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SAFETY FIRST

The company keeps a strict check and balance on safety issues. It aims at producing its all product with safe and healthy acts.

WHY SAFETY FIRST? Keeps you aware of the Hazards and its consequences To ensure safe working environment and risk free atmosphere at plant site. Ensure compliance with all applicable safety related FFCL requirements, statutory requirements, government regulations, and industry standards. Ensure that safety requirements are appropriately applied to all project elements through appropriate interaction between the FFCL Team and Contractor. Implement a vital Safety Program which trains, motivates and rewards all employees for compliance and safety performance.

A BIRDS EYE VIEW OF THE PLANT

The plant comprises of various sections, in order to affectionately workout the plants production, protection, maintenance & distribution. The hierarchy of position distribution makes the system efficient and error free.

Plant has got the following important areas and distributions Control Rooms (CCR1, CCR2) Electrical Sub-Stations Administration Building & Technical services Building (TSB) Technical Training Centre (TTC) Workshops Material Warehouse Fire Station Laboratory Office cum Emergency Accommodation. (OCEA)

Every section is acting as a wing to support the plants production. The section heads are responsible to keep a strict eye on the performance of their respective sections. Work permits are issued from the concerned responsible persons before any job is performed at the plant site. The complex includes the following process units, offsite & utilities:

Process Units:
One Ammonia Unit (Re-located Plant) designed to produce 1500MTPD of NH3. One urea unit designed to produce 1500 MTPD of Prill Urea. One C.A.N. plant designed to produce 1500MTPD of granulated CAN. One Nitric Acid unit designed to produce 2500MTPD on 60% basis & 1500MTPD on 100% basis.

Utilities Production Units:


Power generation unit with 2 gas turbines of 26.0 MW each & 2 Emergency Diesel Generators. Raw water pre-treatment & Demineralization Units. Cooling water System. Heating, ventilation & Air Conditioning (HVAC) unit. (ISOLATED yet) Steam generation units include waste heat recovery. Instrument/service air system.

Off-Sites & Buildings:


Fire water storage & distribution system. Natural Gas receiving station. Waste water treatment facilities.

Finished Product, Raw Material & Chemical Storage:


Final Product storage & Bagging facilities. Ammonia Storage Tank of 5000MT capacity. One Nitric Acid Tank of 5000MT One Sulphuric acid storage Tank at Plant Site. Liquid Nitrogen Storage facility at Plant site. One Liquid Urea tank at Urea Side.

Objective:
The main objective of my 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. I was assigned to offsite & utility department for 4 weeks to understand all the offsite process and their working. Offsite mean the processes which are taking place away from the plant site e.g. water treatment process, natural gas receiving station and fire water storage and distribution system. Utility is that quality in a commodity by virtue of which it is capable of satisfying a human want. Air, water (free goods) and food, cloth etc. (economic goods) satisfies peoples wants and hence they possess utility. In the same way Industry also want utilities to run its processes smoothly e.g. polished water, steam, gas and electricity. The processes which I saw and learnt on the plant are as under.

Raw water Pre-treatment & Demineralization Units

Lime is mixed

General flow chart Water Reservoir


Direct Pipe line Cooling tower
Used in emergency

Sludge is removed Mixing Chamber

Neutralize the water Clarifier Tank Clarifier Basin

Remove turbidity & organics

Neutralization Basin Used Normally Dual Media Filter

Cooling tower

Hypochlorite is added, to remove impurities

Clarifier Storage Tank Fatima Town Potable Water Unit Plant (Domestic)

Condense water + Dual Media Filter Remove impurities, using chemical adsorption

Carbon Activated Filter Reverse Osmosis

Exchanging the cation water with resin

Cation Bed Exchanger

Degasifier

CO2 is removed

Anion Bed Exchanger Demineralized water Mixed Bed Exchanger

Exchanging the anion water with resin

Polished water

Detailed
Water is coming to Fatima Fertilizer from Ahmed Pur Lamma. 19 tube wells are installed at APL site which suck the water from the earth and with the help of 3 centrifugal pumps water is transferred from APL to FFCL. Water first comes to fire water pumping station where we have installed 4 pumps. 3 are motor driven and 1 is diesel driven pump. Diesel driven pump is used when we have total blackout at plant site (No Electricity) is available and 1 pump is always in operation to maintain the fire water pressure at 7bar. Water first passed through screens to stop the macro molecule e.g. leaves and sticks. And then it passed through settling pits of different capacity to settle down the stones and other impurities. After that water is moved to firewater pond and then to large reservoir of 52000 m3 capacity for storage. Water is transferred from storage reservoir to mixing chamber where lime is mix. Lime makes the solid particle in granular form. Then water is moved to clarifier basin where granular particle called sludge will settle down and with the help of slug pump remove all the sludge into sludge pit. Then water is moved toward neutralization mixing basin where we neutralize the water with different chemicals. Neutralize water is transferred to dual media filter, as its name is implying that it contains two filters, one anthracite coal and second pressurize sand filter. That is used to remove the turbidity, organic metals and de chlorination. Then this water is transferred to clarifier tank for storage then clarifier tank transfers the water to portable water unit. Where sodium hypochlorite dissolved into water it will slowly decompose, releasing chlorine, oxygen and sodium and hydroxide ions. 4 NaClO + 2 H2O 4 Na+ + 4 OH- + 2 Cl2 + O2 Whereas more filtration and cleaning action are performed, here all impurities are removed except minerals, gases and ions. Now here water is drinkable and useable for domestic purpose. So from here water is transferred to Fatima town for domestic purposes.

