SUMMER TRAINING REPORT

INDIAN FARMER FERTILIZER

COOPERATIVE LIMITED
PHULPUR,ALLAHABAD
U.P. INDIA

SUBMITTED BY
RADHEY KRISHNA
B.TECH. (MECHANICAL
ENGG.) 4th Year

MNNIT, ALLAHABAD
 A
REPORT ON
SUMMER TRAINING
at
INDIAN FARMER FERTILIZER COOPERATIVE
LIMITED.
Submitted as partial fulfillment of the requirement for the award of
Bachelor degree
In

Mechanical engineering

SUBMITTED TO SUBMITTED
MR. R K PANDEY BY RADHEY
KRISHNA

DURATION --- 18/06/23

TO /07/23
2
 HISTORY OF IFFCO

1. INTRODUCTION
Indian Farmers Fertiliser Cooperative Limited, also known as
IFFCO, is a multi-state cooperative society. IFFCO is wholly
owned by Cooperative Societies of India. The society is engaged in
the business of manufacturing and marketing of fertilizers.
IFFCO is headquartered in New Delhi, India. Started in 1967
with 57 member cooperatives, it is today the biggest co-op in the
world by turnover on GDP per capita (as per World Cooperative
Monitor 2021),[2] with around 35,000 member cooperatives
reaching over 50 million Indian farmers.
With around 19% market share in urea and around 31% market
share in complex fertilizers
(P2O5 terms) IFFCO is India's largest fertilizer manufacturer.

Indian Farmers Fertilizer Co-operative Limited (IFFCO) was

registered on November 3,
1967 as a Multi-unit Co-operative Society. On the enactment of the
Multistate Co-operative
Societies act 1984 & 2002, the Society is deemed to be registered
as a Multistate Co-
operative Society. The Society is primarily engaged in
production and distribution of
fertilisers. The byelaws of the Society provide a broad frame work for
the activities of IFFCO

IFFCO commissioned an ammonia - urea complex at Kalol and

the NPK/DAP plant at Kandla both in the state of Gujarat in 1975.
1
Another ammonia - urea complex was set up at Phulpur in the
state of Uttar Pradesh in 1981. The ammonia - urea unit at
In 1993, IFFCO had drawn up a major expansion programmed of all the four plants under
overall aegis of IFFCO VISION 2000. The expansion projects at Aonla, Kalol, Phulpur and
Kandla were completed on schedule. All the projects conceived as part of VISION 2000 had
been realised without time or cost overruns. All the production units of IFFCO have
established a reputation for excellence and quality. Another growth path was chalked out to
realise newer dreams and greater heights through Vision 2010. As part of this vision, IFFCO has
acquired fertiliser unit at Paradeep in Orissa in September 2005. As a result of these
expansion projects and acuisition, IFFCO's annual capacity has been increased to 3.69
million tonnes of Urea and NPK/DAP equivalent to 1.71 million tonnes. In pursuit of its
growth and development, IFFCO had embarked upon and successfully implemented its
Corporate Plans, „Mission 2005‟ and „Vision 2010‟. These plans have resulted in IFFCO
becoming one of the largest producer and marketeer of Chemical fertilisers by expansion of its
existing Units, setting up Joint Venture Companies Overseas and Diversification into new
Sectors.

HIGHLIGHTS OF PLANT
MAIN FEATURES:
1. plant and township land area - 747 acres
2. cooperative society

PRODUCT PRESENT CAPACITY:

1. Ammonia - 5 lakh MT
2. urea - 7 lakh MT

MAJOR INPUTS
1. natural gas
2. water
3. plant technology
4. ammonia 2
5. urea
 IFFCO MISSION

 IFFCO's mission is "to enable Indian farmers to prosper through

timely supply of reliable, high quality agricultural inputs and services
in an environmentally sustainable manner and to undertake other
activities to improve their welfare“
 To provide to farmers high quality fertilizers in right time and in
adequate quantities with an objective to increase crop productivity.
To make plants energy efficient and continually review various
schemes to conserve energy. Commitment to health, safety,
environment and forestry development to enrich the quality of
community life. Commitment to social responsibilities for a strong
social fabric.
 To institutionalise core values and create a culture of team
building, empowerment and innovation which would help in
incremental growth of employees and enable achievement of strategic
objectives. Foster a culture of trust, openness and mutual concern to
make working a stimulating and challenging experience for stake
holders. Building a value driven organization with an improved
and responsive customer focus. A true commitment to
transparency, accountability and integrity in principle and practice.
To acquire, assimilate and adopt reliable, efficient and cost
effective technologies. Sourcing raw materials for production of
phosphatic fertilisers at economical cost by entering into Joint
3
Ventures outside India.
 SAFETY MEASURES

 Always wear helmet for protection of head.

