Six Months Industrial Training File Including Project Report

Degree : Mechanical Engg

College : Global college of engineering and technology khanpur khui ( Ananadpur sahib )
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, NAYA NANGAL. This industry helped me to boost up my practical skills correlating the
theories of book into actual work environment.

A TRANING REPORT
On
Six Month Industrial Training
At
NATIONAL FERTILIZERS LIMITED
NANGAL UNIT
Submitted to
PUNJAB TECHNICAL UNIVERSITY, JALANDHAR
In partial fulfillment of the requirements for the award of Degree of Bachelor of Technology
In
Mechanical Engineering
By
RAJAT KUMAR
100331130054
Under the guidance of
Er.VISHAL JASWAL A.K. SAINI
Academic Tutor Industrial Tutor

Department of Mechanical Engineering Global College of Engineering & Technology

Anandpur Sahib
INDEX
Sr.No. TOPICS PAGE NO.
1 PREFACE 3
2 ACKNOWLEDGEMENT 4
3 INTRODUCTION TO N.F.L 5
4 NAYA NANGAL UNIT 9
5 N.F.L AT A GLANCE 12
6 MECHANICAL WORKSHOP 13
7 UREA PLANT 33
8 STEAM GENRATION PLANT 50
9 PROJECT 66
10 HOW INDUSTRIAL TRAINING IS USEFUL
85
11 REFERENCE 86
LIST OF FIGURES
SR. NO. DESCRIPTION PAGE NO.
1. NFL PLANTS LOCATION 5
2. FRODUCTION SHARE OF NFL IN COUNTRY 6
3. LATHE MACHINE 15

4. PARTS OF LATHE MACHINE 17

5. SLOTTER MACHINE 38
6. SHAPER MACHINE 40
7. PARTS OF SHAPING MACHINE 46
8. PARTS OF MILLING MACHINE 51
9. GRINDING MACHINE 54
10. PLANNER MACHINE 55
PREFACE
Mechanical is a multidiscipline subject, which embraces physics, metallurgy thermodynamics,
mechanics fluid, chemistry and electrical principles and as such is an interesting and often
stimulating area of engineering.
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, NAYA NANGAL. 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 period of 6 weeks. The report concerns with the
workshops, ammonia plant, steam generation plant, urea and begging plant and section where I
have been deputed in the training.
The information and data furnished in the context are on the basis of my information collected
through interaction with the Engineers, Technocrats, Technicians, and Workers working in the firm.
Despite taking every effort to procedure an error free report, I apologize for any mistake in the
context on my part.
The main objective of industrial training is to enable the students to apply the theoretical
knowledge to practical situations &to expose themselves to the industrial environment. It helps the
students to understand the importance of discipline, punctuality & teamwork & also cultivates a
sense of responsibility in them. With the help of training students get exposed to the current
technological developments & also understand the psychology of the workers.
ACKNOWLEDGEMENT

Out of deep sense of gratitude I express my sincere thanks to Mr.N.K Gupta (Sr. manager, HRD
deptt.), Mr. Umesh Kumar (Ammonia II workshop) and Mr. Ram Prasad,(mechanical workshop) for
timely helping me in the technical and operational aspect
I sincerely express my thanks to Training and placement incharge, Global College, Anandhpur
Sahib for providing me this opportunity.
I express my sincere thanks to Mr. N.K.Gupta (Sr.Manager,HRD Dept. NFL Nangal) for their timely
help. I am equally thankful to Mr. Tara Chand (Manager Mechanical Workshop), Mr. S.K.Negi
(Manager Ammonia), Mr. K.P.Singh (Manager SGP) & Mr. Amrit Lal (Manager Urea & Begging) for
helping me with the technical and operational .
This project would not have been a success without my dear friends in this department. I am
grateful to each and every one of them for their love and affection extended to me.
Without the support and wishes of my parents, I could have never completed my project work.
From depth of my heart, I acknowledge them with regared and affection.
RAJAT KUMAR
100331130054
INTRODUCTION TO N.F.L.
Today, NFL stands for hope, prosperity and growth. It has succeeded in enthusing its people with
a sense of dynamism and pride by developing a work culture, where team spirit takes precedence
over personal factors. NFL is already geared up to meet the challenges of 21st century. National
Fertilizers Limited has been established as a conglomerate of fertilizer units on 1st April 1978.
Presently, 5 world scale fertilizer plants and a bio-fertilizer plant are under the ambit of NFL
operating in different parts of the country.
They are:
NFL Nangal unit(Punjab)
NFL Bathinda unit(Punjab)
NFL Panipat unit(Haryana)
NFL Vijaypur 2 units(Madhya Pradesh)

 Bio-fertilizers Indore unit(Madhya Pradesh)

