Contents
Topic
Page No.
Preface...3
Acknowledgements...4
Introduction...5
Plant Sections.,..6
Uses Of Ammonia.9
Detailed Process Description...10
Raw Synthesis Gas Preparation.......11
Knock Out Drums.11
Hydrotreator...12
Primary & Secondary Reformer...13
Waste Heat boilers.14
HTS And LTS15
Carbon dioxide Removal16
Uses of Urea24
Manufacturing of Urea28
UREA Process..30
Detailed Process Description....31
UREA SECTIONS...31
High pressure CO2 Compressor...32
1
UREA REACTOR:..34
Concentration Section:....35
Prilling tower:.36
Recovery Section..37
Process Condensate Treatment Section.........37
UTILITIES SECTION38
REFERENCES39
PREFACE
This report is about the learning outcomes of internship in
Pak American Fertilizers Limited (PAFL) Iskandrabad,
Mianwali currently known as AGRITECH covering
details of its environment, process, operations and other
technical information. Most of the Information was
collected from Engineers and other technical staff of every
department and is written according to internship schedule
provided by PAFL. This helps to understand various steps
involved in achieving certain efficiency or the quality of
the product. Undoubtedly there is so much to learn from
this industry and this is a small effort to compile as much
information that has been collected in six weeks span.
ACKNOWLEDGEMENTS
I express gratitude and praise to ALMIGHTY ALLAH, the
creator of universe, who is beneficent and merciful, guided
me in difficult and congeal circumstance, who endowed me
with the will to complete this Internship. Great respect our
Holy Prophet Hazrat Muhammad (PBUH), who taught me
to learn till lap to grave.
I would like to grant my heartiest gratitude to the
Engineer Muddassir (graduated from CIIT Lahore) for
all the guidance and support that he has given me to
complete our Industrial training. Dear Sir, please accept
my sincere thanks for your kind hearted support and
genuine friendly attitude shown towards my work. Thank
you very much for spending your precious time to share
your knowledge & experience with us.
Then again, I must not forget all the staff members of
Chemical & Process Engineering department, including
the head of the department Dr. ASADULLAH KHAN for
all the assistance and support given us to arrange this
industrial training. Without your support we may have not
come this far, so please accept our sincere thanks
4
INTRODUCTION
On August 01, 2014 I was granted the unique opportunity for an industrial
training at PAK-AMERICAN FERTILIZERS LTD as a part of an internship
program for BS(Chemical engineering). I was lucky enough to have four
weeks of vigorous training that broadened our knowledge of various industrial
processes.
INTRODUCTION TO COMPANY
Pak American Fertilizers Limited (PAFL) is located at Iskanderabad
(Daudkhel), Distt: Mianwali and produces 1050 metric tons of urea per day.
PAFL is the subsidiary of National Fertilizer Corporation of Pakistan (NFC).
Japan Bank of International Cooperation (JBIC) provided loan for setting up
the fertilizer plant. The plant was commissioned in 1999. The old plant was
closed down in 1997 and a new Ammonia/Urea Plant commenced commercial
production in 1999. The new plant is designed to produce 600 Ton/Day
Ammonia and 1,050 Ton/Day urea using natural gas as feed and fuel. Both
plants have been designed by TOYO Engineering Japan. Ammonia plant is
under license from Kellogg International, USA, while urea plant is TEC's own.
The plants are latest in design and most modern. The company possesses over
11,481 Kanals of land, comprising 6,432 for Factory, 2,818 for Housing
Colony and 2,230 for experimental farm.
PLANT SECTIONS
There are two main sections in Pak American Fertilizers Limited, which are
enlisted below:
Ammonia Production
Urea Production
AMMONIA PRODUCTION
INTRODUCTION:
Ammonia, NH3, is a comparatively stable,
colorless gas at ordinary temperatures, with a
boiling point of 33C. Ammonia gas is lighter
N2 + 3H2
Temperature (0C)
25
200
300
400
500
2NH3 (G)
Keq
6400
.44
.0043
.00016
.000015
AMMONIA MANUFACTURING:
Ammonia is generally manufactured from natural gas using the steam
reforming process. There are several reaction stages and catalysts are key to
the economic operation of ammonia production plants.