 Always wear spectacles for protection of dust

 Wear dust mask to protect dust from entering nose.

 Wear gloves while doing oily work.

 Always wear shoes to protect our self from electric shock.

PHYSICAL PROPERTIES OF UREA

1. melting point - 132.6

2. molucular weight - 60.05
3. boiling point - decomposes at atm
4. density of room temperature- 1.335 kg/meter cube
5. heat of combustion - 2531cal/g
6. critical humidity -70.1
7. fusion heat - 59.95kcal/kg
8. thermal conductivity - 191 kcal/sec
9. specific heat at room temp --- 0.321cal/gm/k
 Compressor

A compressor is a device that increases the pressure of a substance

(usually a gas) by reducing the volume of the substance.

5.1 TYPES OF COMPRESSOR

1. Positive Displacement
Compressors
2. Reciprocating Compressors
3. Single-acting Compressors
4. Centrifugal Compressors
5. Axial Compressors
1. Positive Displacement Compressors

In positive displacement compression, the air is drawn into one or more compression
chambers, which are then closed off from the inlet. The enclosed volume of each chamber
decreases through the displacement of one or more moving parts and the pressure increases,
compressing the air internally. Once the pressure reaches the maximum pressure ratio, a port
or valve opens; the continued reduction of volume in the compression chamber discharges the
air into the outlet system.

Positive Displacement compressors are divided into two categories: Reciprocating and rotary
compressors.

2. Reciprocating Compressors

The piston compressor also denoted reciprocating, is a displacement compressor type

that consists of a moving piston that compresses the air. It has high efficiency both at
full and partial loads, but less positive aspects are that it is noisy and demands more
space than other types of compressors. Also, due to many moving parts in this type of
compressor that may wear out, the cost of maintenance is higher than for other
compressor types. Reciprocating compressors can come both as oil lubricant-free as
well as oil lubricant-injected compressors.
 3 .Single-acting Compressors

Single-acting reciprocating compressors compress gas only when the piston is moving in one direction. When the
piston moves toward the cylinder head, the gas is being compressed but when the piston is moving away from the
head, suction is pulling gas into the cylinder.

These compressors are less costly compared to other types of reciprocating air compressors and are very easy to
maintain. Besides, they are best for cycles having medium duty.

The major disadvantage of the single-acting air compressor is that it has a piston that works in only one direction
at a time. Plus, the spring takes up space and bounds the cylinder working stroke.

4 . Centrifugal Compressors
Centrifugal compressors, also called radial compressors, are a type of dynamic compressor.
In a centrifugal compressor, energy is transferred from a set of rotating impeller blades to
the gas.

In a centrifugal compressor, the gas flow is radial, and the energy transfer is caused by a
change in the centrifugal forces acting on the gas. Centrifugal compressors deliver high
flow capacity per unit of installed space and weight, have good reliability, and require
significantly less maintenance than reciprocating compressors. However, the performance
characteristic of centrifugal compressors is more easily affected by changes in gas
conditions than is the performance of reciprocating compressors.

5 . Axial Compressors
An axial-flow compressor is one in which the flow enters the compressor in an axial direction and
exits from the gas turbine also in an axial direction. An axial-flow compressor compresses its
working fluid by first accelerating the fluid and then diffusing it to obtain a pressure increase.
The fluid is accelerated by a row of rotating airfoils (the rotor) and diffused by a row of
stationary blades (the stator). The diffusion in the stator converts the velocity increase gained in
the rotor to a pressure increase.

These compressors are typically driven by an electric motor or a steam or a gas turbine.

Axial-flow compressors produce a continuous flow of compressed gas and have the benefits of
high efficiency and large mass flow rate, particularly concerning their size and cross-section.
They do, however, require several rows of airfoils to achieve a large pressure rise, making them
complex and expensive relative to other designs such as centrifugal compressors.
 PARTS OF AN AIR COMPRESSOR

There are various types of compressors and thus has wide variety of parts
depending upon the type of compressor. For simplicity and easy
understanding, we will discuss about the common usually found
reciprocating air compressors. The discussion will be on major working
components of a reciprocating air compressor and parts which are essential
for automatic operation are not included as they may vary depending upon
requirement.

