Fertilisers And Chemicals Travancore Ltd.

Udyogamandal Complex

Ammonia plant (990 MTPD)

Ammonia plant at Udyogamandal division was commissioned in March 1988. The plant
is having a capacity of 900MTPD Ammonia and 10800 N3/hr of synthesis gas equivalent
to 90TPD Ammonia and is based on Naphtha as a feed stock. The plant was designed by
M/s Haldor Topsoe A/S, Denmark. The main raw material is Naphtha. The plant is using
RLNG as feedstock from October 2013.
Process Description (Based on Naphtha/LNG as feed stock)
Ammonia is produced from a gaseous mixture of hydrogen (H2) and nitrogen (N2) in
the stoichiometric ratio 3 to 1.The gas mixture will contain limited amounts of inerts
coming from the raw materials, i.e. argon (Ar) and methane (CH4). For this ammonia
plant the sources of hydrogen and nitrogen are Naphtha/LNG and atmospheric air
respectively.
The processes which are necessary for producing ammonia from these raw materials
are as follows:
a. Predesulphurisation of the raw naphtha. The bulk part of sulphur is removed in
this section. When the plant is on LNG, this section is not required.
b. Final desulphurisation of the hydrocarbon feed in one step : Removal of
remaining sulphur compounds.
c. Reforming of the desulphurized hydrocarbons in two steps by steam and air. The
process gas from these steps contains hydrogen and nitrogen as well as carbon
monoxide (CO), carbon dioxide (CO2), methane and argon. The reforming takes
place at a pressure of about 35 kg/cm2g.
d. In the gas purification section, CO is first converted to CO2 and H2 yield. CO2 is
then removed in the CO2-removal section, and afterwards the remaining CO and CO2
in the converted gas are removed in the methanator.
e. The purified synthesis gas is compressed to a pressure of about 135 kg/cm2g and
converted into ammonia by a catalytic reaction.
f. The plant is designed to a nominal production of 900 MTPD ammonia and 10,800
Nm3/h of synthesis gas. The ammonia product produced in the plant is sent to the
caprolactam plant and to atmospheric storage. Synthesis gas is consumed in the
caprolactam plant as well, and in combination with part of the CO2 produced (item
d.above)
 Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

In operation only when Naptha is used as feed

REFORMING
Process air
steam
Hydrogen
PREDESULPHURI Primary Reforming Secondary
Reforming
SATION
Naphtha (Indirect heat by (Direct heating)
Fuel Naphtha / Firing)
LNG

LNG
FINAL
DESULPHURISATION CO CONVERSION
Hydrogen

HT shift converter LT shift converter

MDEA

MDEA for
regeneration

METHANATOR CO2 REMOVAL

CO2
Synthesis gas to
Petrochemical
division

NH3
SYNTHESIS
SECTION

Product Ammonia
Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

Complex Fertilizers

NP 20: 20: 0: 13 (Ammonium phosphate sulphate)

In FACT-Udyogamandal complex, there are two complex fertilizer plants one with 300
TPD capacity and other with 150TPD capacity. The 300 TPD Ammonium phosphate
plant commissioned in 1966 for production of Ammonium phosphate 16:20 grade was
designed by Dorr Oliver. In 1982 the plant was modified to produce 20:20 grade
Ammonium phosphate. The 150 TPD Ammonium phosphate plant commissioned in
1971, was designed by FACT Engineering and Design Organization (FEDO) to produce
Ammonium phosphate 20:20 grade.

Process Description:-

AMMONIUM PHOSPHATE PLANT (300 TPD)

Phosphoric acid, Sulphuric acid and liquid Ammonia are fed to a saturator. The flow is
measured through flow meters and controlled to the required levels. The reactor is kept
agitated.

The neutralized product is a thick slurry and flows to the blunger where it is mixed with
ammonia, re-circulated undersized granules, crushed oversized granules and recovered
dust (Final adjustment of Mole-ratio of ammonia to phosphoric acid is done by addition
of ammonia in the blunger). Granulation is taking place in the blunger.

The blunger is of a double shaft Paddle mixer set on a slope. The granulated wet product
from the blunger flows through a chute to a rotary co-current drier where the material is
dried by hot air produced by combustion of Furnace oil with air. The material leaving
the drier is conveyed to a set of vibrating screens and product is taken out. The oversize
material is crushed and, along with undersize material fed back into the blunger.

The dust coming from the screens and other equipments is driven out by a dust fan
through a cyclone. The air from the drier cyclone and dust cyclone and fumes leaving the
reaction tank enter two nos. scrubbers for the recovery of ammonia and dust.
Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

Scrubbing is done with a mixture of weak phosphoric acid. Part of scrubber solution is
fed back to the reaction tank for further ammoniation.

