.

THE INDIAN FARMERS FERTILISER

CUUPERATIVE LIMITED
uurlng mld slxLles Lhe CooperaLlve secLor ln lndla was responslble for
dlsLrlbuLlon of 70 per cenL of ferLlllsers consumed ln Lhe counLry 1hls SecLor had
adequaLe lnfrasLrucLure Lo dlsLrlbuLe ferLlllsers buL had no producLlon faclllLles of
lLs own and hence dependenL on publlc/prlvaLe SecLors for supplles 1o overcome
Lhls lacuna and Lo brldge Lhe demand supply gap ln Lhe counLry a new
cooperaLlve socleLy was concelved Lo speclflcally caLer Lo Lhe requlremenLs of
farmers lL was an unlque venLure ln whlch Lhe farmers of Lhe counLry Lhrough
Lhelr own CooperaLlve SocleLles creaLed Lhls new lnsLlLuLlon Lo safeguard Lhelr
lnLeresLs 1he numbers of cooperaLlve socleLles assoclaLed wlLh lllCC have rlsen
from 37 ln 1967 Lo 39824 aL presenL

lndlan larmers lerLlllser CooperaLlve LlmlLed (lllCC) was reglsLered on
november 3 1967 as a MulLlunlL CooperaLlve SocleLy Cn Lhe enacLmenL of Lhe
MulLlsLaLe CooperaLlve SocleLles acL 1984 2002 Lhe SocleLy ls deemed Lo be
reglsLered as a MulLlsLaLe CooperaLlve SocleLy 1he SocleLy ls prlmarlly engaged ln
producLlon and dlsLrlbuLlon of ferLlllsers 1he byelaws of Lhe SocleLy provlde a
broad frame work for Lhe acLlvlLles of lllCC as a CooperaLlve SocleLy

lllCC commlssloned an ammonla urea complex aL kalol and Lhe nk/uA
planL aL kandla boLh ln Lhe sLaLe of Cu[araL ln 1973 AnoLher ammonla urea
complex was seL up aL hulpur ln Lhe sLaLe of uLLar radesh ln 1981 1he
ammonla urea unlL aL Aonla was commlssloned ln 1988

ln 1993 lllCC had drawn up a ma[or expanslon programme of all Lhe four
planLs under overall aegls of lllCC vlSlCn 2000 1he expanslon pro[ecLs aL Aonla
kalol hulpur and kandla were compleLed on schedule All Lhe pro[ecLs concelved
as parL of vlslon 2000 had been reallsed wlLhouL Llme or cosL overruns All Lhe
producLlon unlLs of lllCC have esLabllshed a repuLaLlon for excellence and
quallLy AnoLher growLh paLh was chalked ouL Lo reallse newer dreams and
greaLer helghLs Lhrough vlslon 2010 As parL of Lhls vlslon lllCC has acqulred
ferLlllser unlL aL aradeep ln Crlssa ln SepLember 2003 As a resulL of Lhese
expanslon pro[ecLs and aculslLlon lllCCs annual capaclLy has been lncreased Lo
369 mllllon Lonnes of urea and nk/uA equlvalenL Lo 171 mllllon Lonnes ln
pursulL of lLs growLh and developmenL lllCC had embarked upon and
successfully lmplemenLed lLs CorporaLe lans 'Mlsslon 2003' and 'vlslon 2010'
1hese plans have resulLed ln lllCC becomlng one of Lhe largesL producer and
markeLer of Chemlcal lerLlllsers by expanslon of lLs exlsLlng unlLs seLLlng up !olnL
venLure Companles Cverseas and ulverslflcaLlon lnLo new SecLors

lllCC has now vlsuallzed a comprehenslve plan LlLled 'vlslon2013' whlch ls
presenLly under lmplemenLaLlon lllCC has made sLraLeglc lnvesLmenLs ln several
[olnL venLures Codavarl lerLlllsers and Chemlcals LLd (ClCL) lndlan oLash LLd
(lL) ln lndla lndusLrles Chlmlques du Senegal (lCS) ln Senegal and Cman lndla
lerLlllser Company (CMllCC) ln Cman are lmporLanL ferLlllser [olnL venLures As
parL of sLraLeglc dlverslflcaLlon lllCC has enLered lnLo several key secLors lllCC
1oklo Ceneral lnsurance LLd (l1Cl) ls a foray lnLo general lnsurance secLor
1hrough l1Cl lllCC has formulaLed new servlces of beneflL Lo farmers SankaL
Paran 8lma ?o[ana provldes free lnsurance cover Lo farmers along wlLh each bag
of lllCC ferLlllser purchased 1o Lake Lhe beneflLs of emerglng concepLs llke
agrlculLural commodlLy Lradlng lllCC has Laken equlLy ln naLlonal CommodlLy
and uerlvaLlve Lxchange (nCuLx) and naLlonal CollaLeral ManagemenL Servlces
LLd (nCMSL) lllCC ChaLLlsgarh ower LLd (lCL) whlch ls under lmplemenLaLlon ls
yeL anoLher foray Lo move lnLo core area of power lllCC ls also behlnd several
oLher companles wlLh Lhe sole lnLenLlon of beneflLLlng farmers

1he dlsLrlbuLlon of lllCCs ferLlllzer ls underLaken Lhrough over 39824 co
operaLlve socleLles 1he enLlre acLlvlLles of ulsLrlbuLlon Sales and romoLlon are
coordlnaLe by MarkeLlng CenLral Cfflce (MkCC) aL new uelhl asslsLed by Lhe
MarkeLlng offlces ln Lhe fleld ln addlLlon essenLlal agrolnpuLs for crop
producLlon are made avallable Lo Lhe farmers Lhrough a chaln of 138 larmers
Servlce CenLre (lSC) lllCC has promoLed several lnsLlLuLlons and organlzaLlons Lo
work for Lhe welfare of farmers sLrengLhenlng cooperaLlve movemenL lmprove
lndlan agrlculLure lndlan larm loresLry uevelopmenL CooperaLlve LLd (llluC)
CooperaLlve 8ural uevelopmenL 1rusL (CC8uL1) lllCC loundaLlon klsan Sewa
1rusL belongs Lo Lhls caLegory An amblLlous pro[ecL lC1 lnlLlaLlves for larmers
and CooperaLlves ls launched Lo promoLe eculLure ln rural lndla lllCC
obsesslvely nurLures lLs relaLlons wlLh farmers and underLakes a large number of
agrlculLural exLenslon acLlvlLles for Lhelr beneflL every year

AL lllCC Lhe LhlrsL for ever lmprovlng Lhe servlces Lo farmers and member co
operaLlves ls lnsaLlable commlLmenL Lo quallLy ls lnsurmounLable and harnesslng
of moLher earLhs bounLy Lo drlve hunger away from lndla ln an ecologlcally
susLalnable manner ls Lhe prlme mlsslon All LhaL lllCC cherlshes ln exchange ls
an everlasLlng smlle on Lhe face of lndlan larmer who forms Lhe movlng splrlL
behlnd Lhls mlslon

lllCC Lo day ls a leadlng player ln lndlas ferLlllser lndusLry and ls maklng
subsLanLlal conLrlbuLlon Lo Lhe efforLs of lndlan CovernmenL Lo lncrease food
graln producLlon ln Lhe counLry

Some of Lhe well known ferLlllsers used ln lndla are
nlLrogenous lerLlllsers

urea 46n
Ammonlam SulphaLe (As) 21n
Ammonlam Chlorlde (ACl) 26n
Calclum Ammonlam nlLraLe (CAn) 23n

hosphaLlc oLasslc lerLlllsers

Slngle Super hosphaLe (SS) 16 2C3
MurlaLe of oLash (MC) 60k2C
SulphaLe of oLash (SC) 48k2C
ulammonlum hosphaLe (uA) 18 46
8ock hosphaLe (8) 16 20 2C3

nk Crades


102626

123216

143314

131313

162000

171717

191919

202000

232300

282800

Prices of IFFCUs Fertilisers


(Appllcable only wlLhln lndla)
(lndlan 8upees er 1onne (wef 1st Apr|| 2010)


UkLA Nk N DA

N46 102626 123216 2020013 18460
M8 3310 7897 8337 6893 9930
Local 1axes LxLra where ever appllcable

IFFCU PHULPUR UNIT
lllCC hulpur unlL ls belng operaLed ln Lwo unlLs namely unl11 and unl1
2 1he unlL1 sLarLed Lo produce urea ln 1981 and ln 1997 unlL2 sLarLs
producLlon commerclally
A brlef descrlpLlon of boLh Lhe unlLs ls as bellow

0NIT-
Production Capacity,
|ant Capac|ty Supp||er
Ammonla 1213 M1/day M/s ullman kellog uSA
urea 2113 M1/day M/s Snam rogeLLl lLly
ower 8oller 3x123 M1 M/s 8PLL
1urbogeneraLor 1x123MW M/s 8PLL

Main Features,
ero uaLe 26
Lh
May 1976
Commerclal roducLlon 28
Lh
March 981
ro[ecL CosL 8s 20300 Crores
1oLal Area 1070 Acres
lanL 320 Acres
1ownshlp 480 Acres
CardeL 130 Acres
Ash ond 120 Acres

Total Production {Till ..],
Piouuct Total Piouuction (Lakh NT)
Ammonia 89.9
0iea .


UNIT-
Production Capacity,
lanL CapaclLy Suppller
Ammonla 1740 M1/day M/s P 1 A S uenmark
urea 3030 M1/day M/s Snam rogeLLl lLly
ower 8oller 1x200 M1/hr M/s 8PLL
1urbogeneraLor 1x18 MW M/s 8PLL

Main Features,
ero uaLe 20
Lh
Aprll 1993
Commerclal roducLlon 22
nd
uecember 1997
ro[ecL CosL 8s 11868 Crores
lndlan Currency 8s 8398 Crores
lorelgn Currency 8s 3270 Crores

Total Production {Till JJ],
Product Productin {Lakb Mt]
Ammonla 6209
urea 10692












. HISTURY UF DEVELUPMENT UF UREA

urea was flrsL ldenLlfled ln 1773 when lL was lsolaLed by crysLalllzaLlon of urlne lL
was flrsL prepared synLheLlcally from Ammonla and Cynlc acld ln 1828 by Wohler
nP
3
+ PCnC nP
2
CCnP
2



lL was Lhe flrsL organlc compound prepared by synLhesls from lnorganlc maLerlals
1he presenL meLhod of synLhesls from CC
2
and nP
3
ls known ln prlnclpal ln 1868
buL commerclally lL was prepared ln 1922 ln Cermany Powever Lhere was some
commerclal producLlon ln Canada ln 1920 uslng CaCn
2
CaCn
2
+ 3P
2
C nP
2
CCnP
2
+ Ca(CP)
2
urea has been consldered slow released nlLrogen ferLlllzer ln colder reglon
because lL has Lo undergo Lwo LransformaLlons before lL ls avallable Lo crack
llrsL LransformaLlon accordlng Lo hydrolysls Lakes place as
nP
2
CCnP
2
+ P
2
C 2nP
3
+CC
2
Second LransformaLlon accordlng Lo nlLrlflcaLlon Lakes place ln whlch Ammonla ls
oxldlzed ln Lhe soll by mlcroblal means flrsL Lo nlLraLe and Lhen Lo nlLrlle 1hese
reacLlons proceed aL a fasLer raLe ln warm molsL soll and aL slower raLe ln cold
under some clrcumsLances as when urea ls placed Lo seed ln local hlgh
concenLraLlon of ammonla durlng hydrolysls accumulaLlon of nlLrlde durlng
nlLrlflcaLlon presence of blureL can cause excesslve damage Lo crops



















. PRUPERTIES UF UREA
Urea |CO(NH2)2|, also known as carbamide or carbonyl diamide, is marketed as a
solution or in solid Iorm. Most urea solution produced is used in Iertilizer mixtures,
with a small amount going to animal Ieed supplements. Most solids are produced
as prills or granules, Ior use as Iertilizer or protein supplement in animal Ieed, and
in plastics manuIacturing. Five U. S. plants produce solid urea in crystalline Iorm.
About 7.3 million Megagrams (Mg) (8 million tons) oI urea were produced in the
U. S. in 1991. About 85 percent was used in Iertilizers (both solid and solution
Iorms), 3 percent in animal Ieed supplements, and the remaining 12 percent in
plastics and other uses.