NFL is the largest producer of Nitrogenous Fertilizers in the country with installed capacity of
13.70 lakh tons of N per annum i.e. 28.5 tones of
Urea and 3.18 lakh tones of CAN (calcium ammonium nitrate). The average contribution of
nitrogen fertilizer during the preceding five years has been around 13.5%. The name and address
of the industry is as:
National Fertilizers Limited
(A Govt. Of India Undertaking)
Nangal unit,
Naya Nangal,
Dist. Ropar,
Punjab.
Pin-140126.
Brief History of NFL, Nangal Unit
The decision to establish a fertilizer factory at Nangal was taken in 1954 by the Fertilizer
Production Committee, Govt. of India.
Reasons for Setting up Fertilizer Plant (i.e. Calcium Ammonium Nitrate (CAN) Fertiliser) and
Heavy Water Plant at Nangal: The main factors responsible for setting up these plants at Nangal
were:
1) The availability of cheap and abundant power from nearby Bhakra Dam
2) Inter-dependence of the process for the production of Heavy Water (a key material used in the
production of nuclear power) & CAN Fertilizer
3) Suitability of CAN fertilizer to the northern zone
4) Good rail & road communication facilities and

5) Availability of cold water from Sutlej River near the factory.

CAN Fertilizer Plant was commissioned in February 1961 and Heavy Water Plant in August, 1962.
For the establishment of these plants at Nangal, a company in the name of Nangal Fertilizer and
Chemicals Pvt. Ltd. was incorporated on February 17, 1956. Subsequently when the work of
setting up of a project at Trombay was further entrusted to this company, its name was changed
on July 15, 1959 to Hindustan Chemicals and Fertilizer Ltd. Again, when the Govt. of India
decided to amalgamate all the existing fertilizer factories under its control to form one corporation,
the name was changed on January 1, 1961 to FCI (Fertilizer Corporation of India).
NFL (National Fertilizers Ltd.) was incorporated on 23rd August, 1974 for setting up of two Urea
fertilizer plants (along with Steam Generation Plant & Fuel Oil based Ammonia Plant) i.e. one
plant at Bathinda (Punjab) and the other one at Panipat (Haryana) having an annual installed
production capacity of 5.11 lakh MT of Urea each. The commercial production of Urea in these
plants was achieved in 1979.
In 1977-78, at Nangal, one Urea Plant (along with Steam Generation Plant & Fuel Oil based
Ammonia Plant) having an annual installed production capacity of 3.30 lakh MT of Urea was
erected and commissioned. On 1st April, 1978, Nangal Group of Plants of FCI were transferred to
NFL upon reorganization of NFL & FCI.
In 1984, NFL started to set up its 4th Urea Fertilizer Plant at Vijaipur (Distt.- Guna) in Madhya
Pradesh, having an annual installed production capacity of 7.26 lakh MT of Urea. The commercial
production of Urea at Vijaipur was achieved w.e.f. 01.07.1988. Later on expansion of Vijaipur Plant
by setting up another Urea Plant having similar capacity of 7.26 lakh MT of Urea adjacent to the
existing plant was taken up in 1993 for doubling its annual production capacity. The commercial
production of Urea from Vijaipur Expansion Plant was achieved w.e.f. 31.03.1997. Later on, the
Deptt. Of Fertilizer revised the annual installed urea production capacity of Vijaipur Plants (1 & 2)
from 7.26 lakh MT to 8.64 lakh MT of Urea of each plant w.e.f. 1st April, 2000. Each plant (i.e.
Vijaipur Plant-1 & 2) comprises of one stream of Ammonia Plant and two streams of Urea Plant
with one Periling Tower.
Present Installed Annual Urea Production Capacity of Nangal Unit: 4.785 lakh MT of Urea. In Feb,
2001, Urea plant at Nangal was revamped to increase its annual installed production capacity
from 3.30 lakh MT of Urea to 4.785 lakh MT of Urea.
Present Installed Annual Urea Production Capacity of NFL: 32.31 lakh MT of Urea.
NAYA NANGAL UNIT

The Nangal unit of NFL acted as a paragon of excellence in the field of development of the
fertilizer industry in India. It has about 1600 employees working in different plants of the
organization. Nangal unit began with the commissioning of the first fuel oil based fertilizer plant in
India with rated capacity of 900MT/day Ammonia and 1000MT/day Urea. The adoption of versatile
technology and desire for related diversification led to the manufacture of various products and byproducts like Nitric acid, Ammonium Nitrate, Liquid Nitrogen, Liquid Oxygen, Industrial gases, etc.
LOCATION OF THE FACTORY
The factory is located near Nangal Dam and 8kms from Bhakra Dam. The nearest railway station
is Nangal Dam which is connected with Delhi and Saharanpur via Ambala Cant. Shivalik hills of
the great Himalayas are situated 10 km different the area of Punjab and Himachal Pradesh from
the factory and differentiae area of 7X2 sq.km including its township for employees. The one side
of the factory touches another factory of the state govt. PACL (Punjab Alkalis and Chemicals
Limited). The availability of cheap and heavy amount of power from Bhakra is due to the direct
convenience through both, road and sail and large amount of water from river Satluj. Good
weather conditions and cheap labor is another advantage. The location of NFL Naya Nangal is
really unique.
VARIOUS PLANTS OF N.F.L.
Ammonia Plant
Steam Generation Plant
Urea Plant
Bagging Plant
Nitric acid Plant
Methanol Plant
PRODUCTS MANUFACTURED
Nangal unit offers following industrial products:
Nitric acid (54%)
Anhydrous Ammonia