Diagram 1 illustrates the chemistry of the ammonia process and the basic
materials of the catalysts used. The first stage is purification where impurities,
mainly sulfur compounds, are removed from the gas stream. Steam reforming
is performed in two stages. In the primary stage, the endothermic reactions
take place at pressures around 30 bar and temperatures of 800C or higher.
This is followed by an exothermic secondary reformer where air is added to
the partially reformed gas stream. The carbon monoxide in the gas leaving the
secondary reformer is converted to carbon dioxide in the shift reactors and
then removed by scrubbing from the gas stream. Any residual carbon oxides
are then converted back to methane by methanation before compression of the
hydrogen and nitrogen to ammonia synthesis pressure. The final reaction
stage is ammonia synthesis where the hydrogen and nitrogen combine to form
ammonia. This reaction stage takes place at high pressure (100-350 bars) and
is highly exothermic.
8
Diagram 2 shows a simplified block diagram of a typical 1000 tone/day ammonia
plant including details of operating temperatures, catalyst volumes, and catalyst and
gas compositions.
USES OF AMMONIA:
Chemicals
synthesis of:
Explosives
Fibers &
nylon,
Plastics
polyamides
Refrigeration
-[(CH2)4-CO-NH-(CH2)6-NH-CO]-,and
other
Mining &
used
in
nitriding
(bright
annealing)
steel,
Metallurgy
Cleaning
10
Component
Gas mole %
CH4
82.6
C2H6
8.5
C2H8
3.3
C4 + Higher 1.9
CO2
1.3
N2
2.4
Total
100.00
PROCESS:
The process is as follows;
Raw synthesis gas preparation
Synthesis gas purification
Purified synthesis gas compression and ammonia synthesis
Ammonia refrigeration system
Process condensate stripper
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11
feed.
2.
3.
4.
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12
Hydrotreator:
The compressed natural gas then flows to the convection section of primary
reformer where it is heated to 399 0C. It then flows to the hydrotreater, (A101-D), where the hydrogenation of sulfur compounds to H2S takes place.
Hydrotreater consists of 8.6 m3 cobalt-molybdenum catalyst through which the
feed gas flows and conversion of sulfur to hydrogen sulfide takes place.
Reaction is;
S + H2
H2S
After passing through the hydrotreater it passes into desulphurizers, (A-102DA/DB), which contains a 21 m3 layer of zinc oxide catalyst. The hydrogen
sulfide produced is absorbed by the zinc oxide catalyst as a result of which the
gas becomes free of sulfur, ( S < .01 ppm). Reaction is;
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13
ZnO + H2S
ZnS + H2O
Temperature
(371 0C-399 0C)
Pressure
(46.0 Kg/cm2)
21 m3 of catalyst
Feed
14
streams each having 52, catalyst filled, tubes suspended in furnace. Here the
following reactions take place;
2CH4 + 3H2O
CO + CO2 + 7H2
The partially reformed gas from the primary reformer enters the secondary
reformer, (A-103-D), lower combustion chamber nozzle with water jacketed
transfer line, (A-107-D). The temperature at the secondary inlet will be about
833 0C. Here it is mixed with stichiometric nitrogen requirements of ammonia
synthesis reaction. The air supply for combustion in secondary reformer is
provided by steam turbine driven air compressor, (A-101-J). The air is
preheated in the convection zone of primary reformer to about 621 0C. The
exit temperature from secondary reformer is about 1013 0C.
15
CO2 + H2
C.
15
16
After the synthesis gas has been prepared it is purified off carbon dioxide and
carbon monoxide to yield a high purity nitrogen hydrogen synthesis gas.
bottom . The lean aMDEA solution at 50 oC from the lean rich exchanger ( 111CA/CB ) and lean cooler (109 CA/CB ) enters the absorber from the middle inlet via
semi lean circulation pump ( 107J/JA) (518 kg/
) . While the two streams flow
counter current through the absorber, the lean solution gradually absorbs the C
present in the feed gas, and leaves the absorber bottom as rich solution stream at
to LP flash column (104-E). the treated gas at
exists the absorber from
the top , on specification . Mist carry-over to the down stream equipment is
minimized by the packing in thr previous lean absorption section which is now
performing as demister.