Molecular lormula nP
2
CCnP
2

MelLlng olnL 13217

C
PeaL of luslon 3708Cal/gm
PeaL of CombusLlon 2331Cal/gm
CrysLalllne SLrucLure 1eLragonal
nlLrogen ConLenL 466
Colour WhlLe
8ulk uenslLy 672736 Lo 789
kg/m
3

Angle of 8esponse 23 Lo 30
1rlple olnL 1023
ulelecLrlc ConsLanL 332 Lo 02
ulssoluLlon ConsLanL 13
Speclflc PeaL 042 kcal/hr/k
Crushlng SLrengLh 278kg/cm
2
ert|||zer Contro| Crder (CC) has def|ned fo||ow|ng qua||ty of
urea
O rlll slze +28mm noL greaLer Lhan 10
O MolsLure ConLenL 1 max
O 8lureL 13max

















. PLANT DESCRIPTIUN {IFFCU PHULPUR UREA-I]
PRUCESS DESCRIPTIUN
1he urea producLlon process Lakes place Lhrough Lhe followlng maln
operaLlon
urea synLhesls and hlgh pressure recovery
urea purlflcaLlon and low pressure recovery
urea concenLraLlon
urea prllllng
WasLe waLer LreaLmenL
a. Urea Syntbesis and Higb Pressure Recovery
urea ls produced by synLhesls of llquld Ammonla and Caseous Carbon
uloxlde ln Lhe reacLor 81 Lhe ammonla and CC2 reacL Lo form ammonlum
carbamaLe a porLlon of whlch dehydraLes Lo form urea and waLer 1he reacLlons
are as follows
2nP3 + CC2 nP2CCCnP4 + PLA1
nP2CCCnP4 nP2CCnP2 + P2C PLA1s
AL synLhesls condlLlons (1190C 130 kg/cm2) Lhe flrsL reacLlon occurs
rapldly and goes Lo compleLlon Lhe second reacLlon occurs slowly and deLermlne
Lhe reacLlon raLe
1he formaLlon of ammonlum cabamaLe LhaL dehydraLes ls deLermlned by
Lhe raLlo of Lhe varlous reacLanLs Lhe operaLlng LemperaLure and Lhe resldence
Llme ln Lhe reacLor
1he mole raLlo of ammonla Lo CC2 ls around 361 1he mole raLlo of waLer
Lo CC2 ls around 0671 1he llquld ammonla comlng from ammonla sLorage aL a
LemperaLure of around 10C ls preheaLed ln Lhe ammonla preheaLer L10 and
Lhen recelved ln ammonla recelver v1 and hoL llquld ammonla aL 33C from
ammonla planL ls recelved dlrecLly ln ammonla recelver v1
lrom v1 ammonla ls drawn and pumped by mean of cenLrlfugal pump 3
(operaLlng aL 23 A1A dlscharged pressure) parLlally Lo medlum pressure absorber
C1 and Lhe remalnlng volume ls dlrecLed Lo Lhe hlgh pressure synLhesls loop
1he ammonla Lo Lhe synLhesls loop ls flrsL Laken Lo low speed heavy duLy
reclprocaLlng pumps 1 A/8/C 1hese pumps dlscharge ammonla Lo a pressure of
abouL 240 aLm 8efore enLerlng Lhe reacLor Lhe ammonla aL Lhls hlgh pressure ls
used as a drlvlng fluld ln Lhe carbamaLe e[ecLor L!1 where Lhe carbamaLe comlng
from Lhe carbamaLe separaLor Mv1 ls Laken Lo Lhe synLhesls pressure 1he llquld
mlxLure of nP3 and carbamaLe enLers Lhe reacLor where lL reacLs wlLh
compressed CC2
1he CC2 drawn aL urea planL baLLery llmlL aL abouL 11 aLm pressure and
abouL 43C LemperaLure enLers Lhe cenLrlfugal compressors k1 and leaves lL aL a
flnal dlscharge pressure of abouL 133 aLm
A small quanLlLy alr ls added Lo Lhe CC2 aL Lhe compressor sucLlon ln order
Lo passlvaLe Lhe sLalnless sLeel surfaces Lhus proLecLlng Lhem from corroslon due
Lo boLh Lhe reacLanL and reacLlon producL
1he reacLlon producL leavlng Lhe reacLor flow Lo Lhe sLeam heaLed falllng
fllm sLrlpper L1 whlch operaLes aL essenLlally Lhe same pressure as Lhe reacLor
1he mlxLure ls heaLed (by medlum pressure sLeam on shell slde) as lL flows down
Lhe falllng fllm exchanger 1he CC2 conLenL of Lhe soluLlon ls reduced by Lhe
sLrlpplng acLlon of Lhe ammonla as bolled ouL of Lhe soluLlon
1he decomposlLlon of ammonlum carbamaLe ls an endoLhermlc reacLlon
PeaL for Lhls reacLlon ls supplled by 26 aLm saLuraLed sLeam on Lhe shell slde of
Lhe sLrlpper 1he overhead gases from Lhe sLrlpper and Lhe recovered soluLlon
from Lhe medlum pressure absorber C1 Lhe pumped Lhrough plunger pumps
2A/8 flow Lo Lhe hlgh pressure carbamaLe condenser L3/6 where Lhe LoLal
mlxLure excepL some lnerL ls condensed as carbamaLe and recycled Lo Lhe reacLor
by mean of e[ecLor L!1
CondensaLlon of Lhe gases aL hlgh pressure and LemperaLure permlLs
producLlon of sLeam aL 43 aLm ln Lhe hlgh pressure carbamaLe condenser non
condensable gases conslsLlng of n2 C2 P2 and also conLalnlng a small quanLlLy of
nP3 and CC2 unreacLed Lhe condenser are released from Lhe Lop of Lhe
carbamaLe separaLor Mv1 1hls gaseous mlxLure ls send Lo Lhe boLLom of Lhe
medlum pressure decomposer L2

T. Urea Purification and Low Pressure Recoveries
urea purlflcaLlon Lakes place ln Lwo sLages aL decreaslng pressures as
follows
1 Medlum pressure aL 18 aLa pressure
2 Low pressure aL 43 aLa pressure

i. Medium Pressure Purification and Recovery at
8 ata
1he soluLlon wlLh a low resldual CC2 conLenL leavlng Lhe boLLom of Lhe
sLrlpper aL synLhesls pressure ls leL down Lo 18 aLa pressures and enLers medlum
pressure decomposer
1he medlum pressure decomposer has been dlvlded lnLo Lwo parLs
1 1op SeparaLor (Mv2) where Lhe released flash gases are removed before
Lhe soluLlon enLers Lhe Lube bundle
2 uecomposlLlon secLlon (L2 falllng fllm Lype) where Lhe resldual
carbamaLe ls decomposed and Lhe heaL requlred for decomposlLlon ls
supplled by mean of 26 aLa sLeam condensaLe flowlng ouL from Lhe shell
slde of Lhe sLrlpper
1he nP3 and CC2 reach gases leavlng Lhe Lop separaLor (Mv2) are senL Lo
medlum pressure condenser L7 where Lhey are parLlally absorbed ln aqueous
carbamaLe soluLlon comlng from Lhe low pressure recovery secLlon 1he
absorpLlon heaL ls removed by Lempered coollng waLer clrculaLlon ls Lhe Lube
slde of medlum pressure condenser L7
1empered waLer clrculaLlon ls provlded Lo prevenL carbamaLe solldlflcaLlon
malnLalnlng proper coollng waLer LemperaLure lnleL Lo Lhe Lube slde of Lhe
medlum pressure condenser 1he coollng waLer LemperaLure lnleL Lo
condenser ls malnLalned by mean of lnllne pump 19
ln Lhe M condenser Lhe CC2 ls almosL LoLally absorbed 1he effluenL from
L7 flows Lo Lhe M absorber C1 1he gaseous phases (enLerlng C1 along wlLh
llquld effluenLs from L7) enLer Lhe recLlflcaLlon secLlon of M absorber C1
1he recLlflcaLlon secLlon has bubble cap Lrays and effecL CC2 absorpLlon and
nP3 recLlflcaLlon
1he bubble cap Lrays are fed by pure reflux ammonla aL Lhe Lop Lrays whlch
ellmlnaLes resldual CC2 and P2C from gases leavlng M absorber from Lhe
Lop 8eflux nP3 ls drawn from Lhe nP3 recelver and pumped Lo Lhe
recLlflcaLlon column by mean of cenLrlfugal pump 3
lnerL gases (P2 n2 C2) saLuraLed wlLh ammonla and havlng max of 100
ppm CC2 leave Lhe Lop of Lhe recLlflcaLlon secLlon of M absorber 1he
boLLom soluLlon ls recycled by Lhe pump 2A/8 Lo synLhesls recovery secLlon
nP3 wlLh lnerL gases leavlng Lhe M absorber Lop ls parLlally condensed Lhe
ammonla condenser L9 8oLh uncondensed gases phase and condensed llquld
ammonla are sendlng Lo ammonla recelver v1
1he lnerL gases saLuraLed wlLh ammonla llvlng Lhe recelver v1 enLer
ammonla preheaLer L10 where an addlLlonal amounL of vapor ammonla ls
condensed by heaLlng cold ammonla (aL around 10C) comlng from ammonla
sLorage area and used as makeup feed Lo urea planL ln addlLlon Lo hoL
ammonla Laken dlrecLly from ammonla planL 1he condensed ammonla from
L10 ls recelved ln Lhe recelver v1 and so ls Lhe ammonla make um feed
1he lnerL gases wlLh resldual ammonla conLenL are senL Lo medlum
pressure ammonla absorber L11 whlch ls a falllng fllm Lype and where Lhey
meeL counLercurrenL condensaLe flows whlch absorb gaseous ammonla 1he
absorblng heaL ls removed by coollng waLer flow on Lhe shell slde of L11
lrom Lhe boLLom of L11 Lhe waLer ammonla soluLlon ls pumped Lo Lhe M
absorber C1 (aL second bubble cap Lray from Lhe Lop) by mean of cenLrlfugal
pump 7A/8
1he upper parL of M ammonla absorber deslgnaLed as C3 conslsL of Lhree
valve Lrays where Lhe lnerL gases are submlLLed Lo flnal washlng by pure
condensaLe
1he lnerL leavlng Lhe Lop of L11/C3 are pracLlcally free from Ammonla


ii. Low Pressure Purification and recovery stage .
Ata
1he pressure of Lhe soluLlon leavlng boLLom of Lhe M decomposer ls
leLdown Lo 43 aLa and Lhen enLers Lhe low pressure decomposer whlch conslsL of
1op separaLor (Mv3) where Lhe released flash gases are removed before
Lhe soluLlon enLers Lhe lower Lube bundle
uecomposlLlon secLlon L3 (falllng fllm Lype) where Lhe resldual carbamaLe
ls decomposed 1he requlred heaL for decomposlLlon ls supplled by mean
of saLuraLed seam aL 43 aLa
1he gases leavlng Lhe Lop separaLor (Mv3) are senL Lo Lhe low pressure
condenser L8 where Lhey are absorbed ln an aqueous carbonaLe soluLlon
comlng from Lhe wasLe waLer recovery secLlon 1he absorpLlon and
condensaLlon heaL from L condenser L8 ls removed by coollng waLer lrom
Lhe L condenser L8 Lhe llquld phase wlLh remalnlng lnerL gases ls senL Lo
Lhe carbonaLe soluLlon Lank v3 lrom Lhere Lhe carbonaLe soluLlon ls recycled
back Lo Lhe medlum pressure condenser L7 by mean of cenLrlfugal pump
3A/8 Lhe lnerL gases from v3 whlch essenLlally conLaln ammonla vapor and
some lnerL flow dlrecLly lnLo Lhe low pressure falllng fllm absorber L12 where
Lhe ammonla ls absorbed by a counLer currenL waLer flow 1he absorpLlon
heaL ls removed by coollng waLer flow on shell slde of L12 1he Lop porLlon of
L12 has Lhree valve Lrays and ls deslgnaLed as C4 ure condensaLe ls
lnLroduced lnLo Lhe Lop Lray whlch flow down Lhrough oLher Lrays of C4 and
Lhen L12 Lo recover ammonla venL gases leavlng C4 are only lnerL and are
free from ammonla