 Ammonium nitrate Liquid & Solid

Methanol
Urea
Mill Rejected Coal
Carbon Slurry
Ash Slurry
Element Sulpher
Nitrogen Liquid
Hydrogen Liquid
Oxygen Liquid
Carbon Dioxide Liquid (98%)
BI-PRODUCTS
Sodium Nitrate
Sodium Nitrite
NATIONAL FERTILIZERS LIMITED AT A GLANCE
Cost (in crores):
Urea plant 132.00
Industrial Capacity (in tones)
Urea plant 330000.00
Raw Material Requirement
Electricity 40 MW

 Water 80 M Gallon/day
Fuel oil 720 tons/day
Coal 900 tons/day
Naphtha 180 tons/day
Total Production
Urea 1450metric tones/day
Methanol 67 tons/day
Ammonia 900 tons/day
MECHANICAL WORKSHOP
Mechanical workshop at NFL unit mainly committed to the maintenance and repair work. Various
maintenance jobs are done here as per the job orders given by different plants of NFL unit. The
mechanical department has futher different workshops namely-:
Machine shop
Fabrication shop
Fitting shop
Earthmoving shop
Refrigeration shop
Details of the different workshops is given as following.
Machine shop
Fitting shop
Fabrication shop
Earthmoving shop

 Refrigeration shop
Machine shop
Machining of a material involves repeated removal of material from the job to give away the
required shape and size.
Machine shop has various machines that are being used for the machining processes of the jobs
from the plant. Some of the machines in the shops are
SLOTTER MACHINE
LATHE MACHINE
GRINDER MACHINE
BORING MACHINE
DRILLING MACHINE
MILLING MACHINE
PLANNER MACHINE
SHAPER MACHINE
SHEARING MACHINE
SHEET CUTTING MACHINE
LATHE MACHINE
Lathe is a power driven, genral purpose machine used for producing mostly
cylindrical jobs or work pieces. As the piece of metal to be machined is rotated on the lathe, a
single point cutting tool is advanced racially in to the work
piece,removing the metal marterial in forms of chips.Main difference between
lathes where as in the the other machines cutting tools is moved an the work
piece remains stationary.

Parts of Lathe Machine

HISTORY OF LATHE
Most versatile machine tool in the machine shop
Oldest ancestor is the potters wheel(4000B.C)
Next came pole lathe
This was developed into current lathe which are able to make threads
Father of modern lathe HENRY MAUD SLAYS
Types of lathe machines found in the NFL mechanical workshopCentral lathe
Turret lathe
Capstan lathe
Centre lathe or engine lathe
It is most important and widely used machine in the lathe family.its name is derived from the fact
that the earliermachine tools were driven by separate engines or from the central engine with over
head belt and shafts .The stepped cone pulley or gear head are often used for varying the speed
of the lathe machine
Turret lathe
It is a production machine used to perform a lot of task or operation on a single job with minimum
wastage of time.Indexable square tool is Provided on the cross slide or the mounting turning and
parting of tool. The Turret usually accommodates tools for different operations like drilling ,counter
sinking etc
Capstan lathe
These are similar to turret lathe and incorporate capstan slide which moves on a clamped in any
position.It is the best suited for the large scale production of small parts because of its light weight
and short stroke of capstan slide

SLOTTER MACHINE
Slotter machine is also called as vertical shaper machine .the difference being that the ram is in
vertical direction instead of horizontal position.Also the table or bed is mounted on a heavy base
and provided with mechanism that make possible forward backward and side to side movement .
it also has adjusted head mechanism .
Advantages of vertical shaper or slotter machine :1. Setting of the job is more convenient because it is easier to see, align, measure, clamp
2. Press generated by the cutting stroke is better supported by the table bed
3. Circular and hollow jobs can be worked upon
4. Ram of vertical shaper can be adjusted up to 10 degrees.
Main functions of slotting machine : Internal key ways
Tapered key ways
Slots
Centric slots
Internal gear
SHAPER MACHINE
Shaping machine is generally called as shaper. Shaper is being used for both
production and tool room work. The shaper can machine a flat surface on a
horizontal , vertical , angular plane. On this tyoe of machine ,many types of work pieces can be
machined depending upon the tools used and the manner of
adjusting the various parts of the machine . Size of the shaper is determined by
the largest sized cube that can be machined on it. Working principal is quick
return mechanism and forward stroke is cutting stroke and backward is idle