A reciprocating air compressor is one which reciprocates inside a cylinder

(liner) unit. The piston moves up and down continuously to pump the air
after compression into the air receiver. Important parts of a reciprocating air
compressor are as follows:

1. Cylinder Head,

2. Suction/ Intake valve,

3. Delivery valve,

4. Cylinder liner/ Wall/ cooling water jacket,

5. Compressor casing,

6. Crank case,

7. Piston,

8. Connecting rod,

9. Crank shaft,

10, Main Bearings,

11. Bed plate or Bottom structure,

12. Foundation,
1. Cylinder Head and Valve assembly:
2.
An Air Compressor has a cylinder head which differs depending upon
the type. It may be in-line or even in “V”-shape. If it is in-line, usually the
1st stage and 2nd stage are in a same cylinder head block. But in a “V”-
shaped compressor, the 1st stage and 2nd stage may be entirely different
connected by high pressure pipes. The cylinder head consists of pockets
for holding the intake/suction and delivery valves. They also have air
cooling fins or water jacket for cooling water passage. There are usually
network of pipes for cooling water and compressed air delivery to the
next successive stage. One of the main components of the cylinder head
assembly is the suction filter for the air intake. The filter is usually
mounted onto the cylinder head allowing filtered air to enter compressor
unit.

3. Piston, Cylinder wall/Liner, and Connecting Rod:

The piston moves inside the cylinder wall or the liner, reciprocating up
and down. The liner supports and guides the piston, forming a main part
of the air compression chamber. The piston may or may not have rings
for sealing depending on type and purpose. The piston obtains its
reciprocating motion from the connecting rod which connects the piston
to the crankshaft. Thus we can claim that it is the connecting rod which
transfers the rotary motion from the crank shaft into reciprocating
motion of the piston.

4. Crankshaft, Crankcase, and other fittings:

The connecting rod connects the piston and the crankshaft. The
crankshaft is connected to the drive which may be an electric motor,
turbine, or a diesel engine. As the crankshaft rotates it in turn make the
connecting rod to move with it thus making the piston to reciprocate.
The crankshaft is positioned with perfection inside the crankcase, which
is filled with lubricating oil. The entire crankcase, sometimes act as a
lubricating oil sump. The crankshaft rests on bed-plate with the bearings
sandwiched in between. These bearings serve to avoid friction and also
withstand the fluctuating load when the piston compresses air.
The intercoolers and the after coolers are usually mounted on the body.
 TYPES OF RECIPROCATING AIR COMPRESSORS-----

These are the types of reciprocating air compressors;

Single-acting reciprocating air compressor.

Double-acting reciprocating air compressor.

Single-stage reciprocating air compressor.

Two-stage reciprocating air compressor.

Multi-stage reciprocating air compressor.

1 .Single-acting reciprocating air compressor: this type of reciprocating

air compressor accomplishes compression of the air using only one side
of the piston.

2. Double-acting reciprocating air compressor: this is a reciprocating air

compressor that achieves its compression of air using both (two) sides of
the piston.

3 . Single-stage parallel.reciprocating air compressor: this is a type of

reciprocating air compressor that achieves its entire compression using a
single cylinder or a given group of cylinders.
Some compressors regulate their speed dynamically to balance output with
demand. As a
result, it can determine when and where you require how much air pressure or
force to
increase the productivity of any work.

Furthermore, to maintain a manual pumper, we need to be assigned a human

who can
continuously increase or decrease the level of output of a pumper or cooler.
However,
because of advanced technology and sensors, an air compressor can do the same
work on its
own. And it will help to increase productivity without requiring constant
maintenance.

Air Compressor Basics

The concept of compressed air is simple: when atmospheric air is stored
under pressure, it creates potential energy that can be held inside a tank
until it's
needed. Just like a balloon being released, when the pressurized air is
released,
the potential energy is converted into usable kinetic (motion) energy.

What is Air Displacement?

The core of how air compressors work is boiled down to two methods of air
displacement. In order to compress air, the internal components of a compressor
must move or change position to mechanically force the air through the chamber
where it is compressed and stored until use.

Positive Displacement is the method that most compressors use. Air is pulled into
a chamber that opens and closes, where the internal parts reduce the volume of
the chamber and compress the air. Once the cycle is complete, the air is pushed
through the chamber and into a storage tank where it waits to be used.

Piston, rotary-screw, and scroll-type 22

air compressors all use positive
What Drives an Air Compressor?

Belt-Drive Air Compressor Compressor drives are most commonly direct-drive or

belt-driven systems. In a belt-driven system, as the motor turns, the belt turns with
it, thus activating the pump in the system. This is the more economical option and
is widely used across all compressor types because the belts can be adjusted to
change with air demands.

In a direct-drive system, the motor attaches directly to the crankshaft of the

compressor, allowing for smaller designs and fewer maintenance requirements.
Although not much adjustment can be made to these drive systems, they are more
efficient because less power is lost in the transfer of power to the crankshaft.