c. Urea Concentration Section
As lL ls necessary ln order Lo prlll urea Lo concenLraLe Lhe urea soluLlon up
Lo 998 by wL a vacuum concenLraLlon secLlon ln Lwo sLages ls provlded
1he soluLlon leavlng Lhe L decomposer L3 boLLom havlng abouL 72 by
wL of urea ls senL Lo Lhe flrsL vacuum concenLraLor L14 operaLlng aL a pressure
03 aLa 1he llquld/vapor phase comlng ouL from L14 enLers Lhe gas llquld
separaLor Mv6 where from Lhe vapors are exLracLed by Lhe flrsL vacuum sysLem
ML4 whlle Lhe soluLlon enLers Lhe second vacuum concenLraLor L13 operaLlng
aL a pressure of 003 aLa
1he Lwo concenLraLor L14 and L13 use saLuraLed sLeam aL 43 aLa 1he
llquld vapor phase comlng ouL from L13 enLers gasllquld separaLor Mv7 where
Lhe vapors are exLracLed by Lhe second vacuum sysLem ML3
i. First Vacuum System ME-
llrsL evaporaLor ls operaLed aL 130C and 03 kg/cm2 a pressure overhead
vapors from Lhe Lop of flrsL vacuum separaLor ls dlrecLed Lo Lhe shell slde of
precondenser L23 and heaL of condensaLlon ls removed by coollng waLer ln Lhe
Lube slde Ammonla vapor and resldual CC2 ls absorbed ln condensaLe formlng
dlluLe ammonla carbonaLe soluLlon and flow down Lhrough baromeLrlc leg Lo
wasLe waLer Lank v3
uncondensed gases are sucked by Lhe e[ecLor L!2 (moLlve fluld belng 43
aLa sLeams) and dlscharge ln Lhe shell slde of afLer condenser ls L27 whlch also
recelves uncondensed gases from second vacuum sysLem ML3 PeaL of
condensaLlon ls removed by coollng waLer flowlng ln Lhe Lube slde of L27 ulluLe
ammonla waLer soluLlon flow down Lo wasLe waLer Lank and non condensable are
venLed ouL from Lhe shell slde
ii. Second Vacuum System ME-
Second evaporaLor ls operaLed aL 140C and 003 kg/cm2 pressure
Cverhead gases from second vacuum separaLor Mv7 are sucked by a boosLer
e[ecLor L!4 (moLlve fluld belng 43 aLa sLeam) and dlscharged aL sllghLly hlgher
pressure Lo Lhe shell slde of flrsL lnLer condenser L28 where heaL of
condensaLlon ls removed by coollng waLer flowlng ln Lhe Lube slde 1he llquld
soluLlon flows down Lhrough baromeLrlc leg Lo v3
non condensed gases are drawn by Lhe e[ecLor L!3 (moLlve fluld belng 43
aLa sLeam) and dlscharged Lo Lhe shell slde of second lnLer condenser L29 where
Lhe laLenL heaL of condensaLlon ls agaln removed by coollng waLer Llquld flow Lo
v3 and non condensed gases are sucked by e[ecLor L!6 and dlscharged Lo Lhe
afLer condenser L27 where non condensable from flrsL vacuum sysLem also [oln
d. Urea Prilling
1he melLed urea leavlng Lhe second vacuum separaLor ls pumped Lo Lhe
prllllng buckeL ML8A/8 by mean of cenLrlfugal pump 8A/8
1he molLen urea comlng ouL from Lhe prllllng buckeL ln Lhe form of drops
falls along Lhe prllllng Lower ML6 and encounLers a cold alr flow whlch causes lLs
solldlflcaLlon and subsequenL coollng
1he solld prllls falllng Lo Lhe boLLom of Lhe prllllng Lower are senL Lo Lhe belL
conveyer M11 by Lhe roLaLor scraper ML_12 lrom here urea prllls are passed
Lhrough screen ML10 whlch reLalns lumps only roducL prllls are conveyed by
belL conveyer M13 Lo Lhe bulk urea sLorage or bagglng planL
urea lumps reLalned on screen ML10 are conveyed by mean of belL
conveyer M12 an underground Lank v7 where Lhe lumps are dlssolved ln
condensaLe aL 100C 1he urea soluLlon from Lhls Lank ls pumped Lo Lhe maln urea
soluLlon Lank vessel v4 by mean of pumps 9A/8 vla fllLer lL1A/8 Lo remove
any forelgn maLLer

e. aste ater Treatment
1he waLer conLalnlng Ammonla and CC2 comlng from flrsL and second vacuum
secLlon ls collecLed ln wasLe waLer Lank (v3) 1he wasLe waLer conLalns 36
nP3 CC2 1 and urea 113 1hls ls also known as Ammonlcal waLer 1hls
wasLe waLer ls pumped aL Lhe Lop of a dlsLlllaLlon Lower (C2) Lo remove nP3 CC2
and urea 1he nP3 and CC2 gases leaves Lhe column from Lhe Lop and Lhe urea
geL separaLed aL Lhe mlddle of Lhe column and lL ls send Lo Lhe urea Pydrolyser
(831) whlch hydrolyze Lhe urea and converL lnLo carbamaLe Lhen furLher
hydrollzaLlon break Lhls carbamaLe lnLo Ammonla and CC2 1he purlfled waLer ls
dlscharges from Lhe shell slde of a reboller mounLed aL Lhe boLLom of Lhe
dlsLlllaLlon column
1he dlsLlllaLlon column ls operaLes aL Lhe pressure of 23 kg/cm3 1he dlsLlllaLlon
column (C2) ls conslsLs of 43 sleve Lrays 1he feed means wasLe waLer ls
lnLroduced aL Lhe Lray numbers 37 39 and 41 counLlng flrsL from Lhe boLLom
8efore lnLroduclng ln Lhe column Lhe feed wasLe waLer ls geL preheaLed ln Lhe
Lube slde of a shell and Lube heaL exchanger by Lhe effluenL of Lhe reboller ln Lhe
dlsLlllaLlon column ammonla and CC2 ln Lhe feed are sLrlpped by mean of vapor
producL produced ln Lhe reboller whlch ls supplled by 43kg/cm
2
saLuraLed sLeam
1he llquld sLeam from Lhe holder above 20
Lh
Lray ls Laken ouL Lo hydrolyser urea ln
hydrolyser by means of sLeam 1he vapor from Lhe hydrolyser enLers aL Lhe 37
Lh

Lrays and llquld ls recycled back Lo Lhe dlsLlllaLlon column aL 20
Lh
Lrays
1he vapor leavlng Lhe Lop of Lhe dlsLlllaLlon column are condensed ln an
overhead condenser 1he condensaLe (Lhe carbamaLe soluLlon) ls recelved ln Lhe
reflux accumulaLor 8y means of cenLrlfugal pump a parL of soluLlon ls recycled
back Lo Lhe Lop of Lhe dlsLlllaLlon column as reflux whlle Lhe remalnlng parL ls
supplled Lo L carbamaLe condenser
1he dlsLlllaLlon column boLLom effluenL conLalnlng only Lraces of ammonla ls
Laken Lo reboller and Lhen hoL llquld effluenL ls fed Lo Lhe shell slde of Lhe soluLlon
preheaLer where lL ls cooled and pumped by Lhe means of Lhe cenLrlfugal pump
Lo Lhe waLer cooler where lL ls cooled by coollng waLer Lo a LemperaLure abouL
40 C and Lhen dlscharged of Lhe of Lhe facLory effluenL sysLem A provlslon for
ln[ecLlon of small quanLlLy of alr ln Lhe boLLom of Lhe dlsLlllaLlon column ls
provlded Lo passlvaLe Lhe enLlre secLlon
1hls purlfled waLer ls used as Lhe same as uM waLer










. EQUIPMENT USED IN UREA MANUFACTURINC
.. Reactor{R-]
Supplier- MitsuTisbi Heavy Industries Ltd. )apan
1he llquld mlxLure of nP
3
and gaseous CC
2
are fed ln reacLor where Lhese reacL Lo
form ammonlum carbamaLe a porLlon of whlch dehydraLe Lo form urea and
waLer
8eacLor ls verLlcally mounLed and made of carbon sLeel lL ls lnLernally llned wlLh
3mm Lhlck sLalnless sLeel llner 316LAmmonla/carbamaLe and CC
2
feed nozzle
exLend lnslde Lhe reacLor up Lo 18m and each are capped on Lop end lor
dlsLrlbuLlon of nP
3
/carbamaLe feed 343 holes (lu10 mm equlspaced) are
provlded 1hese are drllled along 833mm lengLh Slmllarly CC
2
dlsLrlbuLor has 270
nos 0f equlspaced holes (lu6mm) provlded over a lengLh of 880 mm lnslde
reacLor boLLom
Uperating Details
CperaLlng ressure 131kg/cm
2
a
CperaLlng 1emperaLure 183

C
ueslgn ressure 166kg/cm
2
a
ueslgn 1emperaLure 193

C
uenslLy of reacLor 930kg/m
3
8eacLor volume 137m
3

Maxlmum 1emperaLure and ressure
CradlenL durlng sLarLup and shuLdown
1emperaLure 30

C/hr
ressure 60kg/cm
2
/hr
Mlnlmum AccepLable 1emperaLure and Maxlmum ressure CradlenL durlng
Pydro 1esL
1emperaLure 20

C/hr
ressure 60kg/cm
2
/hr

Mecbanical Details
1 LengLh 3600mm
2 lu 2303mm
3 Cu 2494mm
4 lnLernal Llnlng 3mm 316L
3 1oLal no of sleve Lrays 10
6 PelghL beLween each Lray 2300mm
7 Poles on sleve Lrays 421 holes of 8mm lu
8 Cverflow lpe(lu) 2191mm wlLh 82 mm
Lhlck
9 nP
3
/carbamaLe lnleL dlsLrlbuLor equally spaced 343
holes of
10 holes dla 10mm
11 CC
2
lnleL dlsLrlbuLor holes equally spaced 270 holes of dla6mm

Material Uf Construction
1 Shell Carbon sLeel
2 Sleve Lrays SS 316L(modlfled)
3 All lnLernal walls and llner ln conLacL wlLh fluld SS316L (modlfled)
4 Man hole CaskeL 1eflon Alumlnlum


.. Medium Pressure ATsorTer :C-
Supplier: B.H.P.V. Visbakbapatnam
M Absorber (C1) conLalns four bubble cap Lrays aL Lhe Lop vapor llquld
mlxLure enLers Lhrough an enLry plpe whlch runs down lnslde column and ls
equally dlvlded lnLo four perforaLed arms Lach perforaLed arm has 270 holes of
12mm dla Lach and are equally spaced on Lhree rows faclng downwards 1here
are four bubble cap Lrays aL Lhe Lop of recLlflcaLlon secLlon numbered from
boLLom A llquld seal of 30mm ls malnLalned on each bubble cap plaLe4
Lh
and 3
rd

Lrays are fed pure reflux nP
3
and aqueous nP
3
soluLlon respecLlvely whlch
ellmlnaLe resldual CC
2
and waLer from Lhe ammonla leavlng C1CarbamaLe
soluLlon from boLLom plaLe downcomer falls ln a closed ended channel and Lhen
overflows Lo a dlsLrlbuLor
Mecbanical Details
LengLh 9000mm
lnLernal dlameLer 1830mm
1hlckness 233mm
no of bubble cap Lrays 4
Cap slze and nos 73mm163 caps per Lray
no of sloL ln each cap 19no recLangular sloLs(23mm helghLwldLh 63mm)
Llquld seal on each Lray 30mm
no of holes ln vapor llquld enLry plpe 270no holes 12mm dla equally
(spaced 3rows faclng down wards)
vapor Llquld lnleL nozzle dlameLer 2032mm
ure ammonla lnleL nozzle dla 762mm
nP
3
soluLlon lnleL 381mm
vapour ouLleL dla 234mm
P
2
C lnleL nozzle dla 234mm
8ecycle soluLlon lnleL nozzle 762mm
SoluLlon Lransfer nozzle dla 1016mm
SoluLlon ouLleL nozzle 2032mm
Manhole dla 308mm

