hydrogen this process also explain the conditions used in the process
such as temperature, pressure catalyst. This process combines
nitrogen from the air with hydrogen derived mainly from natural gas
in to ammonia. The reaction is reversible and production of ammonia
is exothermic. N2+3H2 2NH3
The mixture of nitrogen and hydrogen going in to reactor is in the
ratio of volumes of nitrogen to 3 volume of by hydrogen.

(2.3) USES OF AMMONIA:-

 About 80% of the ammonia produced in industry is used in
agriculture as fertilizer.

 Ammonia is also used as a refrigerant gas, to purify water

supplies, and in the manufacture of plastics, explosives, fabrics,
pesticides, dyes and other chemicals.

 It is found in many household and industrial-strength cleaning

solutions.

 Cleaning solutions for industrial use contain higher

concentrations of ammonia and can quickly cause irritation and
burns.

(2.4) SHORT PROCESS FLOW DIAGRAM OF AMMONIA

PLANT
 Desulphurizition CO2 Removal Ammonia AMMONIA
Reforming Section Shift Section Methanation
section Section Loop NH3

SOURCES OF RAW MATERIAL REQUIRED:

1. Natural gas from IOCL Panipat.
2. The Source of Hydrogen is steam and hydrocarbon in the natural
gas.
3. The source of Nitrogen is Atmospheric air.

 Before entering into desulphurisation section for hydrogenation,

gas is preheated because increase in temperature enhances rate
of hydrogenation. Various types of preheater are installed for
preheating the gas mixture.

(2.5) DESULPHURISATION SECTION:

The natural gas contains organic sulphur compounds and this sulphur
compounds will act as poison for catalyst and can deactivate catalyst
too.
So before entering into reforming section, sulphur content must be
removed from our feed mixture removal of sulphur takes place in this
desulphurization section where firstly, we pass feed through
HYDROGENATOR where organic sulphur compounds are converted
into inorganic sulphur compounds with the help of a catalyst
COBALT-MOLYBDENUM.
Then the second part of desulphurization section is SULPHUR
ABSORBERS which are located in series. [R202A & R202B]
In R202A & R2028. Sulphur gets absorbed from inorganic sulphur
compounds with the help of Zinc oxide (ZnO) catalyst. And the
normal operating temperature of this absorber is 395 degree Celsius.
The sulphur content in the natural gas leaving this section is 0.1 ppm
by wt.

(2.6) REFORMING SECTION:

Now gas is desulphurized, the next step is to convert this into
synthesis gas by catalytic reforming of gas mixture with steam and
air.
Here, higher hydrocarbons are converted into lower hydrocarbons,
finally resulting into methane (CH4) and then into carbon dioxide
(CO2), carbon monoxide (CO), and Water (H2O).
Two reformers are there;
 PRIMARY REFORMER
 SECONDARY REFORMER

 PRIMARY REFORMER:[H201]
Hydrocarbon mixture and steam is preheated at 520 degree celsius
first before entering into primary reformer to attain the minimum
activation energy that is required for the reaction to happen. Then
process gas passes downwards through vertical tubes containing
catalyst (RK-211.RK-201,R-67-71) After passing down through
primary reformer, the hydrocarbons in the feed are converted into
hydrogen and carbon oxides.
Primary reformer contains total number of 120 tubes installed in two
sections that contains furnace which gives amount of heat required for
the reaction to happen.
The outlet temperature of primary reformer is about 771 degree
Celsius.

 SECONDARY REFORMING:|R203]
Here the process gas is mixed with air and the combustion takes place
in upper and lower part of the secondary reformer resulting increase
in temperature. The temperature at the outlet of secondary reformer is
945 degree Celsius with methane concentration 0.60 mole%
As the temperature of the gases from the outlet of 1201 is very high,
so cooling takes place in the waste heat boiler no. 1. and steam
superheater that can be utilize later on. The catalyst that we use in
secondary reformers are as follows