The product separated at the screen is bagged and sent to storage

Sulphuric Acid
Stack
Ammonia Amophos 300TPD

Phosphoric acid Saturator/Reactor

Ammonia Scrubbing
Under
Blunger
& size Furnace oil

Drying

Product
Scrubbing size
Screening Bagging

Over size

Products
Crushing

Fig: 1 300 TPD Amophos Plant

Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

AMMONIUM PHOSPHATE PLANT (150 TPD)

Process involved is similar to 300 TPD Ammonium Phosphate Plant.

Sulphuric Acid

Ammonia
Amophos 150TPD

Saturator/Reactor
Stack
Phosphoric acid

Blunger
Furnace oil
Scrubbing

system Drying

Product
Under size
Screening Bagging section
Over size

Factamphos
Crushing

Fig: 2 150 TPD Amophos Plant

Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

Sulphuric Acid

The 450 TPD single absorption plant commissioned in 1965 was converted to Double
Conversion Double Absorption (DCDA) process in 1981,increasing the capacity to 600 TPD
of Sulphuric acid including facility for producing Oleum equivalent to 221 TPD sulphuric
acid. A 550 TPD SO2/Acid plant of the same DCDA process was commissioned in 1966,to
produce Sulphur dioxide equivalent to 375 TPD Sulphuric acid and 175 TPD of Sulphuric
acid. The Sulphur dioxide produced after cooling and washing is supplied to Caprolactam
Plant. Both Sulphuric acid plants utilize Sulphur as raw materials.

Process Description

550 TPD SO2/Acid plant

The 550 TPD SO2/Acid plant is designed to produce SO2 equivalent to 375 TPD sulphuric
acid and 175 TPD of 100% sulphuric acid by DCDA route.

Sulphur is burnt in the furnace to produce 12% SO2 which is cooled in the waste heat boiler
system to 500 0C. A portion of the SO2 gas is fed to Petrochemical plant after cooling and
removal of any SO3 formed during combustion. The other portion of the SO2 gas is mixed
with dry air to form 10.5% SO2 gas and fed to the first bed of converter at 430 0C. The SO3
in the gas from the 3rd bed of the converter is absorbed in the Intermediate Absorption tower
with 98.4% Sulphuric acid and the unconverted gas is fed to the 4th bed of the converter.
The gas from the 4th bed of the converter goes to Final Absorption tower where it is again
absorbed in 98.4% Sulphuric acid. The effluent gas goes to atmosphere after mist
elimination.
Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

Sulphur
Waste heat Demineralised water
recovery system SO2/Acid
Sulphur melting Air
Heat exchanger 1 96% sulphuric acid

1 Air drying
Filtration
Super heater
Combustion
Heat exchanger
2 Intermediate
Conversion
absorption
Economiser 1 Bed 1
Acid
Bed 2
storage
Economiser 3
Bed 3 Final

Bed 4 absorption
Economiser 2
Gas scrubbing
SO2 to PD
Steam

Fig 1: 550 TPD SO2/Acid plant

Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

600TPD DCDA Sulphuric Acid plant

The DCDA Sulphuric acid plant is having a capacity to produce 600 T of 100% H2SO4.
The plant is based on Double Conversion Double Absorption (DCDA) process.

The raw material for the sulphuric acid plant is elemental sulphur, which is imported and is
transported to the sulphur bin. Sulphur is melted in a melting pit by means of heating coils
fed with steam. The molten Sulphur is fed to the sulphur burner where complete combustion
of sulphur takes place in the furnace after removal of ash to form SO2 gas. The heat of
combustion is withdrawn by means of a waste heat boiler where saturated steam of 16
Kg/cm2g is generated. The gas, cooled to a temperature of 4300C is fed to a converter
having 4 catalyst beds.The SO3 in the gas from the 3rd bed of the converter is absorbed in
sulphuric acid by scrubbing in Oleum tower, where Oleum with 23%free SO3 is produced
then enters the 4th bed. The gas from the 4th bed enters the final absorber where the SO3 is
absorbed by 98.4% sulphuric acid. The remaining gas from the FAT passes through mist
separators located in its upper section before letting out to atmosphere through the stack.
Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

Waste heat
Sulphur
recovery system Demineralised water
DCDA
Sulphur melting Air
96% sulphuric
Waste heat boiler acid
1 Air drying
Filtration

Waste heat boiler

2
Combustion
Oleum Oleum

Conversion
Bed 1 Intermediate

Waste heat Bed 2 absorption

boiler 3
Bed 3
Acid

Bed 4
storage
Economiser
Final absorption

Steam

Fig: 2 600 TPD DCDA PLANT

Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

EFFLUENT TREATMENT PLANT

Process Description:-

Effluents from both phosphate plants and phosphoric acid plant flows to Raw Effluent Tank at
Slip - Way. The raw effluent from this tank is pumped to the Equalisation tank A.