Regeneration takes place in two steps i.e. flashing in 104-E and stripping in 102-E .
The rich solution at
is flashed in the newly installed LP-flash column ( 104-E ) at
0.9 kg/
, via LV1201-A/B . Liquid from 104-E bottom is pumped through 113 J/JA
to lean rich exchanger ( 111-CA/CB ) where it is heated before going to the stripper
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17
102-E through FT-1234 ( 537
level. Part of the solvent will be directed to the bottom section of 102-E via FC-1210,
and boiled in the reboiler ( A-105 )at
. Most of the solvent from the middle
section of 102-E is sent to 114-C and then 117-F through LC-1203 and stripped
directly by SL steam in 114-C. Steam for this purpose is produced in A-113-C and
provision is made to control steam supply from SH and SL headers . Regenerated
solution leaves 114-C ( LIA-1282 ) and goes to 117-F by gravity flow . 117-F is used as
holding tank to provide residence time for 107-J/JA . The lean solution at
from 117-F is then cooled down sequentially in lean rich exchanger ( 111-CA/CB )
and lean cooler ( 109 CA/CB ) to
with 50 % concentration , prior to recycle into
the absorber.
Acid off gas from 105-C , 117-F and 114-C leaves 102-E from the top at
1.1 kg/
and
unit . Water balance in the system is slightly positive , which means that some of
water should be drained from the condenser intermittently , in order to maintain
solvent strength.
Polished water is directly supplied to 113-C for steam generation . Steam
condensate from 114-C is directed to condensate vessel ( 118-F ) from where it is
sent to 101-J/JA and de-super heated via condensate transfer pump 115-J/JA and
LIC- 1209 . SL steam to 114-C is provided from 113-C , SL header and SH to SL
letdown PC-1656. SL flow is controlled by FICA-1235 (HV-1200 old) . PC-1203 will act
as vent.
Anti-foam:
BASF recommends the use of
as antifoam.
is
produced by the Drew Ameroid Company . It is widely used in many aMDEA plants.
This antifoam agent can also be purchased through BASF.
Typical dosage rate of
of Owners capacity.
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18
18
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20
release all absorbed gases and direct them to the fuel gas system; second, as
an integral part of the refrigeration system, the process chillers remove heat
from the synthesis gas in the synthesis gas loop to sub cool the recycle gas to 17.80C for the satisfactory separation and removal of the net ammonia make
from the synthesis loop. These chillers are so located in the refrigeration
system to take full advantage of the various pressures (and temperature) levels
at which it is operated.
Ammonia storage:
Anhydrous ammonia is usually stored as a liquid in refrigerated tanks at
33.3C and atmospheric pressure, often in doubled-walled tanks with the
capacity for hundreds or thousands of tonnes. The low temperature is usually
maintained by the venting of ammonia gas. The vented gas is re-liquefied for
recycling, or absorbed in water to make aqueous ammonia. Relatively small
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21
UREA PRODUCTION
INTRODUCTION:
Urea was first identified in 1773 when it was isolated by crystallization from
urine. It was first was first prepared synthetically in 1828 by Wohler from
ammonia and cyanuric acid.
NH3 + HCNO CO(NH2)2
This preparation was a milestone in science since urea became the first
organic compound prepared by synthesis from inorganic materials previously
it was believed that organic compounds could be produced only by living
organisms. The present method of synthesizing urea from ammonia and
carbon dioxide has been known in principle since 1868, but commercial
production by this method started in 1922 in Germany, in 1922 in the United
States, and in 1935 in England. However, there was some commercial
production in Canada (by DuPont) starting in 1920 using calcium cyan amide
according to the reaction:
CaCN2 + 3 H2O CO (NH2)2 + Ca(OH)2
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GENERAL PROPERTIES:
Under some circumstances urea can be phototoxic, and many cases of severe
damage to crops have occurred, especially when the urea was placed close to
the seeds.