Uperating Details
CoeraLlng ressure 18kg/cm
2

CperaLlng 1emperaLure 1C 473C
8C11CM 88C
ueslgned ressure 22kg/cm
2
ueslgned 1emperaLure 110C
uenslLy of carbamaLe soln 922kg/m
3

Pydraullc LesL pressure 403kg/cm
2


Material Uf Construction
Shell Peads and All lnLernals SS316L
SupporLs SS316L283 CrC
CskeLs Splral wound AlSl316+1eflon


.. Distillation Column{C-]
Supplier: Larsen And TouTro, BomTay
reheaLed Ammonlum carbamaLe soluLlon leavlng preheaLer enLers Lhe Lop of
dlsLlllaLlon columnnP
3
and CC
2
ln feed sLrlpped by means of vapor produced ln
Lhe reboller (L16) and enLer C2 aL Lhe boLLom vapor leavlng Lop of Lhe Lower ls
condensed ln an overhead condenser (L20) from where soluLlon collecLed ln Lhe
reflux accumulaLor v8leed Lo reboller ls Laken from C2 boLLom vapor from L
16 are back Lo Lhe dlsLlllaLlon column below 1
sL
plaLe 8lslng vapor whlle Lravelllng
Lhrough Lray comes ln lnLlmaLe conLacL wlLh soluLlon sLrlp ouL nP
3
and CC
2
1here
are Lwo dlsLrlbuLors one ls below 21
sL
Lray 1he dlsLrlbuLor ls well supporLed Lo
shell and dlvlded lnLo Lhree parLs lrom Lhe mlddle porLlon havlng vapor hood aL
Lhe Lop whlch prevenLs soluLlon from enLerlng Lhrough mlddle openlng only gas
wlll pass Cverhead vapors leave Lhrough 14
Lh
ouLleL nozzle and are Laken Lo
overhead condenser (L20)
lour Lhermocouples are provlded Lo measure LemperaLure above 41
sL
30
Lh
20
Lh

and 10
Lh
plaLe 1wo gauges for level have been provlded aL boLLom
Mecbanical Details
LengLh 33670mm
lu 1248mm
no of sleve Lrays 43
no of bell caps 133
lnsulaLlon 70mm Lhlck
vapor ouLleL nozzle dla 14lnches
8eflux lnleL nozzle dla 13lnches
SoluLlon feed nozzle dla 4lnches
vapor lnleL nozzle dla 16lnches
uLlllLy alr lnleL nozzle dla 1lnch
WaLer ouLleL nozzle dla 6lnches

Uperating Details
ueslgn ressure 4kg/cm
2

ueslgn 1emperaLure 163C
CperaLlng ressure 2kg/cm
2
CperaLlng LemperaLure 133C
volume 44m
3
Material Uf Construction
Shell Peads and lnLernals SS304
SupporLs A240 Lype 304 A 313 Cr33
CaskeLs Compressed asbesLos

.. Stripper{E-]
Supplier: FBM Milano
SLrlpper ls a hlgh pressure falllng fllm Lype heaL exchanger 8eacLor effluenLs are
heaLed ln sLrlpper Lo decompose and sLrlp off unconverLed carbamaLe aL
synLhesls pressure 8eacLor effluenLs are admlLLed aL Lhe Lop porLlon of sLrlpper
and are fed Lo Lhe clrcumferenLlal annular secLlon of Lhe dlsLrlbuLor plaLe
SoluLlon Lhen overflows a welr of dlameLer 1370mm and ls dlsLrlbuLed Lhrough
holes of dlsLrlbuLor over a bed of pall rlngs Pere counLer currenL conLacL Lakes
place beLween Lhe llquld and gases leavlng Lhe sLrlpper Lubes Crld below Lhe
packed bed ls placed [usL above Lhe ferrules Lo keep Lhem ln poslLlon Lach ferrule
has holes aL Lwo dlfferenL planes AL Lhe boLLom plane Lhere are 4 LangenLlal
holes of 24mm dlameLer Lhrough whlch llquld enLers each Lube ln Lhe form of a
fllm along Lhe wall 1he soluLlon ouLleL aL Lhe boLLom ls provlded wlLh a vorLex
breaker 1here are Lwo Lypes of level senslng elemenLs aL Lhe boLLom (a) dp
LransmlLLer (b) radloacLlve source
Mecbanical Details
TuTe
MaLerlal
1lLanlum
PeaL Lransfer area 787
on lum
2
no of Lubes 2780
lu
200mm
Cu
270mm

Ferrule
MaLerlal
28L69
PelghL of boLLom seL of holes from Lube 30mm
sheeL
PelghL of Lop seL of holes from Lube 409mm
sheeL

Bottom Crid
MaLerlal 2 8L 69
no of holes 3376
Pole dla 12mm

Packings
MaLerlal 28L69
1ype all rlng
8lng slze

DistriTutor Plate
MaLerlal 28L69
no of hole 1200
Pole 9mmdla
no of weep holes 43
MaLerlal of shell Carbon sLeel

.. Hp Ammonia Feed Pumps{P-aJBJC]
Supplier: ortbington, HamTurg
1aklng sucLlon from dlscharge header of Ammonla boosLer pumps p3A/8 P nP
3

feed pump pumps anhydrous llquld ammonla aL a hlgh pressure of
240kg/cm
2
1hls llquld ammonla sLream serves as a drlvlng force for e[ecLor L!1 Lo
recycle carbamaLe Lo reacLor 1hls ls a 3 plunger reclprocaLlng verLlcal pump An
elecLrlc moLor drlves lL Lhrough a 1orque converLer and speed reduclng gear
Speed of Lhe pump can be conLrolled from Lorque converLer by ad[usLlng Lhe
openlng of conLrol valve on Lhe Lorque converLer 1he lubrlcaLlon of all Lhe parLs
housed ln Lhe crankcase ls done by a 8oLary oll pump whlch Lakes sucLlon from
Lhe oll sump of crank case 1here ls a pressure swlLch provlded ln Lhe dlscharge
llne of lube oll sump Plgh pressure of lube oll ls relleved by a pressure rellef
valve Lach sLufflng box ls provlded wlLh oll ln[ecLlon Cll from a small
reclprocaLlng pump ls ln[ecLed lnLo Lhe space ln L packlng of each plunger Cll
ouLleL from each plunger ls Laken Lo Mv3 1he speed of each pump can be
conLrolled by a PlC ln dlscharge Lhere are one C one hlgh pressure alarm and a
hlgh pressure Lrlp Lach pump has goL an lndlvldual safeLy valve ln sucLlon and
dlscharge head lollowlng are Lhe maln parLs
O Crank Case 1he frame ls a very rlgld casLlng and ls made of 2 pleces 1he
lower parL of Lhe frame serves as oll sump for lubrlcaLlng oll
O Crank ShafL lL ls a one plece forglng of carbon sLeel Poles have been
drllled ln Lhe crank shafL Lo carry lube oll for pressure lubrlcaLlon
O Maln 8earlngs 3 are llne bearlng and one ls LhrusL bearlng 1hese bearlngs
are sleeve bearlng and made of Lhree comparLmenLs
O ConnecLlng 8od and Crank ln 8earlngs Lach connecLlng rod ls one plece
sLeel forglng Crank pln bearlng spllL shell made of Lhree componenL alloy
O Cross Pead ln 8ushlng 1hese bushlngs are forced flL ln Lhe connecLlng rod
1hese have annular groove on ouLslde surface for lubrlcaLlon purpose lL ls
made of alumlnlum bronze mulLlcomponenL alloy sLeel
O Cross Pead Cross heads are made of nodular casL lron Lurned and ground
Cross heads have annular grooves for lubrlcaLlng cross head area
O Cross Pead ln Cross head pln ls forced flL lnLo cross head and ls held ln
poslLlon by reLalnlng rlngs and dowel plns Lo avold Lurnlng 1he cross head
ls drllled Lo lubrlcaLe Lhe face of Lhe cross head
O 1le 8ods 1wo Lle rods for each head LransmlL Lhe verLlcal cross head
moLlon Lo Lhe plunger 1he plunger ls flxed on Lhe Lle rods wlLh Lhe help of
nuLs 1le rods are made of Cr Mo SLeel



Mecbanical Details
no of plungers 3
lunger dla 86mm
SLroke lengLh 132mm
lunger speed aL 193 rpm 099m/s
SucLlon nozzle dlameLer 4lnches
ulscharge nozzle dla 4lnches
valves wlng
llushlng Cll llow 047L/hr
ulrecLlon of roLaLlon Clockwlse from
coupllng end

Uperating Details
lluld Pndled Anhydrous llquld
nP
3

Mlnlmum CapaclLy 13m
3
/hr
normal CapaclLy 413m
3
/hr
Maxlmum CapaclLy 47m
3
/hr
SpCr aL operaLlng LemperaLure 038
vlscoslLy 013cps aL 40C
Mlnlmum SucLlon 1emperaLure 30C
CperaLlng SucLlon 1emperaLure 40C
ueslgn SucLlon 1emperaLure 6062C
nSP requlred 32m
nSP avallable 10m
normal SucLlon ressure 216kg/cm
2
Maxlmum SucLlon ressure 28kg/cm
2
vapour pressure aL operaLlng Lemp 1483kg/cm
2
normal dlscharge pressure 240kg/cm
2
Maxlmum dlscharge pressure 264kg/cm
2
Mlnlmum Speed 63rpm
Maxlmum Speed 193rpm
normal Speed 1019rpm
942rpm
1062rpm
1298rpm
Mecbanical Details
LengLh 3600mm
lu 2303mm
Cu 2494mm
lnLernal Llnlng 3mm 316L
1oLal no of sleve Lrays 10
PelghL beLween each Lray 2300mm
Poles on sleve Lrays 421 holes of 8mm lu
Cverflow lpe(lu) 2191mm wlLh 82 mm
Lhlck
nP
3
/carbamaLe lnleL equally spaced 343



.. Prilling Tower{Me-]
Erector -MJS. E.C.C., BomTay
1hls ls a concreLe sLrucLure of 96 meLer helghL urea melL enLers roLaLlng prlll
buckeL slLuaLed [usL below Lhe prllllng Lower celllng MelL enLers aL a LemperaLure
abouL 140

C and ls dlsLrlbuLed ln flne dropleLs over Lhe cross secLlon of Lhe Lower
of 22 meLer dlameLer and havlng free falllng helghL of 723meLerslL ls a naLural
drafL Lower where amblenL alr enLers Lhrough boLLom lower openlngs havlng
LoLal area 37m
2
uurlng Lhe fall Lhrough buckeL Lhe dropleLs of urea flrsL solldlfy
and Lhen cooled Lo a LemperaLure of abouL 6063

CPoL alr ouLleL wlndows are

provlded aL Lhe Lop havlng LoLal area 133m
2
1he prllls are scraped by roLaLlng
sLralghL double arm scraper and fed Lo Lhe prlll Lower conveyor Lhrough openlngs
ln Lhe rake floor 1he lnslde wall of Lhe Lower ls palnLed wlLh epoxy palnLlng and
boLLom floor where prllls fall are coaLed wlLh l8 coaLlng Lo reslsL
corroslon1000mm*1000mm lnspecLlon wlndows wlLh llghL are provlded every
four fllghLs of exLernal sLalrway Cne elevaLor runs parallel Lo prlll Lower



.. Prill Bucket And Spare {Me-8 AJB]
Supplier: CAZZULA, ITALY
Llquld urea melL enLers Lhe prlll buckeL ML8A/8 whlch ls roLaLed by varlable
speed moLor CuL of Lhe Lwo buckeLs one wlll be ln use and Lhe wlll be kepL as
spare laclllLy has been provlded for change over of Lhe buckeL and Lhe clogged
buckeL can be washed wlLh condensaLe ln condensaLe washlng Lank provlded on
Lhe oLher slde of Lhe supporL sLrucLure ulrecLlon of roLaLlon of buckeL ls
clockwlse when vlewed from Lop
Mecbanical Details
LengLh of buckeL 280mm
WelghL of buckeL 16kg
Speed of buckeL 200300rpm