Demineralization Units
Carbon Activated filter: In demineralization process we remove all the minerals, gases and ions from the water to use it for industrial purposes. In demin unit first come carbon activated filter, water is taken from the condensation of plant process and from the dual media filter for make up level.

Carbon filtering is a method of filtering that uses a bed of activated carbon to remove contaminants and impurities, using chemical adsorption. Internal design of vessel contains 3 headers on the top containing 99 nozzles and in bottom we have 601 nozzles are attached with bed containing carbon activated filter, which filter the water. Ion exchange resins They are insoluble cross-linked long chain organic polymers with a micro porous structure. The functional groups attached to the chains are responsible for the ion exchanging properties. Resins containing carboxylic (-COOH) or sulphonic acid (SO3H) functional groups are able to replace their H+ ions with other cations, which comes in their contact whereas those containing basic amino (-NH2OH) or substituted amino (quaternary ammonium salts) functional group are able to replace their anions with other anions, which comes in their contact. The ion exchange resins are classified as: Cation exchange resins: Cations exchange resins are mainly styrene-divinyl benzene copolymers, which on sulphonation or caboxylation become capable to exchange their hydrogen ions with the cations in the water for example, AmberliteIR 120, Dowex- 50, and NalciteHCR. These can be represented as R-H+. Their exchange reactions with cations (for example, Ca2+, Mg2+) are shown below: 2R-H+ + Ca2+ 2R-H+ + Mg2+ Anion exchange resins: They are styrene-divinyl benzene or amine formaldehyde copolymers, which contain amino or quaternary ammonium or quaternary phosphine or tertiary sulphonium groups as an integral part of the resin medium. After treatment with dilute NaOH solution the above groups are able to exchange their OH- anions with the anions in the water. For example, Amberlite-400, Dowex-3, and Zeolite-F. These can be represented as R+OH-, their exchange reactions with anions (for example, SO4, Cl-, CO3 etc,) is shown as below: R+OH- + Cl2R OH- + SO-24 2R+OH- + CO-2 3
+

R2-2 Ca2+ + 2H+ R2-2 Mg2+ + 2H+

R+ Cl- + OHR+22SO-2 4 + 2OHR+2 2CO2- 3 + 2OH-

Regeneration: The ion exchange capability of these resins towards the exchange of ions from the water is based upon their ion exchange potential. These resins are said to be exhausted when ion exchange potential is lost/decreased. These exhausted Cation exchange resins can be regenerated by passing a solution of dil.HCl or dil. H2SO4 through the Cation exchange column. The renewal is represented as: R2-2Ca2+ + 2H+ Ca2+ + 2R-H-

The column is washed with de-ionized water and washing (contains Ca2+ Mg2+ and Cl- or SO4 2- ions) is passed to a sink or drain. The exhausted anion exchange column can be regenerated by passing a solution of dil. NaOH; the regeneration can be represented as: R2+2SO2-4 + 2OH2R+ OH- + SO2- 4

The column is washed with de-ionized water and washing (contains Na+ and SO42or Cl ions) is passed to sink or drain. Here in Fatima fertilizer same cation exchange resins and anion exchange resins are used. The water coming from carbon activated filter first passed through cation exchange resin tank, which is almost full of resin, the cation exchange material Remove the Ca2+ and Mg2+ ions, also remove all other positive metallic ions in the process and replace them with hydrogen ions instead of sodium ions. The metallic ions in the water get attached to the ion exchange material, which releases its hydrogen ions on a chemically equivalent basis. Then water is passed from degasfier, where CO2 is removed with the help blower. Now it is passed from anion exchange resin, then the partially treated water is passed through an anion unit containing an anion exchange material normally consists of replaceable hydroxyl anions and fixed irreplaceable cations. Now the negative ions in solution (the anions) are absorbed into the anion exchange material and hydroxyl anions are released in their place. Here our water is de ionized, it is called Demineralized water. This is shifted into the Demineralized tank with help of pumps. But still our water contain some ions, so we passed our water once again through mixed bed exchanger which contains both cation and anion exchange and in this same process is carried out, now the water is called polished water almost free of ions, gases and air. Then it is transferred into polished water tank and from there we transferred the polished water to plant machinery e.g. Boiler & STG.

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