Aside from toxicity, poor agronomic results may be caused by loss of ammonia
to the atmosphere when urea is applied on the surface of the soil or as
topdressing to growing crops. This loss is caused by the formation of ammonia
by hydrolysis under such conditions that part of it escapes to the atmosphere
rather than being absorbed by the soil.
Urea is generally satisfactory for rice and preferable to nitrates for flooded
rice since nitrates are reduced to NO to N2 in the anaerobic zone of the rice
paddy and hence lost to the atmosphere. Also the rice plant, unlike most other
crops, can utilize the ammonium form of nitrogen efficiently. In tropical,
subtropical, and warm temperature zones, the hydrolysis and nitrification (in
aerobic soil conditions) are rapidly completed; thus, there is no delayedrelease effect. For these reasons and because of its high concentration and
favorable production cost, it has become the most popular nitrogen fertilizer
in Asia and in many countries on other continents. An excellent discussion of
the agronomic effects of urea has been presented by Tomlinson who concludes
that urea can be used efficiently, but its use requires a higher degree of
understandings than is the case with simple inorganic salts.
22
23
Structure of Urea:
23
24
USES OF UREA
Agricultural use
Urea is used as a nitrogen release fertilizer as it hydrolyses back to ammonia
and carbon dioxide, but its most common impurity (biuret,NH2-CONH- CONH2) must be present at less than 2% as it impairs plant growth. It is also
used in many multi-component solid fertilizer formulations. Its action of
nitrogen release is due to the conditions favoring the reagent side of the
equilibriums which produce urea. Urea is usually spread at rates of between
40 and 300 kg/ha, but actual spreading rates will vary according to farm type
and region. It is better to make several small to medium applications at
intervals to minimize leaching losses and increase efficient use of the N
applied compared with single heavy applications. During summer, urea
should be spread just before, or during rain to reduce possible losses from
volatilization (process where nitrogen is lost to the atmosphere as ammonia
gas). Urea should not be mixed for any length of time with other fertilizers as
problems of physical quality may result. Because of the high N concentration
in urea, it is very important to achieve an even spread. Make sure that the
application equipment has been correctly calibrated and is properly used. Do
not drill on contact with or close to seed, due to the risk of germination
damage. Urea dissolves in water for application as a spray or through
irrigation systems.
Industrial use
Urea has the ability to form 'loose compounds' with many organic compounds.
The organic compounds are held in channels formed by interpenetrating
helices comprising of hydrogen bonded urea molecules. This behavior can be
used to separate mixtures and has been used in the production of aviation fuel
and lubricating oils. As the helices are interconnected all helices in a crystal
must have the same 'handedness'. This is determined when the crystal is
nucleated and can thus be forced by seeding. This property has been used to
separate raceme mixtures
24
25
A raw material for the manufacture of plastics, to be specific, ureaformaldehyde resin A raw material for the manufacture of various
glues (urea-formaldehyde or urea melamine-formaldehyde);the latter
is waterproof and is used for marine plywood
26
Laboratory use:
Urea is a powerful protein denaturant. This property can be exploited to
increase the solubility of some proteins. For this application, it is used in
concentrations up to 10 M. Urea is used to effectively disrupt the non-covalent
bonds in proteins. Urea is an ingredient in the synthesis of urea nitrate. Urea
nitrate is also a high explosive very similar to ammonium nitrate, however it
may even be more powerful because of its complexity.
