Maint South Plants

CAN,NP, PHS
 32 MAINTENANCE
SOUTH PLANTS
CAN, NP AND PH&S
 Organogram – Maint South
UM
Maint South
Asif Ali Rajput

Sec Head Sec Head

CAN/PH&S NP-FM/ MM
Ihsan Ahmed Khurrum Fayyaz

Engr. CAN Engr. NP-MM Engr. NP-FM

Engr. PHS M. Saleem Usman Khalid
Nauman Anjum
Ismail Leghari Ahsan Latif M. Saad Khan
Javed Akhtar

Sup/Tech/3P Sup/Tech/3P Sup/Tech/3P Sup/Tech/3P

(18) (19) (19) (18)
 Maintenance Objectives
 To maintain mechanical integrity of equipment
through timely and quality maintenance
 To minimize cost of production by
 Minimize cost of maintenance (MTTR, Spares,
Rework etc.)
 Maximize production (Minimizing downtime)
 To support in improving product quality and
capacity enhancement
 Maintenance Objectives

 To achieve maintenance excellence, we need to

ensure
 Trained and skilled staff
 Sound maintenance regime (PMs, Condition
monitoring/ surveillance etc.)
 Efficient and advanced Tooling
 Spare parts inventory
 Root Cause Analysis (RCA)
 South Plants Maintenance
Philosophy

 South plants maintenance philosophy is different from

North plants due to
• Solid material handling and conveying
• Extensive wear and tear of parts
• Corrosive services
• Vibratory motions
• Conveyor belts and bucket elevators
CAN PLANT
CAN Plant
 CAN Plant AN

MTM Evaporator
Lime Stone Grinding Lime Bin
Cyclones
mill
Granulator

Dryer

Oil Amine Lump

Course Crusher
Screens
CAN Product Coating
Drum
Fine DR
Fluidized Screens Crusher
Bed Cooler
 Major Equipment / Machines
• MTM (Medium Speed Trapezium Mill)

For grinding of limestone into fine lime particles

• Granulator

Mixing of AN and lime powder to form CAN granules

• Rotary Dryer

For drying of product. It is the biggest machine of CAN Plant

• Bucket Elevators (03)

For product conveying. Two buckets elevators are chain type and one is belt type.

• Coating Drum

For oil amine coating of product.

• Product Screens

For screening of product size to ensure quality. Coarse screen & Fine Product screens
 Major Equipment / Machines
• Conveyor Belts

For product conveying.

• Lump Crushers

Crushing of lumps formed during process for recycling.

• AN Reactors

Reaction of Ammonia and NA to produce Ammonium Nitrate.

Lump Crusher Belt Conveyor AN Reactor

 Major Equipment / Machines

MTM Granulator Rotary Dryer

Bucket Elevator Coating Drum Vibrating Screens

NP
NP Plant
NP SECTION DM
W
Vent
NOx < 300 Block Flow Diagram
Antifo
NP Plant Simplified BlockA SCHEMATIC
NITRIC ACID ROCK PHOSPHATE
Urea
Diagram ILLUSTRATION OF THE
MAJOR PROCESS
ppm

am Soln. OFF GAS

ROCK Vent SCRUBBING
PHOSPHATE Gas Wash Liquid
2 Trains of 2 CSTRs in to EP
Wash Series
Acid INERT
SEPARATION Sludg BASIC GAS
6 Centrifuges in e SCRUBBING
Parallel Wash Liquid to
CRYSTALLIZATIO COOLANT EP
N REFRIGERA Liquid NH3
2 Trains of 8 Batch Steam
Crystallizers TION Condensa
NH te
3
FILTRATION 2 NEUTRALIZATIO
PRIMAR
Trains
EVAPORATION
N 2 Trains of PRILLING
H3PO4
CN Y Nitric
Phosphoric
2 Trains of 3 CSTRs in NP Soln. Thermosyphon Evap NP Melt
TH Acid Series
SECOND Acid NP
Steam
ARY Product

CN & AN Soln. 55-62% AN Sol. 92%

CN SECTION conc. AN conc.
NA
CN PRE- AN EVAPORATION
NEUTRALIZ. Soln.
CN
55%
conc. Steam Process
CC LIME Condensate To CAN PLANT
NH3 CO2
PRECIPITATION CC & AN FILTRATION
LIME DRYING
AC Wet Calcium
AC SYNTHESIS Carbonate
UNIT Dry Lime / CC
A Natural
ir Gas
 NP-Plant Equipments / Machines–
Section Wise
CNTH CRYSTALLIZATION
ROCK PHOPHATE ROCK PHOPHATE & FILTRATION
HANDLING DISSOLUTION & INERT  Tanks NEUTRALIZATION
 Bucket Elevators SEPARATION  Agitators
 Vibratory Screens  Tanks  Pumps  Tanks
 Grinders  Agitators  Rotary Drum Vacuum  Agitators
 Loss in Weight Feeders  Decanter Centrifuges Filters
 Screw Conveyors  Screw Conveyors  Vacuum Pumps

PRILLING SECTION COOLENT

SCRUBING &
PRILLING & PRODUCT REFRIGRERATION
DEDUSTING
 Pumps HANDLING
SYSTEMS
 Prilling Machines  SES Ammonia
 Fans  Prill Tower Scrapper Compressors
 Vacuum Pumps
 Belt Conveyors  Pumps
 Blowers
 Heat Exchangers