Another benefit of direct-drive is the ability to provide compressed air without

needing to fill a storage tank first, like using a DC compressor for off-roading.

The Mechanics of an Air Compressor

Depending on the type of air compressor, basic air compression requires an electric-
powered motor, a pump with an internal mechanism to compress the air, an inlet/
outlet valve to draw in and release air, and—in most cases—an air storage tank.

Air is drawn into the compressor where the internal components reduce the volume
of the air by creating a vacuum, which drives the pressure of the air up as it is pushed
into a holding tank. Once the maximum pressure is reached inside the tank, the duty
cycle is complete, and the compressor shuts off until the pressure falls below a set
threshold. Positive displacement air compressors do this in different ways: by using
pistons, screws, and scrolls.
Types of reciprocating air compressors

These are the types of reciprocating air compressors;

Single-acting reciprocating air compressor.

Double-acting reciprocating air compressor.
Single-stage reciprocating air compressor.
Two-stage reciprocating air compressor.
Multi-stage reciprocating air compressor.

Single-acting reciprocating air compressor: this type of reciprocating air compressor

accomplishes compression of the air using only one side of the piston.

Double-acting reciprocating air compressor: this is a reciprocating air compressor that

achieves its compression of air using both (two) sides of the piston.

Single-stage reciprocating air compressor: this is a type of reciprocating air compressor that
achieves its entire compression using a single cylinder or a given group of cylinders in
parallel.

Two-stage reciprocating air compressor: this is a type of reciprocating air compressor that
compresses air in two stages and in between the stages the air is cooled.

The two-stage reciprocating air compressor provides higher pressure and is characterised
by lower discharge temperature (1400C to 1600C) compared to the single-stage which has
an air discharge temperature of (2050C to 2400C).

Multi-stage reciprocating air compressor: this is a type of reciprocating air compressor that
achieves its entire compression using three or more steps of compression grouped in series.

They are used where over 100 horsepower is needed thus preferable in most plants.
 MECHANICAL PARTS

LUBRICATION

Lubrication of moving machineries which are having oscillatory motion,

reciprocating motion or rotating motion etc. plays vital role for their longer-
life, safe operation, efficient running and over all performances. Main motive
behind the lubrication is to cool the contact surfaces, to separate them by
providing a film in between the two moving parts, to take the load coming on
the stationary parts in all working conditions, to dissipate heat generated out of
friction and to carry away unwanted micro particles present in the system. For
achieving these objectives various methods of lubrication and a variety of
lubricants are used. Various methods of lubrication may comprise the pressure
feed or forced feed, gravity feed, ring feed splash or submerged oil system, feed
wick and drop feed etc. General kinds of lubricants may come under solid
(grease, graphite powder) and fluid forms (oil & some gases). Greases may be
Na-base, lime-base, lithium base, soda-lime base and Al-base. Oil may be
minerals, vegetables and animals product. But at present practice mineral
oils for most of the lubrication systems are employed.

Properties of lubricants

The duties of lubricants are many and varied in scope, the lubricant is called
upon to limit and control,

Friction

Metal to metal contact Overheating

Wear

Corrosion

Deposits
Lubricating oils Viscosity and viscosity index

Viscosity is the most important property of a lubricant which offers a

resistance to flow. It is measured in poise, centipoises, stokes, centistokes,
eglar, redwood, S.S.U., or SAE units.

Absolute viscosity is obtained by multiplying Kinematic viscosity with its

density. Viscosity is influenced by temperature, pressure , and shear ( fluid
motion ). Required viscosity of the lubricant can be obtained by blending of
two or more oils of different viscosities.

Viscosity index is the empirical system of expressing rate of change of

viscosity of a lubricant with change in temperature. The index number can
be negative or can be greater than 100.

Viscosity Index = Viscosity at 100°F - Viscosity at 212°F

Viscosity at 100°F

Lubrication
Just like your car uses oil, air compressors need lubrication to continue running
smoothly over time.

Lubricated air compressors use oil to reduce wear and friction on their moving
parts. In the case of piston compressors, the oil is applied to the system in one of
two ways:

Splash lubrication: a dipper attached to the piston rod dips into an oil-filled
trough and splashes the oil onto the piston and cylinder.

Pressure lubrication: A pump sends oil through passages drilled inside the
compressor, applying the oil to specific parts. Pressure-lubricated systems are
generally more expensive, but the directed flow of oil keeps them operating
longer than their splash-lubricated counterparts.