Medical use:
Drug use
Urea is used in topical dermatological products to promote rehydration of the
skin. If covered by an occlusive dressing, 40% urea preparations may also be
used for nonsurgical debridement of nails. This drug is also used as an earwax
removal aid. Like saline, urea injection is used to perform abortions. It is also
the main component of an alternative medicinal treatment referred to as urine
therapy.
iagnostic use
Isotopically-labeled urea (carbon- 14 - radioactive, or carbon- 13 - stable
isotope) is used in the urea breath test, which is used to detect the presence of
the bacteria Helicobacter pylori (H. pylori) in the stomach and duodenum of
humans. The test detects the characteristic enzyme urease, produced by H.
pylori, by a reaction that produces ammonia from urea. This increases the pH
(reduces acidity) of the stomach environment around the bacteria. Similar
bacteria species to H. pylori can be identified by the same test in animal.
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27
Textile use
Urea is a raw material for urea-formaldehyde resins production in the
adhesives and textile industries. A significant portion of urea production is
used in the preparation of Urea formaldehyde resins. These synthetic resins
are used in the manufacture of adhesives, molding powders, varnishes and
foams. They are also used for impregnating paper, textiles and leather. In textile
laboratories they are frequently used both in dyeing and printing as an
important auxiliary, which provides solubility to the bath and retains some
moisture required for the dyeing or printing process.
MANUFACTURING OF UREA
in the
2. Pressure
At constant temperature conversion increase with pressure up to the critical
point with is the point at which the vapor phase substantially eliminated and
the reactants are in the liquid state. A further increase in pressure is not
beneficial. The critical temperature is the complex function of the temperature
and composition of the reactor content .For example At 150C the pressure is
27
28
at 100atm might be near optimum for a stiochiometric NH3 and CO2 ratio, but
at this temperature of 180-210C pressure of 140-240atm are commonly used.
4. Other Factors
The presence of water decreases the conversion there most process are design
to minimized the amount of water recycled to the reactor the presence of small
amount of oxygen decreasing the corrosion and all process are used to
minimized the corrosion.
5. Optimum Condition
It is generally not economical to maximize the percentage conversion in the
reactor because this would require an excessive retention time. The aim
therefore is to attain maximum quantity of urea production per unit of time
with regard to the cost of recycling unrelated carbon dioxide and ammonia
and the cost of increased reactor size and corrosion difficulties which increase
with temperature .typically operating condition are temperature 180-140C
and the pressure is about 140-250atm NH3-CO2 ratio is 3.1 and 4.1 and the
reaction time is 36 minutes.
28
29
UREA Process:
Toyo Engineering-ACES Process:
The synthesis section of the Toyo Engineering-ACES (Advanced Process for
Cost and Energy Saving) . In this process the synthesis section operates at 175
bars with an ammonia and carbon dioxide molar ratio of 4.0 and a
temperature of 185 to 190C. Liquid ammonia is fed directly into the reactor
while gaseous is sent from the centrifugal compressor at the bottom of the
stripper the reactor effluent is stripped at essentially reactor pressure using as
the stripping agent. The overhead gas mixture from the stripper is fed to two
carbamate condensers in parallel. Here the gases are condensed and recycled
under gravity to the reactor along with absorbent solutions from the HP
scrubber and absorber. The heat generated in the first carbamate condenser
is used to generate 5.0 bar steam, and the heat from the second condenser is
used to heat the solution leaving the stripper bottom after pressure reduction
The ACES stripper uses a ferrite-austenite stainless steel as do the carbamate
condensers. The reactor and
stainless steel The urea solution that leaves the stripper bottom is further
purified in HP (17.5 bar) and LP (2.5 bar) decomposers. The urea solution is
first concentrated to 88.7% in a vacuum concentrator and then to the required
concentration for prilling or granulating.
Chemical Reactions:
2NH3+CO2 = NH4COONH2 +HEAT
(ammonium carbamate)
NH4COONH2+HEAT=NH2CONH2+H2O
(urea)
Introduction:
Mitsui Toatsu Total recycle process (now Toyo Aces Process) is mostly
commercially used for the production of urea. In Pakistan, Pak American urea
fertilizer used this process. Toyo Koatsu developed of this process.
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30
UREA SECTIONS
Synthesis Section
Purification Section
Concentration Section
Prilling Section
Recovery Section
30
31
1.