stroke.
Difference in shaper and lathe machine :In shaper straight cutting is done where as in lathe circular cutting is done In shaping machine the
tool moves in reciprocator fashion whereas in the lathe machine the tool remains stationary and
the work piece moves.
Parts of Shaping Machine are :BASE : it is the reservoir for supply of oil circulated to the moving parts of machine
ARPON: it supports the table
RAM: It is the main moving part of the shaper machine. It holds and
drives the cutting tool back and forth across the work .
This is attached to rocker arm which is given an oscillating motion by
turning of a large driving gear .this also has an adjustable pin attached to
driving gear which acts as a crank which determines the length of the ram
TOOL HEAD: it holds the cutting tool. it is attached to the front of the
ram. Tool post is fastened to the clapper box
Main functions of the shaping machine :
Making slots
Tapered slots
external key on shaft
Hexagonal nut heads
Square nut head
MILLING MACHINE

Milling machine is one of the most versatile and widely used machine tool for
tool room and production purposes.
Milling is the process of removal of the material with the help rotating multiple cutting tools called
as milling cutter. In general the work piece is fed into the rotating milling cutter
Parts of the milling machine :Column
Knee
Saddle
Table
Spindle
Over arm
COULMN: It includes the base which I the main casting which supports the other parts of machine
. The front of the column, the column face is machined to provide an accurate guide for the
vertical travel of the knee
KNEE: It supports the saddle .feed change gearing is enclosed within the
knee.knee can be raised or lowered on the column face.it is supported and can
be adjusted with a elevating screw.
SADDLE: It supports the table . It is supported by the surfaces of the knee
TABLE: It holds the workpiece. It has T-slots and is used to hold the
jods .bolts fit loosely in the T-slots and are used to clamp the vice.
SPINDLE: it holds and diverts various cutting tools.it has the shaft mounted
on the bearing supported by the column.
OVER ARM: it is mounted on the top of the column. It is guided by the

machined dovetail surfaces

GRINDING MACHINE
Grinding is the process of finishing surface by means of revolving abrasive wheel
In order to finish the job piece efficiently one must not only be able to operate
The grinder but also understand abrasive and grinding wheels ,their shapes and
sizes for different type of work
ABRASIVE: An abrasive is any material that can wear material softer than
itself .sand and sandstone are perhaps the oldest abrasives known to mankind.
Abrasives can be natural or manmade.
Natural Abrasives: Emergy and corundum are two commonly used in the
Industry to sharpen tool edge They occur as a miner deposit in the earth crust .Aluminum oxide is
the best suited for grinding material that has high tensile strength such as high spee steel and
high carbon steel.
Man made Abrasives: these are better than natural ones because in these
purity and grain size can be controlled.
GRINDING WHEELS: Grinding wheel are formed by using a suitable material to cement, bond,
abrasives grains together in the desired shape and size. Hardness of the wheel is dependent
upon the amount and kind of binding
material being used. Hardness of wheel is always understood by means of
strength of bond.
TYPES OF GRINDING MACHINES
Surface Grinder
Cylindrical Grinder
Internal Grinder

 Thread Grinder
SURFACE GRINDER: Surface grinding is the process of producing a finished flat surfaces by
means of grinding machine employing revolving abrasive wheel. Surface grinder machine consist
of spindle mounting a grinding wheel and table or magnetic chuck for holding the work piece
Uses of Abrasive Grinding : Sharpening cutting
Snagging
Finishing
PLANNER MACHINE
Planer is one of the basic machine tools used in machine shop. Main function is
to produce flat surface on piece of work. The main difference between planer
and shaper is that in planer machine the work piece moves In reciprocating
motion while tool is fixed where as in the shaper machine it is other way
round. It can be distinguished in two either Hydraulic or Mechanical.
Main parts of Planer Machine are:
Bed
Table
Saddle
Tool head
FABRICATION The process of joining metals or non-metal to from an object which has specific
shape .This process is known as fabrication. Different types of machines and welding are used in
the fabrication process or to fabricate an object.
THE WORKDONE AT THE SHOP ARE CLASSIFIED AS :
1) Metal cutting method :-