Material of Construction
8uckeL MaLerlal Alumlnlum

Uperating Details
ueslgn CapaclLy 80000kg/hr
normal CapaclLy 63000kg/hr
Mlnlmum CapaclLy 31000kg/hr
urea 1emperaLure 1281C


.8. Mp Ammonia ATsorTer{E-,C-]
FaTricated: Nicola AlTia
M Ammonla Absorber L11 1hls ls falllng fllm Lype heaL exchanger Ammonla
vapors and lnerL comlng from shell slde of Ammonla preheaLer enLer aL Lhe
boLLom of M Ammonla Absorber WaLer comlng from C3 aL Lhe Lop of L11 heaL
exchanger comes down Lhrough ferrules ln Lhe form of a Lhln fllm along Lhe
Lubes upcomlng ammonla ls absorbed by waLer PeaL of soluLlon ls dlsslpaLed Lo
coollng waLer flowlng Lhrough Lhe shell 1he ferrules have Lhe Lwo seLs of holes
on lL 8oLh have 3 holes ln Lhem whlch are LangenL Lo Lube surface and are aL
120

Lo each oLher WaLer conLalnlng ammonla goes down Lhrough a dlsLrlbuLor Lo

Lube sheeL of L11L11 operaLes aL 33 kg/cm
2
pressure aL shell and 17 kg/cm
2
aL
Lube slde Coollng waLer flows Lhrough shell slde
M AMMCnlA A8SC88L8 C3 Cases rlslng from heaL exchanger L11 are
scrubbed wlLh waLer on Lhe sleve Lrays ln columnC3 whlch operaLes aL 16 kg/cm
2

pressure and 78C LemperaLure Cold condensaLe from absorpLlon cooler ls used
as absorpLlon waLer and ls fed Lo 3
rd
Lray Cases are parLlcularly free of ammonla
whlle leavlng absorber aL Lhe Lop Medlum pressure sLream ls ln[ecLed above 3
rd

Lray Lo keep Lhe gases leavlng absorber ouL of exploslve range 1he llquld comlng
down from Lrays ls dlsLrlbuLed over Lube sheeL of exchanger L11

.9. MP Decomposer{E-]
Supplier: Larsen And TouTro Ltd. BomTay
SoluLlon from sLrlpper ls flashed ln M separaLor (Mv2) aL 18 ALa pressure uue
Lo flashlng some ammonla and carbon dloxlde ls released from soluLlon 8esL of
Lhe soluLlon ls heaLed ln M decomposer L2 Lo decompose carbamaLe lnLo
ammonla CC
2
and waLer aL 18 ALa pressure SoluLlon conLalnlng waLer urea
unconverLed carbamaLe and ammonla ls fed over Lhe Lube sheeL SoluLlon enLers
Lhe decomposer Lubes Lhrough a seL of four holes provlded ln ferrule Poles belng
LangenLlal Lo ferrule ensures dlsLrlbuLlon of llquld ln Lhe form of fllm along Lhe
surface of decomposer Lube Level of llquld around ferrules and above Lhe holes
provldes sLaLlc head for soluLlon Lo flow Lhrough ferrule and decomposer Lube

.. MP Separator {Mv-]
Supplier: Larsen and TouTro Ltd. BomTay
SoluLlon from sLrlpper ls leL down Lo 18 ALa and Lhen enLers M separaLor
8educLlon ln pressure reduces some ammonla and CC
2
8emalnlng llquld comes
down Lhrough a downcomer and ls dlsLrlbuLed over a packed bed of 8aschlng
8lngs Cases comlng from decomposer boLLom are aL hlgher LemperaLureMv2
operaLes aL 22kg/cm
2
pressure and 183C LemperaLure 1here ls a heaL exchanger
beLween llquld sLreams flowlng downwards and gaseous phases movlng up lnLo
Lhe packed bed Caseous sLream from packed bed along wlLh gases llberaLed due
Lo flashlng leave M separaLor Lhrough 12
Lh
vapor ouLleL

.. MP Decomposer Holder {Me-]
Supplier: Larsen and TouTro Ltd. BomTay
SoluLlon from M decomposer comes down Lo M holder whlch ls a small vessel
lL has 6lnch soluLlon ouLleL llne lnerL gases from carbamaLe seperaLorMv1 also
enLer here 1here ls one Lapplng for level lndlcaLlon and conLroller 1here are Lwo
slghL glasses whlch are aL 180degree Lo each oLher and gaskeL used for Lhls ls of
1eflon ln fronL of shock glasses a LransparenL shock reslsLanL shleld ls provlded
for safeLy ln case of slghL glass rupLure




.. CarTamate Condenser {E-]
FaTricator: Nuovo Pignone
Cases rlch ln ammonla and CC
2
escaplng from Lhe sLrlpper enLer Lhe carbamaLe
condenser mlxer where Lhe carbamaLe soluLlon from M sysLem ls also fed 1hls
mlxed feed enLers Lhe Lubes of Lhe carbamaLe condenser As nP
3
and CC
2
reacL Lo
form carbamaLe a loL of heaL ls llberaLed 1hls heaL ls uLlllzed ln Lhe producLlon of
43aLa sLeam ln Lhe carbamaLe condenserL3 operaLes aL 147C on shell and 170C
on Lube slde whlle correspondlng operaLlng pressure are 33 and 130 kg/cm
2

respecLlvely Shell slde also has condensaLe comlng from L6 whlch ls lald ln serles
wlLh Lhls condenser CondensaLe level of Lhls heaL exchanger ls an lmporLanL
feaLure lor Lhls Lhere are 8 Lapplngs arLlLlon plaLe keeps bundle submerged ln
Lhe condensaLe
.. CarTamate Condenser{E-]
FaTricator: Nuovo Pignone
CarbamaLe soluLlon wlLh CC
2
nP
3
from carbamaLe condenser L3 enLers
carbamaLe condenser L6 on Lhe Lube slde unconverLed CC
2
reacLs wlLh
ammonla and forms carbamaLe 8eacLlon belng exoLhermlc releases a loL of heaL
whlch ls recovered by generaLlng 43ALa sLeamL6 operaLes aL 147C aL shell and
138C aL Lube slde whlle correspondlng pressure belng 33 and 130 kg/cm2SLeam
condensaLe from M decomposer shell slde comes Lo Lhe shell slde of carbamaLe
condenser L61hls ls a uLube heaL exchangerlor any makeup of condensaLelL
can be drawn from condensaLe pumpCondensaLe from here goes Lo L3A draln
polnL has also been provlded for shell slde
PeaL Lransfer areadlameLerlengLh of LubesmaLerlal of
consLrucLlon gaskeL maLerlal eLc are sameCn shell slde only dlfference ls LhaL no
L8C ls used ln L6 and condensaLe ouLleL nozzle dla ls 6lnch ln L6 and LhaL ln L3
ls 3 lnch

.. Mp Condenser{E-]
Supplier: Larsen and TouTro, BomTay
Cases from M separaLor Mv2 and carbamaLe soluLlon from M carbamaLe
pump 3A/8 enLer Lhe shell slde of M condenser CC
2
and ammonla from M
separaLor condense ln Lhe carbonaLe soluLlon formlng ammonlum carbamaLe ln
Lhe condenser heaL produced by Lhe reacLlon of carbamaLe formaLlon ls removed
by coollng waLer whose lnleL LemperaLure ls conLrolled around 40CShell slde lnleL
and ouLleL LemperaLure are 140 and 82C respecLlvely whlle correspondlng Lemp
AL Lube slde are 38 and 70CCperaLlng pressure aL shell and Lube slde are 17 and
33kg/cm
2
M condenser ls a shell and Lube heaL exchanger havlng carbamaLe
soluLlon on shell slde and coollng waLer aL Lube slde Cases and carbonaLe
soluLlon enLer a mlxer where carbonaLe soluLlon ls sprayed Lhrough a 30degree
cone sprayer lL Lhen flows Lo shell slde of condenser 1empLed coollng waLer
flows ln Lwo passes Lhrough Lube bundle CarbamaLe soluLlon leaves Lhe
condenser wlLh a very llLLle free CC
2


.. Hp Steam De-super beater {Me-]
Supplier: MJS. Kinetics B.V. Amsterdam
SuperheaLed MS sLeam aL 328C ls avallable from Lhe CC
2
compresslon Lurblne
exLracLlon sLage and also from k sLeam desuper heaLer lf any are
desuperheaLed ln M sLeam desuperheaLer (ML11)SuperheaLed sLeam enLers
ln ML11 where desuperheaLlng ls done by spraylng waLer 1he waLer spray
nozzle exLends lnslde Lhe sLeam chamber CuLleL LemperaLure lf P sLeam
desuperheaLer ls conLrolled aL 223ClnleL MS sLeam Lemp ls 328C whlle
condensaLe lnleL pressure ls 32kg/cm
2
16 Lap holes are provlded ln lnleL and
ouLleL flanges and are orlenLed aL 11degreeuesuperheaLed MS sLeam aL 223C ls
used for supplylng necessary heaL aL sLrlpper shells 8ody ls manufacLured from
carbon sLeel whlle nozzle from sLalnless sLeel

.. Prill Tower Rotary Scraper{Me-]
Supplier: MJS. Arenco-BMD Sweden
Scraper ls used Lo unload Lhe producL from prllllng Lower boLLom floor Lo Lhe belL
conveylng sysLem Machlne conslsLs malnly of
lorearm Chasls 1hls ls a sLeel elemenL wlLh flxlng feeL embedded ln Lhe concreLe
floor of prllllng Lower
CenLral Chasls As a base for Lhe roLaLlng parL a welded consLrucLlon wlLh a
roLaLlon race mounLed on Lhe upper and underneaLh Lhe drlve unlLs
urlve unlLs Machlne ls drlven by moLors each coupled wlLh a hydraullc coupllng
and a gear box
Pydraullc coupllng serves a dual purpose on Lhe one hand lL
safeguards agalnsL posslble over loadlng and on Lhe oLher hand lL ensures a
gradual sLarLup SLarLup Lorque of moLor ls reduced by Lhls arrangemenL A speed
conLroller (belL drlven by hydraullc coupllng shafL) ls lncorporaLed Lo monlLor
when normal speed of scraper slows down Lach drlve unlL conslsL of elecLrlc
moLor of 11kW raLlng and 1000rpm speed hydraullc coupllng of consLanL oll
fllllng Lype wlLh safeLy fuse plug gear reducer and gear wheel wlLh plnlon 8ulk
denslLy of producL urea ls 700Mg/m
3
and prlll Lemp ls 6073C lrame chasls and
scraper arm ls made of carbon sLeel palnLed wlLh Lwo coaLs of synLheLlc epoxy
resln Scraper blades are made of sLalnless sLeel llned wlLh hard chromlum
maLerlal