Synthesis Section:
Reactor
Ammonia preheater
Carbamate preheater
Carbamate heater
32
Ammonia Pre-Heater
It is a shell and tube heat exchanger with heating medium process gas on shell
side and NH3 in tube side. Ammonia pre heater recover process heat from
liquid distributer off gases and preheat ammonia from 80F up to 185-200F.
A bypass control valve is installed on ammonia line to preheat which can
bypass ammonia flow to control temperature
Ammonia Heater
There are two sets of shell and tube heat exchanger with counter current flow
of steam. Ammonia flows in the tube at a pressure of 3000-3300psig counter
current to heating medium. Two heating source are available i.e. process
condensate and 100psig steam. Temperature of ammonia is controlled by the
regulating the flow of heating medium through control valve. Maximum
temperature of ammonia is 270F which is maintained through control valve
above 270F flashing of ammonia take place which is undesirable.
Carbamate Heater:
These are u tube heat exchanger in which carbamate temperature is
increased
and
controlled
at
260-265F.before
entering
the
Carbamate Preheater:
This is the simple shell and tube type heat exchanger in preheater increased
the temperature of the carbamate from 190 to 225-235F the carbamate in the
tubes is at the pressure of 3000-3300psig and the heating medium in the shell
side at the pressure of 300psig.
32
33
UREA REACTOR:
Plug Flow Reactor
All the raw material (ammonia carbamate and carbon dioxide are introduced in the
reactor). Reactor unique design is presented by IVO Maverick and manufactured by
Neuter Corporation
2NH3 + CO2
NH4COONH2
NH2CONH2 + H2O
In synthesis section raw material ammonia and carbon dioxide and recycle
carbamate solution are pumped to the reactor at sufficient pressure and
temperature to promote the reaction.
All feeds are maintained at their specified levels to get maximum conversion
efficiency of reactor. After the formation of ammonium carbamate urea is
formed due to the dehydration of ammonium carbamate .This chemical
reaction takes place in the plug flow reactor. The molar ratio of ammonium
carbamate and carbon dioxide is adjusting 4:1 higher the ratio of ammonium
and carbon dioxide means higher the conversion.
2. Purification/Decomposition section
The solution taking from the reactor is passed from the pressure relief valve
and decreases the pressure from 3200psig to 300psig.
Now this solution is pumped at a temperature of 377F in the first decomposer
this solution contain the unconverted ammonium carbamate, thats why it
should decomposed in to ammonia and carbon dioxide. The reactor effluent
solution enter in the decomposer it suddenly reduced the pressure, due to the
reduction of pressure temperature is also decreases. For the decomposition of
ammonium carbamate there is the following reaction is take place:
NH2CO2NH4 CO2 +2NH3
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34
This reaction is the reverse of the first step of the synthesis process and is
strongly endothermic (37.7kcal/kgmol).this energy is provided by steam.
In the decomposition section using the steam for the heating purposes, steam
flows in shell side and urea solution in tube side, so urea containing dissolved
gases its separate and leaving from the top of the decomposer.
The urea solution taking from the bottom of the first decomposer at the
temperature of 343F it enters the second decomposer but before it pass in the
pressure relief valve and reduced the pressure 15psig. Then enter in the
second decomposer same process is happened just like as the first
decomposer. In second decomposer further remove the dissolved gases formed
the urea and un-decomposed carbamate solution is decomposed. The urea
solution taking from the bottom of the low pressure decomposer it enters in the
concentrator for improving the concentration of urea solution.
3. Concentration Section:
Concentrator:
The urea solution coming from the second decomposer enters in the
concentrator. Using the steam for the heating purposes in concentrator we
increased the concentration of the urea solution by evaporating the water.
This system is design to concentrate urea product .heat is providing by 55psig
steam controlled by the steam valve. the gases (ammonia and carbon dioxide,
water vapor) are separated from the top of the concentrator. These gases are
condensed. A 72-73 wt% urea solution is separated from the gases and
concentrated under low vacuum in the Urea Concentrator to an 88 wt%
solution and is then sent to evaporation before prilling or granulation.