29
 Non-lubricated compressors are also referred to as oil-less or oil-free because
their parts are coated in special chemicals or materials like Teflon to reduce
friction instead of conventional oil. The solution here is permanently lubricated
components. The drawback of non-lubricated compressors is that they heat up
faster, and aren't the best option for heavy-work environments.

Most oil-less air compressors are used in industries where clean air is required
for manufacturing, such as in the food, beverage, and electronics industries. For
example, scroll compressors are used in the dental industry because of their
continuous clean and quiet operation.

Measuring Power
When it comes to sizing an air compressor for airflow and air volume, there are two
criteria professionals use to determine if an air compressor can properly handle an
application, and determine the kinds of tools that will be compatible with your air
compressor.

"Pressure" is the amount of force applied to the surface of a given area. For compressed
air and gases, this force is measured in pounds-force per square inch, or PSI. The higher
the PSI rating, the greater the amount of force applied to the air within a compressor.

Airflow volume is a measure of the rate at which air can move into a compression
cylinder and the machine can compress it. For air compressors, the volume of air is
measured in cubic feet per minute, or CFM. The higher the CFM value, the greater the
volume of air a compressor can generate.
 BEARINGS

8.1 Introduction

Bearing is very important part for any equipment. Bearing allows shaft to rotate at the lowest
possible coefficient of friction and carries the axial/ radial loads. If bearings are not
employed, the coefficient of friction for dry surfaces which is in the range of 0.24 to 0.40 will
dissipate large amount energy of the prime mover and this huge amount of heat will generate.
However with properly lubricated bearings the coefficient of friction will drastically reduce
and will b in the range of 0.005 to 0.10. Thus, it will save considerable amount of energy
which would have been wasted otherwise. Several types of bearings are available for specific
duty.

8.2 Bearing classification

1. Radial bearing : A bearing applied to a rotating shaft to hold its axis in line and prevent
movement in a radial direction.

2. Thrust bearing: A bearing applied to a shaft to prevent free endwise movement.

3. Angular bearing : A bearing to limit a shaft against both radial and axial movement.

4. Guides or ways: Bearings to permit end control the rectilinear movement of a sliding
machine element, as a ram or cross-head or slide.

5. Sliding surface bearings: In such bearings the two contact faces kept separated by a film
or lubricant like oil, grease, graphite etc.

6. Rolling contact bearings: In such bearings the two machine elements, moving and
stationary parts are kept away with balls and rollers in between and include all types of ball
and roller bearings.

7. Self-aligning bearings: The parts automatically align themselves when assembled and
loaded.
8.3 Bearing selection

Generally, the type of bearing in a particular equipment is selected by the equipment

manufacturer / designer. However, following factors are considered for the selection of a
particular type of bearing

(a) Radial / Thrust load

(b) Nature of load i.e. constant, fluctuating, cyclic load.

(c) Speed in rpm.

(d) Shaft diameter.

(e) Type of lubrication and their properties.

(f) Temperature.

(g) Corrosive service.

(h) Bearing life.

For heavy equipment running at very high speeds and having high loads, plain journal
bearings with force feed oil lubrication are used e.g. Centrifugal Compressors, Turbines etc.

For equipment running at medium speed having medium loads, the roller/ ball bearing with
oil / grease lubrication are used. e.g. motors, pumps etc.

The rolling contact (anti friction ) bearings are having following five main parts-

(1 ) Inner race ring.

(2) Outer race ring.

( 3) Cage or separator.

(4) Balls or rollers.

( 5) Seals.

20
These bearings are manufactured from steel, alloy steel and stainless steel. The balls/ rollers
and contact surface of the inner/outer races are hardened suitably to withstand wear and tear.
The brass, Babbitt, lead and gunmetal are widely used for plain journal bearing as these
materials possess very good bearings properties.

8.4 SAFETY RELIEF VALVES

With modern process industry becoming more and more complex in design and operation,
the safety of the mankind, equipment and the plant has become of utmost importance. Hence,
different kind of precise control devices are provided which will control various parameters
in order to make the operation safe, such as temperature control, flow control, pressure
control by precise instrumentation. For example, the steam pressure in boiler is controlled
automatically be controlling fuel firing in furnace. In spite of this, the emergency arises and
pressure becomes uncontrollable due to failure of such control devices, may be due to failure
in air supply or power supply in instrument or due to mal-functioning of the instrument.
However, in a continuous process plant, boiler can not be shut down.

22
 CONCLUSION

So this is all about the learning's at Indian Farmers Fertilizer Co-

operative Limited (IFFCO) within 30 DAYS. To do my summer
training in IFFCO was a phenomenal learning experience for me.
This one month was a joy ride for me in the mechanical field, and
now on completion of my training I can say that I have gained
very sound knowledge in mechanical field.