.. Blow Down {Me-]
Supplier: MJS. Kaveri Structurals, Madras
All safeLy valves blowlng ammonla/CC
2
vapor sLeam eLc are recelved by sLack
llve dlfferenL llnes carrylng relleved vapors of Sv [oln Lhls sLack SLack ls provlded
wlLh sLeam heaLlng and condensaLe flushlng arrangemenL SLeam enLers Lhrough
2lnch nozzle aL Lhe neck and 1lnch nozzle aL Lhe boLLom sLack 1lnch sLeam llne aL
boLLom ls exLended up Lo 1900mm lnslde SLeam comes ouL Lhrough 10 nos
drllled holes faclng downwards 8low down ls deslgned aL aLmospherlc pressure
and 200C Lemp CapaclLy of Lhls ls 86m
3
SLack dlameLer aL boLLom and Lop ls
2000 and 1047mmShell and heads are made of A283CrC whlle lnLernals of
A106Cr A and gaskeL maLerlal ls compressed asbesLos
.8. Vent Stack {Me-]
Supplier: MJS. Kaveri Structurals, Madras
venLed nP
3
/CC
2
vapour along wlLh lnerL gases from M absorber (C1)M nP
3

absorber(C3)L nP
3
absorber (C4)8eflux accumulaLor (v8) and oll nP
3
separaLor
(Mv12) are senL Lo Lhls sLack SLack ls provlded wlLh sLeam heaLlng and
condensaLe flushlng arrangemenL SLeam enLers Lhrough 3lnch nozzle aL Lhe neck
and 1lnch nozzle aL boLLom1lnch sLeam llne aL boLLom exLends up Lo 630mm and
sLeam comes ouL Lhrough 10nos drllled holes(3mm dla) faclng downwards SLack
ls provlded wlLh 16lnch manhole and 1lnch overflow slphon breaker Any nP
3
/CC
2

condensaLe collecLed ln Lhe sLack can be senL Lo draln collecLlng Lank vla 2lnch
overflow llne and 1lnch draln llne Shell and heads are made of A 283 Cr C and
gaskeLs of compressed asbesLos
.9. Vent Stack {Me-]
Suppller M/S kaverl SLrucLurals Madras
Any nP
3
and CC
2
vapours released from urea soluLlon Lank(v4)wasLe waLer
Lank(v3) and draln collecLlng Lank (v6) are senL Lo ML16 SLack ls provlded wlLh
sLeam heaLlng and condensaLe flushlng arrangemenL SLeam enLers Lhrough 2lnch
nozzle aL Lhe neck and 1lnch nozzle aL boLLom1lnch sLeam llne aL boLLom ls
exLended lnslde up Lo 630mm closed aL Lhe end SLeam comes ouL from 1lnch llne
vla 10 drllled holes of dla3mm1lnch waLer lnleL nozzle ls provlded aL Lhe neck
SLack ls provlded wlLh 16lnch manhole and 1lnch overflow slphon breaker SLack
dla aL Lhe boLLom ls 730mm and aL Lop ls 260mm MaLerlal of consLrucLlon ls
same as 1
sL
venL sLack


.. Stripper Steam Condensate Drum{Mv-]
Supplier: B.H.P.V. ,Visbakbapatnam
lrom sLrlpper shell ouLleL condensaLe ls recelved ln Lhls Lank where condensaLe ls
separaLed and senL Lo M decomposer shell 1he vessel ls verLlcally erecLed
SLeam condensaLe from sLrlpper shell enLers ln Mv4 Lhrough 6lnch nozzle Cne
6lnch ouLleL nozzle comes ouL from boLLom from where condensaLe ls senL Lo L2
shell LqulpmenL ls provlded wlLh one 8lnch dla manhole 1he condensaLe level ls
conLrolled by L8C3LqulpmenL ls also provlded wlLh Lapplng for level gauge for
level conLroller hlgh and low level alarms LqulpmenL operaLes aL 223C and 23
kg/cm
2
LqulpmenL ls of helghL 2600mm lu 1000mmLhlckness 13mm provlded
wlLh 90mm Lhlck lnsulaLlon Shell ls manufacLured from AS1M A316 Cr70carbon
sLeel and gaskeLs of splral wound AlSl304 wlLh lmpregnaLed asbesLos


.. Hydrolyser{R-]
Supplier: Larsen and TouTro
1he waLer from dlsLrlbuLor (above 20
Lh
Lray) of C2 conLalnlng around 1 welghL
of urea ls pumped Lo hydrolyser vla preheaLer L31A/8 1hls soluLlon enLers
hydrolyser Lhrough 4lnch nozzle of Lhe boLLom aL one end urea presenL ln Lhe
soluLlon hydrolyses Lo nP
3
and CC
2
aL hlgh Lemp and hlgh reLenLlon Llme
SoluLlon passes Lhrough 4 comparLmenLs one afLer oLher where lL ls heaLed Lo
240C wlLh Lhe help of 33kg/cm
2
pressure superheaLed sLeam 1he sLeam enLers
Lhrough 3lnch nozzle SoluLlon leaves hydrolyser Lhrough 4lnch nozzle aL oLher
end 1hree 2lnch vapour ouLleL nozzles from dlfferenL places are provlded for gas
ouLleL from Lop of Lhe hydrolyser All Lhree llnes [oln Lo 2lnch vapour ouLleL
common header lour draln llnes are also provlded ln Lhe hydrolyser Lo draln Lhe
four comparLmenLs Lo cy 1wo more 2lnch nozzles are also provlded for Sv401
and pressure LransmlLLer 8C403Pydrolyser shell ls made of carbon sLeel and
cladded wlLh 3mm Lhlck mln SS 316 L All lnLernals are made of SS 316 L and
baffle plaLes are 8mm Lhlck Pydrolyser operaLes aL 240C and 33kg/cm
2
pressure
LengLh of hydrolyser ls 8300mm lu ls 2600mm and corroslon allowance ls noL
provlded

.. Ammonia Receiver{V-]
Supplier: BHPV, Visbakbapatnam
1he recelver serves as a sucLlon vessel for ammonla boosLer pump(
3A/8)Condensed ammonla from ammonla condenser(L9) ls recelved ln
ammonla recelver(v1)1he lnerL gases saLuraLed wlLh nP
3
leavlng Lhe recelver
enLer ammonla preheaLer(L10) where an addlLlonal amounL of ammonla ls
condensed by coollng wlLh cold makeup ammonla from ammonla sLorage
Condensed ammonla ls Lhen Laken Lo Lhe ammonla recelver(v1)lresh ammonla
aL around 1C from ammonla sLorage ls recelved ln v1 vla preheaLer L10PoL
ammonla of around 30C from ammonla planL [olns d/s llne of L8C11v near vl
1he vessel ls erecLed horlzonLally Cne 762mm ammonla recycle llne ls connecLed
aL Lop from 3A/8 dlscharge Cne 1016mm llne ls connecLed Lo recelver Lo
collecL ammonla ln case safeLy valves of 1A/8/C blows 8oLh llquld ammonla
lnleL llnes from L9 and L10 run down lnslde v1 up Lo 2900mmvessel ls
provlded wlLh Lapplng for hlgh level alarm low level alarmv1 operaLes aL 37C
and 162kg/cm
2
operaLlng pressure lL ls of lengLh 9630mm lu 3000mmLhlckness
303mm and corroslon allowance of 3mmShell and header are made of carbon
sLeel and gaskeLs of splral wound AlSl304 wlLh lmpregnaLed asbesLos

.. Steam Condensate Vessel{V-]
Supplier: B.H.P.V., Visbakbapatnam
1hls ls horlzonLal aLmospherlc Lank CondensaLe requlred ln urea planL are
supplled from sLeam condensaLe vessel(v2)uM waLer from offslLes enLer
sLeam condensaLe vessel(v2)3lnch L sLeam Lapplng ls also Laken Lo sLeam
condensaLe vessel(v2) for heaLlng of condensaLe durlng sLarLup CondensaLe
from v2 ls pumped by condensaLe pump 10A/8 1 P washlng pump 11
sucLlon sLrlpper u/ cell flushlng pump 18A/8 sucLlon PW and LW flushlng
neLworks desuperheaLer ML11 and ML23 and M and L ammonla absorbers
As operaLlng pressure of sLeam condensaLe vessel ls aLmospherlc some of Lhe
condensaLe flashes Lo form sLeam 1hls sLeam ls condensed ln L13 abd
condensaLe reLurns back Lo v2 1aplngs are Laken from v2 for hlgh and low level
alarms Cne local level gauge ls also provldedv2 ls equlpped wlLh one slde
manhole draln and overflow llnesv2 operaLes aL 100/130C and 01/20kg/cm
2

pressure Shell ls made of CsLeel(AS1M A316 Cr60) and gaskeLs of compressed
asbesLos


.. CarTonate Solution Tank {V-]
Supplier: Rolle, Italy
CarbonaLe soluLlon from L condenser (L8) along wlLh some lnerL gases flow Lo
carbonaLe soluLlon Lank(v3)CarbonaLe soluLlon ls recycled Lo M condenser(L7)
by medlum pressure carbonaLe soluLlon pump3A/8 lnerL gases essenLlally
conLaln nP
3
vapour whlch flow dlrecLly Lo low pressure absorber(L12/C4)1here
ls one safeLy valve Sv29 whlch proLecLs Lank from over pressurlzaLlon 1he Lank
ls equlpped wlLh Laplngs for level gauge and level conLroller lrom M
absorber(C1) soluLlon can be Lransferred Lo Lhls Lank vla 1016mm nozzle 1here
ls provlslon for 43ALa sLeam coll lnslde Lhe Lankv3 operaLes aL 40C and
22kg/cm
2
pressure lL ls of lengLh 11000mmlu 4300mmLhlckness 12mm and
equlpped wlLh 70mm Lhermal lnsulaLlon Shell ls manufacLured from SS304
supporLs of SS304 and A283 Cr C and gaskeLs of compressed asbesLos


.. Urea Solution Tank{V-]
Supplier: MJS. Vi|ay Tanks and Vessel Pvt. Ltd
urea soluLlon Lank(v4) ls used Lo collecL 71 urea soluLlon ln case of shuLdown
or sLarLup and urea melL ln case of prllllng fallure lL ls also used Lo recover urea
soluLlon comlng from urea soluLlon recovery Lank (v7) afLer belng pumped by
9A/8 and fllLered Lhrough fllLers lL1A/8 1he Lank ls equlpped wlLh sLeam coll for
malnLalnlng soluLlon LemperaLure aL around 100CCne Lhermocouple ls provlded
aL Lhe boLLom Lo lndlcaLe soluLlon LemperaLurev4 Lop venL llne ls connecLed Lo
2
nd
venL sLack ML16 and as such lL ls operaLed under aLmospherlc pressure 1he
Lank ls provlded wlLh condensaLe connecLlon urea soluLlon ls pumped by urea
soluLlon pump (20A/8) Lo 1
sL
sLage Cne 3lnch recycle llne wlLh lsolaLlon valve ls
provlded from urea soluLlon pump(20A/8) common dlscharge llne Lo v4Cne
vacuum breaker ls provlded aL Lhe Lopv4 operaLes aL 110140C and aLmospherlc
pressure lLs helghL ls 7320mmlu ls 3900mmLhlckness 3mm and lnsulaLlon
38mmlL ls manufacLured from AlSl304


.. aste ater Tank{V-]
Suppller M/S vl[ay 1anks And vessels
WaLer vapour along wlLh small quanLlLles lf ammonla and carbon dloxlde ls
condensed ln vacuum condensers of 1
sL
and 2
nd
vacuum sysLem and ls reLurned Lo
wasLe waLer Lank (v3) vla baromeLrlc leg 1he Lank ls dlvlded lnLo Lwo
comparLmenLs 1he baffle whlch dlvldes aL boLLom havlng 3mm Lhlckness and rlse
up Lo 1000mm1he baffle ls placed aL a dlsLance of 1300mm from Lhe wall on Lhe
dlameLer of Lhe Lank 1he blgger comparLmenL recelves soluLlon from draln
collecLlng Lank and wasLe waLer scrubber 1he smaller comparLmenL recelves
waLer from condensers of vacuum sysLem wlLh Lhe plpes dlpplng lnLo Lhe llquld so
as Lo provlde Lhe waLer seal requlred 1he Lank ls equlpped wlLh vacuum breaker
Lo avold pulllng vacuum ln Lhe Lank especlally durlng shuLdown Cne 3 lnch
Lapplng ls Laken from v3 Lop for venLlng of vapours Lo venL sLack lurLher 1lnch
LW condensaLe connecLlon ls provlded for fllllng up durlng lnlLlal sLarL 1aplngs
are Laken for level lndlcaLor and LemperaLure lndlcaLor 1ank v3 ls equlpped wlLh
local level gauge and also wlLh hlgh and low level alarms 1he Lank ls provlded
wlLh one 20lnch roof manhole and also one 24lnch shell manhole WasLe waLer
ouLleL nozzle ls Laken ouL from blgger comparLmenL whlch ls pumped bu 4A/8
Lo Lhe dlsLlllaLlon column (C2) vla soluLlon preheaLer(L18)v3 operaLes aL 43C
and aLmospherlc pressure lLs helghL ls 3490mmlu ls 3000mm and Lhlckness ls
3mmlL ls manufacLured from AlSl 304