Oxy fuel gas cutting

Plasma cutting
2) Metal joining method :Oxy-acetylene welding
Arc welding
Tungsten inert gas welding
Oxy-acetylene Gas welding:
This process is particularly suitable for joining metal sheet and plates and having thickness 2 to
50mm.
The filler metal is the addition metal, which is added to weld in the form of welding rod.
The composition of the filler rod is usually the same or nearly the same as that of the part being
welded.
To remove the impurities and oxides present on the metal to be joined and to obtain stationary
bond flux is always implied during the welding expect sheet.
Various gas combustions can be used for producing a hot flame for welding metals. Common
mixture of gases oxygen and other fuel gases.
The oxy-acetyl welding mixture is used to a much greater extent than other in the welding
industry.
The temperature of this welding flame in its hottest region is about 3200 C.
CaC2 + 2H2O C2H2 + Ca(OH)2
ARC WELDING METHODS
Metal arc welding: In the arc welding metal rod is used as an electrode,
while the work being welded is used as another electrode. The temperature
produced is about 2400C and 2600C on the ve and +ve electrode

respectively. During the welding operations, this metal electrode is melted

by the heat of the arc and is fused with the base metal, thus forming a
solid union after the metal has been cooled. Both AC and DC can be
used .Adjusting the machine to correct amperage, which is determined by
then size of the rode to be used ,start the welding operations. The correct
welding speed is important.
SPECIFICATION OF ELECTRODES:
Where
1. E is used for covered electrode that is for coated electrode.
2. Next two XX multiplies with 1000spin shows the tensile strength.
3. Next X shows the position of joint to be welded in current condition i.e. it may horizontal, vertical
or inclined
4. Last X shows the types of coating.
UREA PLANT
Urea plant has a rated capacity of 1550Te/day of prilled urea produced in a single stream plant
employing MITSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS.
Features of the plant are as under:Sl no. Features MTC-C-IMPROVED
1. Type of process Conventional
2. Molecular ratio
NH3 : CO2
H2O : CO2

4:1
0.544:1
3. Conversion percentage 70%
4. Reactor conditions
Pressure kg/cm2
Temperature 0C
250
200
5. Reactor lining Titanium
6. Reactor features Hollow
7. Excess NH3 recycle As liquid NH3
8. Decomposition stages 1st: 17.5kg/cm2
2nd : 2.5 kg/cm2 ( 5% CO2 fed to 2nd decomposer)
3rd: 0.3 kg/cm2
9. Heat recovery in carbonate condenser For supplying heat to crystallization to urea slurry and
heating hot water.
10. Sp. Cons.
Te NH3/Te urea
Te CO2/Te urea
Power /Te urea KWH
Steam /Te urea
0.58

0.76
86.4
1.24
11. No. of conc. Stages One
12. Type of prilling tower Induced draft
13. Approx. prilling height 40M
14. Salient features a.) power saving as 5% CO2 is fed to LD
b.) P.T. height is less cause of cooler at bottom.
c.) Low biuret
d.) Because of Ti lining in reactor corrosion rate is less and thinner liner.
e.) Water recycle is less due to counter current flow of liquid and vapour in decomposers.
The plant is divided into four sections:
1. Synthesis section.
2. Decomposition section.
3. Crystallization and prilling.
4. Recovery.
5. The brief description of various sections is given as under:
SYNTHESIS SECTION
In MITSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS liquid ammonia is recycled since
it is easier to handle but require equipments like rectification column storage tanks etc. and higher
capacity liquid ammonia pumps.
Recycling of carbamate requires higher capacity carbamate pumps.
CO2 is received from ammonia plant at a pressure of 0.2 kg/cm2 and 200C and is compressed in

a centrifugal booster compresser,UGB-101 to 32 kg/cm2 in 3 stage unit. The compressor supplied

by M/S BHEL has a normal capacity of 25256NM3/hr and has 2 barrels 2 M.C.L. 805 and MCL
455. The drive of the compressor is an extraction and condensing type by steam turbine supplied
by M/S BHEL. The turbine is driven by 40K super heated steam and has a rated output of
5792KW.
UREA SYNTHESIS
2NH3 + CO2 NH2CONH4, H = -37.64Kcals 1
NH2CONH4 NH2CONH2+ H2O, H = 6.32Kcals 2
Where as reaction 1 is an exothermic and rapidly goes to completion of 2 and is endothermic and
is always incomplete. The overall reaction is exothermic and hence heat has to be removed
continuously for the equilibrium reaction to proceed. The conversion of ammonium carbamate to
urea depends upon:
1. Reaction temperature.
2. Mol. Ration of NH3/CO2, H2O/CO2 of the feed reactants.
3. Residence time.
The conversion increases with the increase in temperature, NH3/CO2 ratio and residence time
and decreases with H2O/CO2 ratio since the presence of water tends to shift reaction 2 in the
backward direction. The pressure employed depends on the reaction temperature and has to be
kept higher than the dissociation pressure of ammonium carbamate at that temperature. Further
since the dehydration of ammonium carbamate to urea takes place in liquid phase only. The
pressure employed must also be higher than the vapour pressure of ammonium carbamate which
is rather high.
High ratio of NH3/CO2 increases conversion and helps to minimize corrosion. As this ratio
increases the load on recovery section increases since excess NH3 over stoichiometric
requirement has to be recovered and recycled back to reactor. This excess ammonia can either
be recycled as liquid NH3 or carbamate. In each case it becomes necessary to inject CO2 into
carbamate condensers.
The compressed CO2 is washed with water in a packed bed tower called methanol absorber for
removal of entrained methanol in CO2 which is normally 100ppm. The washed CO2 is further
compressed to a pressure of 260kg/cm2 in a two stage compressor, UGB-102 supplied by M/S
KOBE STEEL, JAPAN. This reciprocating compressor has a normal capacity of 26260NM3/hr and