Top layer: RKS-2 NiO

Main layer: RKS-2-711 Al2O3

CaO
Bottom layer: RKS-2
CH4 + O2 CO2 + 2H₂O
Operating Pressure: 30 kg/cm³G H2/N2 Ratio: 3.0
(2.7) SHIFT SECTION:
The carbon monoxide in the process gas leaving the reforming section
is converted into carbon dioxide and hydrogen according to shift
reaction:
CO+H2O CO₂+H2+ heat
Two converters are present where shift reaction takes place;
 HT CO- Converters
 LT-CO-Converters
In HT-CO CONVERTER, Cu-promoted iron/chromium based
catalyst is installed in the form of pellets.
Reduction is carried out in process gas containing hydrogen during
start-up of the reforming section.
HTS operates with 360 degree C inlet and the LTS with a 205 degree
C inlet each storages of shift utilizes a different catalyst with its own
distinct advantages.
In the HTS converter, a relatively low cost and more durable copper
promoted iron/chromium based catalyst produces the bulk of the shift
conversion to 3.15 mole% carbon monoxide. A more favourable
equilibrium concentration (lower CO) is attained with the low temp
shift (LTS) copper oxide, zinc and chromium oxide based catalyst.
The CO leakage obtained from this combination is 0.29 mole%
Low temperature (LT) CO shift conversion at about 180 to 250 °C
down to approx. 0.2 % CO on dry basis at the reactor outlet.

For every process a special catalyst will be used in a fixed bed reactor
to get maximum yield of H2 product. The use of HT CO shift
conversion is state of the art in almost every hydrogen plant.

The application of the low temperature CO shift conversion is

normally installed downstream of the HT shift at already reduced CO
content in the feed gas.

(2.8) Carbon Dioxide Removal:

The Carbon Dioxide Removal unit uses a two stage aMDEA
(Activated methyldiethanol). The process gas enters the bottom of the
CO2 Absorber at about 70°C. It is contacted counter-currently with
semi-lean aMDEA solution: The gas then flows upward into the top
section of where it is contacted with lean aMDEA solution. The
treated gas leaving the top of the absorber contains less than 500 ppm
(dry basis) of carbon dioxide and is sent to the methanation section.
Rich MDEA solution from the bottom of is first passed through a
power recovery.
Hydraulic Turbine: - The power recovered in the hydraulic turbine
is used to drive one of the Semi-Lean Solution Pumps. The rich
aMDEA solution is then sent to the High Pressure (HP) Flash where
most of the dissolved inerts are flashed from the rich solution.
As the flash gas from contains a fair amount of carbon dioxide, this
gas is further scrubbed with a slipstream of lean aMDEA solution in
the HP Flash Gas Scrubber, to recover almost all the carbon dioxide
Semu-Jean aMDEA solution is drawn from the bottom of the LP
Flash. Most of the semi-lean solution is pumped to the bottom section
of the CO Absorber. About 17% of the semi- lean solution is pumped
by the Semi-l.can Solution Circulating Pumps, heated to about 111°C
in the Lean/Semi-Lean Solution Exchanger, and then seat to the CO
Stripper. LTS effluent gas supplies heat to the CO: Stripper Reboiler
which is used to strip carbon dioxide from the aMDEA solution. The
stripped carbon dioxide flows up the stripper and is sent to the LP
Flash Lean aMDEA solution is drawn from the bottom and thus lean
solution is cooled by exchanging heat against semi-lean solution
AMDEA solution is then pumped by the Lean Solution. To maintain
the concentration of aMDEA solution in the system, a continuous
make-up of about 220 kg/hr of demineralized water is required.

The CO: leaving the top of the CO; stripper is at 96C The lean
solution from the bottom of the CO; stripper is cooled to 500C
through sol heat exchanger DMW preheater, the lean solution cooler
before being pumped from the top of the absorber by lean sol pumps
flash gas From HP flash drum is routed to primary reformer fuel
system.

(2.9) METHANATION:-
Methanation is the conversion of carbon monoxide and carbon
dioxide to methane through hydrogenation. The methanation reactions
of COₓ were first discovered by Sabatier and Senderens in 1902. COₓ
methanation has many practical applications. Methanation is the final
stage in the purification of synthesis gas and most modern ammonia
plants plus some older hydrogen plants use the simple and convenient
methanation reaction to remove traces of carbon oxides from the
process gas.
As oxides compounds are poisonous for the catalyst, its better to
convert carbon oxides into methane as methane act as an inert gas in
the synthesis loop.
Following reactions takes place in the Methanator (R301):
CO+3H2 CH4 +H2O+HEAT
CO2+ 4H2 CH4 +2H2O+ HEAT
The process gas from CO2 absorber is heated at 300°C and passes
through gas-gas exchanger and trim heater. The Methanator contains
nickel (Ni) based catalyst.
The probed gas then flows through the Methanator where carbon
oxides in the gas are converted to methane by reaction with hydrogen
over a nickel catalyst.
CO2+4H2 CH4+ 2H2O (exothermic)