.. Hp CarTamate Solution Pump{P-aJB]
Supplier: ortbington, HamTurg
Ammonlum carbamaLe soluLlon from M absorber C1 ls boosLed up Lo synLhesls
pressure and ls senL Lo Mlxer ML1 by Lhese P carbamaLe pumps normally one
pump ls requlred for conLlnuous servlce and Lhe oLher lnsLalled sLandby 1hls ls a
3 plunger verLlcal reclprocaLlng pump lL ls moLor drlven Lhrough a Lorque
converLer and speed reduclng gear 1orque converLer varles Lhe speed over a
wlde range of 30 Lo 100 whenever requlred 1he power end of Lhe pump ls
lubrlcaLed wlLh Lhe help of a gear pump whlch ls run by a moLor 1he crank case
serves as Lhe oll sump A pressure swlLch and a low pressure alarm are provlded
ln Lhls oll clrculL Lo save Lhe machlne from damage ln case of any oll fallure 1he
oll pressure ls ad[usLed by a pressure seLLlng rellef valve 1he sLufflng boxes are
supplled wlLh LW condensaLe 100kg/cm
2
pressure or wasLe waLer from 4A/8
dlscharge for seallng and lubrlcaLlng normally wasLe waLer remalns ln llne 1hls
waLer goes ouL Lo Lhe closed draln sysLem 1here ls a pulsaLlon dampener ln Lhe
sucLlon and dlscharge sldes of each pump SafeLy valves are provlded on sucLlon
dampeners Lach safeLy valve has bypass valve ln sucLlon as well as dlscharge
slde of Lhe pump adequaLe flushlng waLer connecLlons have been provlded 1he
pump ls provlded wlLh speed lndlcaLor and conLroller ln fleld as well as ln Lhe
conLrol room A hlgh pressure Lrlp wlLh an alarm ls provlded ln dlscharge llne A
pressure gauge and hlgh pressure alarm are also provlded 8efore Lwo dlscharge
valves a recycle valve ls provlded uurlng Lhe sLarL up of Lhe machlnes lL recycles
Lhe soluLlon back Lo M absorber C1
Mecbanical Details
no of plungers 3
lunger dla 103mm
SLroke lengLh 132mm
lunger speed aL 126rpm 064m/s
SucLlon nozzle dla 4lnches
ulscharge nozzle dla 3lnches
valves Wlng Lype
lluld flow raLe 13m
3
/hr
ulrecLlon of roLaLlon Clockwlse when seen
lrom coupllng end
CL8A1lnC uL1AlLS
lluld handled CarbamaLe soluLlon
Mlnlmum CapaclLy 13M
3
/hr
normal CapaclLy 418M
3
/hr
ueslgn CapaclLy 470M
3
/hr
Mlnlmum SucLlon 1emp 60C
normal SucLlon 1emp 73C
ueslgn SucLlon 1emp 110C
nSP 8equlred 61m
nSP Avallable 63m
Mlnlmum SucLlon ressure 13kg/cm
2
normal SucLlon ressure 17kg/cm
2
Maxlmum SucLlon ressure 22kg/cm
2

Mlnlmum Speed 41rpm
normal Speed 112rpm
Maxlmum Speed 126rpm











. Ammonia Production

Ammonla ls synLheslzed from hydrogen (from naLural gas) and nlLrogen
(from Lhe alr) naLural gas conLalns some sulfurous compounds whlch damage Lhe
caLalysLs used ln Lhls process 1hese are removed by reacLlng Lhem wlLh zlnc
oxlde eg
nC + P2S nS + P2C
1he meLhane from Lhe naLural gas ls Lhen converLed Lo hydrogen
CP4 + P2C 3P2 + CC
CP4 + 2P2C 4P2 + CC2
CC + P2C P2 + CC2
Alr ls mlxed ln wlLh Lhe gas sLream Lo glve hydrogen Lo nlLrogen raLlo of 31
WaLer carbon monoxlde and carbon dloxlde (all of whlch polson Lhe lron caLalysL
used ln Lhe ammonla synLhesls) are removed 1he carbon monoxlde ls converLed
Lo carbon dloxlde for use ln urea producLlon and Lhe carbon dloxlde removed
CC + P2C CC2 + P2
1he remalnlng Lraces of CC and CC2 are converLed Lo meLhane and Lhen
Lhe gases cooled unLll Lhe waLer becomes llquld and can be easlly removed
1he nlLrogen and hydrogen are Lhen reacLed aL hlgh LemperaLure and pressure
uslng an lron caLalysL Lo form ammonla
n2 + 3P2 2nP3

lllCC hulpur planL has been operaLlng ln Lwo separaLe unlLs wlLh common
offslLe planLs Clder one ls known as unl11 and Lhe newer one ls known as
unl12 8oLh Lhe unlLs have separaLe urea and ammonla planLs 1he capaclLy of
unl11 ls 1213 M1 ammonla per day suppller of Lhls planL ls M/s ullman kellog
uSA ln unl12 1740 M1 ammonla ls belng produced per day suppller of Lhe
process ls M/s P1AS uenmark









. Uff-sites

.. D. M. Plant
ln Lhe uM planL Lhe deep bore raw waLer conLalnlng varlous lmpurlLles ls
demlnerallsed le feed from Lhe varlous mlnerals presenL ln lL Lo make lL 100
free from parLlculaLe maLLer for lLs uses as boller feed waLer and process waLer
SpeclflcaLlon of Lhe processed waLer ls as bellow
1 pP 773
2 1urbldlLy 3n1u
3 Slllca conLenL 33 ppm max
4 1oLal Pardness 348 ppm as CaCC3
3 Calclum Pardness 160 ppm as CaCC3
6 Magneslum Pardness 188 ppm as CaCC3
7 M AlkallnlLy 424 ppm as CaCC3
8 AlkallnlLy 0
9 SulphaLes 63 ppm as CaCC3
10 Chlorldes 37 ppm as CaCC3
11 lron o06 ppm as le
12 1uS 630 ppm
8ecommended quallLy of uM waLer belng used ln hlgh pressure boller ls as
bellow
1 ConducLlvlLy mho/cm 03 mlcro
2 Slllca 0o13 ppm as SlC2
3 Pardness nll

Plant Description
Dem|nera||zat|on |ant
1he LreaLmenL scheme adopLed ln lllCC uM planL hase 2
nd
conslsL of unlL llke
ressure Sand fller (Sl) SLrong 8ase CaLlon (S8C ) uegasser (uLC) Weak 8ase
Anlon (W8A) SLrong 8ase Anlon (S8A) and flnally mlxed bed (M8) 1he seL of
Lhese unlLs consLlLuLe a sLream and Lhen are dlvlded lnLo Lwo numbers of such
sLreams(excepL Sl) each havlng Lhe normal capeclLy Lo produce 140 m3 of hlgh
purlLy uM waLer flL for boller feed 1he operaLlon conLrol and monlLorlng of planL
ls LC based semlauLomaLlc sysLem uependlng on Lhe requlremenL of uM waLer
and avallablllLy of unlLs boLh Lhe sLreams can be Laken ln servlce
Removal of Impurities
uemlnerallzaLlon process ls Lhe mosL efflclenL and rellable process of raw waLer
purlflcaLlon Lo produce hlgh quallLy boller feed and process waLer uelonlzaLlon
uses Lhe exchange of Lhese lons as a prlnclpal of purlflcaLlon lL ls Lherefore called
an lon exchange process 1he solld Laklng acLlon ln Lhe exchange processes have
mlcro porous sLrucLure llke flsh neL on whlch Lhe moblle lons are aLLached
Lemporarlly are called lon Lxchange 8esln
1he exchange of lons Lakes place beLween llke charged lons and
equlvalenLs 1hus demlnerallzaLlon process ocurs ln Lwo sLeps ln flrsL sLep
dlssolved caLlons ln waLer are echanged wlLh equlvalenL hydrogen lons (for
Pydrogen fromm caLlon resln) presenL on exchange slLes of caLlons exchange
resln whereas ln second sLep dlssolved anlos ln waLer aL on exchange slLes of an
anlon exvchange resln

Process Description
Excbange of Cat-ions
When waLer conLalnlng dlssolved salLs ls passed Lhrough a resln be whlch can
exchange caLlon and whlch ls properly charged wlLh hydrogen lons llke sulphaLe
chlorldes carbamaLe eLc Whlch form correspondlng mlnerals aclds llke P2SC4
PCl P2CC3 eLc respecLlvely
AfLer cerLaln reacLlons exLenL of exchange of lons durlng servlce perlod Lhe
caLlon resln becomes poor ln sLock of hydrogen lons and ls sald Lo be exasLed ln
order Lo make Lhe resln bed acLlve so as Lo glve deslgned LreaLed waLer quallLy lL
ls regeneraLed uslng dlluLe acld soluLlon
8e2Ca + 2PCl 28eP + CaCl2
8e2Mg + 2PCl 28eP + MgCl2

Excbange of Anions
When Lhls waLer ls passed Lhrough Lhe bed of anlons Cl CC3 SlC2 eLc comblned
wlLh resln maLrlx replaclng Lhelr hydrogen lon
ln Lhe uM planL Lhe exchange of anlon ls performed ln Lwo sLage llrsL ln
W8A where almosL sLrong anlons are removed and second ln S8A where almosL
weak anlon exchange may be represenLed as follows

8eCP + PCl 8eCl + P2C
28eCP + P2SC4 8e2SC4 + P2C
28eCP + P2CC3 8e2CC3 + P2C
28eCP + P2SlC3 8e2SlC3 + P2C

Regeneration.....
8eCl + naCP 8eCP + naCl
8e2SC4 + 2naCP28eCP + na2SC4
8e2CC3 + 2naCP28eCP + na2CC3

Slnce ln Lhls planL have Lwo anlon exchanger beds ln serles W8A S8A Lhe
Lhorough fares regeneraLlon procedure ls adopLed ln whlch four Lo flve percenLs
causLlc soluLlon ls flrsL passed Lhrough S8A and Lhe effluenL released from S8A ls
Lhen passed Lhrough W8A for furLher dlluLlon

Reverse Usmosis
1he 8C planL ls generaly used for Lhe flnal purlflcaLlon of Lhe effluenL or
wasLe waLer for lLs reuLlllsaLlon for Lhe sake of envlronmenL conLrol 1he waLer
from Lhe coollng waLer uM planL and waLer sofLenlng planLs are senL Lo Lhe 8C
planL for Lhe purlflcaLlon 1he LreaLed waLer from Lhe 8C planL ls used for
lrrlgaLlon for caol spraylng Lo seLLle Lhe coal dusL for horLlculLure and Lhe lefL
over ls flnaly Lhrouwn away
8C ls done Lhrough a membrane fllLer of Lhe range of angesLrom(10
10
)
scale 1he slze of Lhe lmpurlLles and Lhe dlssolved salLs ls of Lhe range of max 10
9

and hence are sLoped buL Lhe membran and only waLer mollcules can pass
Lhrough lL 1he membran maLerlal ls splral wounded polyamlde buL Lhe exacL
speclflcaLlon are noL even Lold Lo lllCC by Lhe manufacLure
8efore sendlng Lo Lhe 8C planL effluenL waLer ls flrsL send Lo Lhe
preLreaLmenL planL ln LhlsdolomlLe (43 CaC and 32MgC) ls used Magneclum
slllcon can noL be removed by any chemlcal LreaLmenL 1he concnLraLlon of
magneclum slllcaLe reduced from 17 ppm Lo 10 ppm ln Lhe preLreaLenL planL
llnaly Lhls waLer ls senL Lo Lhe 8C planL for Lhe flanl LreaLmenL
.. Cooling Tower
ln sny process lndusLry Lhe wasLe heaL generaLed durlng Lhe varlous
processes ls Lo be removed or uLlllzes Lhrough exchanger or some oLher
equlpmenL by clrculaLlng coollng waLer whlch laLer becomes hoL on absorblng
heaL So Lhe hoL waLer has Lo be cooled Lo a cerLaln requlred LemperaLure ln Lhe
coollng Lower
1he prcess of coollng hoL clrculaLlng waLer ln coollng Lower ls a qulLe slmple
process 1he hoL waLer when comes ln conLacL wlLh alr releases lLs heaL ln Lwo
ways
1 1ransfer of senslble heaL due Lo Lhe dlfference ln Lhe LemperaLure of alr
and hoL waLer
2 1ransefer of laLenL heaL due Lo evaporaLlon of a parL of waLer

varlous Lypes of coollng Lower used now a days are
a ALmospherlc coollng Lower
b Spray pond Lype coollng Lower
c naLural urafL Coollng 1ower
d Mechanlcal urafL Coollng 1ower
(Lhese are belng used aL lllCChulpur)