Vacuum is maintained in the Urea Concentrator by a single stage vacuum
system using a very small amount of steam, only about 10 to 18 inches of hg
(in the aspirator part of concentrator). The condensed overhead vapors are
condensed. After it urea solution comes out in the urea filter.
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35
Urea filter:
One of the two filter remains in service for 24hrs the filter is designed to
reduced oil and iron in the product solution. It consists of filter leaves which
are coated with filtering medium diatomaceous earth which absorbed the oil
and removes iron partial. After filtration, urea solution flows to vacuum
evaporator.
Evaporator:
Filling film type evaporator is used for these purposes. An atmospheric air
swept falling film Evaporator, with heat being supplied by low pressure steam,
evaporates the 88 wt% urea product to a 99.7 wt% urea melt product, ready
for prilling or granulation.
4. Prilling tower:
It is the natural draft prilling tower, the height of the prilling tower is 73
meterandinner diameter is 17 meters. There are the 16 window at the bottom
of the prilling tower for the entry of air and lovers are installed in the
windows to control air flow and prevent prills from falling out similarly there
are 16 window at the top for exiting hot air out. Louvers are also installed at
the top windows for exiting air and preventing rain water into the prills tower.
Scrapper:
Scrapper rotates at speed of 2 rpm with the help of motor through gear.
Scrapper consists of two arms with inclined blades which direct urea prills to
the central discharge cone. Scrapper motor speed in indicated in local panel
for smooth operation of scrapper.
36
Contant
Quantity
Biuret
1.25 max
Moisture
0.6 max
Fines
3.0 max
Size
2.2 max
Crushing strength
800
5.
Recovery Section:
The gases produced from the top of the second decomposer are introduced at
the bottom side of a unit name as second absorber. At the top of the second
absorber quantity of water is introduced at the top of the second absorber the
solution collected at the bottom of the absorber is recycled into the unit so the
concentration of the carbamate formally become seasonable.
Most of the carbon dioxide coming from the second decomposer is fixed up
carbamate solution. Unabsorbed ammonia is recovered at the top side of the
second absorber. Since the absorption of the ammonia and the carbon dioxide
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37
The gaseous ammonium is recovered at the top of the first and second
absorber is compressed and liquefies and finally returns in to the ammonia
storage tank.
6.
The process condensate leaving the system is purified to 1ppm of urea and
1ppm of NH3. The gas effluent from prilling tower (or granulator) is scrubbed
through a packed bed scrubber to reduce the urea dust content of the effluent
to 30mg/Nm3-air.
UTILITIES SECTION
Raw Water Section
Cooling Water Section
Steam Generation
Power Generation
Fire Water Section
Water Treatment Section
Fuel Section
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Storage
Raw water storage tank of 3000+1100 m3 capacity
Pumping
03 motor driven pumps of 580 m3/ hr capacity
01 diesel engine driven pump of 280 m3/ hr capacity
15000 m3 / hr.
43 oC
33 oC
30 oC
0.01 %
Evaporation losses
1.66 %
44.4 m / Sec.
9.0 seismic
Tower site
Ground level
228.5 m
Tower exposure
Open
STEAM GENERATION
Babcocks & Wilcox boiler
Type
Capacity
Water tube
1550o0 Ib/hr
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Steam pressure
96,400 Ibs
Mitsui boiler
Type
Water Tube
Evaporation at peak
90,000 Kg/hr
Design pressures
60 Kg/cm2 G.
Steam temperature
450 + 5 oC
Pakage boiler
Type
Water Tube
Capacity
30000 Kg/hr
Design pressures
50 Kg/cm2 G.
Steam temperature
395 + 5 oC
POWER GENERATION
Steam Turbines
Out put (Rated)
11.5 MW
Steam press.(Max.)
Normal speed
3000 rpm
5 m3
Gas Turbine
Uses natural gas as fuel
Generates 7 MW of power
Plant, water pumping station and housing colony uses approximately
5.5 MW of power
Exhaust of turbine at 420 C is used to generate 70 Ton/Hr of steam
REFERENCES
Pak American Fertilizer Process Manual
39