(2.10) Ammonia Synthesis:

The ammonia synthesis process takes place in the ammonia converter
according to following:
N2+3H2 NH3+HEAT
The reaction is reversible and only part of the hydrogen and nitrogen
is converted into ammonia when the gas passes though the catalyst
bed. High pressure and low temp a high equilibrium concentration of
ammonia. Since the reaction is very much favored by a high temp the
value in the is chosen. About nitrogen and hydrogen gets converted to
ammonia and the unconverted will be recycled to the compressor after
separation of the liquid ammonia product,
Normal operating temp for the first bed is 370-460 degree celcius.
Maximum pressure as per design is 260kg/cm2. Normal operating
pressure is 187kg/cm2
At reduced load the low pressure will increase. After this the
ammonia will be condensed of lowering its pressure. As illustrated,
the converter effluent is then cooled. The mixture of the synthesis gas
and liquid passes from the synthesis economizer to ammonia
separator, in which the liquid ammonia is separated at a temp of 1
degree C. This liquid ammonia is depressurized to 27kg/cm2 and
taken to the product let down tank in which the main part of the
dissolved gases is liberated. Ammonia product is drawn from the
bottom of the let down tank. The gas leaving the separator contain
5.8(vol) % NH3. It is used as cooling medium in the synthesis cold
exchanger, before it is mixed with make-up gas and taken to the
recirculating part of the compressor and the same cycle is repeated.
The make-up gas contains a small quantity of inert gases CH4 and
argon. In order to prevent these gases from accumulating in the loop,
a certain quantity of circulating gas is purged. The purged gas is taken
from the loop after the ammonia separator.
In order to recover the ammonia contained in the purge gas, a new
recovery system is installed.
(2.11) PROCESS CONDENSATE STRIPPING:
Process condensate, which is separated from the synthesis gas
produced in the front end, is purified in the process condensate
stripper Small amount of ammonia are form in the secondary reformer
and small amounts of methanol are formed in the low temp CO
converter
Together with the carbon dioxide in the raw synthesis gas, these
compounds enter the process condensate according to the following
equilibrium reaction.
The process condensate stripper operates at a pressure of 37 kg/cm2
The overhead stream from the process condensate shipper is returned
to the front end and used as process steam for the reforming section
In the reforming section, methanol and ammonia undergo chemical
reactions and end-up as nitrogen hydrogen and CO The stripped
condensate is finally cooled to about 90 degree C in the process
condensate feed (effluent exchanger, where it is used to preheat the
process condensate going to the process condensate stripper.
The stripped condensate is finally cooled 45 degree C in the fuel gas
preheated and stripper condensate cooler and exported to the BFW
preparation unit.
 UREA
PLANT

 PRODUCTION CAPACITY:- 1500 MTPD

(3.1) HISTORY OF UREA:
Urea is an important nitrogenous fertilizer. Its utilization is increasing
steadily, it being the preferred nitrogen fertilizer worldwide. It is used
in solid fertilizer, liquid fertilizer, formaldehyde resins and adhesives
Rouelle first discovered urea in urea in 1773. His discovery was
followed by the synthesis of urea from ammonia and cyanic acid by
wochler in 1828, this is considered to be the first synthesis of an
organic compound from an inorganic compound in 1870, Bassaros
produced urea by heating ammonium carbamate in a sealed tube in
what was the first synthesis of urea by dehydration.
Fertilizer is generally defined as "any material, organic or inorganic,
natural or synthetic, which supplies one or more of the chemical
elements required for the plant growth. The main aim of the fertilizer
industry is to provide the primary and secondary nutrients which are
required in macro quantities. Primary nutrients are normally supplied
through chemical fertilizers. They are chemical compounds
containing one or more of the primary nutrients and are generally
produced by chemical reactions. Whatever may be the chemical
compounds, its most important ingredient for plant growth is the
nutrient content.