Chemlcal LreaLmenL of Lhe waLer ls also done so as Lo overcum problem llke
corroslon scale formaLlon foullng ang blologlcal foullng ( due Lo presence of
bacLerla algae and fungl) 1o avold corroslon corroslon lnhlblLor are added and
dlspersanLs are used Lo avold scale formaLlon and foullng



.. ater Softening Plant
ueslred quallLy of Lhe LreaLed waLer ln Lhe sofLenlng planL are as follows
1 pP 104 107
2 1oLal Pardness 30 ppm as CaCC3
3 Calclum Pardness 40 ppm as CaCC3
4 1urbldlLy 12 n1u

Cold llme sofLener ls used for waLer purlflcaLlon and ls furLher used ln Lhe
coollng Lower as a makeup Pardness ln Lhls process ls reduced from 330400
ppm Lo 30 ppm by Lhe cold llmee process

















8. ProTlem at IFFCU Due To Corrosion

Corrosion of Urea Plant Equipment
ln manufacLure of urea Lhe corroslveness of Lhe synLhesls mlxLure has
posed Lhe urea manufacLure Lo lay very sLrlcL demond ln Lhe quallLy of
maLerlal of consLrucLlon MosL severe corrosslon ln urea planL ls aL locaLlon
where urea and Lhe corbamaLe soluLlons are handled aL Lhe hlgh LemperaLure
and pressure
ln vlew of hlgh pressure LemperaLure concenLraLlon and Lwo phase
mlxLure ln Lhe urea reacLor a llner of Lhe sLalnless sLeel 316L ls used ln Lhe
consLrucLlon ln ealler years of urea manufacLure lead and sllver were used Lo
llne Lhe urea reacLor 1hese were good only ln Lhe LoLal absence of oxygen lor
day reacLor LlLanlum zlrconlum and sLalnless sLeel used as llner maLerlal
Corrosion in Tbe H.P. Section
ln Lhe hulpur planL Lhe P equlpmenLs are reacLor sLrlpper P
condenser carbamaLe mlxer carbamaLe separaLor where soluLlon are handled
aL hlgh LemperaLure and hlgh pressure maLerlal ln conLacL aL hlgher raLe
unless proper maLerlal are selecLed and adequaLe proLecLlon ls provlded
urea reacLor aL lllCC hulpur unlL ls llned wlLh Lhe modlfled 316L sLalnless
sLeel P condenser and separaLors are also made up of sLalnless sLeel 316L
sLalnless sLeel surfaces of all Lhese P equlpmenL have passlve fllm of oxlde
Corrosion in MP Section
Severe corroslon condlLlon exlsLs ln M decomposer and mlxer aL lnleL of
M condenser where aggresslve condlLlon prevalls due Lo hlgher operaLlng
LemperaLure whlch ls more Lhan 130
0
C A maLerlal used ln Lhls secLlon ls 316L
lrom P secLlon carbamaLe are senL Lo Lhe M decomposer boLLom 1he
oxygen helps Lo help Lo passlvaLe Lhe enLlre M secLlon
Corrosion in LP Section
ln Lhls secLlon corroslon ls noL as severe as handled aL lower LemperaLure
and pressure SLalnless sLeel 316L and 304L grade have been used as maLerlal
of consLrucLlon

Corrosion in aste ater Treatment Section
MaLerlals used ln Lhls secLlon are sLalnless sLeel 303L and 304L ln
dlsLlllaLlon column chances of corroslon are due Lo Lhe hlgh Lurbulence of
ammonla and CC2 vapors whlch ls sLrlpped by means of vapor produced ln Lhe
reboller

Corrosion Due To Urea Dust
urea prllls and dusL belng hygroscoplc absorb molsLure and corrode
concreLe and sLeel sLrucLure badly All sLrucLure and open elecLrlc lnsLallaLlon
LhaL may come ln conLacL wlLh Lhe urea dusL musL be proLecLed elLher by anLl
corroslve palnLlng or by provldlng sulLable cover

Corrosion in Prill Tower
lnslde walls and prlll Lower base whlch are ln Lhe conLacL wlLh Lhe urea
are sub[ecLed Lo corroslon due Lo reasons menLloned ln Lhe above problems
rllllng Lower walls ln conLacL wlLh urea are palnLed wlLh Lhe anLlcorroslve
palnLs such as epoxy palnL 8uL ln hulpur unlL prlll Lower base are coaLed wlLh
l8 whlch has a beLLer corroslve reslsLance properly Lhan epoxy palnLs


9. Tbe -L {Modified] Stainless Steel
Background
Crade 316 ls Lhe sLandard molybdenumbearlng grade second ln lmporLance Lo
304 amongsL Lhe ausLenlLlc sLalnless sLeels 1he molybdenum glves 316 beLLer
overall corroslon reslsLanL properLles Lhan Crade 304 parLlcularly hlgher
reslsLance Lo plLLlng and crevlce corroslon ln chlorlde envlronmenLs
Crade 316L Lhe low carbon verslon of 316 and ls lmmune from senslLlsaLlon
(graln boundary carblde preclplLaLlon) 1hus lL ls exLenslvely used ln heavy gauge
welded componenLs (over abouL 6mm) 1here ls commonly no appreclable prlce
dlfference beLween 316 and 316L sLalnless sLeel
1he ausLenlLlc sLrucLure also glves Lhese grades excellenL Loughness even down
Lo cryogenlc LemperaLures
Compared Lo chromlumnlckel ausLenlLlc sLalnless sLeels 316L sLalnless sLeel
offers hlgher creep sLress Lo rupLure and Lenslle sLrengLh aL elevaLed
LemperaLures
Key Properties
1hese properLles are speclfled for flaL rolled producL (plaLe sheeL and coll) ln
AS1M A240/A240M Slmllar buL noL necessarlly ldenLlcal properLles are speclfled
for oLher producLs such as plpe and bar ln Lhelr respecLlve speclflcaLlons
Composition
@ab|e 1 ComposlLlon ranges for 316L sLalnless sLeels
Crade C Mn Sl S Cr Mo nl n
316L
Mln 160 200 100
Max 003 20 073 0043 003 180 300 140 010
Mecbanical Properties
@ab|e 2 Mechanlcal properLles of 316L sLalnless sLeels
Crade
1enslle SLr
(Ma) mln
?leld SLr
02 roof
(Ma) mln
Llong
( ln
30mm) mln
Pardness
8ockwell 8
(P8 8) max
8rlnell (P8)
max
316L 483 170 40 93 217
Pbysical Properties
@ab|e 3 1yplcal physlcal properLles for 316 grade sLalnless sLeels
Crade
uenslL
y
(kg/m
3
)
LlasLlc
Modulu
s
(Ca)
Mean Coeff of
1hermal Lxpanslon
(m/m/C)
1hermal
ConducLlvlLy
(W/mk)
Speclfl
c PeaL
0
100C
(!/kgk
)
Llec
8eslsLlvlL
y
(nUm)
0
100
C
0
313
C
0
338
C
AL
100
C
AL
300
C
316/L/
P
8000 193 139 162 173 163 213 300 740
Crade Specification Comparison
@ab|e 4 Crade speclflcaLlons for 316L sLalnless sLeels
Crade
unS
no
Cld 8rlLlsh Luronorm Swedlsh
SS
!apanese
!lS 8S Ln no name
316L S31603 316S11 14404
x2CrnlMo17
122
2348
SuS
316L
noLe 1hese comparlsons are approxlmaLe only 1he llsL ls lnLended as a
comparlson of funcLlonally slmllar maLerlals not as a schedule of conLracLual
equlvalenLs lf exacL equlvalenLs are needed orlglnal speclflcaLlons musL be
consulLed
PossiTle Alternative Crades
@ab|e S osslble alLernaLlve grades Lo 316 sLalnless sLeel
Crade Why lL mlghL be chosen lnsLead of 316?
317L
Plgher reslsLance Lo chlorldes Lhan 316L buL wlLh slmllar reslsLance
Lo sLress corroslon cracklng
Corrosion Resistance
LxcellenL ln a range of aLmospherlc envlronmenLs and many corroslve medla
generally more reslsLanL Lhan 304 Sub[ecL Lo plLLlng and crevlce corroslon ln
warm chlorlde envlronmenLs and Lo sLress corroslon cracklng above abouL 60C
Consldered reslsLanL Lo poLable waLer wlLh up Lo abouL 1000mg/L chlorldes aL
amblenL LemperaLures reduclng Lo abouL 300mg/L aL 60C
316 ls usually regarded as Lhe sLandard marlne grade sLalnless sLeel" buL lL ls noL
reslsLanL Lo warm sea waLer ln many marlne envlronmenLs 316 does exhlblL
surface corroslon usually vlslble as brown sLalnlng 1hls ls parLlcularly assoclaLed
wlLh crevlces and rough surface flnlsh
Heat Resistance
Cood oxldaLlon reslsLance ln lnLermlLLenL servlce Lo 870C and ln conLlnuous
servlce Lo 923C ConLlnuous use of 316 ln Lhe 423860C range ls noL
recommended lf subsequenL aqueous corroslon reslsLance ls lmporLanL Crade
316L ls more reslsLanL Lo carblde preclplLaLlon and can be used ln Lhe above
LemperaLure range Crade 316P has hlgher sLrengLh aL elevaLed LemperaLures
and ls someLlmes used for sLrucLural and pressureconLalnlng appllcaLlons aL
LemperaLures above abouL 300C
Heat Treatment
SoluLlon 1reaLmenL (Anneallng) PeaL Lo 10101120C and cool rapldly 1hese
grades cannoL be hardened by Lhermal LreaLmenL
elding
LxcellenL weldablllLy by all sLandard fuslon and reslsLance meLhods boLh wlLh and
wlLhouL flller meLals Peavy welded secLlons ln Crade 316 requlre posLweld
anneallng for maxlmum corroslon reslsLance 1hls ls noL requlred for 316L
316L sLalnless sLeel ls noL generally weldable uslng oxyaceLylene weldlng
meLhods
Macbining
316L sLalnless sLeel Lends Lo work harden lf machlned Loo qulckly lor Lhls reason
low speeds and consLanL feed raLes are recommended
316L sLalnless sLeel ls also easler Lo machlne compared Lo 316 sLalnless sLeel due
lLs lower carbon conLenL
Hot and Cold orking
316L sLalnless sLeel can be hoL worked uslng mosL common hoL worklng
Lechnlques CpLlmal hoL worklng LemperaLures should be ln Lhe range 1130
1260C and cerLalnly should noL be less Lhan 930C osL work anneallng should
be carrled ouL Lo lnduce maxlmum corroslon reslsLance
MosL common cold worklng operaLlons such as shearlng drawlng and sLamplng
can be performed on 316L sLalnless sLeel osL work anneallng should be carrled
ouL Lo remove lnLernal sLresses
Hardening and ork Hardening
316L sLalnless sLeel does noL harden ln response Lo heaL LreaLmenLs lL can be
hardened by cold worklng whlch can also resulL ln lncreased sLrengLh
Utber Applications
1yplcal appllcaLlons lnclude
lood preparaLlon equlpmenL parLlcularly ln chlorlde envlronmenLs
harmaceuLlcals
Marlne appllcaLlons
ArchlLecLural appllcaLlons
Medlcal lmplanLs lncludlng plns screws and orLhopaedlc lmplanLs llke LoLal
hlp and knee replacemenLs
lasLeners