Effluents from Ammonium Sulphate plant, DM plant, scrubber liquid from Acid plant,
rain/floor wash water collected in sump pits are also pumped to Equalisation tank -A. Effluents
from Acid plant collected in Delay pond is pumped either to Equalisation tank –A if or Spray
pond based on pH of the effluent.

The effluents from Equalisation tank - A over flows to ‘B’ tank. Floor wash/rain water collected
in north gate area is also pumped to Equalisation tank – B. From where it is pumped to the Flash
mixer. In the flash mixer the raw effluent is mixed with the Lime slurry where the reaction takes
place. The effluent then overflows from the flash mixer to the centre of the clariflocculator
where the remaining reaction and sludge settling takes place.

The treated effluent from the clariflocculator over flows to a holding tank from where it is
pumped to the spray pond. In the spray pond, free ammonia if any in the treated effluent is
removed by stripping/spraying. After pH correction, the effluent is pumped to Guard pond. In
Guard pond after final pH correction, the effluent is pumped to the A drain which finally drains
to the river.

Specification of the treated effluent sending out to the river from pollution control plant is:

pH : 6.5 to 8

Free Ammonia : 4 ppm max.

Total Ammonia as N ppm : 75 max.

Phosphates as P ppm : 5 max.

Fluorides as F ppm : 1.5 max.

Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

The sludge collected at the bottom of clariflocculator is drained intermittently to equalisation

tank – A. The sludge and the gypsum accumulation from the equalisation tank –A is removed
frequently using crane and the material is transported to the Hazardous waste storage at FACT-
CD using tippers.

Seepage & washing

Effluents from NAS, Ammophos plants

Equalisation

A B
Effluents from acid plants

Lime

Hot Water pH correction

Lime slurry Flash mixing
(delay pond)
preparation
Sludge Clariflocculation

Ammonia removal
(Spray pond) Acid/Alkali

pH correction
Acid/Alkali
(neutralization pit)
Final pH correction(Guard
pond)
River(A drain)

Fig: 3 EFFLUENT TREATMENT PLANT

Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

Ammonium Sulphate
The plant is designed to produce 682 TPD Ammonium Sulphate using Ammonium
Sulphate liquor formed as byproduct at different stages in the manufacture of
caprolactam.

The ammonium sulfate solution fed to the unit consisting of two separate streams from
Caprolactam Plant. One feed stream is Lactam ammonium Sulfate solution and the
other feed stream is Oxime ammonium sulfate solution. Oxime ammonium sulfate
solution is fed into 1st Effect Oxime A.S. Evaporator after pre-heating in the Oxime A.S
preheater.
The concentrated solution is sent to No.1 & 2 Oxime A.S.crystallizer. Oxime ammonium
sulfate slurry from No.1 Crystallizer are sent to prethickner, where pre-thickening of
slurry is carried out. Then, the slurry is fed to Oxime A.S.Centrifuge where crystals
are separated out

The lactam ammonium sulfate solution is fed to 1st Effect Lactam A.S.Evaporator and the
concentrated solution goes to Lactam A.S.Crystallizer where the ammonium sulphate in
the feed is crystallized. Lactam ammonium sulfate slurry is treated by the same method
as Oxime stream.

Both of oxime and lactam sufate crystals from the centrifuges are fed to Dryer-Cooler
where it is dried and cooled by fluidization technique using hot air and cold air. The
exhaust air from dryer-coolers contains fine particles that are recovered in a ventury
scrubber system.

The crystals from Dryer- Cooler system are weighed and are bagged using Bagging
Machines.

Ammonium Sulphate through the Direct Neutralization Route(DN):

Ammonium sulphate production through the direct neutralization route was started on 26th
September 2008. Ammonia and sulphuric acid is directly reacted in a vessel to give the
required ammonium sulphate slurry. This is further concentrated and crystallized using the
same process as above.
 Fertilisers And Chemicals Travancore Ltd.
Udyogamandal Complex

OAS LIQUOR STEAM LAS LIQUOR

CW

VACUUM SYSTEM
OAS LIQUOR STORAGE LAS LIQUOR STORAGE

STEAM
PURGE LIQUOR STEAM
STORAGE
EVAPORATION & EVAPORATION &
CRYSTALLISATION NH3
CRYSTALLISATION

H2SO4
STEAM &VAPOUR
CONDENSATE STORAGE

EXTRACTION & EXTRACTION &

CENTRIFUGING CENTRIFUGING

MOTHER LIQUOR
STORAGE

DRYING & SCRUBBING TO AMOPHOS PLANT

AIR
STEAM

STORAGE & BAGGING

Fig: 4 682TPD AMMONIUM SULPHATE PLANT