(3.2) ABOUT UREA:

Urea, also known as carbamide, is an organic compound with
chemical formula CO (NH₂)₂. This amide has two –NH₂ groups
joined by a carbonyl functional group. Urea serves an important role
in the metabolism of nitrogen-containing compounds by animals and
is the main nitrogen-containing substance in the urine of mammals.
It has the highest nitrogen content available in a solid fertilizer (46%).
It is easy to produce as prills or granules and easily transported in
bulk or bags with no explosive hazard. It leaves no salt residue after
use on crops. Its specific gravity is 1.335, decomposes on boiling and
is fairly soluble in water. The principal raw materials required for this
purpose are NH and CDs Two reactions are involved in the
manufacture of urea.
First ammonium carbamate is formed under pressure by reaction
between CO2 and NH3. This highly exothermic reaction is followed
by an endothermic decomposition of the ammonium carbamate to
urea and water.

(3.3) PROPERTIES OF UREA:

 (PHYSICAL PROPERTIES OF UREA)
i. Urea is colourless, crystalline solid.
ii. It is highly soluble in water but less soluble in alcohol. It is
insoluble in ether.
iii. Urea behaves as a mono acid base. It reacts with acids to
form salts.
iv. It is odourless, hygroscopic solid. It is non-corrosive.

 (CHEMICAL PROPERTIES OF UREA)

i. It reacts with nitrous acid to form nitrogen, carbon dioxide
and water.
NH2CONH2 + H2N2O2 H2CO3 + 2N2 + 2H2O
ii. Urea reacts with hydrazine at 373 K to form semi
carbazide
NH2CONH2 + N2H4 NH2CONHNH2 + NH3

Molecular Weight 60.05

 Relative Humidity 60%
Maximum Nitrogen Content 46.6%
Specific Gravity 1.335
Heat of Fusion 60 Cal/gm
Heat of Solution, in Water 58 Cal/gm
Bulk Density 0.74 gm/cc

Specific Heat (KJ/Kg deg Celsius) of Urea

TEMPERATURE (deg Specific Heat

Celsius)
0 1.398
50 1.66
100 1.89
150 2.11

(3.4) USES OF UREA:

i. It is mainly used as a nitrogen release fertilizer to make the

product water-soluble.
ii. Urea is used as a stabilizer in most nitrocellulose explosive
products.
iii. It is used in manufacturing high explosive materials like urea
nitrate (CH5N3O4)
iv. It is used as an important reagent in lanthanide chemistry.
v. It is used in creams/ointments that are used for rehydration.
vi. It is used in hair removal creams and dish soaps.
vii. It is used as a browning agent for pretzels.
viii. It is used in manufacturing melamine.
ix. It is used to detect the bacteria in the stomach through the urea
breath test.
FERTILIZER CONTROL ORDER SPECIFICATION
Moisture contain by wt. 1.0%
Total Nitrogen in Neem coated 46.0%
Urea by wt. (min)
Biuret by wt. (max) 1.5%
Prill Size At least 80% should retain in b/w
1.0 mm & 2.8 mm sieve
Benzene Soluble Neem Content 350 ppm

PROCESS TECHNOLOGY:
Although there are several processes currently for the mature of us,
the underlying principle for all the processes is same Our ultimate al
is v tam UREA which is act the reaction of AMMONIA with
CARBON DIOXIDE for carbamate which further changes to the
urea. The two main reactions involved are
1) 2NH2 + CO2 NH2COONH4 [-37.64kcal]
2) NH2COONH4 NH2CONH2 + H2Ọ [6.32 lcal]
Undesirable side reaction taking place is
2NH2CONH2 NH2CONHCONH2 + NH3
This is a troublesome stop and bure formation must be kept low
because it adversely afflicts the growth of some plants. The first
reaction is highly exothermic and instantaneous whereas second
reaction in slightly endothermic and slow and this slew step is the
male determining step.
Overall reaction EXOTHERMIC lower temperature will increase
conversion but for hanging the rate of our reaction, temperature has to
be kept and 200 °C High temperature and pressite will increase the
overall conversion.
Temperature and pressure requirements are as follows:
Temperature-200 Deg Celsius
Pressure- 250 kg/cm³G
THE VARIABLES THAT AFFECT THE REACTIONS ARE:

1.)Temperature
The covers of acetum carbamate to sea gradually increases as the
temperature, increases However, after a particular temperature,
depending upon the pressure, the conversion suddenly drops with
further increase in temperature.
2.)Pressure
The main reaction is sufficiently slow at atmospheric pressure. There
is reduction in volume in the overall reaction and so high pressure
foes the forward reaction. This pressure is selected accenting to the
temperature to maintain & NH3: CO2 ratio.
3.)Concentration
Higher the concentration of the reactants, higher will be the forward
reaction according to the law of mass action CO2 being the limiting
reagent NH3:CO2 higher ratio favors conversion. Since dehydration of
carbamate results in urea production lesser H2O:CO2 ratio favors
conversion Water intake to the reactor should therefore be minimum.
4.)Residence time
Since urea reaction is slow, and takes about 20 mins to attain
equilibrium sufficient tine is to he provided to get higher conversion
Reactor is designed to accommodate this with respect to the other
parameters of temperature, pressure and concentration.
5.)Biuret formation
A problem faced during manufacture of area is the formation of biuret
during the production of urea. It is not a desirable substance because it
adversely affects the growth of some plants. Its content in area should
not be more than 1.5% by weight.
2NH2CONH2 NH2CONHCONH2 + NH3
(3.5) UREA PLANT: Overview
Urea Plant has a rated capacity of 1550 Ton/day of prilled urea
produced in a single stream plant employing MITSUI TOTATSU
TOTAL RECYCLE CIMPROVED PROCESS of Toyo Engineering,
Japan.
Features of the plant as under
FEATURES
Type of Process Conventional
Conversion (%) 72% in terms of CO2
Reactor Condition Pressure= 250 Kg/cm^2
Temperature= 200 Deg Celcius
Reactor Lining Titanium
Reactor Features Hollow
Decomposition Stages 1st stage = 17.5 Kg/cm^2
2nd stage = 2.5 Kg/cm^2
3rd stage = 0.3 Kg/cm^2
Concentration Route Crystallization route
Type of Prilling Tower Induced Draft cum Forced Draft

THE PLANT IS DIVIDED INTO FOUR SECTIONS:

Crystallization
Synthesis Decomposition Recovery
and Prilling
Section Section Section
Section
(3.6) SYNTHESIS SECTION:
This is the section in which Nits is made to react with CO2 to give
ammonium carbamate which further changes to urea with the removal
of water.
Urea synthesis takes place in urea synthesis reactor. The CO2 coming
from ammonia plant initially passed through KOD-1 i.e knock drum
which is a packed bed which absorbs mature from the Then it passes
through multistage centrifugal compressor. The compress is run by a
turbine whose inlet seats is at 40 Kg/cm^2 and extraction pressure is
12Kg/cm^2. The compressor has two parts High pressure
compression (HPC) and Low Pressure Compression (1.PC) stages the
LPC has two stages and HPC has one stage
The suction of first stage after KOD-I is 0.27 Kg/cm^2 and then the
discharge 2.88 Km/cm^2 pass through the UEA-101-E1 e intercooler
for first stage and then through KOD-2 where moisture separated as
water Due to this there is drop in suction of second stage Then after
the second Compression cycle the pressure is 12.1 Kg/m, similar
process happen and it passes through UEA 101-E2 and KOD-3 and
the action for HPC 11:25 Kg/cm^2 Then goes for further compression
to reciprocating compressor
The compressed CO2 washed with water in packed bed called
methanol absorber for the removal pf entrained methanol in CO The
washed CO2 is further compressed to a pressure of 250 Kg/m² in a
multistage compressors (2 stages) UGB-100 supplied by KOBE
STEEL Japan
The compressor is single cylinder double acting type. The find suction
is 29.5 Kg/cm^2 and second suction is 92.5 Kg/cm^2 and between it
passes through in intercooler UE-102-E3 and after that UEA 102-12
to maintain the second suction temperature at 50 C
Liquid ammonia at 11 and 18 Kg/cm^2 pressure is received in the
ammonia reservoir (UFA-401) from the Horton sphere Ammonia
booster pump UGA-104 (A/B) increases the presser up to 24 Kg/cm
to provide action for Ammonia feed pumps UGA-101 (ABCD) The
ammonia feed pumps deliver the liquid ammonia at 250 Kg/cm^2 to
ammonia pre-heater. The pre-heated ammonia at 65°C is fed to the
urea reactor at bottom.
The recycled carbamate solution is abo delivered to the urea reactor at
bottom by recycle carbamate solution pumps 102(A/B) at 250
Kg/cm^2.
The three feeds ie CO2, liquid Ammonia and recycle pump solution
are fed to a Titanium lined multi wall area reactor. The rector
temperature is maintained at 200 °C max. The slurry from reactor top
and let down e 175 Kg/cm^2 pressure through a pressure control
valve PCV-101 and fed to the high pressure decomposer UDA-201