CN CONDITIONING LIME CONVEYING

LIME FILTRATION LIME DRYING UNIT
UNIT
 Tanks  Pressure Filter  Screw Conveyors
 Agitators  Bag Filters
 Screw Compressors  Disintegrator
 Heat Exchangers  Screw Conveyors
 Pumps  Furnace
 Pumps  Rotary Valves
 Belt Conveyors  Blower
 Blower
 NP-Plant Machines – Installed
Quantity

A total of 233 drives are installed at NP plant. Details are:

Machine Category Qty Installed Machine Category Qty Installed

Agitators 46 Grinder 2

Centrifuge 6 Rotary Valve 7

Compressor 5 Vibratory Screen 1

Blower 12 Distributors 2

Fan 6 Screw Conveyor 17

Pumps 105 Belt Conveyor 10

Bucket Elevator 3 Prilling Equipment / Column 1

Drum Filter 4 Prilling Tower Scraper 1

Pressure Filter 1 Prilling Bucket 2

RT Filter 1 Disintegrator 1
 NP-Plant Major Equipment –
Brief Overview
Dissolving Reactors
1. Dissolving Reactors play major part in plant
production and these are present in very first
step of production. Major dissolution of Acid and
Rock Phosphate is done here.
2. Material of this Tank is SS-316L an thickness of
5mm.
Centrifuges
1. Centrifuges are used to separate inerts like Silica
from soultion of dissolving tanks.
2. Decanter type centrifuges are of Japanese Origin
(M/S Sojitz)
3. These centrifuges are dual drive having a
differential speed between outer bowl and inner
screw.
4. Mjor correctives jobs that are done on
centrifuges are bellows and Bowl tiles.
 NP-Plant Major Equipment –
Brief Overview

Pressure filter
1. Pressure Filter is the critical machine of NP Plant.
It separates Ammonium Nitrate and Calcium
Carbonate (CACO3) from slurry. Both these
Ammonium Nitrate and Calcium carbonate uses
as raw material for production of CAN fertilizer

RVDF
1. To remove CNTH crystals and extract mother
liquor (phosphoric acid).
2. A total of 04 drums are installed. Out of which 02
are primary and 02 are secondary.
3. All four drums have nylon cloth and SS mesh for
separation of CNTH cystals.
4. 06 Vacuum pump are installed to provide the
required vacuum for mother liquor extraction.
 NP-Plant Major Equipment –
Brief Overview
Liquid Ring Vacuum pumps installed at NP plant are used to provide vacuum for
mother liquor extraction in RDVF.
 NP-Plant Major Equipment –
Brief Overview

Belt conveyors are installed in the

RP Grinders serve the purpose of
product handling, lime filtration, drying
grinding coarse RP into fine RP.
units to handle product and wet lime.
 NP-Plant Major Equipment –
Brief Overview

Bucket Elevators are installed to serve the purpose of bulk material.

A total of 03 bucket elevators are installed.
Out of 02 are belt type and are used for RP handling.
3rd one is chain type and used for product cooling as per requirement.
 NP-Plant Major Equipment –
Brief Overview
Multiple screw conveyors are installed throughout to handle RP, decanter sludge, RDVF
repulped cake, wet and dry lime.
PH&S
PH&S (Product Handling &
Storage)
 Major Equipments
• Conveyor Belts (Urea / CAN / NP / RP)
• Reclaimers
• Vibrating Screens
• DDU Unit
 Conveyor Belts

The product handling system is divided into two main

lines :
1. Bulk Handling
2. Bagging

Bulk line is further divided into two categories:

1. Cycle-I: Transfers product from plant to bulk
storages.
2. Cycle-II: Transfer fresh product or product from
bulk storage to bagging building
Total no of Conveyors 181. (38 bulk , 143 bagging)
Total length of Belt Conveyors is 8110 Meter.
 Reclaimers

Reclaimers are used for product reclamation

from bulk stores.
Main components of reclaimers are Chain,
Buckets, Fluid coupling & Driving gearbox.
Total no. of Reclaimers : 03 (Urea, CAN, NP)
 Vibrating Screens
Vibrating Screens are installed to ensure product quality. Purpose of these screens is to
screen out oversize and fine product from normal size product.
Total 6 screens are installed
 De-Dusting Unit

De Dusting Units are installed on Urea, CAN &

NP bagging system. Purpose of dedusting units is
to extract dust of fertilizers during its conveying
and screen out this useful dust before emission
into the atmosphere.
De dusting system consists of Bag filter house,
Blowers, Screw conveyors and Rotary valves.
08/05/2024 PH & S Plant 32
South Maint Workshop
Maintenance Workshop –
South Plants
 FM-South Workshop Facility
FM-South workshop has following facilities

1. Management Offices (Area Engineers)

2. Staff Offices (Maintenance, E&I, Scaffolding team)
3. Fabrication Area
4. Machines Reclamation Area
5. Tool Room
6. Stores (spare parts)
7. Insulation Area
8. Valves Reclamation Area
9. Hose Hydrotesting Area
10. Canteen