is driven by a 2.2MW synchronous motor. Anti corrosion air at the rate of 120NM3/hr is fed to CO2
at the suction of centrifugal CO2 booster compressor.
Liquid ammonia at 110C and 18kg/cm2 pressure is received in the ammonia reservoir, UFA-401
from the Horton sphere. Ammonia booster pump UGA-404A&B boost the pressure of the feed
ammonia to 24kg/cm2 and feeds at the suction of plunger type ammonia feed pumps UGA-101AD. the ammonia feed pumps are of URACA MAKE driven by 3.3kV/450KW and have capacity of
53.2M3/hr, 178RPM and 89% efficiency. The ammonia preheater UEA-101 and 102. The
preheated ammonia at 85.30C is fed to the urea reactor at bottom.
The recycled carbamate solution of CO2 concentration, 7.5 lit per 25ml, at 1050C and 260kg/cm2
pressure is delivered to the urea reactor at bottom by recycle carbamate solution pumps UGA102A&B. these pumps are centrifugal type and are driven by back pressure steam turbine,
supplied by M/S EBARA,JAPAN and have a capacity of 81M3/hr.
The three feeds i.e. CO2 liquid ammonia and recycled pump solution are fed to a Ti lining multi
layer urea reactor. The reactor is a 12 layered C.S vessel with Ti liner thickness of 5mm, 4mm and
3mm for the 1/6th, 1/6th and 2/3rd of total height of the reactor from bottom. The reactor top
temperature is maintained at 2000C maximum. The effluents from urea reactor from top are let
down to 17.5kg/cm2 pressure through a pressure control valve PCV-101 and fed to the high
pressure decomposer at 1240C.
DECOMPOSITION SECTION
MITSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS is a conventional process.
The decomposition reaction
NH4COONH2 2NH3 + CO2
Is favored by lower pressure of system or by low partial pressure of one of the reaction products
i.e. NH3 and CO2. Conventional process means the process where the decomposition is affected
by lowering in pressure in successive stages followed by indirect heating whereas the processes
where decomposition takes place by lowering the partial pressure of either NH3 or CO2 followed
by indirect heating are called STRIPPING PROCESSES.
The reactor effluents at 17.5kg/cm2 and 1240C enters the part of high pressure decomposer UDA-201 having sieve trays at upper and falling film heater at lower section. The flashed gases go
up and liquid flows down through sieve trays. On 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 vapour are used to evaporate the excess ammonia and to

decompose the carbamate.

This helps in minimizing water evaporation and thus reducing water recycle to reactor. The
reboiler further heats the liquid by 12kg/cm2 steam to release excess ammonia and carbamate
gases. The temperature at middle is maintained at 1510C by a temperature control valve TCV201. The temperature at bottom is maintained at 1650C through TCV-202. The falling film heater
is used to minimize residence time in order to reduce biuret formation and hydrolysis of urea.
Anti corrosive air is fed to high pressure decomposer and reboiler through air compressor UGB201@ 2500ppm as air. Overhead gases from HD are absorbed in HAC(high pressure absorber
cooler). The bottom liquid flows to L.D. (low pressure decomposer) at 2.5K, 1450C,upper part,
having 4 sieve trays. A similar phenomenon occurs in the low pressure decomposer. The reboiler
U-EA-202 provides heat using 7kg/cm2 steam for decomposition and hot stream from H.D heats
up the solution from L.D in an exchanger before entering the upper part. The temperature is
maintained at 1300C at middle by TCV-203. Small amount of CO2 is fed below packed bed for
improved stripping of decomposed gases. The overhead gases from low pressure decomposer
are absorbed in low pressure absorber U-EA-402. Bottom liquid flows to 3rd stage of decomposer
called gas separator U-DA-203. The upper part of gas separator operates at 1060C, 0.3K and
lower part with packed bed operates at 1000C and atmospheric pressure. The sensible heat of
solution from low pressure decomposer is enough for evaporating the overhead gases. In the
lower part, air containing trace amounts of NH3 and CO2, is blown under the packed bed, by off
gas recycle blower UGB-401. The urea solution is concentrated to 70-75% and sent to
crystallization section.
CRYSTALLIZATION AND PRILLING SECTION :
The urea solution obtained from the last decomposition stage i.e. gas separator contains 25%
H2O since every mole of urea one mole of H2O is formed. Urea has to be concentrated to 99.5%
before prilling.
MTC-C-IMPROVED PROCESS employs crystallization-remelt prilling route and uses spray
nozzles for prilling. The prilling tower is of induced raft type.
The solution from gas separator enters lower part of crystallizer, U-FA-201. The upper part is
vaccum concentrator with two stage ejectors and barometric condenser.
In vaccum concentrator. Operating at 75mm of Hg and 600C, water is evaporated and
supersaturated urea solution comes down through barometric low into the crystallizer, where urea
crystals grow. The heat required for water evaporation comes from:

1. Sensible held of feed urea solution.

2. The heat of urea crystallization.
3. Heat recovered by urea slurry circulated through high pressure absorber.
The crystallizer is operated at 600C and atmospheric pressure, so the slurry leaving the bottom
contains 30-35% urea crystal by weight.
Hot water from hot water pump is used in jackets of crystallizer and pipe to avoid crystal build up
on vessels walls which may cause choking otherwise. The urea slurry is pumped from crystallizer
bottom to centrifuges U-CF-201A-E (1000RPM, 43Te/hr of slurry) maintaining minimum
recirculation to crystallizer to prevent choking of lines.
Biuret remains with mother liquor, which after separation from urea crystals in the centrifuges is
recycled back to the system. Because of excess ammonia in reactor biuret, thus recycled is
converted back to urea.
NH2CONHCONH2 +NH3 2NH2CONH2
Urea crystals separated from slurry with 2-4% moisture are discharged to fluididsing dryer UFF301 at 1100C. The mother liquor flows down to mother liquor tank, provided with steam coils.
Mother liquor is pumped back to crystallizer via LCV-207. a part of mother liquor going to low
pressure absorber has been cutoff and instead dust chamber overflow solution has been lined up.
Air is blown from blower U-GB-301(82360NM3/hr) and heated to 1000C in air heater. This hot air
droes the crystals to 0.1% to 0.3% moisture content. Dried crystals are conveyed by a pneumatic
duct to cyclones at the prilling tower top. The collected crystals are melted in melter (1370C) and
urea melt is sprayed through 12 nos. acoustic granulators. Prills are cooled in fluidizing bed called
CFD,installed at the prilling tower bottom. Air/cyclone scrubbed for urea dust separators. Air
containing urea dust from P.T column is scrubbed with water and passed through 144 sets of poly
urethane filters before exhaust to atmosphere to reduce air pollution.
RECOVERY SECTION
The gases from gas separator are condensed in off gas condenser UEA-406 to 620C and enter
the bottom of off gas absorber DA-402(OGA). Condensed liquid flows down to off gas absorber
tank UFA-203. After cooling to 360C, liquid is sent to top portion of OGA as absorbent. OGA
bottom fluid is recycled as absorbent at OGA middle position (2nd bed).
Air from top of OGA is blown to gas separator by GB-401 blower. The gases from low pressure

decomposer are absorbed in low pressure absorber (EA-402) bubbling a sparger. Dust chamber
over flow solution (10-15% urea) is used as absorbent. Low pressure absorber temperature is
controlled at 450C and CO2 concentration 2.2 lit/2.5ml.
Solution from LA is pumped by GA-402A/B to high pressure absorber (DA-401) middle through
mixing cooler where liquid ammonia is mixed and serves as medium in the absorber.
The gases from HD top are bubbled through a sparger in high pressure absorber cooler EA-401,
where 65% of CO2 is absorbed. Remaining gases from HAC go to HA and are cooled down to
800C max. in middle cooler at the bottom of HA 35% of CO2 is absorbed in packed bed by a
mixture of lean carbamate from low pressure absorber through FCV-401 and liquid ammonia from
GA-404A/B( temp. max 600C) through FCV-402. the scrubbed gas then passes through five nos.
of condensers(EA-404A-E) and purge condenser EA-403. Liquid ammonia flows down to
ammonia reservoir FA-401. Non-condensable gases flow to ammonia recovery absorber.
Recovery loop pressure is controlled by PCV-405 at top of EA-405 lV. Cold steam condensate is
fed for absorption. Aqueous ammonia is with drawn from recovery absorber bottom by GA405A/B.
OFFSITES AND UTILITIES PLANTS
The 0&U group of plants consist of the following sections : i) Raw Water Plant.
ii) D.M. Water Plant.
iii) Instrument .Air Compressor House.
iv) Cooling Tower.
a) RAW WATER FILTERATION PLANT
This water treatment plant has a design capacity to treat 2400 NM3/hr of raw water into portable
occasional over lead of 20%. The plant consists essentially of flash Mixers Clarifloculators, rapid
gravity filters and a chemical House comprising of Alum tanks, lime tanks and a chlorine room etc.
The raw water from the pumping main is received by the inlet of the RCC Ventury flume. In the
ventury flume the calculated amount of alum solution is closed for mixing with the raw water. The
chemically treated water then flows to clarifloculators. The pludge thus formed after chemical
treatment settles down in the clarifloculator where from it is expelled out while the clear water
overflows to the launder leading to filter beds. The filter water is disinfected with the addition of

chlorine and then collected in filter eater sump.