(3.7) DECOMPOSITION SECTION:

Decomposition is required to remove excess ammonia and to separate
urea from water and ammonia carbamate so as to avoid backward
reaction
NH4COON4 CO2 + 2NH3
The decomposition reaction in favoured by lower pressure of the
system or by low partial pressure of one of the reaction products NH3
and CO2 conventional process mean that the process where
decomposition is effected by lowering in pressure in successive stages
fallowed by indirect heating whereas the process where
decomposition takes place by lowering the partial pressure of either
NH3 or CO2 followed by indirect heating are called stripping
processes
The reactor let enter the upper part of high pressure decomposer
UDA-201 having 4 sieve trays at upper and falling film heater at
lower section. The flashed gases goes up and liquid flows down
through sieve trays. On the trays the high temperature gas from
reboiler UEA-201 and falling film heater contacts with the liquid
flowing down. The sensible heat of gas and heat of condensation of
water vapours are used to evaporate the excess ammonia and to
decompose the carbamate.
This helps in minimize water evaporation and thus water recycle to
reactor. The temperature of middle is maintained at 165-C through
TCV-202. The falling film heater is used to minimize residence time
order to reduce biuret formation and hydrolysis of urea.
The overhead gases from HPD are absorbed in UEA-401 HPAC (high
pressure absorber cooler). The bottom liquid flows to UDA-202 LPD
(low pressure decomposers). Upper part passing through U type heat
exchanger UEA-203: In UEA-203 the heat is exchanged between the
line from HPD bottom to LPD top who is giving host to slurry
temperature maintaining line coming and going in LPD. In LPD a
similar phenomenon occurs. The reboiler UEA-202 provides the heat
using 7 kg/cm^2 steam for decomposition.
Small amount of CO2 is fed below packed bed tie improved stripping
of decomposed gases. The overhead gases from LPD are absorbed by
UEA-802 PAC-Lon (Low Pressure Absorber Cooler) Bottom liquid
flows to 3 stage decomposer UDA-203 In the lower part air
containing trace of N and CO2 is blown under packed bed by gases
recycling blower UGB-401. The urea solution is concentrated to 70-
72% and sent to crystallization section.
Another important fact that we need to keep in mind is to control the
formation of BIURET. At low partial pressure of NH and temperature
above 200 degree Cures converts to form ammonia and biuret and
formation is undesirable as it damages our crops so we need to take
control of temperature and other parameters so as to avoid burst
formation.
2NH2CONH2 NH2CONHCONH2 + NH3

(3.8) RECOVERY SECTION:

It is not practical to compress the ammonia-carbon dioxide mixture
and return this to urea synthesis reactor. Compression causes the
recombination ammonia and carbon dioxide to solid ammonium
carbamate and results in clogging of the compressor.
The gases from the gas separator are condensed in off gas condenser
UEA-496 and enter the bottom of off gas absorber UDA-402 (OGA)
Condensed liquid lows down and sent to potion of OGA as absorbent.
OGA bottom fluid is recycled as absorbent at OKA middle position (2
bed) Air from top of OGA is blown to gas separator by UGB-401
blower.
The gases from LPD are absorbed in LPAC bubbling through a
sparger. Dust chamber over flow solution (10-15% urea) is used as
absorbent Solution from LPAC is pumped by UGA-402 (A/B) to
HPA (UDA-401) middle through mixing cooler where liquid
ammonia is mixed and serves as medium in the absorber.
The gases from HPD top are bubbles through a sparger in HPAC,
where 65% of CO is absorbed. Remaining gases from HPAC go to
HPA and are cooled down to 80 degree C max in middle cooler at the
bottom of HPA 35% CO is absorbed in packed bed by a mixture of
lean carbamate from LPAC through FCV401 and liquid ammonia
from LGA-404 (A) through FCV402. The scrubbed as the passes
through 5 Nos. Of bubble cap trays in order to absorb residual CC by
a main of aqua ammonia (L/CIA÷405 A/11 and liquid ammonia
(UGA404 A through FCV 30x Ammonia gas from HPA temperature
50 C is pure and condensed in 5 Nos of condenser UEA-101
(A/UCDT and purge condenser ULA-403. Liquid ammonia lose down
to ammonia recovery reservoir.
Non condensable gases (inserts and some ammonia) flows to
ammonia recovery absorber. Cold steam condenstate in fed (CV-408)
for absorption and Aqua ammonia is withdrawn from recovery
absorber bottom by UGA-415(A/B).
(3.9) CRYSTALLIZATION AND PRILLING SECTION:
Urea has to be concentrated upto 99.5% before prilling
MTC-C IMPROVED PROCESS follows crystallization-re-melt
prilling route and uses spray nozzles for prilling. The prilling tower is
of Induced Draft com Forced Draft (Balance Draft).
The solution from gas separator enters lower part of crystallizer UFA-
201. The sipper part is vacuum concentrator with no stage injectors
and barometric condense. The vacuum concentrator at 75 mm Hg and
60% water is evaporated and supersaturated a solution comes down
through barometric log into the crystallizer, where urea grows. The
heat required for water evaporation comes from
 Sensible heat of feed urea solution
 The heat of urea crystallization
 Heat recovered by urea slurry circulated UEA-401
The crystallizer is operated at 60 degree C and atmospheric pressure,
so that slurry leaving the bottom contain Minimum 35% urea crystal
by weight.
Hot water from hot water tank is used in the jackets of crystallizes and
concentrator and pipe so avoid crystal build up on the vessels wall, so
that there is no choking otherwise
The urea slurry is pumped from crystallizer bottom to centrifuges
maintaining minimum recirculation to crystallizer to prevent choking
of lines. Biuret remains with mother liquor, which after separation
from the urea crystals in the Centrifuges is recycled hack. Because of
excess ammonia in reactor hurt formation is minimum. Biuret
formation is maximum in mother liquor tank and melter as there is
low ammonia environment which facilities the forward reaction of
biuret formation. This is avoided by low residence time and
continuous circulation of slurry. Urea Crystals separated from slurry
with 2-4% moisture are discharged to fluidizing dryer. The mother
liquor flows down to mother liquor tank, provided with steam coils.
(3.10) ADVANTAGES OF NEEM COATED UREA:
Soil fertility is determined by three major elements namely Nitrogen,
Phosphorus & Potassium (N. P.K) of which nitrogen plays a very
important role. For this reason, Urea (containing 46% of N)
consumption is very high all over the world. Unfortunately, more than
half (up to 60%) of the nitrogen leaches out or vaporizes in the form
of nitrogen gas, ammonia & nitrous oxide due to the presence of
denitrifying bacteria in the soil.
As per notification dated 25-05-2015 all the urea producers in country
are producing 100% urea as NCU in order to improve crop
productivity and reduce the subsidy
 Slow down the process of nitrification of urea.
 Improved yield
 Decrease urea requirement
 Controls soil born nematodes, termites and other pest due to
pesticide properties
 Redaction in environmental pollution of ground water due to
leaching of nitrates and gaseous emissions
 Opportunity for entrepreneurs to commercialize local Neem
Resources and Development of Small Scale Industries in rural
areas
GTG PLANT
(Gas Turbine
Generator)

.
4.1 ABOUT GAS TURBINE:
Today, gas turbines are one of the most widely-used power generating
technologies. Gas turbines are a type of internal combustion (IC)
engine in which burning of an air-fuel mixture produces hot gases that
spin a turbine to produce power. It is the production of hot gas during
fuel combustion, not the fuel itself that gives gas turbines the name.
The use of gas turbines for generating electricity.
4.2 Working principle:
 Air is compressed (squeezed) to high pressure by a compressor.
 Then fuel and compressed air are mixed in a combustion
chamber and ignited.
 Hot gases are given off, which spin the turbine wheels.
 Gas turbines burn fuels such as oil, nature gas and pulverized
(powdered) coal.

Gas turbines have three main parts

i) Air compressor
ii) Combustion chamber
iii) Turbine

4.3 How a gas turbine works:

As we say Gas turbines are comprised of three primary sections

mounted on the same shaft: the compressor, the combustion chamber

(or combustor) and the turbine.

The compressor can be either axial flow or centrifugal flow. Axial

flow compressors are more common in power generation because
they have higher flow rates and efficiencies. Axial flow compressors
are comprised of multiple stages of rotating and stationary blades
(or 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. Although no heat is added, the compression of
the air also causes the temperature to increase. Because the
compressor must reach a certain speed before the combustion
process is continuous – or self-sustaining – initial momentum is
imparted to the turbine rotor from an external motor, static
frequency converter, or the generator itself. The compressor must
be smoothly accelerated and reach firing speed before fuel can be
introduced and ignition can occur. Turbine speeds vary widely by
manufacturer and design, ranging from 2,000 revolutions per
minute (rpm) to 10,000 rpm. Initial ignition occurs from one or more
spark plugs (depending on combustor design). Once the turbine
reaches self-sustaining speed – above 50% of full speed – the
power output is enough to drive the compressor, combustion is
continuous, and the starter system can be disengaged.

Gas turbines can utilise a variety of fuels,

Including natural gas, fuel oils, and synthetic fuels. Combustion
occurs continuously in gas turbines, as opposed to reciprocating IC
engines, in which combustion occurs intermittently.

Typical performance values for new gas turbines 

Gas turbine type Power output Efficiency, Efficiency,

(MW el) Simple cycle (%), LHV Combined cycle (%),

LHV

Aeroderivative 30-60 39-43 51-54

 Small scale heavy 70-200 35-37 53-55

duty

 Large scale heavy 200-500 37-40 54-60

duty

(4.4) Compressor:
  Supplies high pressure air for combustion process

 Compressor types

 Radial/centrifugal flow compressor

 Axial flow compressor

Radial/centrifugal flow

 Adv: simple design, good for low compression ratios (5:1)

 Disadvantage: Difficult to stage, less efficient

Axial flow

 Good for high compression ratios (20:1)

 Most commonly used

Controlling Load on Compressor

 To ensure maximum efficiency and allow for flexibility,
compressor can be split into HP & LP sections
 Vane control: inlet vanes/nozzle angles can be varied to control
air flow

 Compressor Stall
Interruption of air flow due to turbulence

Use of Compressed Air

 Primary Air (30%)
Passes directly to combustor for combustion process
 Secondary Air (65%)
Passes through holes in perforated inner shell & mixes with
combustion gases
 Film Cooling Air (5%)
Insulates/cools turbine blades

(4.5) Combustion Chambers:

The combustion chamber is the element of the gas turbine arranged
between the compressor and the turbine, inside which is performed
the mixture of the fuel fed by the injectors, with the air fed by the
compressor and the combustion of said air and fuel mixture.
The combustion leads to an important increase in temperature of said
air, which increases its energy, the fraction of which may be
recovered through expansion is used on the one hand for driving the
above-mentioned compressor and, on the other hand, for supplying
propelling power in the case of a jet engine or of the mechanical
power in the case of a turbine engine.
 Where air & fuel are mixed, ignited, and burned
 Spark plugs used to ignite fuel
 Types
 Can: for small, centrifugal compressors
 Annular: for larger, axial compressors (LM 2500)
 Can-annular: for really large turbines

(4.6) Turbines:
  Consists of one or more stages designed to develop
rotational energy.
 Uses sets of nozzles & blades.
Applications of gas turbine:
 Drive pumps, compressors and high speed cars.
 Aircraft and ships.
 Power generation (used for peak load and as stand-by unit).

OPEN CYCLE GAS TURBINE POWER PLANTAND ITS

CHARACTERISTICS
Gas turbines usually operate on an open cycle Air at ambient
conditions is drawn into the compressor, where its temperature and
pressure are raised. The high pressure air proceeds into the
combustion chamber, where the fuel is burned at constant pressure.
The high-temperature gases then enter the turbine where they expand
to atmospheric pressure while producing power output. Some of the
output power is used to drive the compressor. The exhaust gases
leaving the turbine are thrown out (not re-circulated), causing the
cycle to be classified as an open cycle.
CLOSED CYCLE GAS TURBINE POWER PLANT AND ITS
CHARACTERISTICS
 The compression and expansion processes remain the same, but
the combustion process is replaced by a constant-pressure heat
addition process from an external source.
 The exhaust process is replaced by a constantpressure heat
rejection process to the ambient air.

THE HRGS IS DESIGNED TO PROVIDE STEAM AT THE

FOLLOWING PARAMETERS
PARAMETERS UNITS VALUE
HP LP
Steam TPH 70 9.46
Generation[MCR]
Steam TPH 45 8.27
Generation[Perf]
Steam Pressure at Kg/cm2 (g) 108 9
MSSV Outlet
Steam Pressure at Deg C 504 ± 5 Saturation
the SH Outlet