b) D.M. WATER PLANT
D.M. water plant was supplied by M/s Ion Exchange (India) Ltd. It consists of cation units,
Degasser Towers, An-ion units. Mixed bed units No.l&2. Filtered water coming from raw water
filtration plant is received in filter water reservoir. From reservoir filter water passes through a
strongly acidic cat-ion exchange resin where cat-ions like Ca, Ng & Na are removed, the water
passes through degasser tower where dissolved, Ce2 is removed. Then water passes through
Anion exchange resin and Anion like CI, S, Se4 and silica, are removed in this unit. Free from
cations and anions water passes through mixed bed unit No.l, where further removal of cations
and anions takes place. Then treated water coming out from MB, unit goes to DM water tank.
Return condensate from Ammonia and Urea Plants is collected in D.M. water tank after treatment
in cat-ion unit No.2. Then D.M. water is pumped from DM water tank to mixed bed No.2(MB) for
further polishing and collected in polish water tank, which is supplied to boilers through Ammonia
Plant.
INSTRUMENT AIR COMPRESSORS HOUSE
The purpose of this section is to supply instrument air and service air to all the plants. The
instrument air compressor house consists of three instrument air compressors and one service air
compressor. One is kept in line generally. The compressed air from instrument air compressors at
9.3 kg/cm2 absolute pressure passes through two sets of dryer, which is filled with silica-gel for
removal of moisture. Air coming out from dryer is sent to instrument air feeder for supplying to
different plants through instrument air receiver in order to drive various valves and instruments.
(iii) COOLING TOWERS
The cooling water system provided in NFL, Bathinda is closed re-circulating system supplying
cooling water to various consumers in the plant. The system mainly consists of cooling towers,
cooling water re-circulation pumps, supply & return headers and cooling water treatment facility.
There are three cooling water systems : C.W. system supplies cooling water to Ammonia Plant.
Urea Plant and Boilers, Instrument -Air Compressor, Caustic dissolving facilities & Sulphur
Recover Plant.

C.W. system supplies cooling water to Crystallization section of Urea Plant.

D.M. WATER PLANT
Water in its natural form contains no. of dissolved salts such as sulphates, chlorides and nitrates
of calcium magnesium and sodium. If water is used as such in the boilers for raising steam, these
salts will form scale on the tubes, which in addition to heat losses lead to many other many
problems. Hence, removal of these salts from the water becomes quite essential. Ion exchange
resign are used for this purpose of salt removal.
The de mineralizing water plant of NFL Bathinda was supplied by M/s ION exchange (India) ltd
Delhi.
It consisted of three units each of cation, anion, mixed bed, four secondary mixed bed and three
units of condensate cation. At the time of setting up of a captive power plant, another stream to
augment the existing capacity of polish water generation was by M\s BPMEL. It consisted of one
unit each of cation, anion, primary mixed bed, two secondary mixed bed and two condensate
cations.
Filtered water is received from raw water filtration plant into two filtered water reservoir feed water
pumps discharge water from these reservoir tom cation units. These are total five feed pumps
each having a capacity 0f 130m3/hr and four cation units. Three of these are charged with 13125L
of cation resin and fourth unit is having 11900 0f resins. Cation like Na+, Ca++, and Mg++ present
in the water are removed in the cation unit once exhausted, these units are regenerated with the
counter current flow of dilute sulphuric acid.
The present day resins are made of cross linked polystyrene and cross linking is done by di vinyl
benzene.Cation resins are made of sulphonated polystyrene SO3H can be represented by as
RH.anionic resin is similarly made but is chloromethylated and then is animated. The final product
is quaternary ammonium compound a strong base and is represented by ROH.
CATION UNIT:
In the cation units free H+ ion of the resin is replaced by Ca and Mg or Na ions as per the
following reactions.
RH + NaCl---------------RNa+ HCl
2RH + MgSO4--------------------- R2Mg + H2SO4

2RH + Ca (HCO3)2---------------------------R2Ca +2CO2 + 2H20

Natural salts are converted into respective mineral acid and alkaline salt split into carbon dioxide.
The outlet water has low pH.
DEGASSER:
From the cation units water move to the degasser. Here the free CO2 content of the water is
splitted off with the help of air by passing the water over by the rasching ring packed bed. Water
from the degasser is received into three Nos. degasser water sump each of having a capacity
40m3 from these sump degassed water pumps discharge water into the anion units. There are
total five Nos of pumps each having a capacity of 150M3/ hr.
ANION UNITS:
Anionic impurities of water beside CO2 and silica are removed in the anionic unit. There are total
four No of anionic units. Two anionic units having a capacity 7920L of resin while the two are 5965
and 8400L of resin.